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“With NI LabVIEW, we finished
nine months ahead of schedule.”
Danny Hendrikx, Production Machine Designer, SLI Lighting
For its next-generation production machines, SLI Lighting, one of the world’s
largest integrated lighting companies, required high throughput, high accuracy,
and a complex control system. With the reliability of a PLC, the performance
of a PC, and the flexibility of custom hardware, National Instruments
Programmable Automation Controllers (PACs) provided the ideal integrated
NI CompactRIO
Machine Control System
>>
solution. Using LabVIEW graphical programming, SLI Lighting completed
the project in just 25 percent of the budgeted development time.
Learn how to reduce your machine design time at ni.com/industrial
800 433 3488
© 2007 National Instruments Corporation. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks
of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 2007-8742-221-101-D
CD0803_FPA.indd 4
2/25/08 10:55:20 AM
contents
features
March 2008
10
BEST
Named
one
of the
U.S. Trade Publications
34 Cover Story
Change Is Natural
by the American Society
of Business Publication
Editors — July 2005
Web-Based Product Research Expands Its
Influence. Users Are Changing the Way They
Volume 12, No. 3
Get Information
Named
one
of the
Joe Feeley, editor in chief
U.S. Trade Publications
45 Drives & Motion Control
The Not-So-Odd Couple
34
Like an Old, Married Couple, a Motor and Its Generator Are Bound
+
–
Ernst Dummermuth
+
+
–
+
Together. One Does Not Exist Without the Other
+
+
58 –
Machine –
Control
A Machine Renaissance
Shrink Wrapper OEM Maximizes Design Flexibility With a PC-Based
Controls and Ethernet Solution That Teaches Users How to Operate
–
the Machines
45
Joe Morrissey, Conflex
–
+
65 Product Roundup
–
–
+
Positioning Solutions Abound
Above-Average LVDT Growth Leads the Way in Sensor Market
+
Patti Pool, new products editor
–
+
–
58
A
Position of Rotor
10
+
B
C
-10
+
+
CD0803_05_07_TOC.indd 5
B
–
www.controldesign.com +
+
+
0
+
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 630/4671124.) Periodical postage paid at Itasca, IL, and at additional mailing offices. Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States.
©Putman Media 2008. All rights reserved. The contents of this publication may not be reproduced
owner. POSTMASTER: Send address
– in whole or part without consent of the copyright
+
+ – SUBSCRIPTIONS:
changes to Control Design, Post Office Box 3430, Northbrook, Illinois 60065-3430.
To apply for a free subscription, fill in subscription form. To non-qualified subscribers in the United States and its possessions, subscriptions are $60.00
for Canada–and Mexico are $60.00. Foreign subscriptions
– per year. Single copies are $15.00. Subscriptions
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outside of Canada and Mexico accepted at $99.00 per year for surface and $199.00 for airmail. Putman Media also publishes CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING,
industrial networking, PHARMACEUTICAL MANUFACTURING and PLANT SERVICES. CONTROL DESIGN assumes no responsibility for validity of claims in items reported. Canada Post
International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor information: World Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario,
Canada N9A 6J5. Printed in the United States.
–
C
A
Time
March 2008 Control Design
5
0 60 120 180 240 300 360 60
Phase Angle in Degrees
2/26/08 10:01:48 AM
CD_Vision_0308_OL.indd 1
CD0803_FPA.indd 6
2/21/08 9:51:31 AM
2/25/08 10:55:41 AM
contents
Columns
8 ControlDesign.com
Browse Constructively
19 Editor’s Page
The Great Supplier Purge
29 Machine Builder Mojo
Don’t Let the Media Get You Down
31 Embedded Intelligence
IEC 61131 Cage Match—Prologue
33 Live Wire
Teenagers Take Test Flights in JETS
64 TechFlash
Make Controls Kaboom-Proof
78 OEM Insight
22
Do Your Duty Cycle Diligence
Hot Buttons
21 Feedback
71
22 InDiscrete
Hands Across the Water
71 Real Answers
What Are the Choices on Enclosures?
73
75 Product Showcase
control design exclusive
73 Balluff’s Tiny Sensors Bring New Possibilities
www.controldesign.com CD0803_05_07_TOC.indd 7
2/26/08 1:24:48 PM
CONTROLDESIGN.COM
kbonfante@putman.net
•
managing editor, digital media
•
Katherine Bonfante
Here’s what’s new this month at ControlDesign.com, the exclusive home
of our virtual content.
Browse Constructively
Are you the type of person who enjoys browsing the Internet
when your work flow is low? Looking for something to do online
to ease your brain from your work tasks?
If your brain needs a break, stop by ControlDesign.com this
month and let us help you in your search for online work-related
diversions.
Innovator Awards
If you know any industrial machine builders and system integrators
who have used automation and controls technology in an innovative
way, maybe they should be considered for Control Design’s Annual
Innovator Awards. We are currently accepting nominations. Visit
ControlDesign.com/innovator and fill out the online entry form.
Poll: Test Your Safety PLC Knowledge
Participate in our current web poll by answering the following
question at ControlDesign.com/webpoll. What type of controller do
you use as part of your machine safety system?
You can also access our web poll from our home page, ControlDesign.com, just click on our Web Poll button and you will be redirected to take this poll.
Multimedia Library
Control Design has a fast-growing online multimedia library. This is
New White Papers
Internet Access in a
Control Environment
PLC technology allows you to
accomplish almost anything via
the Internet.
Industrial Ethernet…
more than just another
fieldbus Ethernet-based
fieldbus systems perform basic
tasks and so much more.
Removable Storage Media
Add Flexibility to Modern
Day PLCs Why can’t my PLC
interface easily to off-the-shelf
devices?
Transient Surges and
Surge Suppressor
Technologies: Comparing
Apples to Oranges Physical
location influences the
selection of a suppressor
to protect a point upon an
electrical distribution system.
Download PDFs of these white
papers at ControlDesign.com/
whitepapers.
our latest addition to our web site, and it contains video demonstrations by and interviews with
some of the biggest names in
the Machine Builder Nation.
Check out our video of
the United States Bowling
Congress’ robotic bowling ball
thrower, and meet Harry, who
Special to the Web
Machine Builder Forum
React to, comment on or
disagree with postings from
all the Control Design editors at
ControlDesign.com/mbf.
is part of the equipment testing and research effort at the
USBC test facility in Greendale,
Wis. Harry is a key contributor in USBC’s two-year study of bowling ball motion and how
advanced, high-tech equipment could inf luence lane conditions
and scoring in the sport.
Log on to our library, ControlDesign.com/multimedia, and watch
this video to see Harry in action. Browse our library and find out
from this and other videos what the latest trends in the industry are.
Do you have any machine builder video demonstrations that
you’d like to see hosted on our site? Contact Managing Editor Mike
Did you know you can
receive Control Design
electronically? Subscribe
to the digital issue of Control
Design and you’ll be able to
download a high-quality PDF
file of the magazine exactly
as it appears in print. Not only
that, we’ll send you an e-mail
each month when it’s ready for
you! Go to ControlDesign.com/
digital.html.
Bacidore at mbacidore@putman.net to submit your video.
8
CD0803_08_WebTOC.indd 8
Control Design March 2008 www.controldesign.com
2/26/08 1:25:42 PM
1:31 AM
CD0803_FPA.indd 9
2/26/08 1:49:42 PM
Quality.
Producing only the highest Quality products has
shaped our company for more than 100 years.
Our strategy is “to produce the highest quality,
most energy efficient products available and sell
them to value-minded customers.”
Quality is perceived differently from one
customer to the next. Quality is measured
in many ways, including the “quality of the
information provided, the products supplied, the
service offered and more.”
Now we have brought three great companies
together who share the same understanding
of Quality. Providing consistent Quality, as
perceived by our customers, is fundamental
to our way of doing business.
www.baldor.com
Bringing the Best Together
©2007 Baldor Electric Company
CD0803_FPA.indd 10
2/25/08 10:56:14 AM
The Great Supplier Purge
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
630/467-1300
Fax: 630/467-1124
Editorial team
editor in chief
Joseph Feeley jfeeley@putman.net
The thing I learn from inter-
22% who said price caused them
preting the results of our annual
to change. No matter how much
machine control professionals’
progress machine builders make
research and buying habits study
to teach customers about lifecycle
for our cover story (p34) is that
costs and the importance of flex-
you never can ask too many
ibility and configuration ease in
follow-up questions.
their machines, there’s still brutal
There are dozens more ques-
pressure to provide a low-cost
participants. But you’re busy folks.
of you simply have to change sup-
managing editor
Answering more of our questions,
pliers to juggle the priorities of low
however focused and subject-ex-
cost and performance. So, I’m OK
panding, just is not going to crack
with that finding.
mike bacidore mbacidore@putman.net
managing editor, digital media
senior technical editor
Walt Boyes wboyes@putman.net
the top of your to-do list.
That’s a bit humbling for us.
editor in chief
Katherine Bonfante
kbonfante@putman.net
•
machine that does all that. Some
Jim Montague jmontague@putman.net
There has to be more behind
this 30% who dumped suppliers
But, listen, I spent many years in
for bad performance and qual-
Dan Hebert dhebert@putman.net
jobs very much like yours, so I
ity. I need you to tell us more.
contributing editor
have a fair sense of time allot-
I’ve made a posting on Machine
ment. You don’t have enough time
Builder Forum at ControlDesign.
Patti Pool ppool@putman.net
to do everything, by any stretch of
com/buyinghabits, so there’s a
editorial assistant
the imagination.
senior technical editor
Joe Feeley
tions we’d love to ask these study
executive editor
editor’s page
www.controldesign.com
•
new products editor
Lori Goldberg lgoldberg@putman.net
columnist
So, having just tried here to
Jeremy Pollard jpollard@tsuonline.com
ingratiate myself to your good
Design/Production
graces, I need to ask for more
art director
information from you.
Derek Chamberlain
multimedia director
I was genuinely surprised that,
Scott Babcock
as you’ll see, half of the study
Subscriptions
participants changed a primary
customer service
supplier in one or more impor-
888/644-1803
circulation
audited June 2007
Air & Gas Compressors
892
Engineering & Systems
8,180
Integration Services
Engines & Turbines
1,754
Food Products Machinery
1,856
Industrial Fans, Blowers,
& Air Purification Equipment
893
Industrial Heating, Refrigeration,
& Air Conditioning Equipment
1,579
Industrial Process Furnaces & Ovens
546
Machine Tools
4,731
Materials Handling, Conveyors,
1,895
Conveying Equipment
Metalworking Machinery
3,154
Mining Machinery & Equipment
578
Oil & Gas Field Machinery & Equipment 1,038
Packaging Machinery
941
Paper Industries Machinery
482
Printing Trades Machinery & Equipment 604
Pumps & Pumping Equipment
1,063
Rolling Mill Machinery & Equipment
182
Semiconductor
Manufacturing Machinery
945
Textile Machinery
290
Woodworking Machinery
239
Other Industries & Special Industrial
Machinery & Equipment NEC
13,177
TOTAL
45,019
tant product categories in the
convenient place for you comment on this or any other part of
the study.
hat’s the conversation
W
like with a vendor that
disappoints you enough
to switch?
What’s the conversation like
past year. What’s more, 60% of
with a vendor that disappoints
these changers (31% of the total)
you enough to switch? Did they
did so in more than one product
promise change for the better?
category. That’s serious turnover
Did they try to make it all better
by anyone’s estimation.
with a price cut?
The machine builders we know
Did you put them on notice,
are, as a rule, pretty reluctant to
continue to buy from them and
change component suppliers. Their
finally conclude improvement
preference is to build long-term
wasn’t in the cards?
relationships with a limited cadre
Maybe most importantly, did
of vendors that don’t require them
you end up better off with the
to jump ship because of price, per-
new vendor?
formance or support problems.
There’s a big disconnect here,
don’t you think? Nearly 30% said
Too early to tell? Are they likely
to be that new, long-term partner
or next year’s ex-supplier?
it was product performance and
quality problems that led them
to dump a supplier.
I can get my head around the
March 2008 Control Design
CD0803_19_Edit.indd 19
jfeeley@putman.net
Loren Shaum lshaum@putman.net
19
2/26/08 1:26:47 PM
ControlDesign.qxd:Layout 1
2/11/08
1:36 PM
Page 1
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CD0803_FPA.indd 20
2/25/08 10:56:40 AM
Junk Mail Doesn’t Help Me
I read Scott Gee’s OEM Insight column [“Why Is
I can’t begin to estimate the time expended and
Safety Information So Pricey?” Jan08, p 66, Contr-
money I’ve wasted chasing standards, only to
olDesign.com/payforsafety], and I couldn’t agree
fi nd one paragraph or less that had relevance to
more. I’m an electrical engineer for a packaging
the work I was doing. This is an issue of signifi-
machinery builder. Not only are the documents
cance to any engineer trying to protect himself
absurdly expensive, it’s extremely difficult to
and his business.
fi nd the information pertaining to the situation
As to standards organizations, I’ve often felt
under investigation. It’s not unusual for these
some of them could significantly cut costs if they
standards to refer to other
would stop sending mail pushing their wares.
standards that are, again,
Think of the printing and postage that’s
absurdly expensive and
wasted. I order standards when I need them.
difficult to navigate.
All the junk mail goes to the recycle bin.
It’s my understand-
FEEDBACK
Isn’t It Supposed to Be About the Safety?
BRIAN WILLIAMS, principal member,
ing that these standards
B.R. Williams Control Services, williamscontrol.com
are established so the
equipment is safer. People
Ukraine Has Problems, Too
should be encouraged to
The problem has international character. In
use them. They should be
Ukraine, to receive the standard is even more
readily available at a min-
difficult. Even having paid, it’s possible to run
imal cost. They should be
into the Internet of swindlers. The position of
written and organized so
the state in a question of safety standards is
they’re easy to use.
not clear. The safety standards certainly should
MIKE DIMOND, electrical engineer,
be public and free. They’re important not only
Federal Engineered Systems, fesfillers.com
for the manufacturer, but also for a customer.
Now, someone makes business on the public
New, But Not Improved
interests paid by our taxes.
Well put Scott, but don’t stop with UL. The IEC
Electronic form standards (pdf file) has more
standard business is just as bad! How have we
convenient possibilities for search than looking at
managed to get from a point where, for example,
hundreds of paper pages.
back in the early ’80s the British standards were
available on microfiche. OK, they were hard to
access. You had to get access to a reader, but you
VOLODIMIR MAXIMOV, principal engineer designer of
department computer-aided systems and control
Khartep, khartep.com
only paid a one-off license fee.
But all of the information was available, and it
was worth seeking out. Now we have a the absurd
“improvement” brought by the Internet, which is
GIVE US A PIECE OF
YOUR MIND
easy to access, but is a difficult-to-navigate, information lottery, where you pay exorbitant amounts
for wordy documents that fail to provide value!
WYN OWEN, senior electrical instrument engineer,
The Savola Group, savola.com
Government Subsidies
Imagine how safety would improve if standards
were available for little or no cost. The government can subsidize corn, but not safety. Why do
we pay for an entire document when we only
need a small portion?
GLENN VIOLET, maintenance supervisor,
WE WELCOME your comments, suggestions,
criticism and praise. We’re particularly fond of the
praise, but we really do value the criticism.
E-MAIL US at CDFeedback@putman.net.
SOUND OFF on our forum at ControlDesign.com/MBF.
If you prefer, WRITE TO US at
CONTROL DESIGN, 555 W. Pierce Rd., Ste. 301,
Itasca, IL 60143
CALL US at 630/467-1300, or
SEND A FAX to 630/467-1124.
WE RESERVE the right to edit your comments for
clarity and space considerations.
Tooling and Equipment International, teintl.net
www.controldesign.com
CD0803_21_Feedback.indd 21
March 2008 Control Design
21
2/26/08 1:28:28 PM
OEM Sp otlight
indiscrETE
Hands Across the Water
Trumpf Uses Tele-Diagnostics to Fix 90% of Its Machine Problems
The Trumpf Group finished
its 2006-’07 fiscal year with
worldwide sales of €1.94 billion. Founded 85 years ago
in Stuttgart, Germany, when
Christian Trumpf acquired
Julius Geiger GmbH, the Trumpf
Group (trumpf.com) is the parent of Trumpf Inc., Farmington,
Conn., which manufactures
fabricating equipment and inTRUMPF
dustrial lasers for customers in
Canada, Mexico and the U.S. In
North America, Trumpf designs
and produces precision punching machinery, laser machin-
In-Sync ASSEMBLY
Trumpf’s Synchro Laser Machine Assembly addresses the demand for shorter
delivery times and keeps stock levels low.
ery, laser diodes, and gas and
solid-state laser resonators.
to physically attend to the
customer. “Tele-diagnostics
blocked by a firewall.
“For tele-diagnostics to work,
Diagnose From Anywhere
has become one of our most
the customer must be at his
Because of the global nature
powerful tools to provide our
machine to assist in estab-
of Trumpf’s business, after-
customers with very fast, real-
lishing communication and
sales support is more than
time and extremely effective
to ensure personnel safety,”
an afterthought. “Service is a
support” says Domingue. “It
explains Peter Grollman, prod-
clear indicator of a company’s
enables our technicians to ex-
uct manager, TruMark. “The
commitment to its customers
amine the customer’s machine
Trumpf service technician dials
and long-term growth,” says
controls without traveling
the number the machine is
Kevin Domingue, vice president
there. For the customers, it
attached to, the machine con-
of customer services. “Trumpf
means reduced travel expenses
nects, and the technician has
sets itself apart in the market
and waiting times. For us, it
full access and control.”
by supporting equipment with a
means that we can serve more
strong and committed customer
customers in less time.”
services and after-sales team.”
A variety of sensors em-
The exchange between
technician and customer is
supported through WebEx.
bedded in each machine
Through a graphing monitor
technologies in all areas of the
allow technicians to diagnose
system, screen shots are taken
company, including customer
remotely. Trumpf’s TruMark
and reviewed for deviations. “If
services, explains Domingue.
machines, for example, contain
a problem is detected, the tech-
Every contact with customers
more than 240 sensors that
nician can walk the customer
is recorded in an expansive and
gauge everything from electri-
through fixing the problem,”
customized database, so a full
cal and laser power to water
says Grollman. Trumpf can fix
machine and customer history
and air temperature. Data
90% of problems through tele-
is available to every service
is transmitted by an analog
diagnostics, he says.
technician, trainer, spare-part
phone line, using the PCAny-
administrator or CSR.
Where software and through
Trumpf embraces new
If a machine problem oc-
the Internet via WebEx, provid-
curs, in most cases a service
ed that the customer’s machine
technician usually is required
has Internet access that isn’t
22
CD0803_22_26_Indiscrete.indd 22
Control Design March 2008 More, More, More
To read more about Trumpf, visit
ControlDesign.com/trumpf.
www.controldesign.com
2/25/08 12:56:02 PM
CD0803_FPA.indd 23
2/25/08 10:56:55 AM
INDISCRETE
Milking Robot Uses Ethernet for Data
DUTCH COMPANY Lely
Industries’ (lely.com) Astronaut robotic milking system
uses sensor technologies and
integrated data management
to create a total dairy farm
management solution. The A3
model employs Ethernet to
optimize data communication.
Because a farmer can’t turn off
LELY
a cow’s milk production, reliability is a key issue.
“Our robots work 24 hours
a day, seven days a week, and
with our first implementation
NON-STOP PRODUCTION
Because a farmer cannot turn off a cow’s milk production, the Astronaut
milking robot is equipped for reliability.
of Ethernet networking in our
environment applications.”
Astronaut system, we wanted
botic milking systems, at Lely,
to have the highest levels of
in Maasslius, the Netherlands.
reliability,” says Sander J.P. van
“Furthermore, it’s unmanaged,
ernet switches are used for
Leeuwen, product specialist, ro-
so we chose switches for harsh
real-time data communication
Westermo’s SDW 550 Eth-
management between the
peripherals and the central
supervision PC, where information about the cows, milking, milk quality, feed-take
and machine setup is stored.
The peripherals can include
a direction system, which
sends the cows to a paddock
when they don’t need to be
milked or to a separate area
for veterinary checks; a cleaning system, which is used for
hygiene and food regulations;
a feeding system, which allocates feed to the cows; and
an alarm system, which alerts
the dairy farm manager of
problems occurring with the
cow or the robot that require
immediate attention.
When a cow enters the
milking robot, an identification system recognizes the
cow through its responder and
retrieves data from the database to determine if the cow is
due to be milked. A predetermined ration of concentrates
www.controldesign.com
CD0803_22_26_Indiscrete.indd 24
2/25/08 12:56:12 PM
RL-214 Data Station Ad_Control Design.qxd
3/16/06
11:22 AM
Page 1
let’s make this
simple.
Data Station. Protocol conversion. Ethernet gateway. IT-ready data logging. It’s all
here. With the new Data Station Plus from Red Lion, getting all your devices on the
same page is easy. First, the Data Station’s integrated protocol converter bridges the
communication gap between disparate serial and Ether net devices. And that’s just
the beginning. The “port sharing” facility allows the Data Station to act as a remote
serial port to your PC, meaning you can reprogram any connected serial device
from virtually anywhere in the world. An extensive selection of drivers allows easy
mapping of PLCs, PCs, SCADA Systems and more. The Data Station Plus collects and
stores values in “IT-ready” CSV (comma separated variable) files that can be
immediately used in applications such as Microsoft® Excel. And a built-in
CompactFlash® card slot provides unlimited data storage.
Web-enable your process. A built-in web server enables devices for remote
monitoring, operation, diagnostics and data acquisition via your LAN or the Internet. So now you can
easily create a "virtual" HMI for realtime monitoring from a remote PC, a PDA, or even a mobile phone.
Alarm notifications can be sent via email or text messages.
Handles data like SCADA. For thousands less. Best of all,
the Data Station series is remarkably affordable. Which makes the decision
very simple indeed. See all the features at www.redlion.net/datastation
trust+innovation®
Red Lion Controls ph: (717) 767-6511 fax: (717) 764-0839 www.redlion.net
CD0803_FPA.indd 25
2/25/08 10:57:16 AM
indiscrETE
then is allocated to the animal.
ing process, allows regulation
times the milk has to be trans-
Subsequently, brushes ensure
of each teat. The MQC-C sensor
ferred to an external bucket
thorough cleaning of the cow’s
system, which establishes
because the cow had antibiot-
teats, as well as udder bottom,
cell counts and checks milk
ics or is producing colostrum,
and the teat cups are attached.
color, conductivity and flow,
the first milk it produces for a
Teat positions are established
can detect and separate milk
calf. This decision and the cor-
by the TDS sensor, which
containing blood. X-Link is an
responding pumping have to
produces a rapid and accurate
ergonomically designed inter-
be processed quickly to allow
three-layer scan of the animal’s
face display with touchscreen
the next cow to be milked.
udder. Stimulation of the teats
control that allows on-machine
All data related to each
and udder during the cleaning
data management. The milking
milking also is processed in
process initiates and acceler-
box includes a rubber weighing
real time, including informa-
ates the onset of the milk flow.
floor equipped with sensors for
tion on milk quality, and are
The Astronaut A3 milking
determining the cow’s position
registered in the T4C man-
robot incorporates a variety
and an open-air gate, so cows
agement system, making it is
of features. A robotic arm, ca-
don’t feel separated from the
possible to access and manage
pable of withstanding a cow’s
herd, which puts them more at
the data of each individual cow
weight if stepped on, conveys
ease during milking.
from any location.
At the end of the milking,
A cow is free to visit the
cow so as not to upset the ani-
every robot asks the PC if it is
robot when it chooses and as
mal. The 4effect pulsation sys-
allowed to pump the milk to
often as it likes, resulting in
tem, which expedites the milk-
the main milk tank. Some-
yield increases of up to 20%.
the teat cups underneath the
YourTurn...
Get Reliable Angle Control
Without Contact
The RSC 2800 rotary
position sensor features
non-contact technology,
high accuracy and clearly
defined specs for ultimate
reliability and performance.
As with all Novotechnik
products, the specs tell
the story. Novotechnik’s
RSC 2800 Series sets the
standard against which
others are measured.
•
•
•
•
•
•
•
•
Angle measurements to 360º
Extended life >50 million movements
12-bit resolution
Independent linearity ±0.5%
Repeatability <0.1%
Sealed up to IP 67
Housing diameter of only 28mm (0.66 in)
Redundant output available
For our free position sensor catalog, contact:
CD0803_22_26_Indiscrete.indd 26
Novotechnik U.S., Inc.
155 Northboro Road • Southborough, MA 01772
Telephone: 508-485-2244 Fax: 508-485-2430
Web: www.novotechnik.com
MERGERS,ALLIANCES,
AND ACQUISITIONS
The Automation Federation
(automationfederation.org),
comprising ISA, OMAC, WBF and
WINA, has begun collaboration
discussions with the Manufacturing
Extension Partnership (mep.
nist.gov) on the identification
of projects and opportunities
to improve manufacturing
productivity and competitiveness.
The OPC Training Institute
(opcfoundation.org) has selected
Kepware Technologies as its
preferred demonstration product
for use in OPC hands-on training
workshops.
Wonderware (wonderware.com)
signed a strategic agreement with
Beijer Electronics and launched
a bundled solution that includes
a runtime license for a subset
of Wonderware InTouch 10.0
software and Beijer Electronics’
operator panel hardware.
www.controldesign.com
2/25/08 12:56:32 PM
Mar08-Linecard (CD).qxd:ELECTRONIC PRODUCTS
� 3M
� Cera-Mite/Vishay
� Chemtronics — See
ITW/Chemtronics
� Cherry Electrical Products, Inc.
� Chicago Miniature Lamp — See
� Aavid Thermalloy
CML Innovative Technologies
� Abbatron/HH Smith
� CII — See Tyco Electronics
� Abracon Corporation
� Advanced Micro Devices (AMD) � Cinch
� Agastat — See Tyco Electronics � Clarostat — See
Honeywell/Clarostat
� Agilent Technologies —
� CML Innovative Technologies
See Avago Technologies
� Coleman Cable Inc. (CCI)
� Agilent Technologies Test
� Collmer.com — See HVCA
Equipment
� AIM Electronics — See Emerson � Comair Rotron
� Condor — See SL Power
Network Power
� Akro-Mils
� Contact Connector — See
LAPP USA
� Alcoswitch — See Tyco Electronics
� Control Concepts — See
� Allied
Emerson Network Power
� Alpha Wire
� Conxall
� Altech Corp.
� Cooper Bussmann
� American Beauty
� American Electrical, Inc.
� Cooper Tools
� American Power Conversion (APC) � Copal Electronics —
See Nidec Copal Electronics
� American Zettler, Inc.
� Corcom — See Tyco Electronics
� Ametek — National Controls
Corporation (NCC) — See NCC � Cornell-Dubilier
� Cosel U.S.A. Inc.
� Ametek/Pittman*
� Ametek/TIP
� Crouzet
� Crydom Inc.
� AMP® — See Tyco Electronics
� Crystek Crystals Corp.*
� Amperite
� CSI/Speco — See
� Amphenol
Speco Technologies
� Amprobe
� Custom Connector
� Analog Devices, Inc.
� AND/Purdy Electronics
� Cynergy3 Components
� Anderson Power Products
� Angstrohm/Vishay
� APC — See American Power
� Dale/Vishay
Conversion
� Dallas Semiconductor
� API/Delevan
� Danaher/Veeder-Root
� APM Hexseal
� Dantona Industries, Inc.
� Arcotronics America, Inc.
� Davies Molding
� Areva/FCI — See FCI
� Dearborn — See
� Aromat — See Panasonic
Manhattan Wire Products
Electric Works
� Desco
� Aromat Controls — See
� Dialight
Panasonic Electric Works
� Diversified Electronics — See ATC
� Artisan Controls
� Draloric/Vishay
� ASC Capacitors
� Duracell
� Assembly Technologies — See
� Dymo — See Also RHINO
American Beauty
� ATC
� Atmel
� Augat — See Tyco Electronics
� Ault Incorporated — See SL Power � E-T-A Circuit Protection & Control
� Automatic Timing & Controls — � Eagle Picher
� EAO Switch
See ATC
� Eaton/Commercial Controls
� Avago Technologies
� Eaton/Heinemann
� AVX
� Axicom — See Tyco Electronics � ebm-papst
� EBT Optronic — See
� AZ Displays, Inc.
CML Innovative Technologies
� Ecliptek Corporation
� Edwards Signaling &
Security Systems
� Banner Engineering
� EIKO
� BCcomponents/Vishay
� BEI Duncan
� Elco/AVX
� Electrix
� Belden
� Electrocorp — See
� Beyschlag/Vishay
� BK Precision
Honeywell/Electrocorp
� Electronic Hardware
� Bogen Communications, Inc.
� Bomar Interconnect Products
Corporation (EHC)
� Bourns
� Electroswitch Inc.
� Box Enclosures
� Elmwood — See
Honeywell/Elmwood
� Brother International
� Buchanan — See Tyco Electronics � Elpac Power Systems
� Emerson Network Power
� Bud Industries
� Energizer
� Bulgin Components, plc
� Bussmann — See
� EnerSys (formerly Yuasa)
Cooper Bussmann
� ENM Company
� EPCOS
� EREM — See Cooper Tools
� ETI Systems
� Excelta Corporation
� C&K Components
� Extech Instruments
� C.K Tools
� Caddock
� Cambridge Products — See
Emerson Network Power
� Carling Technologies
� F. W. Bell (Sypris Test &
� Carlo Gavazzi, Inc.
Measurement)
A
D
© Allied Electronics, Inc 2008 ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.
An Electrocomponents Company.
E
CD0803_FPA.indd 27
B
C
F
2/4/08
5:29 PM
� Fagor
� Fair-Rite
� Fan-S — See Qualtek
Electronics Corp.
� FCI
� Fenwal — See
Honeywell/Fenwal
� FerriShield
� Floyd Bell Inc.
� Fluke
� Foil Resistors/Vishay
� Fox Electronics
� Freescale Semiconductor
� Fuji Semiconductor, Inc.
Page 1
� Jonard — See OK Industries
K
�
�
�
�
�
�
�
�
�
K-Sun
KEMET
Kester Solder
Keystone Electronics
Keystone Thermometrics — See
GE Infrastructure Sensing
Kilo International
Kilovac — See Tyco Electronics
Klein Tools
Kroy, Inc.
G
�
�
�
�
�
�
�
�
�
�
�
�
Garrett Electronics Corp.
GC Electronics
GE (General Electric) Capacitors
GE Infrastructure Sensing
General Cable Corp.
General Semiconductor/Vishay
Global Specialties
Globe Motors™
Grasslin
Grayhill
Greenlee
Guardian Electric
�
�
�
�
�
�
�
Hammond Manufacturing
Hammond Power Solutions
HARTING Elektronik
Hartman — See Tyco Electronics
HellermannTyton
Hermetic Switch, Inc.
HH Smith — See
Abbatron/HH Smith
High Voltage Power Systems —
See HVCA
Hirschmann*
Hobbs — See Honeywell/Hobbs
Honeywell
Honeywell/Clarostat
Honeywell/Electrocorp
Honeywell/Elmwood
Honeywell/Fenwal
Honeywell/Hobbs
Honeywell/MicroSwitch
Honeywell/Opto Products
Honeywell/Sensotec*
Honeywell/SenSym
Hoyt
Hubbell Wiring Device-Kellems
Hurst
HVCA
L
�
�
�
�
�
�
�
�
�
�
�
L-com Connectivity Products
Lambda Americas, Inc.
LAPP USA
Lascar Electronics
Lattice Semiconductor
Leecraft — See Lighting
Components and Design
Lighting Components and Design
Linemaster
Littelfuse
Lumberg
Lumex
H
�
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ICC/Intervox
Ico-Rally
ICP DAS USA
Ideal Industries
IDEC Corporation
Identification — See
Tyco Electronics
IEE
igus
Illinois Capacitor, Inc.
Infineon
Insultab
Integrated Device
Technology (IDT)
Intel
Interconnect Devices, Inc. (IDI)
International Rectifier
Intersil
Itailiana/Vishay
ITT/Cannon — See
C&K Components
ITW/Chemtronics
J
� JAE Electronics, Inc.
� Johnson Components, Inc. —
See Emerson Network Power
M
�
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Macromatic
Magnecraft/SE Relays
Mallory — See Cornell-Dubilier
Mallory Sonalert
Manhattan Wire Products
Marathon Special Products*
Marsh Bellofram — See ATC
Master Appliance
Maxim/Dallas Semiconductor
Measurements Group/Vishay
Menda
Merlin Gerin
Metcal
Meterman
MG Chemicals
Micro-Measurements/Vishay
Microchip
Microdot — See Tyco Electronics
Micron Technology, Inc.
Microsemi
MicroSwitch — See
Honeywell/MicroSwitch
Midtex — See Tyco Electronics
Mill-Max
Modutec (Jewell Instruments)
Molex
Molex/Waldom
Motorola Semiconductor — See
Freescale Semiconductor
Mueller
�
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�
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P&B — See Tyco Electronics
PacTec
Paladin Tools
Panasonic
Panasonic Electric Works
Panasonic Electric Works/Sunx
PanaVise
Panduit
Pass & Seymour*
Patlite
Payne Engineering
Pepperl + Fuchs
PerkinElmer Optoelectronics
Phihong
Philips Semiconductors —
See NXP Semiconductors
Phoenix Contact
PICO
Pilz
Plato Products
Platt Luggage
Polycase
Pomona Electronics
Potter & Brumfield — See
Tyco Electronics
Power-One
Power-Sonic
Primary Power Components
(PPC) — See Qualtek
Electronics Corp.
Products Unlimited —
See Tyco Electronics
P
�
�
�
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Q
� Q-Cee’s — See Tyco Electronics
� Qualtek Electronics Corp.
� Quest Technology
International, Inc.
R
RAF
Raychem — See Tyco Electronics
Recom*
Red Lion Controls
Redington Counters, Inc.
RHINO — See Also Dymo
Richco
Roederstein/Vishay
Rotron — See Comair Rotron
Ruland
�
Nanonics — See Tyco Electronics �
�
National Controls Corporation
(NCC) — See NCC
�
National Electronics
�
�
National Semiconductor
NCC
�
Neutrik
�
Nidec Copal Electronics
�
NKK Switches
Northern Technologies
�
NTE Electronics, Inc.
�
NXP Semiconductors
�
�
�
�
�
OEG — See Tyco Electronics
�
Ohmite
�
OK Industries
�
OKW Enclosures
�
Olflex Wire and Cable —
�
See LAPP USA
�
Olympic Wire and Cable Corp.
�
Omron Automation
�
Omron Electronic Components
SAIA-Burgess
SanDisk
Sanyo Batteries
Schaffner
Schrack — See Tyco Electronics
Schurter
Selco
SemiKron
Sensotec — See
Honeywell/Sensotec
SenSym — See Honeywell/SenSym
Serpac
Sfernice/Vishay
Shurite
Siliconix/Vishay
Silonex
Simpson
SL Power
SloanLED
SMC
Sola/Hevi-Duty
Souriau, Inc.
Speco Technologies
Spectra•Strip/ITD — See Amphenol
Spectrol/Vishay
O
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Omron STI
ON Semiconductor
Optek Technology*
Opto 22
Orion (Knight Electronics Inc.)
Osram/Sylvania, Inc.
�
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Sprague/Vishay
SRC Devices
SSP/Vishay
Staco Energy Products Co.
Stancor/White-Rodgers
Steinel
Sti (Scientific Technologies Inc.) —
See Omron STI
STMicroelectronics
Storm Interface
Streamlight
Struthers-Dunn
Sunbrite — See Lumex
Sunon Fans
SunX/Aromat – See Panasonic
Electric Works/Sunx
Superior Electric
SurgX — See Cooper Bussmann
Switchcraft
Sypris Test & Measurement —
See F.W. Bell
T
�
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�
Tadiran
Tapeswitch
Techspray
Techno/Vishay
TEKO
Tektronix
Teledyne Relays
Telemecanique
Texas Instruments
Thermometrics — See
GE Infrastructure Sensing
Thin Film/Vishay
Thomas & Betts
Thordarson Meissner
Time Mark Corporation
Toshiba
Triad Magnetics
Tripp Lite
TURCK
Twin Industries
Tyco Electronics
Tyton Hellermann — See
HellermannTyton
U
� Ultronix/Vishay
V
� Vector Electronics & Technology
� Viewsonics — See
Emerson Network Power
� Vishay
� Vishay Semiconductors
� Vitramon/Vishay
� Volex Power Cords
S
W
�
�
�
�
�
�
�
Waber by Tripp Lite
WECO
Weller — See Cooper Tools
White-Rodgers
Wire Pro, Inc. — See WPI
Wiremold
WPI
X
� Xcelite — See Cooper Tools
� Xicor
� Xilinx
Y
� Yuasa — See EnerSys
Z
� Zettler Magnetics
*New Supplier
Supplier Linecard
Your first choice for world-class brands.
1.800.433.5700
2/25/08 10:57:32 AM
www.eAutomationPro.com/US
CD0803_FPA.indd 28
1-800-205-7940
2/25/08 10:58:12 AM
Don’t Let the Media Get You Down
tic sea ice last year reached the highest level ever
recorded by satellites, it was pretty much ignored.”
internationally? Should we invest in next-gen-
He adds that Katrina in 2005 was a supposed
eration automaton systems for our machines?
harbinger of a coming stormier world. When the
The answer to all these questions is “Not if you
next two hurricane seasons were fairly calm, the
read the headlines.” But letting media headlines
alarmists changed the subject. “Droughts in Cali-
drive business decisions is problematic as the
fornia and Australia became the new harbingers of
media feeds on greed and fear, two of the most
climate change (never mind that a warmer planet
visceral human emotions.
is projected to have more, not less, precipitation
During most of my lifetime and certainly this
decade, the media focus has been on fear. It directly
contradicts long and short-term historical evidence.
History has been recorded with enough ac-
over all),” writes Tierney.
Tierney adds that Roger A. Pielke Jr., a professor of environmental studies at the University of
Colorado, recently noted the very different recepthe link between hurricanes and global warming.
The U.S. stock market has risen by an average of
“He counted 79 news articles about a paper in the
about 10% per year since 1925. More recently, the
Philosophical Transactions of the Royal Society and
global economy just completed its fifth straight
only three news articles about one in a far more
year of more than 4% growth, the longest period
prestigious journal, Nature. Guess which paper
of such strong expansion since the early 1970s.
jibed with the theory — and image of Katrina —
particularly long-term, reversals in these trends
would be rare and require irrefutable evidence.
Instead, the media takes the opposite tack and
daily proclaims the imminent demise of society
as we know it, unless we do something drastic.
bleak future, wandering a barren Earth in a futile
or every apocalyptic vision of the
F
future, why isn’t there a movie
depicting a much more likely and
dramatically better future?
Gloom and doom is not limited to newspapers
search for food and shelter. Who would hire any-
and magazines; movies chime in. I don’t recall
one or invest in anything, given such predictions?
one movie released during my adult lifetime that
Global warming is perhaps the best current ex-
dhebert@putman.net
take: it is already too late and we are doomed to a
ues Tierney in his article.
•
Those are the optimistic articles. The pessimistic
presented by Al Gore’s Inconvenient Truth?” contin-
portrayed the future in a positive light. For every
ample of media gloom and doom. Temperatures
Blade Runner-type apocalyptic vision of the future,
on Earth have been going up and down since the
why isn’t there a movie depicting a much more
dawn of human existence, and our ancestors
likely and dramatically better future? Shouldn’t the
seem to have coped fairly well. But now, predicted
burden of proof be on those who predict a radical
rises of a couple of degrees in temperatures over
reversal of undisputed historical evidence?
the next century are supposed to bring us to our
knees and destroy the global economy?
Don’t expect any rational opinions from the
Why is the media so relentless with unrealistic predictions of a dire future? My theory is
secular types who don’t believe in an afterlife
media in this area. Good examples of global
are terrified they will miss an earthly future
warming gloom and doom can be gleaned from
better than the present. The only way to assuage
a recent New York Times article, “In 2008, a 100
their fears is to convince themselves that the
Percent Chance of Alarm,” by columnist John
future will be downright awful.
Tierney. Here’s an excerpt. “When the Arctic sea
Believing headlines can lead to bad decisions.
ice last year hit the lowest level ever recorded by
In next month’s column we will show you how to
satellites, it was big news and heralded as a sign
get behind the headlines to source data and how to
the whole planet was warming. When the Antarc-
analyze these source data to get the real facts.
www.controldesign.com CD0803_29_Mojo.indd 29
senior technical editor
Knowing all this, any prediction of short, and
•
tion received last year by conflicting papers on
improving dramatically for thousands of years.
Dan Hebert, PE
curacy to know that standards of living have been
machine builder mojo
Should I hire that promising new person?
Should we push forward to expand our markets
March 2008 Control Design
29
2/21/08 9:57:22 AM
ESX10EDN_Single Pg Ad_v2
1/23/08
11:38 AM
Page 1
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For more information go to: www.e-t-a.com/future
CD0803_FPA.indd 30
2/25/08 11:08:00 AM
IEC 61131 Cage Match—Prologue
ISSC, knew what those advantages could be. But
standard for industrial control programming of
the reality didn’t live up to the claims.
PLCs and embedded controllers. “This emperor
OMAC promoted IEC-based programming for
has no clothes,” stated Ken Crater, president of
any controllers that were to be used. GM, one
Control Technology Corp., in his remarks at the
of the biggest contributors to OMAC, decided to
ISA conference session I organized some 12 years
standardize on Allen-Bradley hardware, and its
ago, making an analogy to an age-old fable.
software was not IEC-based. So much for that.
Dick Morley, the consensus inventor of the
IEC 61131 is an opportunity for vendors to use
PLC, had mugs made that rather sarcastically
words such as compliant and compatible, a mar-
read: “IEC 61131 and MAP—Partners in Suc-
keting tactic to gain some traction. It’s like high
cess.” Clive Smith, then product manager for
school: Even though you can’t dance, you still
Schneider Electric, the developers of Concept
need to be at the party.
IEC 61131 programming software, broke one
IEC-based software isn’t a requirement in the
minds of most end users. Vendors have chosen
that Morley was old school and off the mark.
to support the specification because of percep-
Schneider Electric had bought Morley’s old
tions, global marketing and support for multiple
company, Modicon, and developed an IEC 61131
hardware platforms. There’s also another impor-
programming package for this product line.
tant reason: They can buy a third-party devel-
In several upcoming columns, I’ll let off a little
opment package, tune it to their hardware and
have a programming solution without a huge
surrounding IEC 61131, particularly what it is,
development effort. The success of OPC allows
what it isn’t and what it really means to a user.
a hardware vendor to develop a communication
2006, I was the North American managing director for PLCopen, the international organization
“Standards are great. There are so many
to choose from.”
supporting IEC 61131. I learned a lot during that
time about the document and its user and vendor
driver, buy the development environment and
support, and I made many presentations on the
have a full software support system without
technology and its applications.
leaving its core competencies.
One of the first vendor presentations on the
But do we, the technology consumer, care about
subject I witnessed was from a sales guy from
having a standard? Is it important to be able to do
what was then Moore Process Solutions. He held
some things with Siemens software that we can
up a floppy disk—yep, it was that long ago—and
do with Rockwell software?
said that a program from any IEC 61131 control-
We are in the same pickle we’ve always been
ler could be loaded into a Moore process system
in—attempting to use proprietary software with
simply by loading the program from the disk.
proprietary hardware.
That was wrong. I knew it, but no one else did.
In that time and place of independent software
I think the IEC 61131 specification is not a userbased spec or standard, but a vendor specification
companies, there were many that grabbed the
for software development. It is a standard much
opportunity to develop and promote IEC-based
like SQL and UNIX are. While a software method
products, especially in the soft-PLC world. Many
might be called a standard, it really isn’t. TCP/IP is
product performance claims were made to pro-
a standard—there’s no waffling from the design.
mote the sales needed to recoup the development
costs. These comments made the product seem
complete and regularly promoted the future of
portability and standardized programming.
Those who had struggled with the transition
between Modicon and Allen-Bradley, and maybe
www.controldesign.com CD0803_31_EmbedIntel.indd 31
jpollard@tsuonline.com
I’m not exactly neutral about it. From 1999 to
•
steam about this “standard” and bust some myths
Jeremy Pollard, CET
of these mugs with a hammer, suggesting
embedded intelligence
The topic was IEC 61131, the international
Who was it that said, “Standards are great.
There are so many to choose from.”?
jeremy Pollard has been writing about technology and
software issues for many years. Publisher of The Software
User Online, he has been involved in control system
programming and training for more than 25 years.
March 2008 Control Design
31
2/22/08 10:03:09 AM
CD0803_FPA.indd 32
2/25/08 11:08:31 AM
WeC
Teenagers Take Test Flights in JETS
Students are invited to “try on” engineering in
the Explore step. “Experience in our two com-
education organization you might not know about.
petitions has helped students make decisions
About half of JETS’s 40,000 student participants
about engineering careers,” says Yoder. Whether
it’s through the National Engineering Design
underrepresented in engineering and technology
Challenge (NEDC), a team competition in which
fields. And those students are reached largely
students create a real-life, assistive-technology
through 10,000 educators at 6,000 high schools.
device to aid individuals with disabilities, or via
While JETS might be relatively unknown by the
TEAMS, a one-day, two-part-test competition for
Mike Bacidore
each year come from groups that typically are
LIVE WIRE
The Junior Engineering Technical Society
(jets.org) is quite possibly the oldest engineering
•
high school students held on university and col-
educational groups is what gives JETS its wings.
lege campuses around the U.S., participants have
“We attend various educator conferences,”
says Leann Yoder, executive director of JETS in
the opportunity to take an engineering career
out for a test drive, of sorts.
Alexandria, Va. “We’re well-known by our current
Real World, Real Solutions
ing out to other organizations. We’re developing
JETS’s big payoff is NEDC. This year’s winner,
new ways to get our university and professional
Gardner Edgerton High School, in greater Kan-
societies to become better advocates of what JETS
sas City, designed and built the bag attachment
does. We’ve also developed an alumni network
and replacement technology (BART) for a real
that we hope will get those people that benefited
school custodian who has a disability. Real
from JETS programs to become advocates of JETS.”
world. Real solution.
firmware designer at Rockwell Automation in
Milwaukee, where he first was exposed to JETS in
high school at Boys Technology and Trade School.
“Experience in our two competitions has
helped students make decisions about
engineering careers.”
mbacidore@putman.net
One JETS alumnus, Brian Cieslak, is senior
•
contacts, but we need to step it up when reach-
managing editor
general public, its longstanding affiliations with
“JETS was the science club at Boys Tech,”
explains Cieslak. “Being a child of the Space Race
“He couldn’t tie the trash bags,” explains
and Nuclear Age, I was always interested in sci-
David Kling, Edgerton’s industrial technology
ence, so when I learned about JETS from a friend
and energy manager. “Our students analyzed
of mine, I was excited to start hanging out with a
the problem, modeled it, and went about finding
bunch of fellow amateur scientists.”
a solution. They tested and tested and reconfigured. It evolved from that. Steven, the custodian,
Explore, Assess, Experience
JETS encourages students to look at engineering
now uses this regularly in his job.”
Kling, who coaches the team along with
and technology as career options by offering a
chemistry and physics teacher Larry Ward, had
three-step process of discovery.
invaluable help from Stacey Heine, a retired Hon-
In the Explore step, students go online, read sce-
eywell engineer, who acts as the team’s advising
narios, articles and profiles, watch videos and learn
engineer. Kling explains that the recognition
about the many areas of engineering. “By relating
for winning the competition needs to go to the
stories and scenarios to real life, young people can
students, and how well they worked together in
see where they might fit as an engineer,” says Yoder.
a variety of disciplines.
In the second step, participants take inventory
of, or assess, current abilities in subject areas
important to success in engineering. “This step
doesn’t rule out or verify a specific area of engineering, but it lets students determine if they’re
on the right path in subject areas important to
More, More, More
To read more about JETS, visit
ControlDesign.com/jets.
To read JETS’s in-depth interview with Brian
Cieslak, visit ControlDesign.com/cieslak.
engineering success,” she explains.
www.controldesign.com CD0803_33_LiveWire.indd 33
March 2008 Control Design
33
2/26/08 1:58:16 PM
ow the Control Design audience researches, specifies and buys
machine automation products and services is the subject of
research we conducted earlier this year to determine whether
the habits of this population are changing in these endeavors.
The first two years of this annual study confirmed the steady migration away from more-traditional distributor relationships and tradeshow trips to a far wider use of Internet-based tools.
This year, we looked into some of those areas again to see if things are
still changing and added other areas of this subject to explore. We use these
findings to get a better sense of how to build content that helps you with these
issues. It also provides something of a snapshot of how your buying habits are
evolving, compared with those of your peers. In previous years, it has pointed out issues
that the supplier community needs to pay heed to in order to better serve your needs.
Calling The Shots—More Than Ever
In 2006, our respondents said they make the primary automation choices for their
machines about 67% of the time, with customers doing so about 28% of the time. That
seemed high. We asked the same question in 2007 and got similar results—65% said
they make those choices for their machines.
We repeated that question this year and, once again, 64% of the machine
builders say they make the decisions, with customers calling the shots
about a quarter of the time.
34
Control Design March 2008 CD0803_34_43_CvrFtr.indd 34
www.controldesign.com
2/26/08 11:56:06 AM
We asked system integrators the same question
more product categories in the past year. About
and found when they’re involved in a machine
one-quarter said they’ve changed primary sup-
automation project, they make the automation
pliers for controllers, I/O, sensors/measurement
decisions about half the time, with the machine
and motors/drives (topped the list at 27%). Some
user doing so about one-third of the time.
16% said they’ve changed their primary supplier
There wasn’t a great deal of variation in these
responses among the various machine builder
market segments participating (see demograph-
of mechanical components, while 17% changed
OI/HMI suppliers.
Given the level of churn, we surely wanted to
know why (Figure 1). Of those who changed sup-
ics breakdown).
pliers for at least one product category, 29% cited
Change Partners
product quality and performance problems. Price
This year we asked the study participants about the stability of their
was cited by 22%. And a discontinued product line
was noted by 20% of the respondents.
supplier relationships. Anecdotally, it seems that suppliers
and users want to establish
lasting partnerships.
This was the most surprising finding this year.
Fifty-two percent said
they changed primary
suppliers for one or
The Search Leads to …
Each year we ask about our participants’ primary
method for doing product research. We expect
a continuation of the trend toward more use of
Web-based research tools at the expense of local
distributors and trade shows.
This year, 35% of our respondents say their
most-used method for automation product research is searching vendor web sites. That’s up
from 30% last year and 25% in 2006.
Meeting/speaking with local reps and distributors stayed statistically constant at 25% this year
from 26% in 2007 and 27% in 2006. Figure 2 summarizes these findings.
In Your Face to Face
We wanted to follow up on evidence that said our
respondents want more direct contact with suppliers’ technical people and cite frustration due
to a lack of availability of these experts.
Figure 3 indicates what we found when
participants agreed or disagreed with various
statements about the values that direct contact
with vendor experts can bring.
A clear 63% strongly agreed they get better
technical information directly from the vendor
source than from local distributors. But only 38%
strongly agreed it was better than information
from local sales reps. In both cases, the total that
agreed strongly or somewhat exceeded 90%.
A full 42% strongly agreed and an additional
39% agreed somewhat that they can have more of
www.controldesign.com CD0803_34_43_CvrFtr.indd 35
March 2008 Control Design
35
2/26/08 11:57:12 AM
Of those who changed suppliers for at least one product category,
29% cited product quality and performance problems.
a solutions-based discussion with
the suppliers’ technical experts.
the experts were eager to please.
On the downside, 54% of the
A new question this year finds
that nearly four in 10 admit that
respondents disagreed somewhat
part of the problem in successfully
that the supplier’s technical
or disagreed strongly that these
working directly with the experts
experts were eager to help, a reas-
experts are easy to reach or that
is that they themselves are guilty
suring 54% agreed somewhat that
they receive prompt callbacks.
of being non-responsive to the
While only 16% strongly agreed
manufacturers’ advances.
Search and Annoy
Once these respondents decide
to do their product and specification research on the Web, where
do they start if they don’t have a
particular brand in mind? The clear
destination is Google, but the trend
continues to drift down: 60% this
year, 63% last year and 68% in 2006.
It appears that the frustration
of trying to do technical search
via this type of search engine is
growing. Looking further into their
beliefs about and expectations of
What
happened...
Google, Yahoo and other search
Respondent Demographics
Assembly . . . . . . . . . . . . . . . . . . . . . 9%
Machining Centers. . . . . . . . . . . . . 4%
Material Handling . . . . . . . . . . . . 11%
Metalworking. . . . . . . . . . . . . . . . 10%
Packaging . . . . . . . . . . . . . . . . . . . 12%
Plastics/Molding . . . . . . . . . . . . . . . 4%
Printing/Converting . . . . . . . . . . . . 6%
Semiconductor Tools . . . . . . . . . . . 5%
Specialty Machines. . . . . . . . . . . . . 3%
System Integrators . . . . . . . . . . . . 18%
Other . . . . . . . . . . . . . . . . . . . . . . . 17%
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Other . . . . . . . . . . . . . . . . . . . . . . . . 2%
Is your Internet access
at work limited by:
Company policy . . . . . . . . Yes . . 40%
Security issues . . . . . . . . . Yes . . .41%
Bandwidth limitations . . Yes . . .18%
RESPONSES FROM 200+ STUDY PARTICIPANTS
36
Control Design March 2008
CD0803_34_43_CvrFtr.indd 36
www.controldesign.com
2/26/08 11:57:54 AM
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CD0803_FPA.indd 37
2/20/2008 2:01:04 PM
2/25/08 11:09:11 AM
Perhaps, our biggest invention
since the original PLC.
When we introduced the first
programmable controller back in
1968, the Modicon ® PLC quickly
became the standard for
machine control in a wide
range of applications. Forty
years later, the world has
changed and Schneider
Electric has not only
evolved with it, but
continues to be a
pioneer in the industry.
Proof of point, the
new Telemecanique ®
brand Modicon ®
M340™ programmable
automation controller
(PAC). More powerful
than any other PLC in
its class, its modular
design and networking
abilities make it ideal
for both simple and
complex applications.
But even more important is
the peace of mind you get from
the 40-year history of excellence
built into every Schneider Electric
automation product.
That makes the Modicon M340 PAC our biggest
innovation to date. Even if it is only 4 inches high.
45940_SD_ControlDesign.indd 1
CD0803_FPA.indd 38
2/12/08 3:57:22 PM
2/25/08 11:10:21 AM
FIGURE 1. WHY YOU CHANGED SUPPLIERS
Quality/Performance
Price
Discontinued product line
Hard to contact/get info/help
Poor after-sale support
Wanted open-standards architecture
Old supplier merged/bought by another company
29%
22%
21%
9%
7%
7%
5%
engines, 14% agreed strongly and
want: be easy to navigate, have
another 55% agreed that first-page
easy-to-find technical details, and
search results contain well-fo-
offer downloadable product manu-
cused hits. Those numbers were
als, schematics and similar refer-
20% and 60% last year.
ences, as well as price lists they
The respondents also agreed
can trust. Many of the respondents
(48%) or agreed strongly (32%) that
want to find complete, uniformly
too many of the results have noth-
presented specifications, so they
ing to do with what they’re actu-
can do product-to-product and
ally looking for. Nineteen percent
vendor-to-vendor comparisons.
HART
The number of complaints
agreed strongly last year.
about sites not providing this
Vendor Site Seeing
seemingly basic help is significant
The largest segment of respon-
and is most often accompanied
dents begins its search at supplier
by a reaction that they’re being
web sites, and many visit multiple
marketed to, not helped.
vendor sites to be satisfied they’ve
Two prevalent complaints
seen enough. Fifty-one percent
involved “finally seeming to find
said they visit two or three sites
the area you were looking for only
to do their research. Another 36%
to be asked to register or fi ll out a
need to visit four to six sites.
‘contact me’ form.”
There’s a wide range of respons-
When it’s good it’s good: “We
es, based on actual experience,
are a very small company,” says
as to what makes a supplier web
another respondent. “We mostly
site good or bad. The hundreds of
buy motors, drives and other
comments distill down to a few
control components through
no-brainer basics that visitors
established local distributors,
FIGURE 2. PREFERRED METHODS FOR PRODUCT RESEARCH
Meet/speak with local distributors
Meet/speak directly with automation supplier
technical engineers/product managers
Visit suppliers at trade shows
Search independent, non-vendor web sites,
automation communities, magazine web sites
Search the suppliers’ web sites
Read trade magazines
80%
0% 10% 20% 30% 40% 50% 60% 70%
Most used
www.controldesign.com
CD0803_34_43_CvrFtr.indd 39
Second-most
Least used
March 2008 Control Design
39
Jumpflex_CD_Mar o.indd 1
2/26/08 11:58:14 AM
2/14/08 4:00:33 PM
“We are very small. We mostly buy components through local distributors, but we
greatly value web sites that provide complete engineering and product specs.”
but we greatly value web sites,
which provide complete engi-
Global Search Angst: What You Think About Search Engines
neering and product specification
data and allow us to buy all our
software, communications adapters, accessories and simulation
software online.”
Practical applications were on
the wish list: “All product vendors
would benefit by providing user
examples with their content.
Many times, after I review an
example, I can properly decide if
this is the right product for me.”
The first page of results contain well-focused hits
I worry that the top of the list is simply bought
and paid for regardless of its relevance
Too many results are biased vendor product plugs
Too many results are outdated information
Too many results actually have nothing to
do with what I'm looking for
It's a pain to sift through the results, but at this point
there's no better Web-based research tool for me
Buying Online?
0
With your stated move to more
Strongly agree
use of online research tools, we
10
Agree
20
Disagree
30
40
50
60
Strongly disagree
anticipated fi nding some corresponding increase in the number
decline compared with the 2007
21% said they buy from online
of controls professionals who buy
fi ndings. Only 19% of the respon-
catalog stores. The number was
automation and control compo-
dents said they buy online via a
about one-third in both catego-
nents online. We actually found a
manufacturer’s web site, while
ries last year.
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CD0803_34_43_CvrFtr.indd 40
WWW.ADALET.COM
2/26/08 11:59:05 AM
FIGURE 3. DIRECT CONTACT WITH SUPPLIER TECHNICAL EXPERTS
Get better technical info than from distributors
Get better technical info than from local sales reps
Get better updates on full product line
Get more discussion of solutions, not just products
Easy to reach
Get prompt callbacks
Eager to help
Doesn’t matter if I’m an existing customer or not
They don’t give you much time to explore the problem
Tend to push “canned” solutions
Sometimes expertise is actually low
You don’t respond well to direct inquiries from the experts
0
Strongly agree
Agree somewhat
10
20
30
Disagree somewhat
40
50
60
Strongly disagree
Decision Making
All About Delivery?
The study respondents evaluated
Our job as a content provider is to
the importance of various factors
deliver high-quality information
in their purchasing decisions. The
in ways that best help machine
factors most identified as extreme-
control professionals research
ly important were “easy to use,
and specify products and ser-
install and maintain,” followed by
vices. We have to try to evaluate
“dependable after-sales service
and anticipate your affi nity for
and support,” and then “connects
newer and emerging methods of
easily with existing systems” and
information delivery beyond a
“offers highest product quality.”
print product.
Lowest price was an “impor-
Until last year, we had little
tant” factor for 48% of the respon-
more than anecdotal evidence
dents, but only 13% considered it
about the value you place on
extremely important. The most
information-delivery methods,
ambiguous result here showed
such as webinars, video, podcast/
40% finding it important that a
MP3 downloads, online forums
product already be installed in
and blogs, but more importantly
their machines, and 14% consid-
whether you use any of them to
ered it an extremely important
help you do your job.
purchasing factor. Forty-six
As we continue to track usage,
percent disagreed, calling it a “not
we’ll begin to sense trends in
very important” factor.
your affi nities or lack thereof to
www.controldesign.com
CD0803_34_43_CvrFtr.indd 41
March 2008 Control Design
41
2/26/08 11:59:32 AM
“Forums provide the opportunity to send your question to many people—
experts, novices—and maybe some of them can help.”
“Forums provide the oppor-
these methods. This migration to
of the bunch is forums/bulletin
embracing “different” content-de-
boards. This year, 14% of respon-
tunity to send your question to
livery methods still is a slow work
dents said they use the medium
many people—experts, novices—
in progress (Figure 4).
weekly, and 41% use it monthly.
and maybe some of them can
That’s far better than any of the
help,” says a respondent. “The
others we asked about.
probability is that more than one
The one medium clearly perceived as the most worthwhile
person has had the
type of problem I have.”
Peak Performance
Another respondent says he
likes “the almost unrestricted
sharing of knowledge on many
issues concerning my job as a control automation engineer.”
One in 20 responders said they
use webcasts weekly in job-related
activities. Another 16% said they
use them monthly. That’s hardly an
endorsement, but you might argue
there’s some curiosity about them,
as another 38% said they use them
on rare occasions/no more than a
few times a year. A quarter of the
respondents never use them at all.
“They are quick, no lost travel
time and informative,” is one comment. “If the topic isn’t appropriate,
I just disengage.” Another respond-
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er says he uses webcasts from time
to time to be able to see a demonstration of a product without having to leave the office.
On the other side, “podcasts
and videos take too long to extract
content,” says a participant. “You
can’t speed-read them. I can read
or reread faster than someone can
speak or have to re-cue to review
… would prefer to read as opposed
to watch/listen.”
A perceivable theme among
those thinking well of webcasts is
a preference for product demos,
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not industry issues.
Podcasts/MP3 downloads of interviews with vendors or machine
builders barely have a pulse again
this year. Less than 8% make use
of these podcasts/MP3 downloads
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Control Design March 2008
CD0803_34_43_CvrFtr.indd 42
at least monthly. About half of the
respondents said they never use
them at all.
www.controldesign.com
2/26/08 11:59:57 AM
ContDes_MAR08_Relays_v2:Weidmuller_ContDes_1_3
PUSH US
AROUND
FIGURE 4. HOW YOU VALUE NEWER METHODS OF INFORMATION DELIVERY
Webcasts
MP3s/podcasts (interview vendors)
Space-Saving Relays—
Now With Push-In
Connection Technology
MP3s/podcasts (interview machine builders)
Videos from/about vendors/products
• Reduce installation
time by 70%
Video downloads (interview machine builders
and show automation on machine)
CONNECTION
TECHNOLOGY
• DIN-rail mounted
compact footprint
Forums/bulletin boards
Web logs (blogs)
0
Use often (weekly)
for job
Use occasionally
(monthly) for job
10
20
Use rarely (once or
twice a year) socially
30
40
Never use
for job
50
60
Never use
socially
Videos might show some prom-
tion. “Same goes for most forums
ise, although the responses are an
and blogs. Lots of time and effort
emergent data point we didn’t ask
to get very little benefit.”
about last year. However, 23% of
Another says, “Yes, you must
the respondents say they use this
accept that many of the listed
medium at least monthly, in par-
responses are very biased. But the
ticular vendor-created videos about
nature of the discussions and the
products. “I really like vendors who
types of questions presented serve
have videos on how to configure
to offer important information
and deploy products,” reflects the
about a product and the organiza-
thoughts of many respondents.
tion behind it.”
Blogs showed some life com-
It seems that there’s a loose
pared to last year, when 12% said
confederation of engineers out
they used them in job-related
there that thinks its best bet for
activities at least once. This year,
unbiased Internet-based opinion is
we discussed information delivery
the forum, but they’re wary of an
and frequency. We found 7% use
inherent bias/agenda in bloggers.
blogs weekly, and another 19% use
them monthly. As with webcasts,
any use for these tools at all, it’s
there might be some curiosity
easy to summarize the comments.
that could turn into more interest:
The clear belief, experienced or
30% say they’ve on rare occasions
presumed, is these types of mate-
visited a job-related blog.
rial are too much commercial,
“Most vendor videos and many
provide enough real user help.
sales pitches with too little engi-
Additional study findings
neering info to be worth my time
can be found at ControlDesign.
to watch,” is a pretty typical reac-
com/08habits.
CD0803_34_43_CvrFtr.indd 43
US:
March 2008 Control Design
i n f o @ w e i d m u l l e r. c o m
1-800-849-9343
w w w. w e i d m u l l e r. c o m
C a n a d a : i n f o 1 @ w e i d m u l l e r. c a
1-800-268-4080
contain too much bias and don’t
webcasts and podcasts are flash
www.controldesign.com Learn more about
Rider Relays at:
Among those who don’t have
w w w. w e i d m u l l e r. c a
M e x i c o : c l i e n t e s @ w e i d m u l l e r. c o m . m x
01 222 2686267
w w w. w e i d m u l l e r. c o m . m x
43
2/26/08 12:00:21 PM
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Drives & Motion C ontrol
The Not-So-Odd Couple
Like an Old, Married Couple, a Motor and Its Generator Are Bound Together.
One Does Not Exist Without the Other
by Ernst Dummermuth
Some important properties and characteristics
+
of electric motors and electric generators can be demonstrated easily using an actual motor and generator.
Grade or middle-school students could conduct these
–
+
+
+
–
–
+
+
–
experiments. Through my own experience, I’ve obtory table, can be very useful as a teaching tool.
Basically Speaking
Motors come in all shapes and sizes and are used mostly to convert electrical energy to mechanical energy
via the rotation of a shaft. The primary electric source
in a home is single-phase, 110 Vac. For simplicity and
–
–
served that these experiments, executed on a labora-
+
DC Motor dynamics
–
+
Figure 1: The
– stator has the fixed, permanent magnet, while the
rotor is composed of a number of windings. To sustain rotation,
+
and since the permanent magnet cannot
the
– be reoriented,
+
electromagnets must be activated or deactivated. This shows
rotor postion at–startup and after one commutation.
reduced control circuits, many of these motors turn
A
Position of Rotor
Time
only in one direction. In your car, the motors run on 12
on the stator and one magnet is on the rotor. If those
Vdc—the starter being the strongest electric motor in
magnets aren’t lined up, the rotor
A will Bturn until
C they
+
designed for higher DC voltages or multi-phase AC
–
+
mechanical outputs, and use much larger motors
+
+
0
+
Industrial applications often require much higher
+
–
+ – rotation
do. Once the
stops.
– magnets are lined up,
–
a conventional automobile.
10
–
–
+
–
These magnets+could be permanent, rare-earth,
magnets or quasi-permanent
magnets—electromag-10
C
B
nets with coil windings driven
a DC
0 60by
120
180 current.
240 300 360The
60
Phase Angle in Degrees
voltages. These motors also have much higher cur-
other magnet is an electromagnet, the orientation of
rent ratings.
which is modified continuously. As a result, the rotor
Generators usually aren’t found in a household.
keeps trying to line itself up. If this magnet modifica-
Some houses have emergency generators, in case pow-
tion is done in an intelligent way, such as in a rotation
er is lost. Every automobile has a generator to provide
to the right, then the rotor will rotate to the right.
electricity for ignition, various fans, accessories and
lights, and to recharge the battery.
DC Motors
On the whole, most generators are big and supply
To sustain rotation, and since the permanent magnet
power grids with electricity. It takes a lot of mechani-
can’t be reoriented, the electromagnets must be acti-
cal power to crank these shafts. Mechanical power is
vated or deactivated. In a typical DC motor (Figure 1), the
obtained by making steam in power plants from coal,
gas and nuclear sources, with diesel engines or hydro
turbines, or more recently with wind turbines on hilltops, often in groups as windmill farms.
Motor Designs 101
Motors are based on the principle that opposite polarity magnets attract each other, while magnets of the
BASICALLY SPEAKING
How helpful do you find refreshers and primers
on engineering topics? Do back-to-basics articles
provide you with the kind of information
that helps you to perform better as a controls
engineer? Which topics would you find helpful?
Sound off at ControlDesign.com/refresher.
same polarity repel each other. One magnet is located
www.controldesign.com CD0803_45_56_Drives.indd 45
March 2008 Control Design
45
2/26/08 12:13:05 PM
ARE YOU CONFIDENT WITH
THE PROTECTION PROVIDED
IN YOUR PLANT?
+
–
+
+
+
+
+
–
–
Drives & Motion C ontrol
–
–
–
+
–
–
+
–
+
+
–
Position of Rotor
Time
A
The brushless
DC Motor
10
Figure 2: The permanent magnet is on the rotor. External
A
B
C
+
solid-state switches turn on the proper stator winding as a
–
0
function of the rotor orientation.
+
C has the fixed, permanent
B -10 magnet and the rotor is
stator
+
+
+
–
+
+
+
–
–
+
–
–
–
–
0 60 120 180 240 300 360 60
composed of a number of windings.
Phase Angle in Degrees
Basically, one or two windings are activated at a
time via commutation, depending on the number of
coils on the rotor. At start-up (referring back to Figure
1), the green winding is activated. With the polarity
shown, the rotor will turn clockwise, trying to align
the green magnet with the stator magnet. As the rotor turns, the blue coil becomes activated, while the
green coil is deactivated, and so on, as shown after
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CD0803_45_56_Drives.indd 46
discrete steps, according to the number of rotor windings, while the rotor turns. Details about pole shaping
and arrangement of air gaps aren’t shown. The rotor
could have many more individual windings, and for
that reason, two or three adjacent windings could
make contact through commutation at any one time.
In another form, called a brushless DC motor or an
inside-out DC motor (Figure 2), the permanent magnet
is on the rotor. This magnet again can be a rare-earth
magnet or a fixed electromagnet connected via slip
rings. External solid-state switches turn on the proper
stator winding as a function of the rotor orientation.
The commutation takes place in the stator windings.
When the red stator coil in Figure 2 is turned on, the
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first commutation. The rotor field is reoriented in
At that time, commutation moves to the blue coil and
excitation moves from one phase to the other, turning
the different stator coils on and off. At standstill and low
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Synchronous Motors
A synchronous motor is basically the AC equivalent
to the brushless DC motor just discussed. In these
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2/26/08 12:13:19 PM
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CD0803_FPA.indd 47
2/25/08 11:11:24 AM
+
–
–
A
Position of Rotor
In general, the outside field for
tor is lined up almost exactly with
C
B
–
B
C
–
–
+
+
obtained from the three-phase, 60
is connected to the motor, the ro-
0
+
+
–
phase, sinusoidal excitation
A
+
Time
+
10
+
same speed as the outside field.
–
motors, the rotor turns at the
a synchronous motor is a three-
+
–
Drives & Motion C ontrol
Hz line. When no mechanical load
–
+
+
+
+
–
–
–
-10
0 60 120 180 240 300 360 60
Phase Angle in Degrees
the stator field (Figure 3). As the
mechanical load increases, the rotor lags the stator field by several
synchronous = AC brushless
degrees, but is still in step with
Figure 3: In general, the outside field for a synchronous motor is a three-phase,
sinusoidal excitation obtained from the three-phase, 60 Hz line.
the field. If the load is increased
beyond the rated value, the rotor
started from standstill by simply
Induction Motor
turning on the three-phase AC. It
At first glance, an induction motor
the rotor follows behind the sta-
needs to be brought up to speed
(Figure 4) looks like a combina-
tor field by several degrees. If the
by auxiliary means before it can
tion of the DC motor (Figure 1) and
load increases, the lag increases
be connected to the line. Then it
the synchronous motor (Figure
and vice versa.
turns synchronously with the three
3). It has many rotor windings,
phases no matter what the torque.
similar to the DC motor, but they
will fall out of synch and stop.
With a moderate load applied,
A synchronous motor can’t be
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CD0803_FPA.indd 49
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2/25/08 11:11:50 AM
Drives & Motion C ontrol
–
C
+
–
+
– B
–
+
–
C
0
B
–
–
+
+
A
+
–
+
Time
Current
10
+
+
A
+
–
–
-10
0 60 120 180 240 300 360 60
Phase Angle in Degrees and Rotor Orientation
Time
A
10
+induction motor also has many rotor windings, they are
Figure 4: While an
A
C
individual short-circuit windings in different orientations.
+
0
+
–
again, and the strong stator magaren’t connected to any external
source or commutation. These are
C -10 nets now appear 60º turned. Note
Induction Motor Characterisitics
+
–
–
–
+
+
+
–
that the rotor magnet is reestab-
individual short-circuit windings
–
0 lished
60 120
180 240
300 360
60 the
through
induction
when
in different orientations.
Current Phase Angle in Degrees
current in the stator changes most
If a fluctuating stator field is applied, the changing magnetic flux
rapidly at zero crossings of the sta-
induces a current in at least one
tor current.
The condition described here is
of the rotor windings, and thus
creates a rotor magnet of opposite
under no load. Under load, induc-
polarity in that plane. At the same
tion motors turn more slowly than
Time
A
Current
the driving stator field.
This speed
10
loss is called the slip. When slip
tor windings—60º
+ and 120º offset
A the rotor
B basically
C falls one
occurs,
to the rotor magnet—produces
+
strong stator magnets.
+ As with the 0 rotor-winding back and continues
+
–
–
–
+
+
time, the current in the other sta-
+
–
–
–
to fall further back over
time.
Slip
align. After a 60º turn of the rotor,
increases with load. If the load is
– B
–
A
+
and come to a halt. Because of that
0 60 120 180 240 300 360 60
slip, however, induction motors
Phase Angle in Degrees and Rotor Orientation
Time
10
–
+
C
–
–
+
+
0
C
–
A
+
+
–
+
excessive, the rotor will drop out
-10
field now excites the rotor winding
+
C
changed by 60º. The new stator
+
–
the stator excitations also have
+
DC motor, the rotor now rotates to
–
–
-10
0 60 120 180 240 300 360 60
Current Phase Angle in Degrees
Single-Phase Start-up
Figure 5: With a single-phase source, low-power induction motors temporarily
require an auxiliary phase via capacitor connected to the primary phase.
50
CD0803_45_56_Drives.indd 50
Control Design March 2008 www.controldesign.com
2/26/08 12:13:54 PM
Drives & Motion C ontrol
can start from standstill by just
the rotor movement and the cor-
connecting the stator excitation.
responding stator fields along the
In the gray rotor coil in the il-
time line.
Many applications use three-
lustration, the current in C changes
rapidly, going through zero. The
phase, 60 Hz line directly, but
is switched in a sophisticated
in the three-phase windLEFTsequenceRIGHT
ings. Control circuits are called
+A variable-frequency inverters or
CAP
solid-state drives because the pri-
gray coil through induction. At
advances in solid-state power – C
110V 60HZ
switches made it possible to cre-
that time, A is positive, Not A is
ate three-phase, quasi-sinusoidal
negative, B is negative, and Not B is
phases at virtually any frequency.
rate position and velocity feedback
–Aneeded to properly control
are
positive. We can see that the rotor
The incoming AC is rectified, and
the artificial phase generation.
will move clockwise and follow
a DC voltage is created. The DC
Control is difficult at low speeds;
rotor magnet is established in the
mary applications
are servo drives.
+C
Since the rotor slips, very accu-
The Motor Experiment
For this demo, I used a ComairRotron Model MD12B1 brushless DC
motor. Get a 9 V alkaline battery
+
with a snap-on connector, an
RIGHT
LEFT
9V
–
+
alligator clip, a PR3 flashlight bulb
–
and some copper wire. You’ll also+A
CAP
need a small soldering iron and
solder to make connections. –C
+C
Mount the fan,
battery
110V
60HZ and
flashlight bulb on a piece of
plywood. Drill a hole to stick the
A high stall current, or start-up
motor. It’s actually a smaller current
–A
lightbulb into the plywood, and drill
current,FAN
is typical for motors. At startback out of the motor in the opposite
FAN VOLTAGE
smaller holes as needed to run wires
VOLTAGE
up, the
bulb shines SPEED
brightly
and
then
direction. So every motor is a builtCURRENT
FAN VOLTAGE
from top to bottom, for conductors
dims while the current decreases until
in generator. If this fan is forcefully
STILL CURRENT
or for fastening equipment.
full speed
is reached and just a weak
made to rotate even faster, then
SPEED
SPEED
Motor behavior can be observed
glow remains. The voltage across the
the opposing back-EMF
voltage may
under all conditions—stalled, start-up,
fan increases with speed. This voltage is
eventually exceed the battery level,
some load, no load—by controlling the
the back-electromotive force. Because CURRENT
and the battery will begin to recharge.
movement of the fan with your hand.
the fan is turning, it becomes its own
A strong hair dryer can help to
These same characteristics are present
little generator, generating a voltage
verify this behavior. If air is blown
in high-powered
that opposes the 9 V battery, and in
into our experiment fan to help
+ motors.
SLOW DOWN WITH HAND
BACK AT FULL SPEED
RELEASE
STANDSTILL
9Vthe relationship between the the
–
Notice
+
experiment
at
full
speed,
it
was
it rotate faster, the light bulb
–
current through the motor—indicated
measured at about 7.0 V, with the
completely darkens, and the backby the brightness of the bulb—the
battery itself holding at 7.7 V.
EMF is increased. If air is blown from
voltage on the motor and its speed for
Indeed, every motor generates this
the other side to slow down the fan,
various operating conditions. Voltage
back-EMF while rotating. The backthe lightbulb gets brighter since the
can be measured with a voltmeter.
EMF opposes the current flow into the
back-EMF is now reduced because of
increased load.
The generator capability can
FAN
FAN VOLTAGE
be
demonstrated with the battery
VOLTAGE
SPEED CURRENT
FAN VOLTAGE
removed from the circuit. Using the
STILL CURRENT
hair dryer, blow air into the fan,
SPEED
SPEED
making it spin backward. Once the fan
turns fast enough, the lightbulb will
CURRENT
glow since the fan is generating power.
Generally, blowing from either side
will work, but this particular fan motor
is polarity-protected, so only one
SLOW DOWN WITH HAND
BACK AT FULL SPEED
RELEASE
STANDSTILL
direction works.
www.controldesign.com CD0803_45_56_Drives.indd 55
March 2008 Control Design
55
2/26/08 12:14:11 PM
Drives & Motion C ontrol
rotor lags behind. If the rotor is driven by an external
force, such as a turbine, to overtake the outside rotat-
RIGHT
LEFT
ing field, then current flows from the windings back to
the source, and the rotor now leads the rotating field.
This is the primary mode of electric power generation.
+A
CAP
–C
Because it has no magnetic field of its own and because it slips with varying loads, the induction motor
+C
110V 60HZ
in Figure 4 isn’t typically used as a generator. It still has
the same properties, however, and certainly develops a
back-electromotive force. Running in idle, this back-EMF
is nearly as large as the driving voltage. Under load,
–A
turning more slowly, the back-EMF is reduced, and the
motor consumes more current. In a stalled condition,
like the DC motor, it draws very large current.
Single-phase start-up help
Figure 6: Circuit for single-phase induction motor with
required auxiliary phase to intitiate motor start-up.
Dr. Ernst Dummermuth is a consultant in process control,
motion control, automation and intellectual property. He has
been involved in advanced technology endeavors including
architecture proposals, fast prototyping, concept verification,
standardization and product development. His work has
yielded 46 patents and dozens of publications. You can reach
him at ehdummermuth@juno.com.
at standstill, it becomes tricky. Actually two rotating
excitations with equal strength are overlapping each
other; one rotates left, and one rotates right. When a
command is given to move right, the strength of the
left excitation is diminished, and the strength of the
9V
+
pears
on its way.
– completely once the motor is +
More, More, More
right one increased. Eventually, the left one disap-
–
Low-power induction motors can be driven from
Dr. Dummermuth has contributed several wellreceived technical articles to Control Design during the
past few years.
a single-phase source (Figure 5). However, the single
phase isn’t sufficient to get the motor started from a
standstill. An auxiliary phase is required. A capacitor
is connected to the primary phase to create the aux-
Autonomous Cooperating Agents
iliary phase, 90º ahead of the primary. This creates a
In a rod mill, multiple cooling functions coordinate
efforts to achieve an overall performance characteristic.
Go to ControlDesign.com/agents.
rotating field. Once the rotor reaches its rated speed,
FAN
VOLTAGE
SPEED
the auxiliary phase can be disconnected.
FAN VOLTAGE
Observing the gray rotor coil, the current in C
SPEED CURRENT
changes rapidly, going through zero. The
rotor
magFAN
VOLTAGE
CURRENT
net is established inSTILL
the gray
coil through induction.
At that time, A is positive and Not A is negative, and
SPEED
the rotor will move counterclockwise. After 90º, C is
Warm and Fuzzy
Fuzzy logic can extend traditional binary logic. A heater
control application demonstrates the method.
Go to ControlDesign.com/fuzzy.
negative and Not C is positive. At the same time, the
CURRENT
current in A changes rapidly,
and reestablishes the
Algebraic Solution Beats Fuzzy Logic
rotor magnet. A circuit diagram (Figure 6) shows the
Non-linear, tunable PI controller provides improved
performance in closed-loop control application.
Go to ControlDesign.com/algebraic.
connections for a single-phase induction motor.
SLOW DOWNGenerators
WITH HAND
STANDSTILL
RELEASE
The DC motors in figures 1 and 2 already have been
presented as DC generators. Indeed, some current
BACK AT FULL SPEED
Closed-Loop PID Algorithms
in Motion/Motor Control
ripple exists as commutation takes place. This is true
for both motor and generator.
The synchronous motor in Figure 3 needs no modification to run as a generator. In motor mode, current
Differential feed forward can be used for numerical
controls, or integral feed backward can be used for
trajectory control of motion.
Go to ControlDesign.com/algorithms.
flows from the source into the stator windings, and the
56
Control Design March 2008 CD0803_45_56_Drives.indd 56
www.controldesign.com
2/26/08 12:14:26 PM
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CD0803_FPA.indd 57
The Drive for Quality™
2/25/08 3:40:30 PM
A Machine Renaissance
Shrink Wrapper OEM Maximizes Design Flexibility With a PC-Based Controls
and Ethernet Solution That Teaches Users How to Operate the Machines
by Joe Morrissey, Conflex
The Renaissance period spanning from the 14th
to 17th centuries was a period of rebirth—cultural enlightenment and learning—in western Europe. These
days, the term is applied to everything from government to education, and most certainly to technology.
Our company, Conflex, a builder of shrink-wrapping
machines, has undergone what many of us refer to as
a renaissance. In 2005, Conflex began its own rebirth
by substantially redesigning each machine in the
product line and continued redesigning machines
through the end of 2007. The company’s Modular CW
and ServoFlex lines have undergone a complete mechanical and electrical redesign (Figure 1).
Conflex
Conflex wrapping machines are tailored to the
food, consumer goods, electronic media and printing industries, among others. Typical applications for
our machines include wrapping for frozen foods, bulk
packaging for club stores, CD and DVD packaging and
the packaging of household products and toys.
Most of our builds are standard machines for the
extreme makeover
Figure 1: The ServoFlex line had a complete mechanical and
electrical redesign and now performs better, is more flexible to
program and can teach operators how to use the machine with
automated instruction.
particular industry, but we also develop custom infeeds that connect to our machines to offer customers
last servo moves the seal head back and forth in a fly-
different ways to feed their product into our machines.
ing saw fashion. The seal head matches the speed of
“Tough competitors in our field also
are promoting the latest and greatest
technologies, but ease-of-use also is a
must-have.”
the discharge belt and then places the seal in an exact
location by sensing the gaps between packages.
With our company motto—“Flexible people make
flexible systems” —in mind, we sought a controls
system that could deliver true application flexibility to
customers in these diverse industries. Over the past
Coordinated Motion
five or so years, our customers had been asking our
The ServoFlex wrappers use a DC motor to drive the
industry’s machine builders for increased flexibility,
infeed portion of the machine and all three servo
faster changeovers and easier operation, troubleshoot-
motors follow the speed of this motor. The film feed
ing and remote connectivity capability.
and vacuum belt are run off a servo. Servo motion is
“All of Conflex’s customers demand user-friendly
well-suited for exact bag sizing—particularly for print
machines with intuitive interfaces,” adds Mark Lorenz,
registered applications. The discharge belt is driven
Conflex electrical applications engineer. “New technol-
by a servo that runs either faster, slower or the same
ogy is a critical factor for us. Tough competitors in our
speed as this vacuum belt so the individual packages
field also are promoting the latest and greatest tech-
can either bunch or pull away from each other. The
nologies, but ease-of-use also is a must-have.”
58
Control Design March 2008 CD0803_58_63_MachineCT.indd 58
www.controldesign.com
2/25/08 2:41:23 PM
machine c ontrol
Choose Action, Not Buzz
When servo technology started generating a high level
of industry buzz in the early 2000s, Conflex was one
of the first companies to successfully incorporate it in
shrink-wrapping machines. Today, as open, PC-based
control and industrial Ethernet technologies make a
similar commotion in our industry, Conflex is at the
forefront to actually do something with it.
In particular, the ServoFlex film seal wrapper has
been through dramatic changes since its previous
incarnation. “The old ServoFlex design used numerous intelligent drives that handled the automation and
motion control aspects of the machine,” says Lorenz.
Conflex
“The required programming time for multiple drive
controllers really irritated us. This was a three-servo
system, and each axis had a controller that had to
be individually programmed.” The drives weren’t
equipped for Ethernet connectivity either, which hampered needed networking requirements.
Adding or removing I/O further complicated the
problem. “If even a single I/O point failed in the intelligent drive system, we’d have to replace entire boards,”
Simpler means sophisticated
Figure 2: Conflex uses embedded PCs with TwinCat handling all
PLC functions and motion control on a single device.
openness and flexibility we wanted, the Beckhoff system costs much less than the other vendor’s system.”
We considered using standard PC components, but
adds Lorenz. “It also was very expensive to replace
we didn’t consider them industrial enough, and we
the drives themselves whenever we had a failure. It
would have had to use several suppliers to get all the
became apparent that to be flexible and better manage
needed components.
our controls, we needed a new solution.”
From January 2006 onward, Conflex designed and
built the revamped ServoFlex machines using the
Eleventh-Hour Transformation
CX1020 embedded PC with 1 GHz Celeron M ULV
In late 2005, we had made what we thought was our
processor and TwinCat motion control software as the
final decision on a new platform from a major automa-
main control platform (Figure 2).
tion and controls vendor. “It was an acceptable motion
“With this hardware/software combination, we han-
controller with PLC functionality but didn’t have all
dle all PLC functions and motion control on a single
the programming and design flexibility we hoped for,”
device,” says Lorenz. “The new ServoFlex horizontal
recalls Lorenz. “We just accepted that we had to put
form, fill and seal wrapper is a four-axis system—one
more time and effort into the design than was ideal.”
master axis with three slave axes. It delivers continu-
We planned to order our controllers the following
Monday. Don Seicther, Beckhoff Automation’s (beckhoff.com) Wisconsin regional sales manager, called
us the Friday before and explained how the Beckhoff
ous motion at up to 100 ft of film per minute with an
advanced, reciprocating, hot-knife seal system.”
We found several of the programming libraries in
TwinCat particularly helpful. “The Flying Saw code
product line might be able to help us.
We learned about Beckhoff’s DIN-rail-mounted
embedded PC and IEC 61131-3-compliant automation
and motion control software. “The solution turned out
to be exactly what we were looking for and allowed
us to create our ideal electrical controls system,” says
Lorenz. “We were impressed enough that we decided
to make a major course change at the last possible
Draw your own line
Conflex had confidence in its migration to a PCbased control scheme. What would your strategy
be if some of your customers were uneasy about
leaving well-understood legacy controls behind?
Look for comments—add your own—on this issue
at ControlDesign.com/renaissance.
minute. With the perfect technological match with the
www.controldesign.com CD0803_58_63_MachineCT.indd 59
March 2008 Control Design
59
2/26/08 1:31:09 PM
machine c ontrol
D-Subminiature Power Connectors
FCI offers PCB and cable connectors
providing either power or a mix of
power and signal contacts. Right-angle
and vertical PCB connectors are
available with options for solder or
press-fit termination. Cable solutions
accept solder-bucket or crimp power
contacts and include a variety of
backshell and accessory options.
The robust, shielded D-Sub form
factor is ideal for Power I/O solutions
in communications, industrial, and
medical equipment.
www.fciconnect.com/dsub
Flex Circuit Connectors are ideal
for FFC/FPC/CIC cable-to-board
connections. FCI offers many innovative
features such as front- and back-flip
actuators and ZIF with cable pre-hold.
The connectors employ reliable gas
tight high-pressure contact systems.
Choose from zero insertion force (ZIF)
or non-ZIF cable insertion, straight
or right-angle cable entry, and surfacemount or through-hole PCB
termination, with or without cable
lock alignment systems.
www.fciconnect.com/flex
library saved us time and effort
film. This allows for a very profes-
by providing pre-written software
sional-looking finished product for
functions to achieve a great deal
the end user. “The EL5101 EtherCat
of our motion programming,” says
Terminal is an interface for the
Lorenz. “On the ServoFlex, a vac-
direct connection of incremental
uum conveyor holds the wrapper
encoders with differential/RS485
film and leads it to the sealing area
inputs,” says Seicther. “A 16-bit
that features a reciprocating mo-
counter with a quadrature decoder
tion. We have to hit a very specific
and a 16-bit latch for the zero
“The required programming time for multiple drive
controllers really irritated us. This was a three-servo
system, and each axis had a controller that had to be
individually programmed.”
mark on the film, so the Flying Saw
pulse can be read, set or enabled.
program handles the sealing mo-
Incremental encoders with alarm
tion of the knife moving back and
outputs can be connected at the
forth on the machine. A pneumatic
interface’s status input.” Interval
cylinder closes a sealing jaw while
measurement with a resolution of
the cut is made. Built-in libraries
500 ns is possible, he says
for PID temperature control for the
available compared with our
imposed move for print registra-
previous I/O board challenge,”
tion functions are huge time savers
says Lorenz. “We only buy the
in our area of packaging.”
points we need and can replace as
Any controller we use must
fc566 CD 11-12_07 Sat Strip AF.i1 1
CD0803_58_63_MachineCT.indd 60
needed, one I/O card at a time. The
provide very fast control of the
simple, direct I/O connection to
film-cutting knife to exactly
the embedded PC made this deci-
match the speed of the incoming
sion that much easier.”
wrapper film. EtherCat helped
The main objectives of the Con-
ramp up our control speed on the
flex machinery renaissance were to
ServoFlex machines. “In addition
build a better performing machine
to performance, we had to choose
and to make it more flexible and
a fieldbus that will be supported
easier for manufacturers to operate.
well into the future and won’t
Minitek™ 2mm and BergStik®,
Dubox™, PV® & Quickie® 2.54mm
Modular Systems from FCI include
a broad range of board-to-board,
wire-to-board and flat cable connectors
to support requirements for parallel,
co-planar or perpendicular connections
in electronic equipment or devices.
The FCI connector families include
unshrouded and shrouded pin headers,
crimp contacts and insulators, flat
cable IDC receptacles, board-mounted
receptacles, and shunts. Check our
easy part number selection online at
www.fciconnect.com/basics.
“We have the best solution
machine’s film heaters and super-
To emphasize the learning as-
go obsolete in a few years,” adds
pect of a renaissance, the ServoFlex
Lorenz. “Conflex customers also
HMI includes detailed instructional
enjoy remote diagnostic capabili-
programs that literally can teach
ties for troubleshooting via stan-
users how to operate them (Figure
dard Ethernet connectivity with
3). Operators can view demonstra-
the EtherCat-equipped machines.”
tion videos detailing machine
The ServoFlex uses some
setup, film threading, trouble-
EtherCat I/O terminals to develop
shooting and other how-to videos.
built-in special latching functions
These videos are very helpful when
for hardware interrupt. The latch
companies have to deal with high
input is significant since it syn-
operator turnover. Troubleshoot-
chronizes the machine cutting and
ing guides, electrical schematics
sealing operations to the printed
and machine part drawings can be
60
Control Design March 2008 www.controldesign.com
10/8/07 9:31:47 AM
2/25/08 2:42:17 PM
2.0mm & 2.54mm
MODULAR SYSTEMS
CABLE ASSEMBLIES
COMPACT FLASH
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and outstanding technical support for industrial applications.
To explore how FCI can help you with your next industrial
design, visit www.fciconnect.com or call 1.800.237.2374.
fc565 CD 11-12/07 Industrial App1 1
CD0803_FPA.indd 61
10/8/07 9:34:20 AM
2/25/08 11:12:27 AM
machine c ontrol
new operating systems could even
overwhelm the processors. They
wonder if a migration could be
forced when the OS no longer is
supported, and that could happen
much earlier than they want.
With this Beckhoff system, we
might be tied to a Microsoft OS,
but the OS provides the advantage
of direct access to databases, raw
TCP/IP functionality and direct access to PLCs from HMI implementations, to name a few elements. A
CONFLEX
traditional rack-mount PLC would
require an expensive add-on card
or an additional PC to run software to support these elements.
Watch and Learn
Figure 3: The HMI software is unlike virtually any other in the industry with onboard
instructional videos to train machine operators.
When adding these other pieces to
a rack- mount PLC you are, in our
judgment, not only adding more
viewed, as well. “We run Windows
the HMI software is also running
points of failure to the system, but
CE on the embedded PCs, and
on the CF card, customers can find
adding unnecessary cost.
we were able to create a human-
a replacement display very easily
machine interface (HMI) that is
without reloading any software if
system overhead is a valid concern
unlike any other in the industry,”
a backlight fails on our integrated
when running a “user level” applica-
claims Lorenz. “It’s something that
monitors,” says Lorenz.
tion on top of any OS. On Windows
We’ve heard that operating-
XP Pro and XP Embedded based
couldn’t be done easily using con-
The Microsoft Dilemma?
systems TwinCat doesn’t modify
Some machine builders are
the OS—it provides a kernel-level,
ded PCs is that all the software
concerned about whether us-
real-time package that can run I/O
resides on a CompactFlash (CF)
ing PC-based controls ties you to
and PLC functions deterministically
card, so changes can be made very
companies such as Microsoft, and
to 50 µs. With WinCE-based sys-
easily in the field if needed. “Since
whether additional overheads in
tems, Beckhoff tells us that TwinCat
ventional controls platforms.”
An added bonus of these embed-
CD0803_58_63_MachineCT.indd 62
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ControlDesignAd1_17_08.qxd
1/18/08
10:37 AM
machine c ontrol
takes advantage of the inherent
and we all learned quite a bit to-
real-time nature of that OS and can
gether as engineers in our techni-
run I/O and PLC tasks down to 100
cal discussions,” says Lorenz. “Our
µs. This means you can run every-
machines now are better suited
thing from high-speed I/O tasks to
to integrate more seamlessly into
standard PLC logic to complicated
lines with machines from a variety
motion control.
of manufacturers and extract data
“We only buy the points we need and can replace as
needed, one I/O card at a time. The simple, direct I/O
connection to the embedded PC made this decision
that much easier.”
Renaissance on Repeat
from the entire line. The Ethernet
With the majority of the Conflex
capability is a huge benefit for our
redesigns complete, we now offer
customers and helps us deliver the
smaller machine footprints, more
most flexible machines possible.”
competitive system costs, greater
The controls replacement cost
flexibility and faster machine
on Conflex machines has been
delivery. “Before 2006, Conflex ma-
highly optimized. “The old drive
chines had four separate control
system with integrated intelli-
devices, each with bits and pieces
gence cost about triple what we’re
of code for the machine spread
paying for a Beckhoff system that
throughout,” reminds Lorenz.
does more work.
“Now we have one device on our
With the kind of success we
machines that contains all of our
experienced on the ServoFlex
programming. This is a much
line, we’ve incorporated this
more streamlined approach.”
approach into our AdvantEdge
TwinCat proved to be a highly
series of servo-driven, side-seal
flexible environment for Conflex
wrappers, and will be expanding
machine programming. “We can
the solution into other machine
use a standard set of programs
lines to fully apply our enhanced
for three different models of
PC-based control expertise.
machines that vary depending on
Down the road we expect this
the application,” says Lorenz. “We
HMI and connectivity approach
choose the appropriate program to
to lead us into providing value-
match our customer’s application
adds such as machines that would
when the system boots up. In a
monitor parts due for replacement
few hours we can make immediate
and send an order back to us when
modular design changes that pre-
it’s time. The replacement part
viously would take up to several
could be sent to the customer for a
weeks of cumbersome work.”
just-in-time delivery. In our judg-
To make sure that changes took
ment, the sky’s the limit when it
a minimal amount of time while
comes to what a Windows-based
learning a new system, Conflex
system can provide.
took full advantage of the engineering support available to them.
Joe Morrissey is product manager for
“Beckhoff support always is avail-
Germantown, Wis.-based Conflex. Learn
able to assist with our questions
more about Conflex at conflex.com.
www.controldesign.com CD0803_58_63_MachineCT.indd 63
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63
2/25/08 2:43:08 PM
Before installing machines in hazardous
loosen that limit accessibility, and cost. Explosion-
areas, all sorts of horrific possibilities become
proof enclosures cost much more than a similarly
part of the design consideration to ensure a safe
sized general-purpose enclosure.”
operation. Certain machines are inherently vola-
because it views them as a simple, rugged solution
what the machine produces. Gluing and printing
for electrical components in hazardous locations.
machines come to mind as those that require
Loren Shaum
An alternative protection method, acceptable in
adherence to certain hazard standards. However,
many of the same applications, involves purging or
any machine installation in hazardous environ-
pressurizing the enclosure. “The words purge and
ments must be adapted specifically to that classi-
pressurization commonly are used interchange-
fied environment to assure inherent safety.
ably,” says Quick. “Purging actually describes
In most North American quarters, there are
multiple exchanges of enclosure volumes of air re-
two schools of thought.
quired in Zone 1 and Class 1 applications to expel
1. Buy explosion-proof equipment, but risk much
gases and vapors. Pressurization is the subsequent
higher control costs than might be necessary.
2. Buy more-conventional equipment and purge
to keep a hazardous atmosphere away from the
control devices.
“To make the right choice, the normal function-
action of supplying a positive pressure of an inert
gas or instrument-quality air to keep combustible
substances from entering the enclosure.”
Purge/pressurization systems permit the use of
general-purpose enclosures in hazardous loca-
ing of the apparatus and the eventual malfunc-
tions where this protection method is allowed. By
tioning of the apparatus due to faulty components
purging, says Quick, the area classification inside
“Purged or pressurized enclosures
require constant pressure from inert
gases, which could leak or become
over-pressurized.”
must be considered,” says Chris Romano, product
manager at Pepperl+Fuchs (P+F, us.pepperl-fuchs.
the enclosure is reduced (Div. 1 to Div. 2, Div. 2 to
non-hazardous), which might allow use of lowercost components. In addition, pressurized airflow
reduces moisture and corrosion on internal components, the enclosures are much more accessible,
and multiple enclosures can be connected in line
with a single purge/pressurization system.
The enclosure must have a certain degree
com). “Moreover, all those conditions that can
of tightness. However, there are no particular
occur accidentally, such as a short circuit, open
mechanical requirements because the pressure
circuit, grounding and erroneous wiring of the
supported is not very high. In installations requir-
connecting cables, must be evaluated.”
ing large electrical apparatuses or control panels
Explosion-proof enclosures usually are heavy,
where the dimensions and high-energy levels
cast enclosures that use a multitude of bolts to se-
make it impractical to use an explosion-proof
cure the cover. “They are designed to contain an
enclosure, purging often is the only answer.
explosion inside the enclosure and prevent flame
“The method’s disadvantages include the re-
transmission to the area outside the enclosure,”
quirement for an inert-gas supply, some moving
says Matthew Piecuch, Adalet sales and market-
parts, alarm and monitoring requirements that
ing manager (adalet.com).
might require electronics and electrical power,
One advantage of explosion-proof enclosures is
they can be used in almost any hazardous location
application, says Greg Quick, product manager,
and the purge system typically is mounted to the
outside of an enclosure,” says Quick.
“Purged or pressurized enclosures require con-
Hoffman (hoffman.com). “They also are low main-
stant pressure from inert gases, which could leak
tenance and typically do not involve additional
or become over-pressurized,” cautions Piecuch.
electronics or moving parts,” he adds. “Some
“Proper ventilation and airflow also needs to be
disadvantages, however, include their excessive
considered with purge or pressurization, and this
weight and bulkiness, all those bolts to tighten and
can also fail or become compromised.”
64
CD0803_64_Techflash.indd 64
Adalet recommends explosion-proof enclosures
tile because of the materials incorporated into
•
contributing editor
•
lshaum@putman.net
techflash
Make Controls Kaboom-Proof
Control Design March 2008 www.controldesign.com
2/22/08 10:08:42 AM
Above-Average LVDT Growth Leads the Way in Sensor Market
A recent market study by
lic cylinders and are particularly
CYLINDER POSITION SENSOR
Venture Development Corp.
useful for long strokes. Growth
BIM-UNT universal magnetic-
(vdc-corp.com) reveals the North
of these sensors is expected to
field sensor detects the position
American market for linear
be at an above-average rate over
of a piston on standard pneu-
displacement sensors including
the next five years, with the
matic cylinders via magnetore-
encoders, linear variable dif-
highest growth-rate expecta-
sistive, board-level technology
ferential transformers (LVDTs),
tions for use in metalworking,
laser systems, magnetostrictive,
assembly/robotics equipment
potentiometers, capacitive, in-
and valve applications.
ductive and ultrasonic products
The highest growth rates in
the VDC study are for laser sys-
VDC says the largest market for
tems at 10% and capacitive linear
LVDTs is for military/aerospace
displacement sensors at 8%. The
applications. These devices do
markets for both are small, but
and has a sensing face in the
well in harsh environments;
each is expected to grow since
front of the sensor to help
they have only one moving part
users are seeking higher accura-
detect short-stroke cylinders.
and little friction between the
cies, which these provide. This
The sensor comes with a quick
moving ferromagnetic core and
is particularly the case in the
mount tab that helps seat the
the cylinder in which it moves.
semiconductor and electronics
sensor in the cylinder’s groove.
LVDTs are used in automa-
industries, where more precise
Turck; 800/544-7769; turck-usa.com
shrinking the size of electronics.
•
engineering, power generation,
cdroundup@putman.net
TRUE COLORs
manufacturing, metal stamping/forming, OEM, pulp and
TRue SUPPRESSION
E3X-DAC white LED fiberoptic
paper, industrial valves, R&D
Tru-Vue photoelectric back-
sensor detects true colors in
and test and automotive.
ground-suppression sensors
marks and workpieces inde-
have a 50-mm sensing range
pendent of light intensity and
com) says be mindful that
and deliver target detection
sensing distance variations.
LVDTs might operate at excita-
regardless of target color and
The 10-mm-wide amplifier
tion amplitudes and frequen-
reflectivity, with detection unaf-
unit processes color detection
cies other than those listed by
fected by shiny background ob-
through an RGB light-receiving
the manufacturer. Also, stay
jects, and eliminate the expense
element. One-touch teaching
National Instruments (ni.
within the recommended travel
new products editor
measurement capabilities enable
•
tion machinery, civil/structural
Patti Pool
totaled $339 million in 2006.
PRODUCT ROUNDUP
Positioning Solutions Abound
simplifies setup for high-speed
specification of your LVDT, and
beware of excitation-signal
cross-talk between channels.
A tutorial from Macro Sensors (macrosensors.com) lists
several other reasons why you
should consider LVDTs. They
include infinite resolution,
over-travel damage-resistance,
and installation of reflectors or
single-axis sensitivity, sepa-
through-beam alignment. They
rable coil and core, null-point
have a 4-in-1 output that auto-
packaging and sorting, and
repeatability, fast dynamic
matically detects the connected
electronics packaging including
response and absolute output.
load and sinks or sources.
small parts and fine wires.
Pepperl+Fuchs; 330/486-0001;
Omron Electronics; 866/88-omron;
am.pepperl-fuchs.com
omron247.com
These sensors find extensive
use with pneumatic and hydrauwww.controldesign.com CD0803_65_70_Roundup.indd 65
March 2008 Control Design
65
2/25/08 2:29:45 PM
PRODUCT ROUNDUP
SURFACE-MOUNT RTD
drop, the output is magnetically
for each measurement cycle.
SA1-RTD surface-mount tem-
isolated. The devices are UL,
The ball-bearing tip eliminates
perature sensor mounts on flat
cUL and CE approved.
wear and abrasion damage
or curved surfaces and pro-
AutomationDirect; 770/889-2858;
from contact with high-speed
vides Class A accuracy. Based
automationdirect.com
moving target surfaces.
on a 2x2x0.8-mm thin-film
Keyence Corp. of America;
platinum RTD and supplied in
888/539-3623; keyence.com
PFA-insulated 3 or 4-wire con-
18-MM SENSORS
figurations in 1, or 3 m lengths
S51 18-mm sensors in throughbeam, retro-reflective, polar-
For Restricted Areas
ized retro-reflective and diffuse
MagRes compact, self-con-
modes have a flat, cylindrical
tained, absolute multi-turn
housing that offers mounting
encoder’s high-density housing
choices using traditional 18-mm
has two M12 input and output
locking nuts or by direct-mount-
plugs for integration into Pro-
ing with two-through holes. The
fibus-DP systems where space
is tight. It has 13-bit resolution in single-turn models and
or custom lengths with selfadhesive backing or permanent
mounting, the RTDs can be
used for monitoring motor and
transformer core heat and test
mounting-hole configuration
insulation capabilities.
makes it possible to replace
Omega Engineering; 203/359-1660;
many non-threaded sensors.
omega.com
S51 sensors have a sensitivity
16-bit in multi-turn versions. It
adjustment and a variety of
measures 58-mm diameter and
output configurations.
42-mm deep.
IDEC; 800/262-4332; idec-ds.com
Baumer Electric; 800/937-9336;
They’re CURRENT
ACT current transducers, in
baumerelectric.com
split and fixed-core models,
have jumper-selectable current
IN-LINE MEASUREMENT
inputs and 4-20 mA or 0-10 Vdc
GT all-in-one integrated contact
Sensing and More
outputs. Split-core models make
sensor for height and thickness
Vibration switch is a low-cost,
using portable data loggers
measurements requires no
self-contained monitoring
easier, and simple connection
external PLC or external data
enables power consumption or
processing. Designed for auto-
other motor status display. For
matic in-line measurement, the
safety and to eliminate voltage
IP67-rated GT has a linear ballbearing spindle tip that pneumatically extends and retracts
system for rotating or reciprocating equipment, providing
alarm or shutdown if excessive
vibration levels are reached.
All sensing and electronic
components are included in
the standalone switch with an
alarm LED. It has an integral re-
66
CD0803_65_70_Roundup.indd 66
Control Design March 2008 www.controldesign.com
2/25/08 2:30:08 PM
Switch Safely
guard Short Distances
with both normally open and
PSen non-contact, magnetic
S300 safety laser scanner for
normally closed contacts.
safety switches have a 12-mm
applications where the hazard-
Hardy Instruments; 800/821-5831;
diameter and measure switch-
ous area is less than 2 m. It
hardyinstruments.com
ing distances of 8 or 15 mm.
has low power consumption
An additional signal contact
is available to display the
Ethernet Solution
Temposonics R-series EtherCat
sensor overcomes bandwidth
and node limitations found in
commercial networks. It’s available with one to five position
status of the safety switch via
for oncoming fork detection on
a connected PLC. Approved to
AGVs or safeguarding workers
Category 4 of EN 954-1, PL “e” of
in the path of manned forklifts
ISO 13849-1 and SIL 2 of EN IEC
and transfer cars. It has a 270°
magnets and can be customized
62061, the switches are suitable
scanning angle.
to document position, veloc-
where it is difficult to align
Sick; 952/941-9287; sickusa.com
ity and acceleration, as well as
machine gates precisely or with
custom smart functionality.
high levels of vibration.
MTS Systems Corp.; 919/677-0100;
Pilz Automation Safety;
Safe Braking
mtssensors.com
734/354-0272; pilz.com
LazerSafe LZS-003-HS safe-
PRODUCT ROUNDUP
lay to provide failsafe operation
guarding system developed
for hydraulic press brakes
Fiberoptic Sensor
Handles Agression
makes complex bends with
FX-100 Series fiberoptic sen-
Osiprox inductive cylindrical
a minimum of settings while
sor is 9-mm wide with inte-
maintaining press speeds. Two
grated mounting holes. It has a
flat bands of 40-mm-wide laser
dual digital display for simple
light continuously monitor the
setup and automatic pushbutton
zone below the punch. It can
teaching and external input ca-
sensors were developed for
extreme temperatures, humidity, and equipment washdowns
using chemical agents. With
IP67, IP68, and IP69 ratings,
pabilities. It has threshold track-
these sensors, cables, casing
ing, timers, LED attenuation and
and front face are built with
detect obstructions to 4 mm,
interference prevention.
FDA-approved materials.
while remaining tolerant to
Panasonic Electric Works Corp.
Schneider Electric Sensor
inherent vibration.
of America; 908/464-3550; pewa.
Competency Center; 800/435-2121;
Honeywell Wintriss Controls;
panasonic.com
sesensors.com
800/586-8324; wintriss.com
www.controldesign.com CD0803_65_70_Roundup.indd 67
March 2008 Control Design
67
2/25/08 2:30:31 PM
PRODUCT ROUNDUP
Miniature and Mighty
TIGHT SPACES
MT miniature photoelectric
AST4100 OEM pressure sen-
sensors for industrial machine
sor has 0.875-in. diameter and
applications are available in
stainless steel construction of
polarized-reflective, diffuse-
the header and housing makes
reflective, and through-beam
it suited for corrosive environ-
modes. Each sensor measures
12x33 mm, has sensitivity
adjustment, a yellow LED for
for linear motion and off-axis
output indication, a green LED
rotational measurement in
for stability indication and an
industrial drives, x-y stages or
M8 4-pole connector.
electronic motors. A system-
ASI; 877/650-5160; asi-ez.com
on-a-chip, combining Hall elements and a signal processor
ments with pressure ranges
has incremental measurement
Reduce Setup
0-25 to 0-10,000 psi. Units are
with a resolution to 14 μm per
Series 9000 photoelectric sen-
available in compound ranges,
position step.
sors use ASIC technology for
as well as in bar and Kg/cm2
Austriamicrosystems; +43(0)3136
added functionality. 42GSP-9000
outputs. Outputs include 10 mV/
500 5856; austriamicrosystems.com
V, 0.5-4.5 V ratiometric, 1-5 V,
1-6 V, 0.25-5 V or 4-20 mA.
American Sensor Technologies;
POSITION SENSORS
973/398-9900; astsensors.com
RS 1500-120 fractional-turn,
contactless rotary position sensors measure angular displace-
HALL EFFECT SENSOR
ment of quarter-turn ball and
Model 9360 non-contacting
butterfly valves, air flow damp-
rotary, dual-output Hall effect
has a teach function that
sensor has 360° rotation and
eliminates manual adjustment
is suited for high-vibration
of sensitivity. 42GLP contains a
manual adjustment potentiometer to adjust sensor sensitivity.
Rockwell Automation;
414/382-2000; rockwellautomation.
com
ers and diverter gates used in
Laser World
packaging machines. Available
World-Beam QS18LD laser
environments. Electrical angle
with a 24 Vdc input and 0-10
diffuse and QS18LLP laser ret-
is 0-359.9°. Operating tem-
Vdc output, or a two-wire, 4-20
roreflective sensors use visible
perature is -40–85 ºC. Accuracy
mA loop-powered transmitter
Class 1 lasers and tightly col-
is +/-0.6% FS. The sensor is
I/O.
limated sensing beams. They
ISO9001 and TSI6949 certified.
Macro Sensors; 856/662-8000;
also have extended sensing
Duncan Electronics; 949/341-9500;
astsensors.com
ranges. QS18LD senses targets
beiduncan.com
300 mm away, while QS18LLP
RTDs
delivers retroreflective sensing
up to 10 m.
LINEAR MOTION ENCODER
Line of RTD sensors can be con-
Banner Engineering; 888/373-6767;
AS5305 magnetic linear mo-
figured with options including
bannerengineering.com
tion encoder IC is designed
element type, lead-wire con-
68
CD0803_65_70_Roundup.indd 68
Control Design March 2008 www.controldesign.com
2/25/08 2:30:52 PM
of a few tenths to 2% over the
Model HSE-1 evaluator moni-
selected sensor’s full operating
tors and logs key parameters
range and works with Win-
of resistive and hybrid-capac-
dows 2000/XP/Vista.
itive humidity sensors via a
Ohmic Instruments; 410/820-5111;
USB port. Its screen displays
ohmicinstruments.com
relative humidity, dry-bulb and
dew-point temperature readings. Users can display and
PYROELECTRIC INFRARED
log selectable functions of 12
DigiPyro PYD 1988 and 1978
figuration, termination style,
different sensors. The evalu-
digital photoelectric infrared
sheath materials, lengths and
ator has a display resolution
sensors for industrial motion-
diameters, process connection
sensing applications have
heads, transmitters, thermow-
window-detection sizes of
ells, spring loading, flanges and
4.60x3.4 mm 2 and 3x4 mm 2,
surface mount packages. Oper-
dual-element design, standard
ating range is -200–650 °C. The
three-pin TO-5 metal housing,
linear change in resistance per
15-bit output direct link, and
degree change in temperature
infrared window transmission.
allows for less complex instru-
They have low EMI sensitivity
mentation and requires no cold
and are RoHS-compliant.
junction compensation.
PerkinElmer Optoelectronics;
Watlow; 314/878-4600; watlow.com
877/pki-nyse; perkinelemer.com
CD0803_65_70_Roundup.indd 69
PRODUCT ROUNDUP
HUMIDITY SENSOR EVALUATOR
2/26/08 1:33:31 PM
PRODUCT ROUNDUP
CONTINUOUS FEEDBACK
offer visual and output signal
measurement of whole body
IP68-rated Gemco 953S VMax
diagnostic feedback.
motion immediately after the
linear displacement transducer
Ametek Automation & Process
accelerometer is subjected to a
provides continuous position
Technologies; 800/635-0289;
shock motion and the presence
feedback and has up to 1 µm
ametekapt.com
of severe vibration inputs. Gas
damping and internal over-
resolution and stable position
range stops enable its anisotro-
feedback for cable runs 1,200
ft from the host controller.
CAPACITY TO ACCELERATE
pically etched, silicon sensing
953A (analog), 953D (digital)
Model 7290D variable ca-
element to withstand high
and 953S (SSI) LDTs have ac-
pacitance accelerometer has
shock and acceleration loads.
tive measuring range to 300
onboard, microprocessor-based
Endevco; 949/295-5515;
in., and power supply voltages
temperature compensation
endevco.com
ranging 7–30 Vdc. Analog out-
for high thermal stability for
put units offer programmable
measurement of relatively low-
zero and span, and all units
level acceleration that requires
MORE, MORE, MORE
To see an expanded
roundup including items
from sensor manufacturers
EMX, FCI, Heidenhain, ifm
efector, Migatron, Moore,
Optec and Raytek, browse
to ControlDesign.com/
roundupsarchive.
Were You Featured
In This Magazine?
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your article and simply place it
into the hands of your target
audience. Having been featured
in a well-respected publication
adds the credibility of a third-party
endorsement to your message.
• Sales Aids
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• Trade Show Handouts
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AD Products - The Smart
CD0803_65_70_Roundup.indd 70
Choice
SM
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866.879.9144
sales@fostereprints.com
2/25/08 2:31:27 PM
What Are the Choices on Enclosures?
ments and overhead of creating a custom enclo-
designed for each application, and in many cases
sure and meet your and your customers’ needs.
we find that off-the-shelf enclosures won’t work.
That said, because creating a custom enclo-
Although the major enclosure manufacturers tout
sure can be costly and time-consuming, you
their ability to build custom panels, we haven’t
should exhaust all available resources in locat-
been happy with their prices, delivery or service.
ing a standard, off-the-shelf enclosure from
Are there better alternatives?
any supplier that can meet your needs. Off-the-
—from January ‘08 Control Design
shelf enclosures should be a stock item with
a reasonable price tag. Then evaluate the best
direction, based on your findings. There always
will be a trade-off between using standard or
Meet Needs First
custom enclosures. But some applications are
Custom panels might still be the best alterna-
unique, and only a custom enclosure will do. In
tive, but when you buy from the larger enclo-
this case, a high price tag might be unavoidable.
sure manufacturers, expect to pay a premium,
Brian Alvarado, product manager,
especially if your required quantities aren’t
Pepperl+Fuchs, us.pepperl-fuchs.com
large or consistent. If only a custom enclosure
will fit your needs, then look at smaller, more
Think in Modules
customer-driven suppliers that might be willing
As a manufacturer of custom equipment who
to be competitive in price to gain your business.
has visited several major enclosure manufac-
This takes research, and you’ll find different
turers and collaborated with their associates
cabinet suppliers might suit your needs better,
over 20 years, I can report that these companies
so investigate as many sources as possible.
routinely pass off or toss out the majority of
To optimize your efforts and reduce costs,
custom-enclosure inquiries they receive be-
proper forecasting and planning will let you place
cause they know they’re not in the best position
a large enough order to satisfy the cost require-
to satisfy these applications.
RealAnswers@putman.net
ANSWERS
real answers
Our packaging machines are custom
Alternatives can be found by searching for
MAY’S PROBLEM
“custom metal enclosures” in your favorite search
We’re thinking about upgrading to digital
networks on our machines for communications
among the controller, I/O, sensors and maybe drives.
We’re concerned about diagnosing network faults
and monitoring network performance on the
machine. Are there software and hardware tools we
will need to install directly on our machines? Which
handheld tools can our techs and our customers’
techs use to check out digital networks? How much
training should we expect our support personnel
will need?
will return mostly results for car and home-stereo
SEND US YOUR COMMENTS, SUGGESTIONS OR
SOLUTIONS FOR THIS PROBLEM. We’ll include it in
the May ’08 issue, and post it on ControlDesign.com.
Send visuals if you’d like—a sketch is fine. E-mail us
at RealAnswers@putman.net. Please include your
company, location and title in the response.
sures are attained by mass production, which re-
engine. Avoid the term “custom enclosure,” which
speaker boxes. You’ll find a half-dozen or so qualified companies scattered around the country, each
with a slightly different methodology for manufacturing an enclosure to your exact specifications.
However, while you might gain some added
satisfaction on service and delivery from custom
enclosure manufacturers, prices will be much
higher than standard enclosures due to the limited, if not one-off, volume you’re requesting.
Fast delivery and low prices for standard enclo-
HAVE A PROBLEM YOU’D LIKE TO POSE to the
readers? Send it along, too.
quires no engineering or programming and little or
no human interface once the design is finalized. By
contrast, a custom enclosure often requires intense
development, depending on how much modification
you require and how many similarities between
each variation of the enclosure are incorporated.
The key to your future satisfaction will be
harmonization and compartmentalization of
www.controldesign.com CD0803_71_72_RealAnswrs.indd 71
March 2008 Control Design
71
2/25/08 2:36:22 PM
use of 3-D CAD models com-
your supplier. Think of building
pressed the time from idea to
blocks or modules that can be
reality in custom enclosure
reused to eliminate as much
manufacturing.
Using 3-D modeling soft-
engineering and design effort
as possible. Then, use standard
ware, manufacturers can
enclosures where possible, and
take customer information,
stack on custom pieces where
convert to CNC machine code
needed. The result will be
and produce the part from the
minimalized engineering and
original data supplied by the
production costs that you can
use to maintain competitive
pricing and sustain a reasonable degree of aesthetic value.
MIKE BAUCOM, executive director,
Bebco Industries, okbebco.com
3-D Modeling Streamlines
the Process
Historically, it was panel
STAHLIN
REAL ANSWERS
your designs, regardless of
customer. Custom sizes can be
CUSTOM DRILLED
Custom enclosures for Paneltronics
are modified with additional holes
and silkscreening.
produced easily using the hand
lay-up process. In this way,
the manufacturer serves as an
extension of the customer’s
own manufacturing capabilities
fied standard enclosures were
and helps to reduce redundant
not something most enclosure
paperwork and streamline the
manufacturers engaged in.
entire idea-to-reality manufac-
The growth and use of
builders or other custom
computer-controlled CNC equip-
manufacturers that provided
ment, advances in composite-
this service. Custom or modi-
resin technology and increased
turing process.
MIKE JACKSON,
product marketing manager,
Stahlin Enclosures, stahlin.com
Save up to 50% Off!
•
•
•
•
•
CD0803_71_72_RealAnswrs.indd 72
Save up to 50% off
Same day ship-out on most items
Thousands of enclosures in stock
Custom modifications available
New products added frequently
•
•
•
•
•
Stainless steel
Fiberglass
Painted steel
Non-metallic
Polycarbonate
2/25/08 2:36:35 PM
exclusive
Tiny Sensors Bring New Possibilities
You hear the constant drumbeat. Machine footprints must get smaller, while overall
machine performance, functionality and flexibility expand just as quickly. That means control
system components, even at the sensor level,
have to follow suit because there’s less free space
for device mounting and required access.
Balluff recognizes these new design imperatives. The company has introduced SuperShorties,
a new family of short inductive proximity sensors
intended primarily for industrial OEM applications.
“Inspiration for the SuperShorties came from
our close contact with designers of high-precision machine tools and high-speed automated
assembly equipment in southern Germany,”
says Daniel Rauscher, product marketing, Balluff GmbH. “In Europe, there’s a high premium
placed on floor space, so designers constantly
For more information
Call 800/543-8390, e-mail tom.draper@balluff.com, or
browse to balluff.com/supershorties
seek ways to reduce the machinery footprint.
Our customers found that 15 to 28-mm-length
have such small dimensions and low mass that
sensors were the shortest types available on the
they can be placed directly into a gripper finger
market. This excessive sensor length hampered
without adversely impacting its size or weight.
efforts to push sensors out toward the handling
As rugged inductive sensors, they can survive
mechanisms of their machines, while at the
in close proximity to industrial processes where
same time maintaining or even reducing space
shock, vibration and liquid or particulate contam-
requirements. By leveraging the microelectron-
ination would take optical sensors out of action
ics competency of our Hytech Division in Swit-
quickly.” The sensors carry a protection rating of
zerland, we were able to achieve breakthrough
IP67 and have flex-rated cabling.
miniaturization and deliver fully integrated
sensors only 6 to 18 mm long.”
The new sensors can be installed into cramped
“SuperShorties are available in Ø6-mm smooth
and M08 threaded housings, and prewired cable
models are just 6 mm long, while connector-
places where inductive sensors couldn’t fit before,
ized models are only 18 mm long,” says product
says Henry Menke, Balluff’s product marketing
specialist Jeff Himes. “All have a nominal 1.5-mm
manager. “Their extremely low mass enables
sensing range. The sensing electronics are fully
abrupt acceleration and deceleration on highly
integrated into the housings, so no bulky external
dynamic, fast-moving equipment without adding
amplifiers are required. Despite the small size,
excessive inertial load,” he adds.
their electrical outputs are fully protected against
Claiming the shortest fully integrated inductive
short circuits and polarity reversal.”
sensors on the market, Menke says SuperShort-
The sensors have exceptionally low mass at
ies are designed for high-speed, pick-and-place
0.7 g and are ideal for applications in which rapid
equipment; miniature grippers, linear slides and
acceleration and deceleration is required, adds
valves; compact actuators; and most other highly
Pat Helm, Balluff’s automated assembly business
compact, precision mechanisms.
development manager. “SuperShorties provide
“These sensors are so small that OEM control
simplified installation, and can be glued or
system design engineers now have free reign to
threaded directly into the machine components
integrate sensing functionality in areas that pre-
quickly. Alternatively, a range of optional mount-
viously couldn’t accommodate any conventional
ing accessories is available, including vertical and
sensor,” says Menke. “For example, SuperShorties
right angle brackets,” says Helm.
www.controldesign.com CD0803_73_Exclusive.indd 73
March 2008 Control Design
73
2/26/08 1:34:28 PM
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structured, one-on-one
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specific automation needs—
all in a first-class setting.
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AutomationXchange is
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= F
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CD0803_FPA.indd 74
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2/25/08 2:18:28 PM
2/25/08 2:20:41 PM
46984
PROTECT YOUR POWER SUPPLY
ESX10-T electronic circuit protector has electronic trip characteristics and active current
limitation for selective disconnection of loads connected to
24 Vdc supplies. Selective load
63-mm wide, with voltages of 80
Vdc and 110/230 Vac. Perfor-
includes remote access utilities.
mance ranges between 50 W
The PLC allows 1 MB of logic
and 1 kW. Powerlink and the
memory, has a scan time of 15
X2X remote backplane are on-
µsec per 1K of typical applica-
board as fieldbus interfaces. The
tion and offers up to 38 onboard
cooling design reduces costs by
digital and analog I/Os that can
eliminating the need to carry
expand up to 166 points.
out additional work for climate
Unitronics; 617/657-6596;
control. Typical applications are
unitronics.com
in CNC, packaging, textile and
printing applications.
protection prevents complete
shutdown of the system by
B&R Industrial Automation;
quickly disconnecting the faulty
ELECTRICAL WIRE
path when an overload or short
THHN 19-strand 600 V uncoated
circuit occurs. The protector
copper building wire is avail-
limits the highest possible cur-
able in 4-14 gauge sizes, suitable
SPACE-SAVING CONNECTION
rent to 1.3–1.8 times the rated
for rewiring 600 V applications
FKCN 2.5 spring-cage plug con-
capacity, making it possible to
in wet or dry locations. MTW-
nectors and compatible CCDN
switch on capacitive loads up to
type wire is available in 19- and
2.5 base headers is said to be 30%
20,000 µF. Failure and status are
26-strand 600 V bare, annealed
lower in height than other con-
indicated by a multicolor LED
copper in 1-16 gauge sizes for
nectors up to 12 AWG. The push-
770/772-0400; br-automation.com
and status output signal and
in spring-cage technology allows
can be remotely enabled and
flexible wires with ferrules to be
reset with a digital signal.
connected quickly without any
cdproducts@putman.net
CANopen and UniCAN, and
PRODUCT showcase
products
E-T-A Circuit Breakers;
800/462-9979; e-t-a.com
PLC+HMI
Color displays are becoming
control cabinets, machine tool
common in today’s automation.
applications and appliance wir-
They enable machine builders
ing applications. Both wires are
to show more details on the op-
UL, cUL, CSA and NEMA-rated
erator panels, to display vivid,
and available in 500 ft spools.
attention-grabbing alarms
AutomationDirect; 770/889-7876;
tools. The connector has a large
and, in general, to brighten up
automationdirect.com
wire entry so that it can safely
support flexible wire ferrules.
their systems. Vision350 PLC
Wires can be disconnected using
and enhanced HMI provides
diverse I/O options adaptable to
SMALL DRIVE
the orange actuation levers.
Ethernet connection via TCP/
Acopos micro drive for stepper
Phoenix Contact; 717/944-1300;
IP, GSM/SMS/GPRS, Modbus,
and servo motors measures
phoenixcon.com
www.controldesign.com CD0803_75_76_Products.indd 75
March 2008 Control Design
75
2/22/08 3:38:03 PM
PRODUCT showcase
SOFTWARE
RESOURCES
with parallel-shaft or right-an-
WEB-ENABLED HMI SOFTWARE
MODBUS WHITE PAPER
gle configurations with torque
Genesis64 64-bit-based OPC
“Using Modbus for Process
capacities to 920,000 lb-in. for
Web-enabled HMI/SCADA
Control and Automation”
a variety of soft start mecha-
software suite provides us-
describes how Modbus works,
nisms in a variety of conveying
ers with a 3D visualization
and how it can be used in new
environment. It is completely
and legacy process control and
Web-configurable and uses a
automation. The white paper
Workbench framework. Tak-
notes that an advantage of
ing advantage of Windows
Modbus is that it can run over
Vista, .NET and SharePoint
virtually all communication
technology, the software
media, including twisted pair
allows plant operators and
wires, fiber optics, Ether-
IT professionals to integrate
net, telephone modems, cell
real-time manufacturing and
phones and microwave.
business information into a
Moore Industries-International;
applications. It meets or ex-
common, Web-enabled visual-
818/894-7111; www.miinet.
ceeds AGMA and international
ization dashboard.
com/whatsnew/articles/using
standards, with carburized,
Iconics; 800/946-9679; iconics.com
modbus for process control and
Magna Force
MagnaGear XTR heavy-duty,
cast-iron reducer is available
hardened and precision-ground
automation.pdf
gearing. Tandem HBNR lip seals
are standard for extra protec-
REDUCE DEVELOPMENT
tion, all bearings
AxisLite is a reduced func-
COMPACTPCI EXPRESS
Baldor-Reliance; 864-297-4800;
tionality version of AxisView,
2008 catalog outlines a range
baldor.com
an advanced, multiproces-
of intercompatible 3U Com-
sor, integrated software-
pactPCI and CompactPCI
development environment
Express single-board comput-
TRANSPARENT ENCLOSURES
ers and systems based on Intel
BT Series transparent plas-
and PowerPC architectures.
tic enclosures meet NEMA
Featured is an Intel-based
1/2/4/4X/12/13, IEC52/IP65, and
single-slot F18, based on In-
UL508-4X specs. Suitable for
tel’s T750 CoreT2 Duo proces-
PCB enclosures, junction boxes,
sor with a frequency of 2.2
instrumentation and other ap-
GHz, that functions as either
plications that require monitor-
a 32-bit/33 MHz system slot or
stand-alone board.
MEN Micro; 215/542-9575;
that allows users to evaluate
menmicro.com
the capabilities of AxisView
prior to purchasing the full
suite. It frees developers from
the time and effort needed to
understand the complexities
ing of internal components in
of rapidly evolving hardware
wet, dry and corrosive environ-
architectures. AxisLite is free
ments. Enclosures are available
for download.
in seven sizes.
GE Fanuc Intelligent Platforms;
Bud Industries; 440/946-3200;
800/gefanuc; gefanucembedded.
budin.com
com/axis
76
CD0803_75_76_Products.indd 76
Control Design March 2008 More, More, More
You’ll find hundreds of other
new products, software and
resources in categories that
span the complete range of
your machine control and
automation design needs at
ControlDesign.com/products.
www.controldesign.com
2/22/08 3:38:35 PM
CLASSIFIED
is the only magazine exclusively
dedicated to the original equipment
manufacturing (OEM) market for
instrumentation and controls—the
largest market for industrial controls.
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GROUP ART DIRECTOR
EQUIPMENT
ATTENTION DISTRIBUTORS
Due to a recent expansion of Eurotherm product offerings, we
are actively seeking North American Distributors for a new line
of Motor Drives. Products include Variable Frequency Drives,
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GREG ZAMIN gzamin@putman.net
630/467-1300 Fax: 630/467-1124
555 W. Pierce Rd., Suite 301
Itasca, Illinois 60143
WESTERN REGIONAL MANAGER
LAURA MARTINEZ lmartinez@putman.net
310/607-0125 Fax: 310/607-0168
218 Virginia, Suite 4, El Segundo,
California 90245
DIGITAL SALES SPECIALIST
JEANNE FREEDLAND
jfreedland@putman.net
805/773-4299 Fax: 805/773-0451
Contact: Emily Rogier at erogier@putman.net or call 630-467-1300 ext.335
Reprints are available on a custom basis from
FosteReprints
Contact Claudia Stachowiak at
1-(866)-879-9144 ext.121
or at claudia@fostereprints.com
INSIDE SALES MANAGER
EMILY ROGIER erogier@putman.net
630/467-1300 Fax: 630/467-1124
Introducing
E-MARKETING ACCOUNT MANAGER
JENNY FANNING jfanning@putman.net
555 W. Pierce Rd., Suite 301,
Itasca, Illinois 60143
630/467-1300 Fax: 630/467-1124
EVENTS DIRECTOR
ANDY WUEBBEN
awuebben@automationxchange.com
952/224-7641
ADMINISTRATIVE TEAM
Alarm
Annunciators
PRESIDENT & CEO
JOHN M. CAPPELLETTI
VICE PRESIDENT
JULIE CAPPELLETTI-LANGE
VP, CIRCULATION
JERRY CLARK
IT DIRECTOR
ROSE SOUTHARD
• 8 Field Selectable ISA Alarm Sequences
• 4 or 8-Point Monitoring with Internal Horn
• Shallow Depth 1/8 DIN Case
• Switch, Transistor and Logic Level Inputs
• Highly Visible in Direct Sunlight
• Silence, Acknowledge, and Reset Functions
REPRINTS
FOSTER REPRINTS www.fostereprints.com
CLAUDIA STACHOWIAK
claudia@fostereprints.com
866/879-9144 ext. 121
www.predig.com/vigilante • (800) 343-1001
AD INDEX
ABB Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ad Products . . . . . . . . . . . . . . . . . . . . . . . . . . 70,72
Adalet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Advantech Automation. . . . . . . . . . . . . . . . . . . . . 28
Allied Electronics . . . . . . . . . . . . . . . . . . . . . . . . 27
Ametek, APT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AutomationDirect . . . . . . . . . . . . . . . . . . . . . . 2, 80
Automation Xchange . . . . . . . . . . . . . . . . . . . . . . .74
Baldor Motors and Drives . . . . . . . . . . . . . . . . . . . 10
Beckhoff Automation . . . . . . . . . . . . . . . . . . . . . . 23
Brady Worldwide . . . . . . . . . . . . . . . . . . . . . . . . . 63
c3controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dataforth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ECT International . . . . . . . . . . . . . . . . . . . . . . . . 48
Endress + Hauser . . . . . . . . . . . . . . . . . . . . . . 11-18
E-T-A Control Instruments . . . . . . . . . . . . . . . . . . 30
Exergen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FCI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 61
Maple Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MTS Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
National Instruments . . . . . . . . . . . . . . . . . . . . . . . 4
Novotechnik . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Omega Engineering . . . . . . . . . . . . . . . . . . . . . . . . 3
Omron Electronics. . . . . . . . . . . . . . . . . . . . . . . . . 6
Opto 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-54
Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . . . 46, 47
Phoenix Contact . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precision Digital . . . . . . . . . . . . . . . . . . . . . . . . . 77
Red Lion Controls . . . . . . . . . . . . . . . . . . . . . . . . 25
Rice Lake Weighing Systems . . . . . . . . . . . . . . . . 37
Schneider Electric. . . . . . . . . . . . . . . . . . . . . . . . 38
SEW-Eurodrive . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Software Horizons . . . . . . . . . . . . . . . . . . . . . . . . . 7
Stealth Computer . . . . . . . . . . . . . . . . . . . . . . . . 24
Unitronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Vaisala . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Vision Components . . . . . . . . . . . . . . . . . . . . . . . 69
Wago . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39, 41
Weidmüller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Yaskawa Electric . . . . . . . . . . . . . . . . . . . . . . . . . 57
March 2008 Control Design
CD0803_77_AdIndex_Class.indd 77
77
2/25/08 2:04:47 PM
Jason H. Stallard • jason.h.stallard@cummins.com
oem insight
Do Your Duty Cycle Diligence
As an oem provider of engines that go into
data, which were processed in near-real time.
numerous and often unique applications, it
With this data we were able to examine histori-
sometimes is difficult to know before delivery
cal data when engine failures occurred, predict
just what sorts of duty cycles a given engine
failures before they happened and drive changes
will go through. Power generators could sit for
for platform development. We also found that
weeks between maintenance starts and could
the data-collection equipment was not always
only be needed to provide backup power once
handled well, and several units were returned
ever year or two. A line haul truck could spend
beaten up, filthy or destroyed.
two days crossing the U.S. and then a week run-
Cummins learned several lessons from the
ning local deliveries. When the inevitable call
pilot program. The chosen data-collection hard-
comes in to troubleshoot an engine, the lack of
ware was expensive and not rugged enough for
data for that engine’s duty cycle makes diagnos-
some environments. Sensors required physi-
ing the problem all the more difficult.
cal modification of some installations, which is
In the past, gathering duty cycle data from a
undesirable for customer vehicles. While cell
customer’s installation was a logistical night-
coverage was plentiful, the data throughput was
mare. Getting permission, coordinating access
less than ideal.
to the engine, installing data collection equip-
The total cost of the system prohibits large-
ment, training personnel, retrieving the data and
scale deployment to more than 100 installations.
analyzing it all made gathering this data undesir-
Future duty cycle recording equipment will need
able for all but the most severe problem engines.
to improve by incorporating distributed sensors
Because of those difficulties, how customers
that use wireless or existing vehicle networks;
used their engines on a daily basis was never
the form factor of the data collection device
needs to be about the size of a car radio; and the
I n the past, gathering duty cycle data
from a customer’s installation was a
logistical nightmare.
remote data transfer rates need to increase to as
near broadband as possible.
Cummins also learned that having a duty
cycle recorder installed on a real-world working
vehicle can benefit safety engineering. During
understood well. However, now that technology
the summer pilot program, a couple of vehicles
is catching up with need, we are beginning to get
were involved in accidents and Cummins was
the data needed to help to drive future designs.
able to review the data much like the flight data
Solid-state computers with sufficiently dense
recorders on commercial airlines. Cummins was
storage space now are small enough that we can
able to determine the road speed, position, en-
install recording devices on-vehicle with minimal
gine load and other diagnostic data before, dur-
impact. Now that the cellular infrastructure is
ing and shortly after the accidents. If the right
mature and providing coverage to a significant
set of data were being recorded at these times,
area of the country, we can collect the stored data
the data would prove invaluable to our vehicle
and reconfigure the in-vehicle systems remotely;
manufacturing customers.
and this all can be done with off-the-shelf hard-
Cummins sees duty cycle data becoming an
ware instead of expensive and limiting systems
integral part of our development, testing and sup-
such as satellite.
port efforts. What started as a pilot of 40 vehicles
In the summer of 2007 Cummins launched a
quickly grew to more than 100. By 2010, we expect
pilot program to outfit a fleet of vehicles with
the number of installations to reach 500 and see
this off-the-shelf hardware combined with some
the potential to eventually have every engine
custom software to facilitate recording, storing
coming off the manufacturing line pre-installed
and transfer of data. In all, 40 engineering, field
with duty cycle recording capabilities.
test and customer vehicles scattered around the
U.S. and Canada, running line haul and local
Jason H. Stallard is a software engineer at Cummins
routes, collected more than 500 gigabytes of
(cummins.com) in Columbus, Ind.
78
CD0803_78_OEMInsite.indd 78
Control Design March 2008 www.controldesign.com
2/22/08 3:42:39 PM
2007
When You Spend 75 Years
Mastering Something,
You Learn To Do It A
Million Different Ways.
We have spent the better part of a century focusing on
one thing. Your motion control and power transmission
challenges. At SEW-EURODRIVE, we don’t just make parts.
We create solutions. Solutions custom designed for each
individual. Whether the application is large or small. Simple
or complex. We design the system that is right for you.
Because what is good enough for most may not be what
is best for you. And what is best for you just might be
solution #1,000,001.
www.seweurodrive.com
GEARMOTORS
CD0803_FPA.indd
79
46984 SEW ControlDesign.indd
1
|
DRIVE ELECTRONICS
|
DRIVE AUTOMATION
|
SERVICE
2/25/08
2/21/0811:12:49
1:52:38AM
PM
ENCODERS
• Low-cost motion sensing
starting at $81.50 U.S.
• Incremental and absolute
• 30 to 78 mm diameter bodies
• 60 to 2,500 pulses per
revolution
IEC LIMIT SWITCHES
• As low as $13.75 U.S.
• IEC switches with eight standard actuators
• Die-cast aluminum or double-insulated
PBT bodies
PHOTOELECTRIC
SENSORS
• Starting at $33 U.S.
• Round or rectangular
formats
• Diffuse, reflective and
through-beam sensing
styles
CURRENT
SENSORS
• Monitor loads for
power consumption
or abnormal
conditions
• Current switches offer
discrete outputs with adjustable setpoint, starting at $58
• Current transducers have jumper-selectable input ranges
• Models available with true RMS signal conditioner
PROXIMITY
SENSORS
• Starting at $16 U.S.
• Inductive, capacitive and
ultrasonic technologies
• 3 mm to 30 mm round or rectangular
• Embedded cables or quick-disconnects
SENSORS
Bet on AutomationDirect for a wide range of sensors
at low everyday prices, in stock and ready to ship the
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For complete specifications, pricing and ordering,
visit: www.automationdirect.com/sensors.
CD0803_FPA.indd 80
CHECK OUT OUR PRICES
PROXIMITY
5 mm three-wire DC shielded with M8 Q/D
18 mm three-wire NPN DC shielded with
2 meter cable
18 mm AC shielded with 2 meter cable
AutomationDirect
$35.00
PD1-AP-1F
$20.50
AK1-AN-1A
$31.00
VK1-A0-1B
Allen-Bradley
$107.00
871C-D1NP5-P3
$69.00
872C-DH5NN18-E2
$84.00
872C-A5N18-A2
*All prices are U.S. published prices. AutomationDirect prices are October 2007 prices. Allen-Bradley prices taken from
http://shop.rockwellautomation.com, July, 20 2007. Specifications may vary by dealer and configuration. Prices subject
to change without notice.
Want to get the full deck? visit:
www.automationdirect.com/cards.html
2/25/08 11:13:14 AM