controldesign.com
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MAKE YOUR DIGITAL
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Mosaic of
Modules
FEBRURARY 2012
Modular Machines and Production
Lines Inspire Builders to Combine
Equipment in More Innovative Ways
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CONTENTS
FEBRUARY 2012
FEATURES
24 Cover Story
Mosaic of Modules
Modular Machines and Production Lines Enable Quick Disconnects
and Speedy Changeovers. This Flexible Approach Inspires Builders
to Combine Modular Equipment in Ever More Innovative Ways
Jim Montague, executive editor
Volume 16, No. 2
33 Measurement, Sensing and Vision
Avoid a Pressing Problem
Aluminum Extruder Uses Smart Cameras to Prevent Machine
Damage
24
Mike Bray, CPU Automation
38 Product Roundup
Mobility, Efficiency Push HMI Growth
New Packaging Requirements Also Will Increase HMI Demand
COLUMNS
7 ControlDesign.com
23 Embedded Intelligence
Resolutions So Far
Software Guy, Know
Thy Limits
9 Editor’s Page
33
Lawyer Meets Machine
37 TechFlash
New Game for
Programmable Safety
11 Machine Builder Mojo
Pick Right, and Service
Is Free
50 OEM Insight
13 Live Wire
Push and Pull
of Electronic Drives
Find and Foster Innovation
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
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Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada
N9A 6J5. Printed in the United States.
15 OEM Spotlight
Candymaker Combines,
Simplifies Controls
44 Real Answers
Digital Network Reliability
48 Product Showcase
16 InDiscrete
Manufacturing Technology
Orders Up 74%
February 2012 Control Design
5
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IF YOU READ my December
evidence about how to be more
‘11 column (“A New Resolu-
efficient as a machine builder,
tion,” www.ControlDesign.com/
or how to put green standards
resolution), you know that for
into practice, check out some of
2012 I resolved to improve my
our articles and get a head start
cybersecurity, sustainability and
on your 2012 green and better
efficiency knowledge. I have kept
efficiency path.
THE TRUTH ABOUT ENERGYEFFICIENT MOTORS
This paper delves into the
confusing area of motor
efficiency and how it relates to
saving energy.
2012 PRODUCT RESEARCH AND
BUYING HABITS STUDY
www.ControlDesign.com/
habits12
DID YOU KNOW YOU CAN
RECEIVE CONTROL DESIGN
ELECTRONICALLY? Subscribe
to the digital issue of Control
Design and download a highquality PDF of the magazine
exactly as it appears in print.
We’ll email you each month
when it’s ready.
www.ControlDesign.com/
digital.html
operation and dynamic perfor-
my daily To-Do list and I try
mances might help you find the
to accomplish everything I list
answer. In the white paper “En-
there. My To-Do list consists of
ergy Efficiency for Machines:
personal and professional goals
The Smart Choice for Motoriza-
such as posting daily news and
tion,” Schneider Electric gives
products on ControlDesign.
engineers efficient, economic
com, motivating my coworkers
and competitive solutions
(Jim gets cookies, though he
to help them select efficient
says he’ll work for peanuts) to
industrial motors. Read this
post Machine Builder Forum
white paper at www.ControlDe-
(MBF) entries (www.ControlDe-
sign.com/schneidermotor and
sign.com/mbf), and running
learn how using synchronous
my daily three miles.
motors with higher dynamic
I’ve also become more sustainable with my efficiency plan;
not printing that To-Do list, but
performances can generate at
least 20% energy savings.
Learn the difference between
instead tracking it digitally. My
active and passive energy ef-
lunches are packed in reusable
ficiency, and why companies
containers; there are no more
need to adopt active energy ef-
paper or Styrofoam cups for my
ficiency as the standard to meet
coffee; and if the Chicago winter
greenhouse gas emission goals
weather permits, I run my three
set within the Kyoto Protocol.
miles outside, consuming less
Read “Making Permanent Sav-
electricity at home or at the
ings Through Active Energy Ef-
gym and minimizing my carbon
ficiency” (www.ControlDesign.
footprint.
com/ActiveEnergyEfficiency) to
I’m off to a great start, but
learn this and much more.
I wonder if you set up similar
Lastly, if you want to learn
resolutions for this year, and
ways to improve energy effi-
if you are succeeding as well.
ciency of belt and roller convey-
Do you plan to improve your
ors, you must read “Optimizing
efficiency plans this year? Do
Energy Efficiency of Conveyors”
you have green goals to accom-
at www.ControlDesign.com/
plish? Stop by our forum and let
conveyors. Don’t be the last one
me know (www.ControlDesign.
to read about smart solutions
com/greenresolutions).
that can result in significant
However, if you need some
controldesign.com
at your machine, its modes of
efficient. Every day I type up
savings on a conveying line.
February 2012 Control Design
7
kbonfante@putman.net
CAN YOU TEACH INNOVATION?
www.ControlDesign.com/
innovate
motor technology? A close look
In 2012, I’ve become more
t
WHICH OF THESE WILL
CHANGE YOUR GAME?
www.ControlDesign.com/game
accomplish the rest.
managing editor, digital media
SPECIAL TO THE WEB
to choose the most suitable
t
To download PDF papers,
go to ControlDesign.com/
whitepapers.
Do you know the best way
I still have 10 more months to
Katherine Bonfante
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Lawyer Meets Machine
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
A DISCUSSION OF product liabil-
Engineering standards are critical,
ity issues facing U.S. manufacturers
even if not expressly adopted as
highlighted a session at Rockwell
the law, as elements of proof that
EDITORIAL TEAM
Automation’s Safety Automation
your product is not defective if
Forum this past November.
you followed the standards.”
EDITOR IN CHIEF
JOSEPH FEELEY
jfeeley@putman.net
EXECUTIVE EDITOR
JIM MONTAGUE
jmontague@putman.net
AARON HAND
ahand@putman.net
MANAGING EDITOR, DIGITAL MEDIA
on how to minimize the risks of
and Don Segal, attorney at law,
product liability.
Segal, McCambridge, Singer and
No. 1, know the rules about how
Mahoney, discussed the liability
you build your products and how
potentials when man—and law-
you build them safely and comply
yer—meets machine.
with standards. “It’s tricky, particularly here in the U.S., because
the murkiness of these issues. “I
there are issues about what sorts
SARAH CECHOWSKI
scechowski@putman.net
have machines in the field, built
of rules apply,” Ballesteros admit-
to the standards at that time, and
ted. “So one common denominator
grandfathered in as OK, but the
that is effective is to follow the
standards have changed and so
engineering standards associated
there now are a few elements in the
with machine building and prod-
changes that could improve things.
uct manufacturing.”
SENIOR TECHNICAL EDITOR
DAN HEBERT
dhebert@putman.net
LORI GOLDBERG
lgoldberg@putman.net
COLUMNIST
JEREMY POLLARD
jpollard@tsuonline.com
If you go ahead and do what’s right
Proper warning is also a key
in new design elements and field
element. “There’s not a product
DESIGN/PRODUCTION
changes, are you liable for every-
liability case in which the issue of
SENIOR PRODUCTION MANAGER
thing that’s out there?”
ANETTA GAUTHIER
ART DIRECTOR
This issue, said the lawyers,
DEREK CHAMBERLAIN
can demonstrate that sometimes
SUBSCRIPTIONS
the law actually displays some
CUSTOMER SERVICE
common sense. “It often fits the
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
jfeeley@putman.net
EDITORIAL ASSISTANT
t
ASSOCIATE EDITOR, DIGITAL MEDIA
editor in chief
An audience question recognized
t
KATHERINE BONFANTE
kbonfante@putman.net
The presenters offered advice
dent, law, Rockwell Automation;
Joe Feeley
MANAGING EDITOR
Gary Ballesteros, vice presi-
EDITOR’S PAGE
controldesign.com
“There’s not a product
liability case in which the
issue of warnings doesn’t
come up.”
criteria for making what’s known
as ‘subsequent remedial mea-
warnings doesn’t come up,” Balles-
sures’ that the courts recognize
teros said. “It’s an area where you
as a well-intended improvement,
want to have good expert advice.”
and can’t be used to prove what I
Refining the quest for expert
did before was wrong,” Ballesteros
help, Ballesteros added, “It’s the
said. “If the law of common sense
‘Goldilocks and the Three Bears’
says it’s the right thing to do
advice. Not too much, not too
today, and even if you implement
little; you have to get it just right.”
it only partially because it’s not
The presenters identified some
economically feasible to do it all,
due diligence items that help with
how can that be a bad thing?”
hazard analysis, although one of
Ballesteros reminded the audi-
them is a double-edged sword.
ence, many of whom identified
“Look at what competitors do,
themselves as engineers, that
but don’t assume that they are
the law understands who knows
smarter than you. It’s a useful
about these issues the best. “The
touch point, that’s all.”
law follows you engineers on
this,” he said. “I can’t think of any
state that hasn’t incorporated the
National Electrical Code as law.
February 2012 Control Design
9
Brad
Bundled
Automation
Solutions
®
WHAT WE BRING TOGETHER
IS WHAT SETS US APART
You’re looking for proven solutions for your automation requirements. Distribution boxes. Gateways.
Network I/Os. Or modular wiring systems. We
provide a complete suite of Brad automation products for connectivity, communications, control and
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power. All bundled together to deliver the right solutions for your needs every time. With us, you know
you’re getting products known for their innovative
designs, reliability in harsh environments and worldwide reputation for setting the standard.
Pick Right, and Service Is Free
customers lower their total automation spend,
charge for technical support? Do you think this
while also being able to quickly troubleshoot.
service should be free, or at least built into the
We work hard to maintain a very efficient
cost of the original product? If so, read on and find
business model, so we can offer not only free
out how to get free service.
support, but also detailed documentation and
Before you get too excited, we’re talking about
free technical support here, and not about free
online learning tools.”
Another company that offers free technical
engineering services. The line between technical
phone support is Opto 22 (www.opto22.com),
support and engineering services can be blurry,
and it throws in free software and training as
but you probably know when you’re about to
well. “Our control programming software is
cross it, as do most automation suppliers that
available as a free download,” says Tom Ed-
you’re dealing with.
wards, senior technical advisor at Opto 22.
“Beyond our standard and free product sup-
“Another free piece of software lets OEMs run
the strategies they’ve created in an environment
services,” notes Ron Baysinger, market develop-
that simulates an actual controller. We also
ment manager for control and industry solu-
provide no-charge hardware and software train-
tions at Phoenix Contact (www.phoenixcontact.
ing at our corporate headquarters in Southern
com). “These instances include custom applica-
California. This consists of a three-day class in
tion support, complex solution integration and
which we cover configuration, networking, diag-
on-site service.”
nostics and troubleshooting.”
Many software suppliers charge for service,
ucts, but you should be able to judge upfront if
typically via annual licensing fees, but there are
prices are fair. “Some of the cost of free phone
exceptions.
but it’s Delta’s view that providing good service
is an investment that promotes good long-term
customer relations,” says Bill Savela, market-
t
dhebert@putman.net
ing director at Delta Computer Systems (www.
In theory, the best prices are offered
by firms that provide no service, or
by those that charge for service. In
practice, this isn’t the case.
deltamotion.com).
In theory, the best prices are offered by com-
“Support shouldn’t be a profit center for the
panies that provide no service, or by those that
supplier,” asserts Marcia Gadbois, president of
charge for service. In practice, this isn’t the case.
InduSoft (www.indusoft.com).
Almost all automation firms feel compelled by
“Support needs vary among our customers,
machine builder, robot builder and process skid
but what never changes is the need for knowl-
builder OEMs to offer service—albeit at varying
edgeable support staff familiar with every
levels of quality and price.
aspect of the software,” Gadbois adds. “It’s not
In the traditional automation sales model, the
only the availability of the support that matters
local distributor provides free service, with the
to customers, but the quality. In order to guar-
vendor providing backup assistance, often for a
antee service to all who need it, we maintain
fee. For those vendors using a different distribu-
a network of exceptional support team mem-
tion model, service could be free.
bers, and we’re able to offer free support during
“Our direct-sales model means we don’t have
normal business hours, as well as a paid option
field personnel, so free telephone support is
for 24/7 support. The fee for 24/7 assistance is
critical,” says Stewart Terhorst, member of a
intended to cover time and labor, rather than to
business development team at AutomationDi-
generate profit.”
rect (www.automationdirect.com). “We consider
Price and performance are key drivers when
this part of our responsibility to our custom-
purchasing automation components, and service
ers, as it helps them get the most out of our
is becoming a driver, too, particularly as OEMs
products. Our free technical support helps our
learn to run leaner.
controldesign.com
February 2012 Control Design
senior technical editor
service is built into the price of the products,
t
Free service often means higher-cost prod-
Dan Hebert, PE
port, there are instances requiring billable
MACHINE BUILDER MOJO
DOES IT ANNOY you when automation suppliers
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Find and Foster Innovation
tions, and never get anything to work,” Stoltz says.
competition. Key to the competition was innova-
“You get all sorts of things that you need to deal
tive thinking. They had to develop an innovative
with. There are cultural differences. Some people
idea related to food safety. They also had to come
speak up, and some are more aggressive. But that
up with innovative ways to capture points on the
doesn’t mean that one’s more innovative than
playing field with their robot. But what exactly
another. You have to get all things out in the air. All
qualifies as “innovative” and, more importantly,
ideas are okay without judgment or exclusions. You
how should we—whether FLL coaches or engi-
have to be able to shield the innovative people.”
We hear a lot about innovation. There seemed
Promoting innovation within a group has a lot to
do with choosing the right combination of people,
culture. “Whether the company believes in stan-
address last month, U.S. President Barack Obama
dardization, keeping things the same, or there’s an
mentioned innovation repeatedly, even saying, “In-
openness from management to try new things and
novation is what America has always been about.”
sometimes fail—the effect of innovation or not is
But what’s the best way to “promote” innova-
very strongly linked to company culture.”
tion? Working with the 9- and 10-year-olds to
PopTech (www.poptech.org) is a non-profit
come up with innovative ideas, I and the other
organization that tries to promote innovation by
coaches struggled with the best way to help the
bringing innovators together from many different
kids move in the right (“right”) direction without
fields. One recent find came from 13-year-old Aidan
simply coming up with the ideas ourselves.
Dwyer, who won a national science competition for
It was hard to keep the young kids on task. One
or two of the youngsters had a tendency to come
up with ideas that were so far in left field, they
could never be achieved. Our one fifth grader was
quick to shoot down any idea that anyone else
Promoting innovation within a group
has a lot to do with choosing the right
combination of people, but it also has
to do with company culture.
had, arguing that it wouldn’t work or that wasn’t
how it had been done in the past. Neither sce-
his research showing that solar panels arranged
nario got us headed in the right direction.
like leaves on a tree collect sunlight 20-50% more ef-
I chalked it up to the hazards of working with
such a young group of kids, but the innovation
process isn’t so different for machine builders in the
ficiently than traditional solar arrays. Dwyer spoke
at PopTech’s recent gathering of innovators.
What struck me most about Dwyer was his de-
real world, according to Hendrik Stoltz, director of
termination to continue to innovate and improve
Elopak Equipment Supply (www.elopak.com) in New
on his design despite those who seemed to want
Hudson, Mich. Elopak makes equipment to package
to squash his spirit. “The lesson that I learned is
yogurt and other liquid foods, so I got in touch with
that sometimes the Internet is not a substitute for
Stoltz to run our innovation project by him (which
peer review,” Dwyer quipped at PopTech.
used temperature-sensitive ink to show whether
Dwyer is continuing his research. “I’ve been
packaged yogurt had been compromised by rising
asked to work at the Resilience Research Center in
above refrigeration temperatures while in transit).
Madison, Wis., to design Fibonacci arrays that mid-
Not only did Stoltz say his company had consid-
dle school students can use for research,” he said.
ered a similar solution themselves for measuring
“I’m also collaborating with a professor of design at
whether the “cold chain” had been broken, but
Purdue University to create a Fibonacci array that
he said that any innovation team typically faces
combines technology with functional art.”
similar problems, depending on the personalities
What’s the best way to teach people how to keep
involved. Not everybody is a good fit for an innova-
moving ahead with their ideas—or when it’s time
tion group. “Sometimes you have people who say,
to give up and move on to the next idea?
controldesign.com
February 2012 Control Design
13
ahand@putman.net
but Stoltz says it also has to do with company
Steve Jobs died in October. In his State of the Union
t
to be no end to the discussion when Apple founder
managing editor
neering leaders—promote and foster innovation?
t
somebody might come up with 10 different solu-
graders preparing for FIRST Lego League (FLL)
Aaron Hand
‘It won’t work. It won’t work.’ But on the other side,
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Candymaker Combines, Simplifies Controls
OEM SPOTLIGHT
Cama Handles Chocolates With an Integrated Approach That Needs
Only One Controller for Three Delta Robots
CHOCOLATES MIGHT NOT
seem especially delicate, but
that’s only because human
hands are still unappreciated
miracles of material handling.
However, even with a sophisticated packaging machine,
such confections are marked up
CAMA GROUP
or deformed easily. To ensure
gentle handling, machine builders often use delta-type robots
because they can pick up products precisely without interrupting production.
One of these is Cama Group
(www.camagroup.com) in
OF ONE MIND
Cama’s compact loading unit combines three delta robots under one
controller, enabling high-speed chocolate sorting.
Lecco, Italy, near Lake Como,
which has been manufacturing
sign team has 30 engineers who
unit with three integrated delta
individual machines and com-
collaborate with customers to
robots allows us to achieve the
plete robotic production lines
design the most appropriate
speed our customer needed,”
for the secondary packaging
and cost-effective machine or
says Daniele Bellante, Cama’s
industry for 30 years. Its robotic
line that will produce the best
CEO. “And we saved consider-
packaging lines are used for
quality, most attractive pack-
able space when compared to
handling primary packaging,
age for their product with the
a solution consisting of delta
such as pouches, cups, cans
least wasted material.
robots connected in series,
and other containers in applica-
To meet requests for simpler
each with its own control
tions from picking through to
and better coordinated robots
cabinet.” Besides using fewer
palletizing foods, cosmetics
and controls, Cama’s packaging
robot controllers, Bellante
and other consumer products.
and robotics divisions recently
adds, Cama also implemented
collaborated to build a loading
modular, dual-axis drives from
veteran Paolo Bellante in
machine that can employ up to
Bosch, which reduced cabling
1981, Cama is now run by his
four of its delta-type Triaflex
up to 40%, cut the machine’s
children, Daniele and Annalisa,
robots. Instead of using one
footprint in half, and shrank
who joined the family business
controller per robot, Cama was
the control cabinet by 40%.
in 1994. They continued their
able to integrate them all and
father’s mission after he died of
perform load balancing with
can control up to 16 kinemat-
cancer in 2004, but they’ve also
just one of Bosch Rexroth’s
ics simultaneously, each with a
remodeled the firm to meet
combined motion logic and
maximum of eight interpolating
customers’ needs in the future.
robotic control units. Because
axes and up to four synchronous
one Triaflex robot can run at
belts, Cama’s loader doesn’t re-
build about 150 machines and
120 cycles per minute and a
quire the usual communication
40 integrated packaging lines
“multi-picks” gripper system
interfaces between individual
per year for candy and bak-
allows simultaneous picking of
robot controls that traditionally
ing companies worldwide, but
several products, Cama’s load-
are needed to ensure transmis-
mostly in the U.K. and France.
ing machine can handle up to
sion of camera system informa-
Because every application is
300 products per minute.
tion and to coordinate robot
Founded by cartoning
The company’s 130 staffers
different, Cama reports, its decontroldesign.com
“Our new compact loading
Because its single controller
units to prevent collisions.
February 2012 Control Design
15
INDISCRETE
Manufacturing Technology Orders Up 74%
THOUGH ORDERS FELL
machine orders, which totaled
in metal cutting equipment
almost 28% from 2011’s high in
about $372 million, have fallen
was countered by acceleration
September, U.S. manufacturing
more than 13% since October,
in the fabricating sector, and
technology orders in Novem-
and more than 31% since Sep-
contributed to an increase over
ber reached more than $430
tember. Orders for metal forming
2010 of nearly 75%. Backlogs for
million, which was up almost
and fabricating machines actu-
2012 are very healthy at this
27% compared with November
ally rose in November, however,
point and growing longer.”
2010, according to the Ameri-
to almost $58 million. That’s up
can Machine Tool Distributors’
72% from October. That sector
USMTO showed that all U.S. re-
Assn. (AMTDA) and the Assn.
hit its high in July with nearly
gions fell in November orders,
for Manufacturing Technology
$105 million in orders.
with the Western region hit the
Reporting regionally, the
hardest with a 14.6% drop from
(AMT). Year-to-date orders total
“Manufacturing technol-
close to $5 billion, up about 74%
ogy orders slowed slightly in
October. But the region is up
over the same period in 2010.
November, but maintained
34.3% from November 2010. The
The numbers are based on
their sprint toward the 2011
Northeast region fell the least
data reported by companies
finish line thanks to the bonus
in November, down just 1.8%
participating in the U.S. Manu-
depreciation tax incentive,”
from October, but also down by
facturing Technology Orders
said Peter Borden, AMTDA’s
nearly the same amount from
(USMTO) program. Metal cutting
president. “The order slowdown
November a year ago.
U.S. Manufacturing Technology Orders
$M
$700
$600
$500
$400
$300
$200
$100
$0
Nov-10
Dec-10
Jan-11
Feb-11
Mar-11
Apr-11
Metal Cutting Machines
May-11
Jun-11
Jul-11
Aug-11
Sep-11
Oct-11
Nov-11
Metal Forming & Fabricating Machines
YEAR-OVER-YEAR RISE
Orders for metal forming and fabricating machines hit their high in July, but metal cutting machines, making up the
bulk of manufacturing technology orders, reached their peak in September.
PLCs Make Speedy Recovery
GLOBAL REVENUES from PLCs were nearly 30%
levels to occur until 2013. PLC business was back on
higher in 2010 than they were in 2009, reaching
track three years earlier than expected, however; in
more than $8 billion, according to a 2011 edition
some countries in developing regions, such as China
of IMS Research’s PLC report. This indicates a re-
and India, revenues grew even in 2009.
covery from the downturn that came much earlier
“Although the recovery was unexpected, it
than had been generally expected. Growth contin-
is not hard to explain,” said Alex Hong, market
ued in 2011, though at a lower rate than in 2010.
research analyst in IMS Research’s industrial fac-
After the economic crisis of 2009, most PLC suppli-
tory automation group. “The demand for automa-
ers had been pessimistic about the returning growth
tion products in many ongoing projects stagnated
of their business, not expecting recoveries to 2008
16
Control Design February 2012
continued on page 20
controldesign.com
©2012 Siemens Industry, Inc.
SIMATIC HMI Comfort Panels
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crisp images and graphics and also provide up to 40% more
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information and controls on each screen.
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There is an ideal solution available for any applications thanks to
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FLASHBACK 1997-2012
Feb. 9, 1997: “The Simpsons” became the
longest-running prime-time animated series.
“The Flintstones” held the record previously.
Feb. 13, 1997: Astronauts on the space shuttle Discovery brought
the Hubble Space Telescope aboard for a tuneup, enabling the
telescope to see further into the universe.
Feb. 22, 1997: Scottish scientist Ian Wilmut and colleagues
announced that an adult sheep had been successfully cloned.
Dolly, who had been born July 5, 1996, was the first mammal to
have been successfully cloned from an adult cell.
Feb. 10, 1998: A man became the first to be convicted
of committing a hate crime in cyberspace. The college
dropout had emailed threats to Asian students.
Feb. 27, 1999: Colin Prescot and Andy Elson set a new hot air
balloon endurance record when they had been aloft for 233 hours
and 55 minutes in an attempt to circumnavigate the Earth.
Feb. 7, 2000: California’s legislature declared that
Feb. 13 would be Charles M. Schulz Day. Schulz died
Feb. 12, 2000, and his last original Sunday “Peanuts”
comic strip appeared in newspapers the next day.
Feb. 11, 2000: The space shuttle Endeavor took off to gather
information for the most detailed map of Earth ever made.
Feb. 12, 2001: The space probe NEAR landed on the asteroid Eros,
marking the first time any craft had landed on a small space rock.
Feb. 15, 2002: Honda’s Asimo humanoid robot rang the opening
bell at the New York Stock Exchange.
Feb. 19, 2002: NASA’s Mars Odyssey spacecraft began using its
thermal emission imaging system to map Mars.
Feb. 1, 2003: NASA’s space shuttle Columbia
exploded while re-entering the Earth’s atmosphere.
All seven astronauts on board were killed.
Feb. 10, 2005: North Korea publicly announced for the first time
that it had nuclear arms. The country also rejected attempts to
restart disarmament talks in the near future, saying that it needed
the weapons as protection against an increasingly hostile U.S.
Feb. 14, 2005: YouTube was born when three former PayPal
employees started a website that let people upload and share
videos.
Feb. 16, 2005: The Kyoto global warming pact went into effect in
140 nations.
Feb. 10, 2009: Russian and American
satellites collided over Siberia.
18
Control Design February 2012
controldesign.com
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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.
when investment funding dried
The customers for PLC manu-
restart of projects discontinued
up in the economic downturn.
facturers, mostly builders or
in 2009 and the start of new ones
However, government econom-
users of industrial machinery,
contributed to the high growth
ic stimulus in several countries
had more access to funding to
of the PLC market in 2010.
helped to make money more
purchase more PLCs and other
available at different levels of
automation products to continue
mained high in 2011, though
industry.”
with their projects. Both the
industrial markets differed by
Global PLC revenues re-
region. In Europe, despite the
continuing and worsening Eurozone sovereign debt crisis, Germany (the most important market for industrial automation
products) continued to grow at
a healthy rate. In the Americas,
large projects from some end
users and growing domestic
demand enabled the PLC market
to grow, though the market in
Latin America is still underdeveloped. In Asia, the markets in
the growing economies of China
and India have performed quite
well, though that of Japan was
affected by the earthquake ear-
Together, we can eliminate downtime,
reduce development time and get you
to your tee time.
lier in the year. In general, the
growth of the global economy
in 2011 underpinned the global
growth of the PC market.
PLC suppliers and their
industrial customers are uncertain whether growth will
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continue into 2012. Many factors—including Europe’s unresolved sovereign debt crisis,
tightening economic policy in
China, and the consequences
of the earthquake in Japan and
the recent floods in Thailand—
are affecting the market.
IMS Research contends that
the PLC market will continue to
grow in 2012, mainly because
many large and important PLC
markets, such as Germany,
France, China and the U.S., are
still performing well. In addition, emerging markets, such as
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Brazil and India, which already
account for half the entire PLC
market, will be the main driving
force for future growth.
controldesign.com
MERGERS, ACQUISITIONS
& ALLIANCES
ABB (www.abb.com) will acquire Thomas &
Betts (www.tnb.com) for about $3.9 billion. The
complementary combination of Thomas & Betts’
electrical components and ABB’s low-voltage
protection, control and measurement products will
create a broader low-voltage portfolio.
Mersen (www.mersen.com) acquired Eldre (www.
busbar.com), adding laminated busbars to Mersen’s
existing range of fuses and cooling products for power
electronics applications.
Linear Technology (www.linear.com) acquired Dust
Networks (www.dustnetworks.com), which provides
low-power wireless sensor network technology.
ATEX II3G
IECEx
Cost optimized
DIN-rail
power supplies
in compact rugged metal case
for harsh industrial environment.
International safety approval package
NOTEWORTHY
The umbrella trade association for the Robotic
Industries Assn. (RIA, www.robotics.org), AIA
(formerly Automated Imaging Assn., www.
visiononline.org), and the Motion Control Assn. (MCA,
www.motioncontrolonline.org) changed its name from
the Automation Technologies Council to the Assn. for
Advancing Automation (A3).
WinSystems (www.winsystems.com), which designs
and manufactures industry-standard PC/104, EPIC, EBX,
SUMIT-ISM and STD Bus computer boards, I/O modules,
and enclosures for use by OEMs and system integrators,
celebrates its 30th anniversary this year. In 2007,
WinSystems became an employee-owned company.
TSP-3P Series
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solenoids and other short peak loads
• Power-back immunity
PLCopen Extends
Motion Control Spec
and over-temperature protection
THE SUITE OF PLCopen Motion Control Specifications
has been extended with the release of Part 5 and Part
6. The organization released version 2.0 of the basic
specification, and also extended the suite of functionalities to new areas such as homing procedures and
fluid power. The new specifications can be downloaded at www.plcopen.org.
Part 5 enables users to create their dedicated homing procedures by combining harmonized functionalities. The release of Part 6 adds fluid power as an
application, making the PLCopen Motion Control easy
TSPC Series
80 – 480 Watt
for single phase power systems
• Vibration and shock proof
• Optional decoupling module
• Overload and over-temperature protection
to use in hydraulics. It also enables the merge in the
software environments of electrical and hydraulic
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systems, providing a harmonized look and feel.
controldesign.com
ALLIED ELECTRONICS 800-433-5700 www.alliedelec.com
POWERGATE LLC 866-588-1750 www.powergatellc.com
Power Sources Unlimited 800-966-7784 www.psui.com/traco
Tough Application
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Mastering challenges together — Rexroth makes it easy to implement automation.
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Regardless of the drive technology used, we thought ahead and integrated intelligence
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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
Software Guy, Know Thy Limits
I configured the array from scratch, and put in a
second drive, and it needed verifying. Three hours
better monitor that system. Now, here’s a story
later, it was done and I rebooted. “Recovering er-
about education, tools and resources regarding
rors,” it said. Cool, until it finished and the “boot
servers and server-based functions.
sector error” message popped up. More reading.
A server-based operating system is not a
Again, starting from scratch with both drives
workstation OS like Windows XP or Windows 7.
and using the IBM ServerGuide install disk, I
Windows 2000 server and desktop systems used
created the array with Windows 2000 server.
the same files and structure. A simple registry
I discovered that IBM also has a tool called
switch can change them back and forth. Windows
ServeRAID. Where have you been all my server
2003/2008 are entirely server-based and provide
life? Now things were coming into focus. With
server functionality such as Active Directory, user
this interface you readily can see what the drives
management, and file and web services, along
were and what they were doing, and when you
with functions such as RAID.
put in a second drive to fix a broken one, and it is
Now, I’m a software guy. My customer needed
RAID drive controllers for redundant data. No
not configured, it tells you.
So I installed it on XP. Oops, again. It’s only for
server platforms. I found some drivers for XP, but I
CD that makes this a breeze, and Windows 2000
couldn’t get it to work. After three and a half weeks,
server was put on the machine.
I had put way too much into this, but I learned a lot.
It was decided later to use Windows XP for
Sometimes we know enough to be dangerous. The backup server was running different
based OS, and certain drivers are designed for
software for a SQL database application, which I
server use and some are not.
needed to virtualize. I ripped out one of the drives
jpollard@tsuonline.com
Some RAID drivers are not. The customer
wanted redundant server hardware so that in
case of a failure, the RAID drives could be moved
from one server to another. It’s not as easy as you
might think.
The first thing I learned was that setting up
The first thing I learned was
that setting up RAID in the SCSI
BIOS is not the same as using a
software-based interface.
RAID in the SCSI BIOS is not the same as using
to take home and extract the image. I put in the
a software-based interface. Drive initialization,
spare drive. Wasn’t configured! The drive lights
array configuration and verification can be done.
were flashing in a very strange way. I took out the
Allocating a drive as a hot spare? I have to tell the
recently inserted drive and replaced it with the
system I have put a drive in? And that it was a
original. So I took the whole server home from
spare? Tried that, and it blew up the original array
my customer’s site to get the image. I screwed up
and the data. Oops.
both drives, since neither would boot. After more
More reading. When a drive is configured as
reading, I found Bart’s PE bootable recovery CD.
a simple volume disk (like a workstation disk),
The registry was messed up on both drives, and I
there is no RAID information written on the disk.
had to fix it. That was three days all on its own.
Oh, there’s information written to the disk? Ap-
There is a fine line between tenacity and
parently, and it is serialized to the machine and
stupidity. I crossed that line many times, but
drive controller so you can’t simply transfer one
learned. It remains to be seen if it was worth it.
drive to another machine.
So I talked to a few IT guys, and searched on rep-
Moral of the story: Stick to your knitting. Laugh
about it when you don’t.
licating server hardware. No one had done it, and
the forums weren’t much help. Trial and error time.
I was to have the backup server in place two
JEREMY POLLARD has been writing about technology and
software issues for many years. Publisher of The Software
days after I took the hardware. Although I wasn’t
User Online, he has been involved in control system
working at it constantly, I was at two weeks now.
programming and training for more than 25 years.
controldesign.com
February 2012 Control Design
t
some terminal services. But XP is not a server-
Jeremy Pollard, CET
problem. IBM server hardware comes with a setup
EMBEDDED INTELLIGENCE
LAST MONTH I WROTE about fixing a network
nightmare. Additional tools now are in place to
23
by Jim
agu e
M o nt
, e xe c
utive
editor
Modular Machines and Production Lines Enable Quick Disconnects and
Speedy Changeovers. This Flexible Approach Inspires Builders to Combine
Modular Equipment in Ever More Innovative Ways
D
sensitive to impurities or oxidization,” says Mike Rice,
be busted up into approachable, workable pieces.
dation Engineering division. “As a result, we now have
Dividing machines, production lines, related equip-
more sequence chambers that must be under vacuum.
ment and accessories into standardized sections and
Users also are applying eight or 10 layers on some
blocks not only simplifies overall system construc-
microprocessors, where they once applied just two or
tion, it more importantly improves their operation by
three, so they need even faster and more precise tools
allowing much quicker changeovers and maintenance
that can complete 20–40 recipes for particular steps.”
ivide and conquer. It’s true in war, and it’s
“Films are getting thinner, and so they’re even more
also good advice for machine building. Any
seemingly insurmountable project often can
vice president and general manager of Applied’s Foun-
for increased throughput.
Three to nine reactors usually are arranged around
Applied’s Endura mainframe, and they carry out many
Extreme Thin Film
of the intra-tool, sequential processing steps required
For instance, 20 nm geometries and fi lm
to manufacture semiconductor chips, especially those
depositions that are just two to four
recent years, these mainframe and reactor modules
tor manufacturers to combine more
have been designed to conform to increasingly strict
process steps in a vacuum environment. Consequently, Applied Materials (www.appliedmaterials.com) in
Santa Clara, Calif., is hooking up
and pumping the air out of more
of its wafer-handling mainframe
chambers, robotic interfaces
and 40 different reactor units.
24
that can’t be exposed to atmosphere (Figure 1). In
atomic layers thick push semiconduc-
Control Design February 2012
mechanical, electrical and software standards, so any
chamber can be located next to any other. This uniformity is crucial because Applied Materials typically
ships wafer-handling machines just a month after
they’re ordered, and then assembles and has them
running a month after delivery.
Many aspects of modular machine building are
enabled by fieldbuses and Ethernet flavors of networkcontroldesign.com
ing that simplify cabling by replacing former
tions,” says John Dillon, division president of
point-to-point wiring, and by servo motors,
control solutions at Wynright (www.wynright.
amplifiers, drives and controls that remove
com) in Elk Grove Village, Ill., which operates
much of the traditional need for dedicated and
its Automotion (www.automotionconveyors.com)
less flexible cams, chains and belts. However, just as
division in Oak Lawn, Ill. “To gain more flexibility,
it’s crucial to evaluate the need for automation itself,
we developed our AutoRoll+ conveyor that uses
it’s equally important to determine if modularization
motor-driven rollers (MDRs). This technology embeds
will deliver enough return on investment (ROI) for
the conveyor motor in the rollers, so we can localize
individual machines or processes.
both the controller card and power into 5 ft zones
“To us, modularity means starting with a base
in the conveyor. This gives our end users modular
packaging machine and our common bill of materials
conveyor beds that we can program, plug and
(BoM) with standard modules that define standard
play like Legos, and daisy chain in straight and
equipment and parts, and then bringing other BoMs
curved sections. This also creates a highly sus-
into the machine for voltage components, PLC types
tainable solution because they run at 24 V, have
and different stations and options, such as cappers
fewer moving parts, and are inherently safe.”
and film functions,” says Scott Bivens, electrical
Wynright’s AutoRoll+ has two driven roll-
engineering manager at Oystar North America (www.
ers in a 5 ft zone, which are controlled by an
oystar-group.com) in Covington, Ky., and Daven-
enhanced route switch controller (ERSC) card.
port, Iowa. “It’s a lot like building a pizza. With our
This card houses the fi rmware for each section’s
modularity, all our designs, BoMs and programs are
local control and motor commutation to manage
tested and saved until they’re needed. Then, when
incoming power and keep the rollers running at
a particular project order comes along, we can run
consistent speeds.
through a check sheet, and get most of the engineer-
Similarly, detection, measurement and testing
ing in place within eight to 10 hours. Traditional, non-
systems have long been modular because they’re
modular building means just redoing or copy building
usually wheeled up and plugged into machines or
a machine that’s been done before, and then adding or
built into production lines that make everything
subtracting required functions. However, because it’s
from automotive blocks to medical devices. However,
not standardized, copy building can take 24–160 hours
many of these testing devices also are improving
to do the engineering, depending on the project.”
their modularity and speed by establishing simpler
connections and automatic program loading. Uson
Basic Blocks
(www.uson.com) in Houston builds leak-detection
While modular methods help builders design and
and measurement instruments and turnkey leak-
construct their machines, they’re even more beneficial
testing systems, mainly for manufacturers of medi-
to users. For instance, many production lines and mate-
cal devices and automotive parts, which must be
rial-handling systems typically used conveyors in 200 ft
tested individually. These users require more
sections, each with a continuous belt or chain running
capable testers and systems, especially
throughout, and each driven by a 480 V or similar motor.
for detecting pressure decay
“Over the years, we
grew up with old
conveyors that were
oily, dirty and difficult to reuse because
they were customized
for specific applica-
controldesign.com
in their production systems and
fi nished parts.
“In the past 10–12 years, we’ve
been giving our instruments
more flexible tools for testing
a wider variety of shapes, and
adding quick-change-out tooling, so they can be moved faster
between production lines,” says
Joe Pustka, Uson’s technical
support manager. “Previously,
operators had to connect and
disconnect 10–20 color-coded
lines, but now they’re all on one
leak-tight connector manifold,
APPLIED MATERIALS
which saves a lot of time and
increases throughput. This improved modularity helps customers justify buying detectors and
testing systems. When a system
is modular, it’s easier for them to
sell to their management.”
Servos Move Modules
Though many technologies enable
A CHANGE IN ATMOSPHERE
Figure 1: Applied Materials’ Endura semiconductor manufacturing system includes
a central mainframe chamber surrounded by three to nine reactors. More of these
modules must run in a vacuum to prevent impurities from damaging the ever-thinner
film depositions on wafers.
modular machine building and
operations, none are more helpful
double-gripper system, and the
combined motors and drives make
than servo motor and drive sys-
machine is configurable with sev-
it easy to configure our pouch
tems. As servos have grown more
eral tandem filling stations. Each
machine in different ways.”
sophisticated and able to handle
machine uses eight to 16 motion
more varied tasks, they allow
axes to form seals, index pouch
A Soft Modularity
machine builders to deliver more-
material, cut and open pouches,
To handle its own widely varied
capable machines.
grip and pucker them, apply a top
tasks, Jakob Graphic Services
seal, and pick and place them on a
(www.jakob-gmbh.eu) in Pfung-
popular standup pouch contain-
conveyor. As a result, Innopouch
stadt, Germany, developed its
ers, KHS Flexible Packaging (www.
uses a servo and pneumatics-
RC-500J jumbo-roll collator, which
khs.com) in Sarasota, Fla., recently
based system to improve flexibility
uses servo motors and an auto-
developed its Innopouch K-Series
for timing, make changes on the
mation software suite to collate,
form, fill and seal (FFS) machine,
fly, link functions, and speed up
glue, label, fold and cut insurance
which is servo-driven, has electri-
setup and changeover. Previously,
forms, mailers with cut inserts,
cally integrated pneumatics, and
it might take two to four hours to
brochures with or without a fin-
can handle standup and fin-seal
change pouch sizes, but its new
ish, calendars and similar printed
pouches. Because pouches come
servo and pneumatic system takes
products. Its servos and software
in so many sizes and types, KHS
only a few seconds.
allow functions to be easily di-
To help its customers shift to
says, Innopouch’s four models had
“A servo platform, which is
vided up and assigned, such as al-
to be flexible and modular, have
modular in itself, allows us to put
lowing servo-based cutter format
fast setup and changeover times,
that modularity throughout the
adjustments, and even complete
and be easy to expand.
machine,” explains Randy Uebler,
retooling changeovers in just a few
general manager at KHS. “The
seconds. Unlike traditionally rigid
Pouches are handled by a linear,
26
Control Design February 2012
controldesign.com
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monitors their more and more complex movements.
machines, RC-500J’s use of servo motors means users
“Machines and production lines have been mechan-
are no longer tied down to changing cylinders and
gearwheels to handle different paper formats because
ically modular for many years, but the cabling and
the drive control of the cross cutting or perforating
electronics that ran through them wasn’t modular,”
cylinder now occurs without a shaft.
says Darren Elliott, global technical resource manager
for Rockwell Automation’s (www.rockwellautomation.
Company engineers report that the collator’s primary
design challenge was to ensure that, whatever the
com) OEM Group. “However, as machine builders kept
printing format, its cylinder would allow for variable
driving down costs, they eliminated a lot of point-to-
cut-off formats and easy adjustment of the printed, con-
point wiring by moving to Ethernet, made electronics
tinuous paper webs. For example, the automation suite
and controls more modular, and have used ISA’s S88
supplied by Kollmorgen ensures that a 378 mm calendar
and OMAC’s PackML standards to create control soft-
block is increased by 50 mm during continuous printing,
ware in more modular sections and standalone code
so a common inch format is applied in the process.
for those functions. As all these machines become
“Time-consuming, manual retooling or setup
more modular and data-centric, they’re able to run
measures are a thing of the past thanks to our elec-
more SKUs with minimum energy and scrap. But us-
tronic servo technology,” says Hans-Peter Jakob, sales
ers can’t balance all those KPIs on a clipboard, and so
manager and general manager at Jakob. “Setbacks
software is really modularity’s final frontier.”
Wynright’s Dillon adds, “We began to apply MDR
caused by errors are excluded, and commissioning
technology about 10 years ago, but in just the past
has become a formal procedure.”
couple of years it’s become a mainstream product for
Always Ethernet
us. ControlLogix allows the ERSC cards in each bed to
Two other crucial enablers of modular machine build-
talk to hundreds of others via Ethernet. Previously, all
ing are fieldbus and Ethernet networking, as well as
of the local conveyor control and sensor data had to be
the programming software that determines, runs and
wired back to a PLC. However, we began using Ethernet
REASONS TO BE MODULAR—OR NOT
8IJMFUIFSFBSFNBOZCFOFmUTUPNPEVMBSNBDIJOFCVJMEJOHBOEJUTFGGFDUPOPQFSBUJPOTUIFSFBSFTPNFPCTUBDMFTBOE
QPTTJCMFESBXCBDLTUPP"TBSFTVMUJUTWJUBMUPDPOTJEFSUIFQSPTBOEDPOTBTUIFZSFMBUFUPZPVSNBDIJOFBOEJUTVTFSTBOE
UIFOBOTXFSTPNFJNQPSUBOURVFTUJPOTCFGPSFEFDJEJOHUPVOEFSUBLFBNPEVMBSNBDIJOFSFEFTJHOPSJOTUBMMBUJPO
Pros:
t4JNQMJmFTQIZTJDBMEFTJHOBOEDPOTUSVDUJPO
t3FEVDFTXJSJOH
t*NQSPWFTDPOmHVSBUJPOnFYJCJMJUZ
t4QFFETVQDIBOHFPWFST
Cons:
t*ODSFBTFTEFTJHODPNQMFYJUZPGDPOUSPMTBOETPGUXBSF
t"EETIJHIFSJOJUJBMDPTUT
t3FRVJSFTNPSFUSBJOJOHGPSPQFSBUPSTBOEUFDIOJDJBOT
Crucial questions:
t)PXNBOZEJGGFSFOUQSPEVDUTJ[FTBOEQSPEVDUUZQFTXJMM
UIFFOEVTFSSVOBOEIPXGBTUEPFTUIJTOFFEUPIBQQFO
t)PXPGUFOBSFDIBOHFPWFSTQFSGPSNFEBOEIPXDPNQMFY
BSFUIFZUPEP )PXNVDIUJNFDBOCFTBWFEXJUINPEVMBS
FRVJQNFOURVJDLEJTDPOOFDUTBOEQSFQSPHSBNNFE
SFDPOmHVSBUJPOT
28
Control Design February 2012
t)PXNBOZNFDIBOJDBMMJOLBHFTBOEIPXNVDIEFEJDBUFE
DBCMJOHEPFTUIFGPSNFSNBDIJOFQPTTFTT $BOJUCF
TVDDFTTGVMMZBOETBGFMZSFQMBDFEXJUITFSWPNPUPSTBOE
QSPHSBNNBCMFESJWFT
t8IBULJOETPGQPXFSDPOOFDUJPOTQOFVNBUJDMJOFT
DPNNVOJDBUJPOTXJUDIFTBOEPUIFSOFUXPSLJOHBOE
EJTUSJCVUJPODPNQPOFOUTBSFJOUIFFYJTUJOHNBDIJOF $BO
UIFZCFTJNQMJmFEXJUImFMECVTFTBOE&UIFSOFUUPNBLF
RVJDLEJTDPOOFDUVOJUTXPSLBCMF
t*GTQBDFJTBUBQSFNJVNJOUIFVTFSTGBDJMJUZXPVMEJUCF
QPTTJCMFUPSVOUXPPSNPSFQSPEVDUTPOPOFNBDIJOF
JOTUFBEPGUSZJOHUPBEEBTFDPOENBDIJOF
t%PFTUIFBQQMJDBUJPOIBWFFOPVHIQPUFOUJBMWPMVNF
BOEUISPVHIQVUUPCFHBJOFEUPNBLFNPEVMBSJ[BUJPOB
XPSUIXIJMFJOWFTUNFOU
t)PXNVDIUSBJOJOHBSFUIFVTFSTPQFSBUPSTBOE
UFDIOJDJBOTHPJOHUPOFFEUPSVOBOENBJOUBJOUIFJSOFX
NPEVMBSFRVJQNFOUBOETPGUXBSF
controldesign.com
Cube67+
to complement this approach about
can be switched out easily on a ma-
a year ago, and recently went exclu-
chine or production line, but many
sively Ethernet in conjunction with
machine builders don’t stop there,
AutoRoll+, which also reduced
and keep seeking more time-saving
field wiring costs by about 30%.
innovations. This quest even leads
Because we have
some to investigate
more local control
reintegrating some
through the ERSC
modular functions
cards in each zone,
back into their
programming time
machines.
Though it
firmware handles
doesn’t deviate
basic functions
from the basic
such as monitor-
types of machines
does build some plug-and-play
This also creates new possibilities
stations that can be replaced
for real-time diagnostics, such as
quickly with other units on some
the health of the drive rollers.”
of its machines and production
To help builders organize their
lines. Its FP Series 2x6 cup-filling
modular designs, B&R Automation
machine (Figure 2) works with cup
(www.br-automation.com) reports,
de-nesting and drop stations that
its Automation Studio software
have quick-disconnect power and
uses a master project to which
pneumatic lines, so they can usu-
different hardware configura-
ally handle a couple of different
tions and options can be added.
cup diameters.
Likewise, the software’s modular
“A lot of customers want faster
applications section allows several
and even tool-less changeover,”
engineers to develop control code
Bivens says. “These stations peel
at the same time in different sec-
off the bottom cup and drop it into
tions, and link them together with
the machine, but our machines use
predefined interfaces.
chain-driven platens to hold the
B&R has been working with EMT
cups, so different diameters and
Int’l (www.emtinternational.com)
cup materials mean a different in-
in Hobart, Wis., on its year-old
dex pattern and moving the chain
Chameleon modular finishing
to meet the new profile. Nowadays,
machine. It has at least 10 modules
we can authorize index changes
that can be combined in any way
on our HMI. In general, we’re doing
to perforate, cut, web tension,
more electronic changeover with
punch holes, stack and finish
servos when we can, but there are
documents after digital printing.
always a few mechanical changes
All of the modules can be brought
that still need to be made.”
together in Automation Studio,
ÁlKyOBzOMKBJiOiOl_}`zTny
alz}BiiB}anlz½~v}nä…åâkO}Oyz
Ál}O_yB}OM}`OylO}z„a}K`Tny
daisy chain installations
it builds, Oystar
communications and flow control.
ÁlalKyOBzOMl~kJOynTknM~iOz
- up to 32 on one node
Á"nM~iOzKBlJOalz}BiiOMB}Bl†
position on the communication
cable
is reduced as the
ing sensors, motor
The plus stands for increased
]O…aJaia}†alMOKOl}yBia‰OM
installation technology with
even more modules, longer
cables and higher performance
with...
Though the cup-drop station
and use a PLC to run the motors,
is plug-and-play, Bivens explains
I/O components and other devices.
that the rectangular metal platens
Divide, Then Recombine
ly have one or two rows of 12 holes
It’s both useful and productive to
cut in them to hold the cups before
have standardized equipment that
filling, and so these still must be
in the main filling machine usual-
controldesign.com
February 2012 Control Design
29
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MEASUREMENT
COMPUTING
switched out manually to change
of Novatec’s Resin
cup sizes. However, because many
Systems Controls
users typically run only two sizes
Group. “We used to
of cups, Oystar can mechanically
have just modular
alternate between two platens on
hardware and com-
LOW - COST
DAQ
the same chain in one FP Series
mon equipment,
machine. “This is done by install-
but now we have
ing the two different platens in
modular controls
sequence on the machine, and
and software, and
then phase-shifting the servos, so
so we can organize
Engineered with
Innovation.
each cup size can leapfrog through
and assemble them
the line with its proper platen,” he
to meet any need.”
says. “This option makes FP Series
He estimates that
longer, but both cup sizes can run
Novatec’s modular
on one line instead of perhaps
method saves it
requiring two machines, and its
about 30–40% on labor, while de-
automatic changeover is faster
livering a typical vacuum convey-
than doing it manually.”
ing system takes about one-third
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Likewise, Baltimore-based No-
or four weeks now from 10–12
added PLCs from Siemens Industry
weeks before.
(www.usa.siemens.com/industry) to its FlexTouch (FTS) central
Design, Build, Live Modular
control system, and added Profinet
Once modular methods are ad-
I/O controllers to it FlexXpand (FXS)
opted, veteran practitioners report,
expandable control system. These
it becomes a philosophy that goes
controls run Novatec’s vacuum-
beyond their equipment to altering
based receiving, conveying, load-
the design process and how they
ing, support and other systems for
do business. For example, modu-
plastics processing. Both control
lar machine and production line
systems use a
building is nothing
Profinet backbone
new for Oystar
to network with
and its custom-
the vacuum lines
ers. They’ve used
and their plants.
modular concepts
“Previously, we
and practices for
did a lot of build-
almost 15 years.
to-order and
Contact us
1.800.234.4232
©2012 Measurement Computing Corporation
10 Commerce Way, Norton, MA 02766
info@mccdaq.com
To teach its
custom building
staff to adopt
because each
and practice a
customer’s plant
modular mindset,
is so different, but
Bivens says, Oy-
now our system
mccdaq.com/selguide
as long as before—down to three
vatec (www.novatec.com) recently
star periodically
setup page, Siemens’ TIA Portal
assigns some of its staff to “work
and Smart Services, and some
on the business” by designing and
other tools allow us to shift to pro-
testing standard functional mod-
duction-from-inventory, and build
ules before they’re ordered. This is
using standard components,” says
different from the usual “working
Fred Eichhorn, general manager
in the business” of assembling and
30
Control Design February 2012
controldesign.com
OYSTAR
PEEL, DROP, FILL, REPEAT
Figure 2: Oystar’s FP Series 2x6 cup filling machine has modular options for cup
de-nesting or drop-in before filling and sealing, and can even switch between two
platens to run two different cup sizes in the same machine.
integrating machines and lines
matics—and all of this documenta-
that have already been ordered.
tion eventually grew more modular,
“This shift is difficult for many
too. Oystar’s BoM and schematics
builders because we’re all so
now are coordinated with the Solid-
used to putting out fires,” Bivens
Works software it uses to design its
explains. “Just like a lot of machine
machines and lines.
maintenance is reactive, a lot of
“The way we process modular
machine building is reactive. It
designs also changed,” Bivens adds.
takes a lot of time and forethought
“In the past, the electrical schemat-
to plan and put together standard
ics in AutoCAD used to show all
modules—anything that could be
options, but it was distracting. Now
part of our common parts BoM. Our
we have layered options, and we
team thinks and defines options,
can pick the ones we want. We also
and then creates modules for them.
can reserve sheets in a schematic
We have hundreds of module
for a particular module, develop
groups for voltage, capping, differ-
a final schematic, and take those
ent stations and any other needed
sheets for use in a final design.”
options. Some machines and lines
Bivens adds that one of Oystar’s
are straightforward, but others
modularity projects for 2012 will
have a lot of deviations and are dif-
be a targeted review and upgrade
ficult to modularize.”
of its Chub Maker for packaging
In the late 1990s, Oystar started
bulk sausage and cookie dough.
its common parts materials
This was one of the first ma-
program by developing five or 10
chines it designed and built using
large BoMs that defined some if its
its standardized BoM in the late
major machine functions. These
1990s. “We’ll take its existing mod-
were eventually broken into 50–100
ules and BoMs, remove obsolete
smaller BoMs for more specific
PLCs, HMIs, VFDs and other parts,
tasks, as well as support documents
and replace them with the latest
for electrical and pneumatic sche-
parts in its design,” he says.
controldesign.com
February 2012 Control Design
31
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ME ASUREMENT, SENSING & VISION
Avoid a Pressing Problem
Aluminum Extruder Uses Smart Cameras to Prevent Machine Damage
by Mike Bray, CPU Automation
AS ANY FACTORY-FLOOR engineer can tell you,
perform reliably in harsh environmental conditions
finding solid solutions to the simplest manufacturing
while not breaking the bank.
problems often can yield the greatest benefits.
This was the case recently at Silver City Aluminum
The existing sensing solution had problems. Not
only was the photoelectric sensor solution unable to
(www.scaluminum.com), Taunton, Mass., a third-
perform reliably in this manufacturing environment,
generation, family-owned and -operated manufac-
it wasn’t able to map the entire surface of the bil-
turer of custom aluminum extrusions and finished
let to determine whether a completely clean cut had
parts. Silver City’s 50,000 ft 2 facility houses a range of
been made. After testing other photoelectric sensing
extrusion, fabrication and finishing operations. These
solutions, Johnson decided to bring in his automation
include transforming raw aluminum into thousands
supplier CPU Automation for assistance.
of tooled profiles; performing numerous secondary
CNC milling, punching and various other multi-station
Cameras the Smart Answer
operations; and painting.
Upon reviewing the problem, we determined that a
“Unlike other more-costly and time-consuming
different type of solution was needed, and installed a
metal-forming methods, extrusion can be tooled
dual-camera inspection system using BOA smart cam-
within two to four weeks at costs typically ranging
eras from Teledyne Dalsa (www.teledynedalsa.com).
from $1,000 to $3,000,” explains Larry Johnson, Silver
“Incorporating all of the elements of an industrial
City Aluminum’s maintenance manager. “In addition
machine vision system in a tiny, smart-camera-style
to being cost-effective and time-efficient, the extru-
package, the BOA is an integrated optical inspection
sion process is also pretty straightforward. Large
tool for controlling quality and increasing productiv-
rolls of aluminum—called billets—are fed into the
ity,” says Fernando Serra, Teledyne Dalsa’s Eastern
extrusion machine, pressed into a die using hydraulic
region sales manager. “The BOA is easy to use, and is a
power, and heated. It emerges as a slat, blind or other
cost-effective solution designed specifically for use in
shaped-aluminum product (Figure 1).”
harsh factory floor environments.”
Shaving Can Cause Problems
After the billet has been pressed into the die and
heated for about a minute, a knife drops down,
guillotine-style, and shaves off the excess 3–4 in. of
aluminum. At least, that’s what’s supposed to happen
during normal operations.
“Occasionally, after a billet has been cut, the excess
Not only was the photoelectric sensor
solution unable to perform reliably in
this manufacturing environment, it
wasn’t able to map the entire surface
of the billet to determine whether a
completely clean cut had been made.
fails to fall off,” Johnson says (Figure 2). “When this
hanging piece hits the die, it can destroy it—to the
When a billet leaves the oven, it is automatically
tune of about $10,000 in replacement costs—or cause
loaded onto the extrusion machine. One BOA camera
the machine to shut down, leading to expensive pro-
looks at the billet as it is loaded into the press to
duction losses.”
ensure that it enters the extruder properly. If it is
The challenge for Silver City was to find an
improperly loaded, the camera alerts the PLC to stop
inspection solution that could fit into a space-con-
the press, and an operator manually repositions
strained area, be able to inspect a large area, and
and restarts the machine. The press itself is located
controldesign.com
February 2012 Control Design
33
SILVER CITY ALUMINUM
GOOD PARTS EMERGE
Figure 1: Large rolls of aluminum—called billets—are fed into the extrusion machine, pressed into a die using hydraulic power,
and heated. It emerges as a slat, blind or other shaped-aluminum product.
directly in front of a large window, so infrared lights
properly, the BOA sends a message to a hardwired
are used to help reduce glare and reflections. This
PLC, which stops the machine and activates an alarm
provides the camera a clearer view of the billet, and
to alert workers of the problem. Human intervention
prevents harm to workers’ eyes.
is required only when the vision system detects an
The other camera takes images of the knife when
incorrect cut and triggers the PLC alarm.”
it drops to cut the billet and when it returns to its
original position—a one-minute cycle from start to
Software Tools
finish due to the size of the billet and the nature of the
The system also is connected via Ethernet TCP/IP
extrusion process.
to Johnson’s PC, allowing him to control the camera
from his desk. Since iNspect application software is
“Very little training time was required—
maybe an hour or two—before I felt
completely comfortable running and
editing applications.”
built directly into the camera, Johnson can program
it via an easy-to-use web interface. “I just line it
up where the image looks best, and then I can see
what’s happening on the machine from my office,” he
says. “I make any adjustments that are needed from
my desktop. It’s really easy to use this system. Very
“If the image indicates that the excess alumi-
little training time was required—maybe an hour or
num was sheared off, then the hydraulic press and
two—before I felt completely comfortable running
plunger resume operations automatically,” Johnson
and editing applications.”
says. “If the image shows that the billet was not cut
34
Control Design February 2012
The BOA software contains an extensive library
controldesign.com
ME ASUREMENT, SENSING & VISION
is cut—the BOA alerts the PLC
that there’s a failure.”
SILVER CITY ALUMINUM
Well Worth It
The BOA system has been up and
running for nearly a year and,
during that time, Silver City Aluminum has not lost a dollar due to
a damaged die or machine down-
THE GOOD AND THE BAD OF IT
time. “Before we installed this
Figure 2: After the billet has been pressed into the die and heated for about a
minute, a knife drops down, guillotine-style, and shaves off the excess aluminum
(left). Occasionally, the excess fails to fall off (right) and could damage the die to the
tune of about $10,000 in replacement costs.
vision system, we would be lucky
to get through a month without
a crash and breakdown,” Johnson says. “These cameras have
been 100% reliable. We’ve had no
of tools for solving most vision
“The image gets a score of 100% if
downtime and no production loss,
applications. Silver City uses a
it’s an exact match to the original
which were our two requirements
simple pattern-matching tech-
template. If there are any varia-
for this system.”
nique. “We look at a clean cut
tions from the original template
and teach the system to run that
image—meaning if there is any
MIKE BRAY is an automation engineer
specific pattern,” Johnson says.
aluminum present after the billet
at CPU Automation, Tyngsboro, Mass.
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New Game for Programmable Safety
can achieve higher safety levels. By selecting a
program in a programmable safety controller, a
changes you already should have dealt with that
machine can perform tasks that would be hard
sneak up and surprise you—like a machine safety
or impossible with hardwired components. A
standard that was postponed for two years before
machine and its safety system also can scale up
finally going into full effect.
or down much easier with a programmable safety
That’s right, the EN-954-1 machine safety
controller than with hardwired safety relays.
In addition, we find there can be savings when
62061 standards on Jan. 1. Where the old standard
replacing as few as two safety relay units with a
generally was prescriptive, the new ones report-
programmable safety controller, and it’s simpler
edly require more proof of compliance. So, while
to troubleshoot because it has built-in diagnostics,
use of programmable safety controllers has been
and can detect which device has failed via PLC and
increasing since the revised NFPA 79 standard be-
HMI connectivity. Finally, because the new ver-
gan allowing safety and control communications
sion of ISO 13849-1 focuses on machine reliability
on the same physical network in 2007, it’s pretty
and safety functions, users might be able to use
certain that ISO 13849-1 and IEC 62061 will cause
programmable safety controllers to attain higher
demand for these components to skyrocket.
performance levels by allowing greater diagnos-
“Implementation of programmable safety con-
tic coverage, or creating a different category level
trollers, such as our GuardLogix, has been increas-
based on the input configuration of wiring in par-
ing steadily since it was introduced in 2005, but in-
allel, as compared to wiring in series.”
creasing competence, mainstream awareness and
retirement of traditional expertise is bringing us
to the end of that hockey stick on the graph where
really rapid adoption happens,” says Tim Roback,
marketing manager for safety systems at Rockwell Automation (www.rockwellautomation.com).
“We’ll also see more demand for safety tools and
Aguilar adds that Omron STI is simplifying
the connections between its safety controllers
The new safety standards are stricter,
so more builders are looking at
programmable safety and designing
it into their machines.
services because users are waking up to understand that safety can help improve performance,
and various PLCs via EtherNet/IP, Omron’s FINS
cycle times and configuration. So, in March, we’re
protocol for Ethernet and RS-232. “We’ve also just
going to introduce our PointGuard analog input
released our NJ machine automation controller,” he
safety module for process applications.”
says. “The first version integrates logic, motion and
Robert Muehlfellner, automation technology
director for North America at B&R Automation
(www.br-automation.com), adds, “Changes in the
vision into one platform, and future releases will
integrate safety directly.”
There’s no programmable safety controller that’s
standards already were forcing builders to reassess
as inexpensive as a conventional safety relay, “so
their machine safety, but ISO 13849-1 and IEC 62061
the higher-end products have to come down in
are stricter, and so even more of them are begin-
price,” adds Helge Hornis, manager of the Intel-
ning to design programmable safety into their
ligent Systems Group at Pepperl+Fuchs (www.
machines. Because programmable safety can be
pepperl-fuchs.us). “And we’re seeing safety devices
extended to safe speed and motion control, it can
getting cheaper. In fact, we’re currently introduc-
jog machines within safe axis limits, directions
ing a safety controller that’s competitive as soon
and speeds, and allow operators to safely clear
as a machine requires just two safety relays.
jams in minutes instead of hours.”
Pepperl+Fuchs also will release a safety controller
Sergio Aguilar, product manager at Omron
that starts out as a standalone device for the small-
Scientific Technologies (www.sti.com), adds, “Pro-
est machines, but can expand if added safe inputs
grammable safety controllers are gaining safety
and outputs are needed, become part of a safety
control market share rapidly because they’re more
network, and can ultimately transmit safe informa-
flexible, lower-cost, easier to troubleshoot and
tion between multiple safety networks.”
controldesign.com
February 2012 Control Design
37
Jim Montague texecutive editor t jmontague@putman.net
standard was replaced by the ISO 13849-1 and IEC
TECHFLASH
SOME CHANGES ARE glacially slow. Others happen fast like an earthquake. But it’s usually the
cdroundup@putman.net
PRODUCT ROUNDUP
Mobility, Efficiency Push HMI Growth
New Packaging Requirements Also Will Increase HMI Demand
GROWING INDUSTRIAL DEMAND for energy ef-
PANEL POWER
ficiency and sustainability is pushing up revenues
Power Panel 500 is
for HMI software and services, a market that expe-
equipped with Intel
rienced strong order recovery and growth, accord-
Atom Z510, Z520 and
ing to a new study from the ARC Advisory Group
Z530 processors, and
(www.arcweb.com). Requirements to improve
up to 2 GB of main
manufacturing productivity and safety, as well
memory, and includes
as investments for new and upgraded power and
panels ranging from 5.7 in. VGA to 15 in. XGA dis-
infrastructure projects, also drove growth.
plays with touchscreen and function keys. Gigabit
Demand has increased significantly for the
Ethernet interface is available, and remote I/O and
ability to view and/or control processes via the
drives can be connected using modular fieldbus
Internet or corporate intranets as HMI soft-
interfaces. The devices can be expanded with
ware shifts from standalone computing toward
Powerlink, CANbus, Profibus-DP or others.
client/server architecture, says Craig Resnick,
B&R Industrial Automation; 770/772-0400;
ARC research director and the study’s princi-
www.br-automation.com
pal author. “Demand continues to increase for
HMI thin-client products, which users utilize to
view and/or control a process from a computer
ALWAYS READY
or browser-embedded device on which no HMI
Type 4/4X (IP66) VisuNet Ind 8200 Series HMI Panel
software is installed,” he says. “These thin-client
Mount PCs and Monitors are shock- and vibration-
HMI products and solutions also enable end users
resistant, globally certified for Class I, Div. 2 and
to remotely and securely visualize and execute
Zone 2 (pending) operation, and are rated for 24/7
applications from any location around the globe.”
operation in extended
OEMs make up a key market for HMI. Ap-
temperature environ-
plications can include, for example, plastics or
ments. They are avail-
packaging machinery, where the machinery sup-
able in KVM remote
plier purchases HMI software products to embed
monitor, Ethernet re-
in its machines. As an example, growing global
mote monitor and panel
consumer pull for additional SKUs and more so-
PC configurations with
phisticated packaging requirements are spurring
a chemically resistant 15 or 19 in. touchscreen, in-
new food and beverage applications, which will in-
cluding LED-backlit, anti-glare, transflective LCD,
crease the demand for OEM packaging machinery
and hardened resistive glass.
to support this market growth, Resnick points out.
Pepperl+Fuchs; 330/486-0002; www.pepperl-fuchs.us
This trend will increase demand for HMI for both
on-machine and M2M applications, he adds.
KEYPAD HMI
TWO FEET OF DISPLAY
AKI Series keypad HMI
Panel PC series with a 24 in. TFT display and
panels are available in 5.7
1920x1200 pixel resolution has an optional
and 10.4 in. screen sizes,
touchscreen and can be customized. The displays
with LED status indicators
are available with integrated CPUs or as display-
to give users confidence
only panels. CP7xxx series
that inputs are correct.
offers IP65 protection;
The panels are programmed using Visualization
CP6xxx panel series has
Builder software, and keypad and touchscreen
IP20 at the back and IP65
HMI panels are available with a variety of tem-
at the front.
plates for common process screens, as well as
Beckhoff Automation;
drive operations and configurations.
952/890-0000; www.beckhoffautomation.com
38
Control Design February 2012
Kollmorgen; 540/633-3545; www.kollmorgen.com
controldesign.com
YOUR APP TO SEE MORE
Status display touchscreen for G9SP program-
C-more remote HMI ap-
mable safety controller displays safety I/O error
plication for iPod, iPad
codes and enables users to view status of safety
or iPhone is available
inputs and outputs without
at the iTunes App Store
indicator lights. Users can
and provides remote
reset up to four zones di-
access and control to
rectly from the touchscreen.
mobile users with a
The touchscreen’s display
Wi-Fi or cellular connection. A C-more panel with
is LCD monotone, with 16
remote connectivity is required, but the app does
shades of gray, rated for more than
not require third-party remote desktop VNC-type
1 million touchscreen operations, and satisfies
applications. Multilevel logon security for up to
relevant IEC and EN standards.
three remote access user accounts are configured
Omron STI; 508/608-3400; www.sti.com
and stored in the panel project.
AutomationDirect; 770/889-2858;
www.automationdirect.com
WIDE-SCREEN WEB
WebOP-2000T industrial
operator panels with 4.3–
WORKS WHEN IT’S HOT
10.1 in. widescreen dis-
NI TPC-2206 and TPC-2212 touch panel comput-
plays accommodate many
ers with extended operating temperature range
PLCs with more than 300
based on the 1.33 GHz Intel Atom processor have
drivers. The NEMA4/IP66
4 GB solid-state drives for reliable operation in
panels feature 128 MB onboard flash memory
extended vibration environments and Windows
and microSD card slot for additional applica-
Embedded OS for long-term deployment and
tions. WebOP Designer, an object-orientated
support. They include 1 GB of
programming application, is included.
RAM, 2 Gb Ethernet ports
and LED back-
Advantech Industrial Automation; 800/205-7940;
light technol-
www.advantech.com/ea
ogy.
National Instruments; 800/258-7022; www.ni.com
MORE TALK
FactoryTalk ViewPoint 2.0 software extends
visualization and real-time capabilities to
WIDESCREEN VIEWING
browser-based remote users, and supports fully
PowerView 8000
scalable and animat-
Series HMIs
ed web displays of
have 7 and
existing FactoryTalk
10 in. wide-
View HMI software
screen TFT
and PanelView Plus
LCD displays
applications. This
with LED
release adds compat-
backlights and 800x480 screen resolutions, and
ibility with Google Chrome 10 and Safari 5, in
come with EasyBuilder configuration software
addition to the existing support for Microsoft
with advanced object libraries, historical and
IE6 7 or 8, and Mozilla Firefox 3. Enhanced
real-time trending, alarm and recipe manage-
security system allows administrators to defi ne
ment, Windows multi-language text display,
user groups and assign them access for view
support for the most popular graphic formats,
and/or write capabilities.
and support for more than 175 drivers on 79
Rockwell Automation; 414/382-2000;
different PLC brands.
www.rockwellautomation.com
Nematron; 800/nematron; www.nematron.com
controldesign.com
February 2012 Control Design
39
PRODUCT ROUNDUP
SAFE TOUCH
PRODUCT ROUNDUP
IN SYNC WITH DATA
CONNECTION OPTIONS
SQL Sync in Crim-
XV and XP Series operator interfaces have serial
son 3.0 program-
and Ethernet connectivity options and include
ming software lets
Visual Designer
users synchronize
software for data
logged data from G3
archiving, recipe
HMIs directly with a
management,
Microsoft SQL Server
multi-language,
with no third-party software or custom script.
SQL database ac-
With dual Ethernet ports, an engineer can assign
cess and web serv-
a fixed IP address to the port connected to the
ing. They are available in screen sizes 3.5–15 in.
appropriate PLCs, drives, etc., and IT personnel
Eaton; 800/386-1911; www.eaton.com
can choose their own IP address or select DHCP to
configure the enterprise port.
Red Lion Controls; 717/767-6511; www.redlion.net
HDOI
Operator interface touchscreens have the same
color conversion technology as LCD TVs with LED
CAN’T MISS ‘EM
backlight intensity
Simatic KP32F PN control panel has 32 large, LED-
to 800 cd/m2, and
backlit and configurable keys, and IP65 protec-
include a 400 MHz
tion. It is suitable
RISC processor,
for safety-related
and built-in video
applications, with
in and audio in/
four fail-safe inputs
out interfaces. Up
connecting one
to four MicroSmart expansion I/O modules snap
or two emergency
onto the back of the panel for simple I/O control.
stop buttons in
It includes 12 MB of user memory, and an SD card
accordance with SIL 3. Flashing LEDs can prompt
and USB flash drive can be used for extra storage.
operator interaction, or changing colors can indi-
IDEC; 800/262-4332; www.idec.com/oi
cate machine status in red, yellow, green, white
or blue. It has two Profinet interfaces.
Siemens Industry; 800/964-4114;
HMI HANDLES MANY TASKS
www.siemens.com/key-panels
UL-listed open-platform, 7 and 10 in. touchscreen
HMIs come with Windows CE pre-installed, with
an Ethernet port, USB ports,
VERSATILE HMI
three serial com ports, an
NS series touchscreen
SD card slot, and an audio
HMIs have built-in
jack. With preloaded
Ethernet communi-
web browser and
cations, alarming/
optional Web Stu-
recipe/data-logging
dio, the HMIs handle
capabilities and live
remote data entry,
video input/display
remote monitoring,
capabilities. The
and support for mul-
CE-compliant HMIs allow users to monitor ladder
tiple devices. The units are CE-certified, RoHS-
programs without using a PC. They have Ethernet
compliant, and UL-listed for both Canada and the
communications and an integrated simulation
U.S. The fanless units draw only 12 W of power
function that simulates ladder programs and
for tight spaces or sealed environments where
screen data simultaneously without the actual
the airflow is restrictive.
hardware. No extra software needed.
Maple Systems; 425/745-3229;
Omega Engineering; 800/tc-omega; www.omega.com
www.maplesystems.com
40
Control Design February 2012
controldesign.com
operator interface is installed using a 22 mm thread
22 in. widescreen Challeng-
through a common hole size used for pilot lights or
er HMI provides intrinsi-
pushbuttons. These models are programmed with
cally safe date transmis-
Pro-face GP-Pro EX development software.
sion in hazardous areas
Pro-face America; 800/289-9266;
1/2 and 21/22, with an IP66
www.profaceamerica.com/22mm
rating, screen resolution
of 1680x1050 pixels and an
aspect ratio of 16:10.
OFF MY BACK
MTL Instruments; +44(0)1582-723633;
Backpack computer
www.mtl-inst.com
compatible with
company’s existing line of panel
MORE SCADA
displays lets users
VTS/VTScada v.10.1 adds a client for smart-
service or change out the computer without
phones and tablets, hierarchical tag organization,
removing the display from its cabinet or enclo-
enhanced security manager, lift station tem-
sure. The computer detaches from the back of the
plates, expanded
display with six screws for ease of maintenance.
application
The displays range 12–20 in. with a stainless steel
version control,
bezel and NEMA 4X rating when panel-mounted.
and new voice for
Comark; 508/359-8161; www.comarkcorp.com
VTS alarm dialer.
It communicates
with most PLCs and RTUs, and replaces master
GRAPHIC SOLUTION
PLCs with a built-in polling driver.
Open-platform
Trihedral; 800/463-2783; www.trihedral.com
HMI iX panels
have IP66 lightweight aluminum
LOTS OF LINKS
construction with
Infilink-HMI Version
keypad and touchscreen options. Five screen sizes
5 industrial automa-
range from 3.5 to 15 in. Included iX software is
tion software for
available in developer and runtime versions for
Windows 7 and
250, 2,000 and 4,000 external tags or an upgrade
XP is for small to
version regardless of tag size.
medium-sized PLC
Beijer Electronics; 847/619-6068;
applications and includes a design mode for drag-
www.beijerelectronics.com
and-drop application design and OPC Server with
communication driver. It has a graphical library
to import drawing tools, buttons and animations;
A CLEAN LOOK
historical and real-time trending; a datalogger;
LabMate 2653AB NEMA
and customizable alarms.
4X flush-mount, in-wall
Kessler-Ellis Products; 800/631-2165; www.kep.com
monitor with an aseptic
design has a stainless steel
enclosure, recessed front
FULL GRAPHICS
door and internal hinges.
GP4000M Series HMI
The 15 or 19 in. display
with 3.5 and 5.7 in.
has a membrane keyboard
LED-backlit LCDs
with sealed trackball, and
has full graphics,
has a KVM extender with
a TFT touchscreen
several KVM options.
interface with serial or Ethernet connectivity. The
Daisy Data Displays; 717/932-9999; www.d3inc.net
controldesign.com
February 2012 Control Design
41
PRODUCT ROUNDUP
TAKE THE HMI CHALLENGE
PRODUCT ROUNDUP
HARSH VISUALIZATION
Atmel ARM-9
HEC-HMI Harsh Environment HMI is available as
processor and two
HMI only or with a PLC in the same enclosure.
serial ports. Qlar-
With extended operating temperature range of
ity object-based
-40 to 80 °C and 8–32
programming
Vdc input power,
language and de-
the backlit LCD
sign environment
is available in 2
is included. The
line x 16 or 4 line
device meets NEMA 4X and IP66 specifications
x 20 character
for hosedown, icing and salt spray.
configurations,
QSI; 801/466-8770; www.qsicorp.com
with nine pushbutton inputs and four
programmable indicators. Network communica-
TAKES THE HEAT
tion is via CAN port or a field-configurable serial
Open HMI explosion-protected touchscreen
communication port for RS-232/422/485.
panel PCs with Intel Atom series CPUs operate at
Divelbiss; 800/245-2327; www.divelbiss.com
full performance to 50 °C. The system can even
briefly tolerate peaks of up to 55 °C. The series is
certified for gas and
RACE FASTER
dust zones 1, 21, 2
Indusoft Web Studio v.7.0 has improvements to
and 22. The closed
the Rapid Application Configuration Environ-
housing contains
ment (RACE) interface designed to create an
modules with
easy-to-use SCADA application development
separate explosion
environment. Native security supports Microsoft
protection that can
be replaced individ-
Active Directory using standard LDAP, and offers
security synchronization between multiple IWS
ually if required, and are available up to a 24 in.
workstations. Intellectual property protection
widescreen format with full HD resolution.
helps machine builders and integrators protect
R. Stahl HMI Systems; +49 221/59808-200;
their custom functionality.
www.stahl.de
Indusoft; 512/349-0334; www.indusoft.com
NO SERVER NEEDED
HMI DEVELOPMENT
Industrial Falcon is a cloud computing-based
PAC Display Win-
solution that lets users view raw data from any
dows-based HMI
OPC server via web browser so there’s no need
development ap-
to maintain web servers, is highly scalable and
plication can create
allows access
graphical interfaces
to multiple
that mimic a process.
users without
Support for alarm
additional cost.
management, recipe handling, operator logging,
It provides a
real-time and historical trending, multimedia and
central reposi-
unlimited tags are included.
tory for data
Opto 22; 951/695-opto; www.opto22.com
where changes
to a system or
operation can
TOUGH TERM
be made and easily propagated to other users
QTerm-G72 panel-mount HMI terminal has
accessing the repository.
a 7 in., 800x480 pixel, LED-lighted, TFT-LCD,
Software Toolbox; 704/849-2773;
resistive touchscreen; 10/100BaseT Ethernet,
www.softwaretoolbox.com
42
Control Design February 2012
controldesign.com
g
in
at rs
r
leb yea
Ce 15
ALL IN ONE
Vision1040 PLC
with a built-in
HMI has a 10.4 in.
display and nine
programmable
function keys.
Onboard I/O can
be added with a
Let Us Pick Your Brain
module onto the back of the PLC. Display options
include more than 1,000 user-designed screens,
and up to 500 images per application.
In upcoming issues of Control Design,
we’ll explore subjects that include:
Unitronics; 617/657-6596; www.unitronics.com
t)PXUPEFTJHONBDIJOFTBGFUZJOUPZPVS
automation system
VESA-READY
t8IBUBOJOUFHSBUFEDPOUSPMTBSDIJUFDUVSFNFBOTUP
EFTJHODPNNJTTJPOJOHBOEPWFSBMMUJNFUPNBSLFU
17 and 19 in. NEMA 4-rated VESA mountable LCDs
have 1280x1024 resolution, are auto-sync compatible with VESA video standards in an aluminum,
thermoset black powder-coated, gasket sealed,
t8IBUZPVOFFEUPLOPXUPDPNQFUFHMPCBMMZ
t8IBUUIFSFBMEJGGFSFODFTBSFBNPOHUIFWBSJPVT
&UIFSOFUnBWPSTPGGBTUNPUJPOCVTFT
vent-free enclosure. Options include resistive,
capacitive or optically bonded touchscreens; extended temperature range; sunlight viewability.
Vartech Systems; 225/298-0300;
www.vartechsystems.com
SMALL, POWERFUL
Magelis STU small-panel HMIs provide data log-
t5IFUISFBUPGFMFDUSPOJDTUPQOFVNBUJDTBOE
IZESBVMJDTBTQPXFSTPVSDFT
t8IFSFSFMBZTmUJOUPEBZTQSPHSBNNBCMF
machine control
t4UFQVQBOEUBMLUPVTBCPVUUIFTFPSBOZPUIFS
NBDIJOFBVUPNBUJPOUPQJDUIBUTBGGFDUJOHUIFXBZ
ZPVEPZPVKPCTUPEBZBOEUIPTFUIBUNJHIUBGGFDU
it tomorrow.
ging, USB port application download and remote
web access capability, along with serial port and
Ethernet connectivity and a 3.5 and 5.7 in. color
graphical touchscreen with QVGA. The HMIs are
certified for IP65,
8FXBOUUPIFBSUIFUIPVHIUTBOE
FYQFSJFODFTPGPVSNBDIJOFCVJMEFS
BOETZTUFNJOUFHSBUPSSFBEFST
NEMA 4X, ATEX/
UL1604, UL508
Joe Feeley
and RoHS.
%BO)FCFSU
editor in chief
senior technical editor
Schneider Electric;
jfeeley@putman.net
dhebert@putman.net
"BSPO)BOE
,BUIFSJOF#POGBOUF
managing editor
digital managing editor
ahand@putman.net
kbonfante@putman.net
800/788-1704;
www.schneider-electric.us
SOFT OBJECTS
JetViewSoft v.3.11 SCADA tool has an object-oriented approach; the user needs no experience in
object-oriented programming. The user can store
+JN.POUBHVF
executive editor
jmontague@putman.net
created objects to libraries for reuse in other projects. Dynamic functions and macros flexibility
is achieved by integration of high-level programming language JetSym STX as scripting language.
Jetter; +49 7141/2550-466; www.jetter.de
controldesign.com
Call us at 630/467-1301
or start the conversation in our Machine Builder Forum on
REAL ANSWERS
Digital Network Reliability
AS WE COMMIT OUR CONTROL system design
But before going through the expense and
to include digital networks rather than hardwired
sometimes increased complexity of adding net-
I/O, we want to be sure about reliability and
work redundancy, some other aspects should be
know where redundant network devices are most
considered when choosing a digital network. One
needed, even if we specify hardened devices for
is network topology. Some networks require a line
many of the components. We worry that adding
architecture, meaning that all devices on the net-
unnecessary network complexity and cost will
work have to be in the same segment. A failure
give us after-sales support headaches. We’d like
in such a network means loss of communication
some seasoned advice.
to all devices behind the point of failure. Other
—From December ’11 Control Design
networks allow much more flexibility in network
architecture such as line, star, tree, ring or any
ANSWERS
combination of those types. Using a mix of line
and star architecture for network segmentation
Reliability Important
can allow for the remaining network segments to
With the digital network now transporting the
function during a failure in one segment without
information of many I/O points, the reliability
investing in redundant network components.
of that network and its infrastructure (cable,
A final consideration is the current separa-
switches, etc.) is that much more important than
tion—and thus quasi-redundancy—of regular I/O
the individual I/O cable it replaces.
and safety I/O via different hardwired signals or
One way to increase reliability and network
networks, leading once again to increased cost
availability is to add redundancy to create a
and system complexity. Technology like open-
system that can tolerate one network failure.
Safety allows data of safety devices to be trans-
Depending on the network architecture, this can
ported over the same digital network as regular
be achieved in different ways.
I/O data. Integrating safety into digital networks
A line architecture can be upgraded to a ring
will therefore reduce the necessary network and
by closing the loop between the last and first
hardwired infrastructure, and allows the same
device in a line. If the data transmission is inter-
network flexibility in terms of architecture in
rupted in one direction, it can then be rerouted
general and redundancy in particular to be used
automatically in the other direction. With a ring
for all I/O, both regular and safe.
redundancy (Figure), a single fault can be toler-
ROBERT MUEHLFELLNER,
ated without loss of communication and without
adding additional network components besides
director of automation technology,
B&R Industrial Automation, www.br-automation.com
the cable closing the loop.
I/O Node
I/O Node
Controller
Fault tolerance
through ring
redundancy
Drive
44
Control Design February 2012
Drive
Drive
controldesign.com
Congratulations Are Due
Because networked I/O solutions will be able to
Congratulations on embracing a fieldbus network
provide a plethora of additional diagnostics data,
instead of hardwired I/O. I believe everyone in the
one might conclude that they have to be more com-
fieldbus communities will state unanimously that
plex. Unfortunately, in many instances, that is the
with distributed I/O you will capitalize on supe-
case. If you intend on benefiting from the diagnostic
rior diagnostics, simpler wiring, improved uptime
advantages and the added flexibility these solutions
and overall cost reductions compared with your
offer, and possibly even put your safety devices on
current hardwired implementation.
the same network, you have to be willing to tackle
Since your concern seems to be with the com-
a certain learning curve. Here are a few guiding
munication network itself, the need for control-
questions (and answers) that you might want to use
ler or even I/O device redundancy does not seem
when picking a digital I/O technology:
to be your need or concern, but instead what
1. Is it possible to work with the network without
the industry calls “added availability” or, more
using a specialized software tool? Ideally, starting
informally, “network redundancy.” Basically, this
up and maintaining the network can be complet-
is a scheme that enables the system to withstand
ed without additional PC configuration software.
faults in the communication network, such as a
2. How much downtime is necessary when more I/O
must be added to the network? Adding field I/O to
cable shear, unplugged cable, or dead module.
Network redundancy even permits the pur-
the network should be accomplished in minutes.
poseful removal and re-installation of a section of
3. Can the same networking solution be used with
devices in the network (“hot connect/disconnect”),
PLCs from different suppliers? You never know
and the remainder of the network can continue
what happens at the PLC market. Any network-
running. EtherCat, for example, needs only an ad-
ing solution that can only work with a small
ditional cable attached to the end of the devices on
number of PLCs is problematic.
the “redundant” section of the network to a second
4. Is the technology deterministic and fast enough
Ethernet port of the controller, and the master will
for the application? A nondeterministic solu-
send out identical frames in both directions (trans-
tion is a nonstarter. I/O update times should be
mit and receive) of the Ethernet cables. The slaves
twice as fast as PLC scan times. Less than 10 ms
do not need any additional configuration and do not
is probably a good number.
“know” they are part of a redundant system. But a
5. Does the technology support machine safety
operations? Even if this is not what you have in
switchover time of 15 μs is inherent in EtherCat devices, meaning a maximum of just one frame would
mind right now, using a technology that does
not support safety will be a problem in the future. Networking safety results in a reduction of
APRIL’S PROBLEM
wiring complexity as high a 90%. Any selected
WE INTEGRATE MULTIPLE machines into a
technology should at least be ready.
complete manufacturing process line. The operator
has to physically attend to all of the machines.
Rather than have an HMI at each machine, we’re
thinking about handheld HMI, maybe wireless,
that the operators would carry with them. We’d
like to hear about experiences with this approach.
6. Can a field module be exchanged without additional tools? You hope that the network you
select is reliable. This means that I/O module
exchanges are infrequent and knowledge about
the solution is not well retained by maintenance. Module exchange must, therefore, be as
simple as “removing the old, inserting the new.”
I also urge you to take advantage of the expertise
your chosen supplier brings to the table. Get them
involved, and describe the application as best as
possible. Your supplier can then review your layouts
SEND US YOUR COMMENTS, SUGGESTIONS OR
SOLUTIONS FOR THIS PROBLEM. We’ll include it in
the April ’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.
and designs, thus reducing cost and making the
digital network run at peak performance.
HELGE HORNIS, manager, Intelligent Systems Group
HAVE A PROBLEM YOU’D LIKE TO POSE to the
readers? Send it along, too.
Pepperl+Fuchs, www.pepperl-fuchs.us
controldesign.com
February 2012 Control Design
45
REAL ANSWERS
Points to Consider
Machine System Reliability
sections of the network continue to function, avoid-
Regarding the system’s network layer, a machine
ing the network errors and system downtime that
designer’s thought process must consider “The
might be experienced in alternative systems.
Theory of Control Reliability” per ANSI B11.19,
Section 2.12 and B11.19, Section 5.5.1.
JOEY STUBBS, PE, PMP, North American representative,
Three principles of machine reliability are
EtherCat Technology Group, www.ethercat.org
redundant components, monitoring and diver-
Plan Your Network
sity. Today’s Ethernet switches incorporate many
First, invest in the proper network components
features to help machine designers meet those
because your machine is only as strong as your
three principles. One such example of vulner-
weakest link. Case in point, most industrial net-
ability on the system is the network storm.
working issues are a result of inadequate cabling. By
Typically, a network storm will cause Ethernet
using more robust equipment like industrial-rated
communication failures, which is a result of con-
cables you can help drive reliable network commu-
necting unmanaged Ethernet switches in a loop
nications. Also, consider incorporating a managed
or ring configuration. Spanning Tree Protocol
switch into your system. Managed switches help
(STP) and Rapid Spanning Tree Protocol (RSTP)
improve network reliability (performance and up-
were developed to detect network loops and
time) by providing important diagnostic capabilities
eliminate broadcast storms. Some manufactur-
and intelligent features such as quality of service
ers have Ethernet switches designed with these
(QoS), port mirroring, loop prevention, and network
features and many others to protect the network.
security. You don’t want the network to be the lim-
They are extremely simple to construct and do
iting factor of your machines’ production.
not require unnecessary hardware, extra wiring
or network complexity.
Network reliability calls for more than robust
equipment, so be sure to thoroughly plan your
network structure and do your homework. For example, if you’re building a machine that end users
will integrate into their infrastructure, we suggest
having dialogues with their IT department to make
sure your machine’s networking won’t violate any
IT policies, especially as it relates to security.
Another concern could be centered on the
machine’s connected devices. In our experience,
embedded switch technology generally lays the
foundation for the most robust network at the
machine’s device level. By embedding the switch
into the device itself, you can use a device-level
ring (DLR) topology that produces a single, faulttolerant network—thus one that’s more resilient.
It simplifies design and configuration while
HARTING
REAL ANSWERS
be lost in such an event. The result here is that both
Pre-terminated cable assemblies with modular connectors
can help eliminate hardwiring errors in the system.
increasing the reliability of the machine network.
So you might have a switch-level ring above the
machine and a DLR at the machine.
Built-in diagnostics and resiliency allow the
On the machine’s physical layer, reliability (or
the lack of) can be traced to point-to-point cabling
or what is commonly known as hardwiring. This
system to run as expected if a failure occurs,
style of wiring can complicate the setup, testing,
instead of stopping production. In fact, when
troubleshooting and debugging of the system.
up to 50 devices are connected, a DLR recovers
When an independent contractor is not experi-
in less than 3 ms. This enables you to schedule
enced with the system they are working with,
maintenance at a later time, providing increased
hardwiring errors are very likely.
flexibility while reducing production waste.
MIKE HANNAH, manager, Networks Business,
Rockwell Automation, www.rockwellautomation.com
46
Control Design February 2012
A solution to this problem is connectorization, or a plug-and-play system. Pre-terminated
cable assemblies with modular connectors to
controldesign.com
any type of redundant network topology required.
take the guess work out of assembling a system.
When using the chain concept, the first step is to
Even within a control panel, the use of connec-
connect Ethernet switches in a chain and then
tors helps to remove one layer of possible wiring
simply link the two ends of the chain to an Ethernet
errors, which is the terminal block. Removing
network. In chain systems, you basically have a
the terminal block and wiring directly to the
“head” switch, a “tail” and multiple members.
device eliminates the chance of human error in
Propriety ring redundancy is commonly used in
one more area. Also, depending on the environ-
industrial applications because of response times
ment the machine is subject to, this removes
typically in the millisecond range and its ease of
one more point of failure if there is the chance of
setup. Although industrial manufacturers will
loose wiring. Finding any opportunity to remove
support regular STP/RSTP, it is often cumbersome
wiring errors can possibly improve the overall
to set up, and an ever-evolving industrial network
reliability of your system.
requires extensive pre-planning. Ring redundancy
CRAIG ZAGORSKI, market and applications manager, NA,
Harting North America, www.harting-usa.com
ensures the non-stop operation of networks with
extremely fast recovery times.
One of the ideal methods to maintain speed
Redundancy Options
and ensure uptime in an industrial network is
Stability is a critical requirement for industrial
to set up networks using redundant ring/chain
networks, and can be enhanced by adding device
topology, which allows recovery time of less than
or network redundancy. When it comes to redun-
20 ms. This system architecture was developed
dancy, the key tradeoff is determining how to
specifically for industrial networks, which require
expand and service the industrialized network
both uptime and rapid installation.
while maintaining performance and system
Many manufacturers have an easy redundancy
uptime. Redundancy is an essential requirement
setup feature via embedded software that is
for most industrial Ethernet networks. There are
activated by a simple check box selection. The
a wide variety of redundant path mechanisms,
switches themselves can determine the fastest
with the most common of these being STP, RSTP,
route from source to destination. Some even can
mesh networking and ring redundancy.
be configured via external DIP switches so techni-
STP is commonly used in enterprise applications. Although it solves the issue of looping in the
path, it has drawbacks such as speed-of-recovery
cians don’t have to get involved with the software, making it a plug-and-play scenario.
Traditionally, ring/chain protocols did not
time, which can be several seconds. RSTP was
work well with existing networks. With newer
created to improve on the slow recovery time for
generations of managed switches, the integra-
STP, with the goal of less than one second network
tion of the two networks can easily be done
recovery. Although RSTP is an improvement,
with some devices able to run both RSTP/STP
high-demand applications such as large networks
and redundant ring/chain architectures at the
require even faster response times. Because it is
same time. Even though many are set up using
an open standard, manufacturers can adapt and
proprietary protocols and are specific to manu-
improve the recovery times of redundant networks
facturers, they are transparent or co-work with
while still adhering to IEEE standards. Out of these
existing RSTP/STP networks.
standards and improvements, many propriety
ring/chain redundancy systems were born.
ANDREW BARCO, product manager, network connectivity,
Weidmüller North America, www.weidmuller.com
Ring redundancy is ideal for systems that have
inherent cabling difficulties. It allows for multiple
connections and multiple rings, thereby allowing
multiple subnetworks to be connected within one
overall redundant system. Setup is as simple as
configuring one master in a ring that auto-negotiates the path through all its connected slaves.
Redundant chain technology is based on an ad-
MORE, MORE, MORE
Find more thoughts on this subject from
Jason Haldeman, I/O product marketing lead
specialist, and Ken Austin, Ethernet product
marketing lead specialist, of Phoenix Contact;
and Phil Marshall, COO, of Hilscher North
America, at www.ControlDesign.com/Real0212.
vanced software that gives network administrators
controldesign.com
February 2012 Control Design
47
REAL ANSWERS
handle everything from power to signal to fiber
PRODUCT SHOWCASE
cdproducts@putman.net
LOCAL TERMINAL
12 A rms peak current. It has a CANopen com-
VTUB-12 valve ter-
munication interface. With elect-
minal for localized
able switching frequency,
machine-mounted
it supports low-induc-
applications can
tance motors.
flow 400 l/min or 14 scfm
Portescap; 610/235-5499;
with a maximum 8 bar or 120 psi. Constructed
www.portescap.com
with engineered polymer and mounted on an
aluminum profile, the valve terminal is available
as a multipin electrical connection. As many as
SINGLES OR DOUBLES
35 valves can be installed on one terminal.
These base or panel-mount 2Z11 right-angle,
Festo; 800/993-3786; www.festo.us
helical-gear drives have single- and double-output shaft configurations. Gear ratios
TOUCHSCREEN CONTROL
stocked are 1:1
3500i CNC control has touchscreen operator
and 2:1, with 1,800
interface. Conversational programming is edited
maximum rpm and
in plain machinist language and uses a set of
1/8 hp maximum
continuous power.
canned cycles. Where
Special options for
additional versatility is needed, G-Code
shafts, material and ratios are available.
programming is
Stock Drive Products/Sterling Instrument;
available via an on-
516/328-3300; www.sdp-si.com/estore
screen keyboard and
a G-code help editor.
It has a built-in 2½D CAM system for complicated
SECURE SENSORS
contours with minimal part data.
BM-PT block-style
Heidenhain; 847/755-5569; www.acu-rite.com
sensor mounts
for M8x1, M12x1,
M18x1 and M30x1.5
MODULAR SAFETY
threaded proximity
PSR-Trisafe/M modu-
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cated from Delrin
connects up to 10 safe
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digital I/O modules via
fasteners is supplied with each kit, consisting of
a T-bus system. Its base
two each of a socket head machine screw, lock
station has 20 safety
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input signals and four safety Category 4 outputs,
SoftNoze; 315/732-2726; www.softnoze.com
and provides outputs for a test pulse, alarm (aux)
and ground switching. The module can be configured as 12 safe digital inputs or eight safe digital
SOFTWARE
inputs and four safe digital outputs.
Phoenix Contact; 717/944-1300;
CNC MONITORING
www.phoenixcontact.com/trisafe
iLimitS CNC
software option
for Fanuc CNCs
LOW-VOLTAGE DRIVE
provides machine
LVD low-voltage servo drive for small and large
process monitoring
brushed dc or brushless motors is 12–48 Vdc
including spindle
powered and capable of 7 A rms continuous and
load, spindle speed
48
Control Design February 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.
and up to four coolant flow devices. If an abnormal process is detected, a warning can be
displayed or an alarm will stop the process before damaging the machine.
Fanuc FA America; 888/fanuc-us; www.fanucfa.com
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
HIGH-LEVEL DEVELOPMENT
CoDeSys Professional Developer edition for application programmers familiar with highlevel language development tools includes SVN integration; an integrated connection to the
source code administration system Apache Subversion; UML
PUBLISHING TEAM
integration; and static code analysis to check the source code
GROUP PUBLISHER & VP, CONTENT
of IEC 61131-3 applications with more than 50 partly param-
KEITH LARSON klarson@putman.net
eterizable rules to detect and debug potential code errors
DIRECTOR OF CIRCULATION
before testing or commissioning.
JACK JONES jjones@putman.net
3S-Smart Software Solutions; +49-831-54031-17;
SALES TEAM
www.3s-software.com
NORTHEASTERN AND MID-ATLANTIC REGIONAL MANAGER
DAVE FISHER dfisher@putman.net
508/543-5172 Fax: 508/543-3061
RESOURCES
24 Cannon Forge Dr.
Foxboro, Massachusetts 02035
SELECT SAFETY
MIDWESTERN AND SOUTHERN REGIONAL MANAGER
2011-2012 Product Selection Guide to Machine and Process Safeguard-
GREG ZAMIN gzamin@putman.net
ing has illustrated articles on safety regulations and directives,
630/551-2500 Fax: 630/467-1124
risk assessment, types of protective measures, and background
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
on safety technologies. Each product page includes a SpeedSpec
WESTERN REGIONAL MANAGER
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LAURA MARTINEZ lmartinez@putman.net
tions, accessories, CAD drawings and installation manuals from
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any company web page.
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Omron STI; 510/608-3400; www.sti.com
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DIGITAL SALES SPECIALIST
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PNEUMATIC SOLUTIONS
jfreedland@putman.net
805/773-4299 Fax: 805/773-0451
SC-OV 20-page brochure has standard and customized pneumatic
INSIDE SALES SPECIALIST
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POLLY DICKSON pdickson@putman.net
tions for industrial pneumatic directional control valves, cylinders
630/467-1300 Fax: 630/467-1124
and actuators, automation/handling devices, vacuum devices, air
preparation, electro-pneumatic pressure control devices, mobile/oil-
EXECUTIVE STAFF
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PRESIDENT & CEO
electronic marine control, and inverted tooth chain.
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Bosch Rexroth; 847/645-3600; www.boschrexroth-us.com
VICE PRESIDENT
JULIE CAPPELLETTI-LANGE
VP, CIRCULATION
MOTION SELECTOR TOOL
JERRY CLARK
VP, CREATIVE SERVICES
Linear Motioneering 2.0 web-based, linear motion system sizing and
STEVE HERNER
selection tool has a motor interface selector to enter motor dimen-
VP, TECHNOLOGY
sions, or any major manufacturer’s motor model number, and the
ROSE SOUTHARD
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provides safety factors for critical system components, and users
REPRINTS
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safety factors on the fly.
JILL KALETHA
Thomson; 540/633-3549; www.thomsonlinear.com
jillk@fosterprinting.com
866-879-9144 ext. 168
controldesign.com
February 2012 Control Design
49
+PIO$BTFZtDBTFZK!GWUDFEV
OEM INSIGHT
Push and Pull of Electronic Drives
JUST AS WITH humans, electric drives can work
operates in torque-control mode with a setting
against each other or share a burden unequally.
that will deliver a guaranteed higher percentage of
Sometimes this produces good results, however.
torque than the rear drum. This torque differential
Some machines require differential torque and
produces tight rolls with wound-in tension.
speed between separate machine axes, and indus-
A mechanical automotive differential allows
trial electronic drives can provide better coordina-
two wheels to turn at different speeds while ap-
tion and control than purely mechanical systems.
plying equal torque to the wheels. If one wheel
In many web-processing machines, drives work
loses traction, that wheel will spin with very low
toward opposite ends. A drive at the unwind end
torque applied, limiting the torque that can be
of the machine pulls the web backward, while a
delivered to the other wheel to that same value.
drive at the windup end pulls the web forward.
This is a case in which uneven load sharing is
The purpose is to maintain appropriate web ten-
desirable, so that higher torque can be applied
sion for the process. It is typical for the windup
to the wheel that maintains traction. An electric
drive to operate in speed-control mode, allowing
motor with dual rotors could supply the required
for adjustment of the machine speed, and for the
differential torque.
braking unwind drive to operate in torque-control
mode to maintain proper tension.
For example, at steady speed, a braking torque of
Electric machines with two or more rotors can
be supplied from separate electronic drives or a
single drive. If a single drive is used with two in-
9,000 ft-lb applied to a 120 in. diameter, 300 in.-wide
duction rotors, and the output frequency from the
unwind roll will result in tension of 6 lbs per linear
drive produces a synchronous speed faster than
inch (pli). The situation is complicated by the fact
both rotor speeds, then both rotors will be driven
that the system also must maintain proper tension
as motors. If the synchronous speed of the supply
Winding processes have been greatly
improved by tension feedback from
electronic load cells and development
of advanced ac drive technologies.
is controlled to be slower than both rotor speeds,
then both rotors will be braked, and energy will be
regenerated. If the synchronous speed of the supply is controlled to be between the rotor speeds,
then the faster rotor functions as a generator and
the slower rotor functions as a motor.
during acceleration, deceleration and at zero speed.
An electric machine with non-coaxial rotors can
Insufficient tension can result in wrinkled product,
provide differential mixing action for chemical-
and excess tension can cause the web to break.
blending applications. A common housing assem-
For webs with low elasticity, the dynamic
bly fixes two rotor axes at an angle to each other,
torque response of the unwind drive is critical.
which provides for blade separation and outward
Historically, mechanical tension feedback devices
thrust components, while maintaining a compact
and dc motors controlled winding machines.
motor head assembly. The electronic control can
Tension feedback from electronic load cells and
be programmed for mixing cycles that include
development of advanced ac drive technolo-
speed changes and periods of either co-rotating or
gies such as direct torque control have greatly
counter-rotating blades. Opposing forces are also
improved these processes. Another improvement
helpful for material stretching or separation pro-
has been regenerative energy recovery from the
cesses, especially after slitting fiber or sheet metal.
braking unwind drive.
Rollers that are slightly angled to each other will
The web-processing industry also provides an
pull material primarily in the same direction, while
example of drives that pull in the same direc-
also pulling outward in opposite directions. Electric
tion but share the load unequally. In a two-drum
drives provide take-up at the desired speed.
winder, paper rolls are wound up by rotating them
in the valley between two driven drums. The rear
JOHN CASEY teaches electromechanical technology at
drum operates in speed-control mode, and serves
Fox Valley Technical College (www.fvtc.edu) in Appleton,
as the master speed reference for the machine.
Wis. He worked as a machine engineer/designer for close
While winding up a paper roll, the front drum
to 20 years at Metso Paper and Pierce Manufacturing.
50
Control Design February 2012
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