Why Is There NO ISA
in STEM?
The Battle for VISION
SUPREMACY
HMI Shouldn’t
Be a PAIN IN
THE NECK
The Truth About the Bottomless Cup of
NOVEMBER 2014
Machine Protection
CD1411_01_Cover.indd 1
Remote Diagnostics and Service Are More
Routine and Secure, More Comprehensive in
Scope and Capabilities and More Adept at
Providing Data to Improve Machine Designs
11/5/14 10:16 AM
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11/4/14 10:53 AM
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© 2014 PHOENIX CONTACT
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CONTENTS
Volume 18, No. 11
FEATURES
26
37
43
COVER STORY
The Truth About the Bottomless Cup
of Machine Protection
Remote Diagnostics and Service Are More Routine and
Secure, More Comprehensive in Scope and Capabilities and
More Adept at Providing Data to Improve Machine Designs
Jim Montague, executive editor
DRIVES & MOTION CONTROL
What’s ‘Pnew’ With Pneumatics?
With Alternative Solutions Available, Machine Builders and
End Users Still Find Plenty of Appeal in Pneumatic Systems
Mike Bacidore, editor in chief
PRODUCT ROUNDUP
Take Control of Control Software
Current Approaches Automate Automation
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfield Rd., Suite 400N, Schaumburg, Illinois 60173. (Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at Schaumburg, IL, and at additional mailing
offices. Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©Putman Media
2014. All rights reserved. The contents of this publication may not be reproduced in whole or part without consent of the copyright owner.
POSTMASTER: Send address changes to Control Design, Post Office Box 3430, Northbrook, Illinois 60065-3430. SUBSCRIPTIONS: To
apply for a free subscription, fill in the form at www.ControlDesign.com/subscribemag. To non-qualified subscribers in the Unites States
and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail
only.) 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.
November 2014 Control Design
CD1411_05_07_TOC.indd 5
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An Electrocomponents Company.
11/4/14 10:53 AM
CONTENTS
COLUMNS
HOT BUTTONS
9 Editor’s Page
15 OEM Spotlight
Volume 18, No. 11
Go Small, Get Flexible
Everything That Rises
Mike Bacidore, editor in chief
18 InDiscrete
11 Live Wire
2 New Solution Factory Facilities in
the Mix; China Adopts EtherCAT as
National Technology Standard
Detour to Builder City
Jim Montague, executive editor
25 Embedded Intelligence
46 SpecMate
Make STEM Teachers ISA
Members
2 Views of Machine Vision
Jeremy Pollard, CET
48 Real Answers
Give Your HMI an Ergonomic
Tune-Up
42 TechFlash
ECAD: Simple or Complex?
Leslie Gordon, senior technical editor
50 Product Showcase
54 OEM Insight
Machinery Safety Labels Matter—
Part II
Geoffrey Peckham, chairman ANSI Z535 Committee
Take a picture of your product.
Tell the sensor what to verify in three quick steps.
Every product on your line is now
visually checked for quality.
NEW XUW Vision Sensor
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Booth #4749
10/20/2014 10:41:26 AM
11/5/14 9:52 AM
Control
Design-PFC200-Nov2014
Outlined.indd 1
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8
10/21/1410:54
1:53AM
PM
11/4/14
Mike Bacidore
In Memory of Julie Cappelletti-Lange,
Vice President 1984-2012
•
editor in chief
•
mbacidore@putman.net
EDITOR’S PAGE
Everything That Rises
1501 E. Woodfield Rd., Suite 400N
Schaumburg, Illinois 60173
630/467-1300
Fax: 630/467-1124
WHEN YOUNG MEN and women
After all, service agreements are
leave home to make lives of their
lucrative add-ons to machinery
EDITORIAL TEAM
own, parents shed some tears
sales. If you’re not watching and
editor in chief
and hope they’ve equipped them
maintaining that machine, some-
to take on the challenges they’ll
one else surely will.
MIKE BACIDORE
mbacidore@putman.net
executive editor
JIM MONTAGUE
jmontague@putman.net
face. Sometimes, they end up back
And it would be really simple to
home for a spell, but for the most
use that existing control system
managing editor
part they’re out there, doing what
to measure almost anything with
NANCY BARTELS
nbartels@putman.net
they were born to do. And parents
the proper sensing device. Most
do their best to let them, secretly
world-class manufacturers have
wishing they still could watch over
recognized the financial benefits
them and protect them.
of avoiding equipment failures and
managing editor, digital media
KATHERINE BONFANTE
kbonfante@putman.net
associate editor, digital media
ERIN MASSEY
emassey@putman.net
senior technical editor
DAN HEBERT
dhebert@putman.net
senior technical editor
LESLIE GORDON
lgordon@putman.net
contributing editor
HANK HOGAN
hank@hankhogan.com
editorial assistant
LORI GOLDBERG
lgoldberg@putman.net
columnist
JEREMY POLLARD
jpollard@tsuonline.com
DESIGN/PRODUCTION
senior production manager
Machines emerge similarly.
profitability. Most of these plants
equip them with appropriate
also have software—it might be
controls, motion components, con-
CMMS, EAM or ERP—that’s used to
nections and safety elements, and
schedule maintenance on equip-
then they’re released to industrial
ment. And that software doesn’t
facilities, where they do what they
talk with control systems. “Oh,
were built to do.
but you can use a data historian,”
One of the big differences
advantage of monitoring is the
aside from the fact that machines
real-time, in-context analytics
won’t ever marry that loser son-
that are available.
in-law who can’t hold a job, is we
can’t monitor the health of our
sons and daughters on a real-time
assoc. art director
basis, but that is in fact possible
SUBSCRIPTIONS
customer service
888/644-1803
CIRCULATION
audited June 2014
Air & Gas Compressors
1,020
Engineering & Systems
Integration Services
6,989
Engines & Turbines
1,812
Food Products Machinery
1,990
Industrial Fans, Blowers
& Air Purification Equipment
759
Industrial Heating, Refrigeration
& Air Conditioning Equipment
1,383
Industrial Process Furnaces & Ovens
672
Machine Tools
3,415
Materials Handling, Conveyors
& Conveying Equipment
1,884
Metalworking Machinery
3,867
Mining Machinery & Equipment
539
Oil & Gas Field Machinery & Equipment 1,358
Packaging Machinery
1,072
Paper Industries Machinery
368
Printing Trades Machinery & Equipment 484
Pumps & Pumping Equipment
752
Rolling Mill Machinery & Equipment
161
Semiconductor Manufacturing
Machinery
1,170
Textile Machinery
225
Woodworking Machinery
284
Other Industries & Special Industrial
Machinery & Equipment NEC
9,816
TOTAL
40,020
CD1411_09_EDIT.indd 9
you say. That’s true, but the big
between machines and progeny,
ANETTA GAUTHIER
ANGELA LABATE
optimizing system capacity. That’s
They’re created by engineers who
with machines. Sensors allow
us to keep watchful eyes on any
number of conditions. And the
If you’re not watching
and maintaining that
machine, someone else
surely will.
Call it convergence or integra-
opportunities to equip machinery
tion, but the ability to use control-
with them keep increasing.
system sensors to monitor ma-
Seven years ago, Contribut-
chines remotely in real time and
ing Editor Dan Hebert wrote
schedule planned maintenance is
about how far remote monitor-
coming. And machine builders will
ing capabilities had come (www.
be able to care for their children in
controldesign.com/machinemoni-
unforeseen ways.
toring), and that technology curve
continues to steepen.
One of the more interesting
On a final note, let me take a
moment to salute Joe Feeley, who
has retired. You all remember him
recent developments has been the
as chief editor of Control Design. I
quest to use the existing control
will always remember him as one
system to facilitate condition
of my greatest publishing mentors.
monitoring and plan for main-
Here’s to you, Joe.
tenance of these machines. “Oh
yeah,” you say, “we’ve been doing
that for years.” It’s quite possible
that you have, on a limited scope.
controldesign.com
November 2014 Control Design
9
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TECHNOLOGY
CD1411_FPA.indd 10
11/4/14 10:54 AM
Jim Montague
•
executive editor
•
jmontague@putman.net
LIVEWIRE
Detour to Builder City
I REALLY NEED to be more careful driving because
and park district all have a hand in supporting the
I can’t help seeing interesting stuff. And my smart-
village’s business community. “Beyond Business
phone doesn’t help because now I can take pictures
Friendly” is its recent motto.
of everything. Well, at least I stop before snapping—
most of the time.
Anyway, I was driving to work a couple of years
“It’s essential for Elk Grove to support our businesses because the industrial park contributes
about 80% of the village’s revenue,” says Josh
ago, when I had to take a detour due to a freight
Grodzin, Elk Grove’s business development market-
train taking a long nap across an intersection up
ing director. “About five years ago, the park’s vacan-
ahead. So I was forced to venture more deeply than
cy rate was 14 to 15%, and so we started some of our
ever before into the huge industrial park just west
more recent efforts, including Made in Elk Grove, to
of O’Hare International Airport and located in the
assist our manufacturers with the challenges they
municipality of Elk Grove Village, Illinois.
face. More recently, we’ve driven the vacancy rate
Now I’ve been all over this area before, or so
I thought, because I came upon a strange sight.
back down to just 7%.”
Ironically, even though the expo featured dozens
One of the big warehouses on Pratt Avenue had its
of machine and equipment builders, end users and
equally big, garage-style doors open, and inside was
product manufacturers, and related suppliers and
an army of old press brakes, machining centers and
service providers, Grodzin adds many more haven’t
other industrial equipment.
attended the event yet.
I’m pretty sure many of the machines were in
various stages of refurbishment, rebuilding or decommissioning, but my glance and mental snapshot
made it look like someone had sealed up an IMTS
exhibit hall about 30 years ago and just let the dust
and cobwebs take over.
I felt a little like one of those anthropologists who
I felt a little like one of those
anthropologists who discovers
an ancient, buried city, except
it’s still up and running like
Rome or Paris.
discovers an ancient, buried city, except it’s still up
and running like Rome or Paris.
This was the first of several wakeup calls alerting
Consequently, because the park is so big, many of
its occupants don’t know what their neighbors are
me to the fact that I’ve been sitting on a hotbed of
building and producing that could be useful to them
machine builders and end users. How convenient for
and are buying products and paying to transport
me covering this field, but not very surprising, given
items they could get in their own town.
the Chicago area’s long and varied industrial history.
Some of the show’s other organizers report one
Even so, after many years covering industrial
of their main aims is to get the park’s residents to
tradeshows nationwide and internationally, I was
realize and use the supply chain that’s all around
startled again when I ran across the Made in Elk
them. Apparently, I’m not the only one who’s un-
Grove Manufacturing & Technology Expo (www.
aware of the hotbed he’s sitting on.
madeinelkgroveexpo.com) on Oct. 21. The one-day
As for me, I now have another rich vein of poten-
event is now two years old and, with 90 exhibiting
tial content and contributors to mine, and I don’t
companies and 1,000 visitors, is as at least as big as
have to get on an airplane to reach them. I’ll inves-
some similar tradeshows covering far larger regions.
tigate and report on as many as I can.
This shouldn’t be too surprising because the expo
You too may find neighbors with capabilities you
draws its exhibitors from the Elk Grove Business
thought you had to cross time zones to get. It hap-
Park, which covers more than 5 sq miles and is the
pens all the time with builders, integrators and us-
largest industrial park in North America. It’s home
ers. Even long-time business associates frequently
to more than 3,600 businesses, which are staffed by
say to each other, “I didn’t know you did this.”
about 100,000 employees.
These companies and their workers are served by
So keep you eyes on road, but also slow down,
stop sometimes and look around. More than likely,
Elk Grove’s municipal services, but its high school,
you’ll glimpse something cool and find some useful
local community colleges and even the library
resources hiding in plain sight.
controldesign.com
CD1411_11_LIVEWIRE.indd 11
November 2014 Control Design
11
11/3/14 11:11 AM
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Traditional ultrasonic sensor designs determine sensor-to-target
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Vehicle detection, such as counting cars entering a parking garage,
provides an excellent example of the benefits in using retroreflective
technology. Optical technologies can demonstrate the problems
caused by varying paint colors and transparent glass windshields.
On the other hand, the smooth, sloped contour of a car body and
windshield deflect ultrasonic echoes away from the transducer,
rendering the target ultrasonically invisible.
An ultrasonic sensor mounted overhead learns the distance to the
floor below. Anytime the sensor detects a change in that distance
or loses the echo entirely, it signals the presence of a vehicle.
Beyond vehicle detection, retroreflective ultrasonic sensors
can also detect humans, whose soft clothing is both randomly
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OEM SPOTLIGHT
Go Small, Get Flexible
Emag Migrates From Large, Custom-Built Equipment
BIGGER ISN’T ALWAYS better, more features aren’t
always helpful, and many bells and whistles are just
noise. All the capabilities a useful machine requires
are no more than what each end user needs to produce its products with the greatest speed, accuracy,
efficiency, safety and quality. And this directive is
even truer for the many small users with shallow
pockets who are just beginning to approach using
automated machines and production for the first time.
These are the customers that Emag (www.emag.
com) has been reinventing several of its machines to
reach. Located in Salish, Germany, and Farmington
JIM MONTAGUE
Hills, Michigan, Emag traditionally builds big, vertical
turning, milling and drilling machines with customized control and operations for manufacturing precision metal parts, mainly for the automotive industry.
However, to expand into new markets, Emag also
began developing smaller, more flexible versions of its
larger machines to serve more Tier 1 and 2 parts suppliers and many mom-and-pop machine shops too.
“We wanted to get into new market segments with
new customers, and so we developed a new modular,
standardized concept and introduced it in Europe
CONCENTRATED CAPABILITY
The VLC 200 H gear-hobbing machine is one of a series of
machining centers that Emag has shrunk to one-half to onethird the size of its traditional vertical machines, but which
retains the Plus, numerical controls, G-code and capabilities of
the company’s larger devices.
three years ago and in North America two years ago,”
says Marius Mazur, Emag’s product line manager.
One especially important milestone arrived in 1992,
“Our traditional machines are two or three times
when Emag introduced its VSC, which it reports was the
larger than our new modular machines.”
world’s first vertical turning center with pickup spindle.
How did Emag pack the capabilities of its older, big
Over time, the VSCs developed into multifunctional,
machines into its new, small ones? Very carefully,
multitasking production centers. For instance, about 10
especially when integrating its PLC, numerical control
years ago, Emag also got into machining threaded parts
(NC), G-code and other essential components into its
for oil and gas piping applications and developed its VL
new half- or one-third-sized footprints. Amazingly,
3, VL 5 and VL 7 vertical centers. Designed to handle
the new, smaller machines still retain the capability
the unique material characteristics and requirements
of the older and larger cousins, employing Siemens’
of process industry components, the VL series are
840 DSL hybrid PLC and NC controller or Fanuc’s 32i
typically managed by Fanuc’s 32i controller and can be
and 33i CNC controllers.
monitored and diagnosed via Emag’s Internet protocol
“Our new modular machines are the same as our
larger ones,” says Mazur. “We just put all our knowledge into smaller spaces.”
Founded in 1867 in Bautzen, Saxony, as an iron
(IP)-based, Ethernet network.
Emag’s equipment covers the entire spectrum of
machining processes in metalworking. In fact, besides Emag’s turning, milling and drilling machines,
foundry and engineering works, Emag was reestab-
the larger Emag Group’s companies manufacture
lished in 1952 in Esslingen, Baden-Württemberg, where
chucked, shaft-type and cubic components. Founded,
it manufactured lathes and special-purpose machines.
organized or acquired mostly since 2000, these
In 1969, it moved to Salish, where it introduced pro-
divisions include Karstens, which makes external,
gram-controlled, automatic turning machines, which it
cylindrical grinding equipment; Naxos-Union, which
began distributing worldwide in 1977, including open-
specializes in crankshaft grinding; Emag Automa-
ing its Michigan-based subsidiary in 1980.
tion, which provides automation for all applications;
controldesign.com
CD1411_15_16_OEMSPOTLIGHT.indd 15
November 2014 Control Design
15
11/5/14 10:15 AM
OEM SPOTLIGHT
“Our new modular machines are the same as our larger
ones. We just put all our knowledge into smaller spaces.”
for electrochemical machining.
Reinecker for internal, precision
While its recent modular
grinding; Kopp for camshaft
grinding; Koepfer for gear hob-
program started with just one
bing; Emag Laser Tec for assembly
scaled-down machine three years
and laser welding; and Emag ECM
ago, Emag reports its new vertical
The MAQ®20 Industrial
Data Acquisition & Control System
JIM MONTAGUE
Rugged Precision
PARTS FOR PROCESS
Emag’s VL 5i vertical machining center is
designed to manufacture parts taking into
account the unique characteristics and
requirements of oil and gas piping applications
line includes VL 2, which produces
parts up to 100-mm diameter; VL
4, which makes parts up to 200mm diameter; VL 6, which makes
parts up to 600-mm diameter; and
VL 8, which makes parts up to
800-mm diameter.
“VL 2 makes small, round gear
and chuck parts, while our VT 2 and
VT 4 have two spindles, so they’re
really two machines in one,” adds
Mazur. “We also typically add our
automated part conveyors to the
Signal Integrity, Compact Design
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outside of our machines. They’re
controlled by small Fanuc servo
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To maintain these controls
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chines via a password-protected
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machines on our Emag network,
Service Plus program, which
network. “Our users can put their
and we can see everything,” says
• PID Software Control
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CD1411_15_16_OEMSPOTLIGHT.indd 16
Mazur. “Our PLC guys can view
the performance of machines on
their individual Web pages via our
Ethernet-based network.”
Instrument Class® Signal Solutions
dataforth.com • 800-444-7644
11/5/14 10:15 AM
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www.IDEC.com/usa
800.262.IDEC
CD1411_FPA.indd 17
11/4/14 10:54 AM
INDISCRETE
2 New Solution Factory Facilities in the Mix
MOSS DOES NOT grow on Tom
Johnstone or Poul Jeppesen. On
Oct. 19, Johnstone, president
and CEO of SKF, and Jeppesen,
president and CEO of SKF North
America, attended the Geico 500
at Talladega Superspeedway in
Alabama to watch Team Penske’s
Brad Keselowski win the NASCAR
Sprint Cup Series race in the SKFsponsored No. 2 car.
Two days later, they were at the
United Center in Chicago, watching the BlackHawks defeat the
Philadelphia Flyers, 4-0.
INNOVATION AND KNOWLEDGE
The Solution Factory that will be included in the GTCA will be the 29th Solution Factory.
In between the two sporting
events, all they did was open
the company’s 28th SKF Solution Factory near Birmingham,
Alabama, and break ground for the
Global Technical Center—Americas (GTCA), which will include the
29th Solution Factory, in Naperville, Illinois.
The Alabama facility is designed to provide customers
with industry knowledge and
value-added solutions. With Solution Factory facilities already in
Houston and Cleveland this is the
third to open in the United States
and joins the growing network of
five others in North America. “The
SKF Solution Factory is another
BREAKING GROUND
Paol Jeppesen, president of SKF North America, A. George Pradel, mayor of
Naperville, Illinois, and Tom Johnstone, president and CEO of SKF, make way for the
Global Technical Center—Americas.
way for us to provide customers
application support, custom-
Netherlands and Sweden. You can
with the resources they need to
ized machined sealing solutions,
even track the progress of the new
meet machinery performance and
mechanical equipment services,
GTCA in Naperville at www.skf.
operating efficiency goals,” said
engineering consultancy and re-
com/gtca. When it opens, it will
Jeppesen. “We’re pleased to bring
mote diagnostics and monitoring.
combine technical resources with
this state-of-the-art facility and
It also includes training courses
knowledge experts in an effort to
its unique portfolio of services to
and seminars.
create a culture of collaboration
this region.”
The GTCA is part of SKF’s plans
and innovation. Over the next two
for a global network of technical
years, SKF will recruit a technical
tory, which focuses on pulp and
centers, including ones built in
staff of 40 employees to work at
paper, food and beverage, mining
China in 2013 and in India in 2011.
the facility, which is being built
and metals industries, offers ac-
Two more are currently under
to LEED Gold standards. SKF also
cess to SKF’s technical resources
construction, adjacent to the exist-
is pursuing ISO 50001 for all of its
for machine productivity solutions
ing technology and manufacturing
manufacturing facilities.
and services, including bearing
process research centers in the
The Birmingham Solution Fac-
18
Control Design November 2014
CD1411_18_23_INDISCRETE.indd 18
The GTCA will be an open
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CD1411_FPA.indd
19
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4:32AM
PM
11/4/14
INDISCRETE
reduction through better energy
and resource efficiency.”
Driving project development
and technical recruitment for the
GTCA is Cengiz Shevket, director,
engineering and emerging segments, renewable energy business
unit, at SKF. “I’m confident that
this will be a great facility, not only
in which to work, but to collaborate
through open visits and workshops
with customers, our distributors
ROOMS WITH A VIEW
When the GTCA opens, it will include a mezzanine viewing balcony and a high-bay
workspace with up to 25-ton lift capacity.
and university researchers,” said
Shekvet. The facility will include
approximately 130,000 ft 2 of space,
laboratory for idea generation,
ich, vice president of communica-
open workspaces, an exhibit hall,
leveraging a modular building
tions at SKF North America. “This
testing capabilities for special-
structure that’s adaptive, open and
new facility will be an eye-opener
ized industries such as aerospace,
informal. “A common refrain from
for our North American customers
energy and automotive, training
even long-standing customers is
and a great opportunity for SKF
classrooms, a mezzanine viewing
‘I didn’t know,’ when they see the
to put its best technology forward
balcony, a wellness center and a
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to solve today’s most pressing
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2014-05-15
09:57:27 09:57:27
INDISCRETE
China Adopts EtherCAT as
National Technology Standard
ON OCT. 21, Dr. Wei Sun, repre-
Technology Group (ETG) at a
sentative of the Standardization
ceremony in Beijing. He informed
Administration of China (SAC),
the crowd that EtherCAT, which
made an announcement about
has seen strong global use for
a milestone and the EtherCAT
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What will you
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national technology standard in
China.
The ceremony in Beijing was
hosted by ITEI president, Prof.
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guest house of the Chinese government and brought together
numerous experts from a wide
range of industries. There, SAC
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In close cooperation with ITEI,
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As a special highlight to the
ceremony, Chinese company
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applications with the audience
members, and they explained
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The ceremony closed with live
demonstrations of various EtherCAT systems featuring a variety
of Chinese and international
EtherCAT products.
CD1411_18_23_INDISCRETE.indd 22
11/5/14 10:52 AM
MERGERS,ACQUISITIONS & ALLIANCES
Zebra Technologies (www.zebra.com) has completed the
acquisition of Motorola Solutions’ (www.motorolasolutions.
com) Enterprise business for $3.45 billion in cash. The
transaction was funded with $200 million of cash on hand
and $3.25 billion in new debt. As part of the sale, 4,500
Motorola Solutions employees from locations throughout
the world will transfer to Zebra.
Rockwell Automation (www.rockwellautomation.
com) has purchased the assets of ESC Services, (www.
escservices.com), a hazardous energy control provider of
lockout-tagout services and solutions. ESC Services, based
in Franklin, Wisconsin, will be integrated into Rockwell
Automation’s Control Products & Solutions segment as part
of its customer support and maintenance business unit.
Terms were not disclosed.
Turck (www.turck.com) has acquired a 50% interest in its
long-term Canadian sales partner, Chartwell Automation
(http://chartwell.ca/). The new company name is now Turck
Chartwell Canada, Inc. On Oct. 1, 2017, Turck will acquire
the remaining shares and thus be 100% owner of the new
subsidiary, Turck Canada.
TE Connectivity (www.te.com) has completed the
previously announced acquisition of Measurement
Specialties. For reporting purposes, Measurement
Specialties will be included as part of TE’s Transportation
Solutions segment.
Mitsubishi Electric (www.meau.com) and Kemper Storatec
(www.kemper-storatec.eu ) have collaborated to introduce
a new, fully automated system that loads and unloads any
existing cutting equipment, regardless of the manufacturer.
In a fully automated laser line, the StoreAutomation
loading and unloading unit takes the raw material from
the raw sheet stack and loads the cutting machine’s table.
After processing, a rack in the machine removes the cut
blank automatically.
Kepware Technologies (www.kepware.com), developer of
software solutions for industrial automation and controls,
has made available its Industrial Data Forwarder for Splunk.
(www.splunk.com). The forwarder, a plug-in for the widely
deployed KEPServerEX platform, enables customers to send
industrial data from sensors, devices and control systems to
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CD1411_18_23_INDISCRETE.indd 23
11/3/14 11:20 AM
TRUE STORY
Every day, IceStation enclosures are washed down
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25
CD1411_FPA.indd 24
11/4/14 10:55 AM
Jeremy Pollard, CET
•
jpollard@tsuonline.com
EMBEDDED INTELLIGENCE
Make STEM Teachers ISA Members
WHAT DO WE need to do with our industry—dis-
This local robotics revolution now boasts 50 teams
crete and process—to engage youngsters who don’t
over two days. The grade school’s gifted program stu-
yet realize they’re really engineers?
dents have had more exposure to science, technology,
I challenged the International Society of Automation (www.isa.org) to “do it differently” (DiD) many
years ago during a conversation with Dick Morley. He’d
engineering and math (STEM) programs. A full day of
the competition is dedicated to them.
Ready says that solutions tend to be more creative
been asked to help guide the society to make it more
coming from the gifted program students, but not
relevant and have a bigger appeal. I sent him a picture
always. He believes that the ability to be unshackled
of its executives and told him this has to change.
from the expected is what leads to solutions that can
There were more white shirts and ties than one
sees at a funeral. And no one was under 50 years old.
We’re paying engineers more now than before,
be unexpected.
There have also been For Inspiration and Recognition of Science and Technology (FIRST, www.usfirst.
which tells me that the resource pool is shrinking,
org) events run at a local college that Ready has
but that isn’t new.
been involved with. Again, where have I been? These
ISA has held YAPFest, which was strictly for the
young automation professional (YAP), during its Automation Week. Nice job, Tracy! It was well attended and
teams have competed in the United States on behalf
of Canada.
So, here’s where the rubber meets the road. I asked
provided attendees an insight into their future with a
Ready if he is a member of ISA, and he said, “Never
conference and tradeshow. But how can we continue
heard of it.”
the YAPFest movement, and how can ISA help?
Since I am a member of ISA and over 50, I get in
the mail a brochure that suggests I can have a voice
in choosing the ISA leadership for 2014.
There are 10 white shirts and nine ties on the 16
candidates. Hopefully, we can DiD somehow.
I recently discovered that my area has a Lego
robotics lab at the central board of education for the
county of Simcoe. All kids from grades four to eight
at a local public school can participate in the standard curriculum involving the techs.
So I tracked down Mike Ready, teacher at Mountain
I then asked him how an international organization
could help grassroots programs such as those he has
been dealing with. In a nutshell—resources.
He tends to believe that the ability
to be unshackled from the expected
is what leads to solutions that can
be unexpected.
Budget restrictions, as well as time resources, tend
to throttle the programs’ efforts. But Ready volunteers his time and is all about the experience for the
View Elementary School in Simcoe County, Ontario.
students. It is teachers like him who care who can
He organized the local “robotics revolution” competi-
make a positive impact.
tion, where more than 20 challenges are presented
The reason I scoped out Ready was to provide
to be solved using Lego robotics. More than 150 stu-
some feedback to the ISA process. Vote you must, but
dents participated this year. Where have I been?
vote for those who can be progressive and have some
Ready was generous with his time and guidance,
for which I’m grateful. I asked him some pointed
questions but remembered that he heads up an au-
determination to make a difference. Who are they? I
don’t know, but find out.
I would then implore the ISA to launch a grass-
tomation program for local grade school kids, where
roots program to encourage educational profession-
budding engineers can be found. So here we go.
als to register for a full membership free of charge.
He refers to specific projects as purpose-driven,
Get resource materials into teachers’ hands to help
which defines the exercise’s end goal. He says the
them to develop those engineers who don’t know
out-of-the-box thinking that results generally makes
they’re engineers yet. It’s time for real innovation.
spotting young engineering minds easier. And he
refers to an additional project, the WonderCoaster
JEREMY POLLARD, CET, has been writing about technology
Contest, where students build scale-model, gravity-
and software issues for many years. Pollard has been
powered coasters. He suggests that unless a project
involved in control system programming and training for
is fun, students’ enthusiasm wanes.
more than 25 years.
controldesign.com
CD1411_25_EMBEDDEDINTEL.indd 25
November 2014 Control Design
25
11/3/14 11:22 AM
The Truth About the Bottomless Cup of
Machine Protection
Remote Diagnostics and Service Are More Routine and Secure,
More Comprehensive in Scope and Capabilities and More
Adept at Providing Data to Improve Machine Designs
by Jim Montague, executive editor
26
Control Design November 2014
CD1411_26_34_COVERSTORY.indd 26
controldesign.com
11/5/14 10:07 AM
CAN’T WORK EVERYPLACE AT ONCE?
Better find a way.
Manufacturers demand 24/7 uptime and system
pneumatic lines for grippers and other functions.”
However, because Tornos deployments to users like
Rolex and other watchmakers are growing along with
availability, but that means machine builders and sup-
the recent resurgence of the industry, it needed a better
port technicians must be ready at a moment’s notice
way to keep tabs on its machines in the field. So about
to maintain, troubleshoot and repair practically every
a year ago, Tornos launched its Tisis machine com-
machine they’ve ever sold in hundreds if not thousands
munication system, which transfers 2D and 3D CAD/
of locations scattered worldwide.
CAM designs to its machines, selects tools and checks
While human cloning isn’t practical yet, and machine
on their programs and operating status. Tisis uses a
builders and other stressed-out professionals can’t make
small, password-protected web server integrated into
all the copies they need of themselves, there are other
its machines, communicates via VPN, Internet protocol
helpful tools they can employ to get in front of all the
(IP) and even Wi-Fi, and delivers HTML-based displays to
equipment they must maintain. Remote monitoring,
PCs and tablets.
support and even control are offering more varied and
“Users can remotely organize parts databases, set
sophisticated capabilities for accessing machines and
production rates to run machines overnight, monitor
production lines from a distance and then examining,
their machines from home and receive preset alerts and
troubleshooting, repairing and upgrading them so users
alarms,” says Cassella. “Besides using passwords, we
need not go to each physical location.
also rely on Wi-Fi’s native encryption for added security.
More recently, rather than communicating via old-
Though it’s not part of Tisis, we also use TeamServer
fashioned modems or asking for permission to access
software to access users’ VPNs with their permission,
virtual private networks (VPNs), the newest remote-sup-
take control of our remote machines and go into their
port methods enable builders and technicians to service
CNC controls to solve most problems.”
protected versions of a machine’s operating data and
A few years ago, remote access was just about
software, which are delivered to virtual, cloud-based
monitoring machines, says Sal Conti, remote monitor-
services that don’t require users and their IT staffs to
ing product manager in Rockwell Automation’s (www.
permit access to their internal networks.
rockwellautomation.com) Remote Support Services di-
For instance, Tornos (www.tornos.com) in Moutier,
vision. “Now it’s allowing machine builders and users
Switzerland, builds Swiss-type lathes and other equip-
to deploy their best engineers anywhere at any time,
ment, such as its six-axis SwissNano CNC machine. It
doing it a lot less expensively, gaining data for much
uses bar stock to manufacture wristwatch, medical and
better proactive maintenance and letting technicians
dental device parts up to just 4-mm wide and 28-mm
know what they’ll be facing and what they need before
long with a precision of ±1 micron. Where watchmakers
going into the field,” he explains. “We do more remote
traditionally used several cam-driven lathes to make
monitoring and troubleshooting and less remote con-
their tiny parts, two-year-old SwissNano can make 85%
trol. However, we tell users how to fix their machines,
of typical watch parts in a footprint that’s only 600-mm
or we can fix them by putting machines into program
wide, but contains a multi-spindle lathe with two rotat-
mode and making needed changes.”
ing tool positions and 12 total positions (Figure 1). Tornos
One of Rockwell Automation’s primary remote moni-
also has a subsidiary company, Almac, which builds
toring and assistance tools is its two-year-old Virtual
milling machines based on SwissNano’s frame.
Support Engineer (VSE), which can be scaled to fit the
“Companies were not making the old cam-operated
size and risk threshold of each user’s application, use
machines anymore because they were so costly to
store-and-forward functions to preserve data, display
build, and so the watch industry wanted a new, differ-
operating trends following alerts and alarms and
ent type of machine with counter-spindles mounted
maintain access via cellular links if an IP connection
on three axes, so they could get better centering and
isn’t available.
alignments. Watchmakers also wanted more tools,
easier access and simple presets to switch out worn
Simpler Security? Sweet!
tools,” says Paul Cassella, applied technology manager
Of course, the dark undercurrent and persistent ques-
for Tornos Technologies US in Lombard, Illinois. “The
tion that goes with all this remote access is how to
watch industry previously used some CNCs, so we
maintain its security. One instructive solution comes
developed SwissNano with Fanuc Oi-TD CNC controls,
from Big Drum Engineering (www.bigdrum-engineering.
chucks from Rohm, vacuum parts recovery and six
com) in Edertal-Giflitz, Germany, which designs, builds,
controldesign.com
CD1411_26_34_COVERSTORY.indd 27
November 2014 Control Design
27
11/5/14 10:07 AM
installs and supports filling machines for the ice cream
and other food industries worldwide. Its machines fill
liquid products in 50-ml to 5-l containers with an output
of up to 50,000 units/hr (Figure 2). The machine builder
reports its end users are increasingly demanding continuous system availability because any downtime can
quickly lead to production and financial losses. Consequently, Big Drum views “demand-oriented maintenance” and fast troubleshooting via safe, secure remote
services as critical for keeping its users up and running.
“With the exception of the Sahara Desert, our
systems are used in almost every region of the world,”
says Andreas Itter, Big Drum’s sales and marketing
manager. “To ensure 100% availability, we’ve developed
an effective and secure remote service infrastructure.
Large customers such as Nestlé and Unilever expect us
to deliver services in accordance with total productive
maintenance (TPM), and similar demands from other
companies have also increased strongly in this area.”
JIM MONTAGUE
Big Drum has provided remote machine support
for about 10 years, constantly monitors its machines
and transmits key parameters to its headquarters,
which allows its technicians to maintain ongoing data
control. Its service department is staffed 24/7 and can
WATCHING WATCH PARTS PRODUCTION
immediately react to any machine disturbances. This
Figure 1: To monitor and service it Swiss-type lathes, Tornos uses its Tisis
machine communication system, which integrates a password-protected
web server into its machines, communicates via VPN, Internet protocol
(IP) and Wi-Fi and delivers HTML-based displays to PCs and tablets. The
builder also uses TeamServer software to access VPNs with permission,
take control of machines remotely and access CNCs to solve problems.
always-on availability typically means users need and
expect a permanent, online connection to Big Drum as a
prerequisite for better service, preventive maintenance
and higher security. All its filling machines with PLCs
from Rockwell Automation are routinely equipped with
remote service modules. The builder reports it presently
accelerated encryption with 3DES (168 bits) or AES (128,
operates more than 100 of these remote systems with
192, 256 bits) and the IP Security Protocol (IPsec). An
different end users.
integrated firewall also helps seal off Big Drum’s system
To achieve secure, online connectivity, Big Drum also
from users’ production networks, and a configurable,
employs mGuard security routers from Innominate
stateful, packet-inspecting firewall protects against
Security Technologies, a division of Phoenix Contact.
unauthorized access. Also, a dynamic packet filter scans
These switches protect IP data connections with a VPN-
for new connection attempts based on their addresses,
enabled Ethernet router and a configurable firewall with
ports of origin and destination, and it blocks any un-
dynamic packet filtering. Technicians connect to users’
wanted traffic.
plant operators via a VPN, and mGuard serves as VPN
These security measures are needed because Big
gateway, connecting the technicians to the plant net-
Drum increasingly performs needs-based maintenance
work via the Internet. These secure, broadband IP and
of devices that can wear out faster and require closer
VPN connections for online monitoring are more reliable
monitoring, such as servo motors and drives. Increased
and stable than former modem connections, and they
temperatures in these components can indicate prob-
can handle increasing data volumes and other services.
lems due to wear. If predefined tolerance values are ex-
In practice, Internet connections to Big Drum only mate-
ceeded, an automatic email warning can be sent to the
rialize when a VPN key is manually switched on.
service team, which conducts indicated inspections and
To safeguard confidentiality and authenticity,
can prevent previously unavoidable interruptions. Like-
mGuard uses cryptographic protocols and hardware28
Control Design November 2014
CD1411_26_34_COVERSTORY.indd 28
wise, its continuous, online connection also allows Big
controldesign.com
11/5/14 10:07 AM
CD1411_FPA.indd 29
11/4/14 10:55 AM
Drum’s technicians to assess and verify new equipment
performance during startups, introduce optimizations
during the warranty period and monitor deviations in
filling volume or compliance with predefined opening
and closing times of the valves or machine-specific
cycle times during the final service phase.
“Our remote services increase users’ system availability, and we’ve reduced fault-clearance times by 70%,”
says Itter. “With access to remote data, not only can
we troubleshoot faster, but we’re less expensive for our
customers due to the elimination of travel costs.”
Unusual Users
BIG DRUM
Logically, once remote support shows it can be used
securely and gains wider acceptance, all kinds of new,
nontraditional and unexpected applications want to
ALWAYS AVAILABLE—SECURELY
Figure 2: Big Drum’s ice cream filling machines, such as its
Choice Filler, can be continually monitored and serviced by
technicians and maintain 100% availability via VPN network
connections enabled by security routers, which serve as
secure, encrypted gateways and firewalls.
try it, too.
For example, VRTX Technologies (www.vrtxtech.
com) in San Antonio, Texas, uses a high-pressure flow
technique called “dynamic cavitation technology” to
clean cooling water in its users’ HVAC, refrigeration
and process cooling systems. However, as its skidbased systems multiplied worldwide, VRTX’s staff
realized it needed access to its PLCs on the skids, even
though accessing them through most customers’ IT
TM
infrastructures was often difficult. In fact, only 5% of
VRTX’s users allow them to access data about their
Modular, All-In-One, PLC + HMI
systems. After talking to several users, VRTX decided
it needed a cellular monitoring system for its water
treatment skids, which would enable it to monitor the
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having to pass through IT systems.
“With direct access to our PLCs, we felt we could
monitor the operation of our systems,” says Carl Steffen,
VRTX’s engineering services manager. “We’d be able to
get alarms, see detrimental system operation and offer
better and more informed technical support.” Following
a lengthy investigation, VRTX selected Netbiter EC220
gateways and Netbiter Argos Web-based, remote monitoring systems from HMS Industrial Networks.
“The initial reason we chose the Netbiter solution was the Netbiter EC220 gateway offered RS-485
interfaces in a small, well-built device,” says Steffen.
“It also offered preprogrammed GSM cards that would
Up to 2,000 I/Os I External memory: microSD, USB Flash I Audio Support:
mp3/wave, via internal speaker or stereo audio-out jack I Ports: 2 Ethernet, 1 RS485,
1 CANbus, 2 USB host, 1 USB programming port I Environment: IP66/IP65/NEMA4X
immediately work in many of our desired countries
without the need to negotiate with local cellular carriers. Although the EC220 offered many standard I/O
connections, we initially only interfaced with our PLC
Unitronics, Inc.
1 Batterymarch Park Quincy, MA 02169 USA
Tel: 617-657-6596, Toll Free: 866-666-6033
w w w. u n i t r o n i c s . c o m
CD1411_26_34_COVERSTORY.indd 30
usa.sales@unitronics.com
via the Modbus interface.”
30
Control Design November 2014
controldesign.com
11/5/14 10:08 AM
as our technicians arrive. It also
ral gas, wind and solar, and all of
VRTX wanted to capture system
gives us insight into the operations
these have a lot more equipment in
information only once or twice per
of our systems on a minute-by-min-
critical paths and need much more
day. However, when its staff learned
ute basis, whereas, in the past, we
remote monitoring.”
they could get information more
only saw changes over long periods.”
Also, based on its long experi-
frequently, they started finding
Remote support benefits upper
ence in helping users gain insight
Steffen explains that, at first,
benefits for its customers that they
levels, as well as end-user sites,
into the health of rotating machin-
hadn’t seen before. The ability to get
and it inspires machine builders
ery and making business decisions
more frequent information also led
because it affects how they do their
to successfully implement predic-
VRTX to change some of the treat-
jobs, explains Kamalina Srikant,
tive maintenance, National Instru-
ment system’s operations, which
product manager for condition
ments recently released its NI
also led to better treatment and a
monitoring solutions at National
InsightCM Enterprise ready-to-run
more consistent product.
Instruments (www.ni.com). “Many
software with tightly integrated
engineers and technicians don’t
and flexible hardware options for
creased the value of our treatment
have to make as many trips to us-
online condition monitoring ap-
skids,” adds Steffen. “It enabled us
ers’ locations, which is changing
plications. It’s used to acquire and
to change system settings without
their thinking and showing up on
analyze measurements, generate
needing to call the customer or send
their bottom lines,” says Srikant.
alarms, visualize and manage data
out a technician. It’s also enabled
“At the same time, traditional
and results and simplify remote
us to troubleshoot failures and have
power-generation applications like
management for large deployments
the appropriate repair parts on site
coal are being joined by more natu-
of monitoring systems.
“Remote monitoring has in-
CFW500 Machinery Drives
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Transforming energy into solutions.
CD1411_26_34_COVERSTORY.indd 31
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Compatible - wide range of accessories
Flexible - application functions with integral PLC
Robust - 150% overload for one minute in an
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www.weg.net
11/5/14 10:08 AM
REMOTE SUPPORT TO-DO LIST
Every application has its own unique characteristics and requirements, but there are some common requirements, methods and tools
that machine builders, integrators and others can use to establish
remote support, monitoring, troubleshooting and even control.
• Reexamine end users’ business performance goals; evaluate
machines, production lines and other equipment for achieving
them; and evaluate how and where report monitoring and support could help.
• Analyze existing network infrastructure, including ports, other
physical and wireless connections, communication protocols,
hardware components and software used.
• Determine if network upgrade from dial-up modems to VPN and
IP-based communications would improve remote support to end
users and establish permissions and policies for granting access.
• Coordinate deployment of remote monitoring components with
existing machines and equipment, especially to make sure remote support devices don’t affect production operations.
• Implement appropriate level of security functions in remote support devices and networks, including secure IP and VPN links, configurable firewalls, packet inspections and dynamic data filtering.
If you have not been able to
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TRIANGLE
RESEARCH
Really Far Out Support
for the installation and spooling of
Naturally, once remote machine
flexible flowlines, umbilicals, cables,
support is established between
wire ropes and coil tubing,” says
builders and users, it’s tempting to
Brian McRitchie, electrical manager
see just how remote that support
at Aquatic’s marine workshop in
can be. Strong IP connections, VPNs
Peterhead, Scotland. “Installed on
and communication signals can go
marine vessels, this equipment can
anywhere, way beyond land-based
include anything from small ten-
shops and factories, but they’d bet-
sioners to dual-tensioner systems,
ter have stellar support.
powered reel-drive systems or a
For instance, Aquatic Engi-
fully modular carousel system with
neering & Construction (www.
built-in tensioner,” he explains. “Our
aquaticsubsea.com) in Aberdeen,
customers hire this service and ex-
Scotland, recently worked with
pect the equipment and the person-
system integrator MAC Solutions
nel that operate it to perform reli-
in Redditch, England, to improve
ably with minimal downtime. These
monitoring of its ship-based ten-
ships can be located anywhere in
sioning machines, which lay down,
the world, so if there’s an uncom-
install, transpool, recover and
mon problem with our machine, we
decommission flexible and semi-
need to resolve it quickly.”
rigid cables and other products
VPN router that Aquatic could inte-
oil and gas, telecommunications
grate with its 85Te dual-tensioner
and energy industries. Though it
system, and found MAC Solutions
strives to make its equipment reli-
and eWon’s 2005CD VPN routers
able and can resolve many issues
and Talk2M Internet-based, remote-
with a phone call, Aquatic wanted
access, support and diagnostics
to quiz its tensioners remotely and
software and service. Aquatic
reduce service engineer call-outs
installed three 2005CD routers with
to vessels.
dual local area network (LAN) and
“Aquatic provides equipment
INTERNATIONAL
32
CD1411_26_34_COVERSTORY.indd 32
McRitchie researched a suitable
on the seabed for clients in the
Control Design November 2014
modem connectivity on the 85Te,
controldesign.com
11/5/14 10:09 AM
OFFSHORE PERFORMANCE ONSHORE
and it monitors the tensioner via
to maximize their efficiency and
VSAT global, satellite-based Internet
identify any potential problems
links or 3G cellular Internet connec-
before they affect production. This
tions. Besides having an Ethernet
integrated, condition-based mainte-
port, two of the three routers also
nance system provides machinery
have SIM cards, so if a VSAT link
protection, prediction and perfor-
is unavailable, Aquatic’s engineers
mance monitoring of all critical
can access their equipment via 3G.
and essential assets, and includes
“To test and fully understand the
Emerson Process Management’s CSI
VPN router and Talk2M, we trialed
6500 machinery health monitor and
the system on one of our 50Te ten-
AMS Suite predictive maintenance
sioners in the workshop at Peter-
software, which is built on Merid-
head,” explains McRitchie. “Every-
ium’s Asset Performance Manage-
thing worked well, and if we didn’t
ment (APM) software.
understand something, the team at
STATOIL AND EMERSON
Figure 3: Statoil is implementing a $2.7-million, condition-based, performance
monitoring and maintenance system on its Gina Krog oil and gas platform in the
North Sea, so onshore personnel can monitor its pumps, compressors and other
mechanical equipment to maximize their effi ciency and identify problems
before they affect production.
These software and hardware
downs and maintain production
MAC Solutions quickly provided us
components will allow Gina Krog
while reducing maintenance costs.
with the necessary technical sup-
to deliver equipment health alerts
In addition, AMS Suite will ag-
port. With Talk2M, it’s as if the ser-
and predictive diagnostics, which
gregate all asset data to present a
vice engineer is physically onboard
will enable the platform’s staff to
clear picture of overall asset health
the ship, next to the machine or
perform corrective maintenance
and performance, so work notifica-
control cabinet, accessing the HMI
actions to avoid unplanned shut-
tions can be created and fed back
display or PLC with a laptop.”
McRitchie adds that eWon and
Talk2M give Aquatic a differentiator in the dual-tensioners it rents
to marine vessel operators. “Some
of our tensioner systems also have
cameras installed, so local opera-
Dream big in small sizes
HARTING har-flexicon®
tors can see what’s happening from
their control rooms or booths,” says
McRitchie. “Talk2M also enables me
to access this same web-camera
view. I can also screen-share with
a user to remotely instruct them
on the operational idiosyncrasies
of the systems or how to navigate
through the more isolated control
and monitoring screens.”
Likewise, Statoil (www.statoil.
com) in Stavanger, Norway, is
HARTING har-flex
har-flexicon
har
-flexicon®
1.27/2.54mm
implementing a $2.7-million condition and performance monitoring
system on its Gina Krog oil and gas
platform in the North Sea (Figure
3), which will allows its onshore
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personnel to continuously moni-
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HRT-10.2014-CD-4.625x4.875-har-flexicon®.indd 1
CD1411_26_34_COVERSTORY.indd 33
10/21/2014 1:24:12 PM
11/5/14 10:09 AM
connect to their operations data.”
to Statoil’s SAP enterprise asset
new for many machine builders
management system for immedi-
and unknown to many others,”
ate attention. The platform also
says Mariam Gallegos, product
mSC is presently supported on PCs
includes a wireless communication
marketing specialists for network
and Android devices, and will be
infrastructure based on Wire-
security at Phoenix Contact (www.
available on Apple iOS in 2015. It
lessHART (IEC 62591), which will
phoenixcontact.com). “Even those
uses IPsec security protocol and
support future enhancements to
who were connected probably had
performs high-level AES 256 en-
capture added equipment data on
remote desktops or public IP links
cryption with hashing algorithm,
the platform at less cost than wired
that weren’t very secure,” says Gal-
says Gallegos. “Remote support
communications.
legos. “Now, VPNs are tied to hubs
used to require dial-up or old-style
and servers and then go straight to
VPNs that users had to maintain,”
Forecast: Mostly Cloudy
cloud-based infrastructures, such as
explains Gallegos. “Now, we host
Beyond routine monitoring and
our free mGuard Secure Cloud (mSC)
sophisticated, simple and flex-
maintenance, many remote support
service, which can also host clients’
ible VPNs for all customers using
tools are gathering and archiving
virtual machines and VPN tasks as
our devices. Their engineers just
large enough amounts of information
needed, and maintain 24/7 secu-
sign in, click to see the data for
to undertake big-data efforts, such as
rity. Tying these functions together
whichever of their machines they
advanced analyses of operations and
saves costs to our customers and
want and get back to making and
improved machine designs.
also means they no longer need to
shipping their products. This isn’t
maintain as much IT knowledge and
machine-to-machine; it’s more like
can instead go to our website and
technician-to-machine.”
“Just three or four years ago,
remote support via VPNs was
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CD1411_26_34_COVERSTORY.indd 34
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11/5/14 10:09 AM
INDUSTRY LEADING
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Providing exceptional customer service since 1982
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CD1411_FPA.indd 35
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11/4/14 10:55 AM
control-design-1114.pdf 1 10/7/2014 10:23:10 AM
C
M
Y
CM
MY
CY
CMY
K
CD1411_FPA.indd 36
11/4/14 10:55 AM
MACHINE INPUT
What’s ‘Pnew’ with Pneumatics?
With Alternative Solutions Available, Machine Builders and End Users Still
Find Plenty of Appeal in Pneumatic Systems
by Mike Bacidore, editor in chief
DESPITE AN EVOLUTION of alternatives, pneumat-
PARTICIPANTS
ics have stood the test of time. Hydraulic and electromechanical systems might offer a better solution
in certain circumstances, but there are still plenty of
pneumatic applications. We gathered input from a
panel of industry veterans to determine how prevalent the technology still is and what to consider when
TJ MCDERMOTT
CHICO MARKS
SCOTT M. MAURER
FRANK LANGRO
JERRY SCHERZINGER
BILL SAVELA
making a decision.
Participants include TJ McDermott, project manager at Systems Interface (www.systems-interface.
com), a systems integrator in Bothell, Washington;
Chico Marks, manager of total plant maintenance,
Subaru of Indiana Automotive (www.subaru-siatest.
com) in Lafayette, Indiana; Randy Nobles, regional vice
president at Womack Machine Supply (www.womack-
festo.com); Jerry Scherzinger, marketing pneumatics
machine.com); Scott M. Maurer, product manager—air
product manager at Bimba (www.bimba.com); and Bill
line at SMC (www.smcusa.com); Frank Langro, direc-
Savela, marketing director at Delta Computer Systems
tor, marketing, product management, at Festo (www.
(www.deltamotion.com).
What do pneumatics have to offer that still make them a
the media, it is a clean source of work when compared
viable solution?
to hydraulics, which uses hydraulic oil. A leak in a
Nobles: Pneumatic systems are still easy to implement
pneumatic system simply vents air to the atmosphere,
and maintain. Also, the operational speed for the
but a leak in a hydraulic circuit discharges oil, requir-
amount of money invested is very attractive.
ing extensive cleanup and proper disposal.
Savela: Pneumatics can provide an optimal combination
Langro: Pneumatics can offer a variety of features that
of force and compliance when controlled by a closed-
still makes it attractive to use. Pneumatics has few
loop motion controller with special capabilities for
electrical connections and can be suitable in washdown
controlling both pressure/force and actuator position.
areas. Also, the power density of pneumatics offers an
Scherzinger: Pneumatic devices are relatively low-
advantage over electrics in applications such as stamp-
cost and typically highly configurable, making them
ing and pressing. When compared to a hydraulic solu-
a great choice for both OEMs and MROs looking to
tion, pneumatics can be a cleaner installation, which is
provide a solution. Standard pneumatic actuators can,
clearly important to industries including pharmaceuti-
for example, be ordered in a wide variety of bore sizes,
cal, food and beverage and semiconductor.
stroke lengths and mounting styles, making them
highly flexible and capable of providing forces ranging
What is your primary reason for choosing pneumatics?
from a few ounces—small bore sizes with low pres-
McDermott: In the short term, a pneumatic solu-
sure—to over 10 tons—large bore sizes at 250 psi air
tion usually costs less than an electric linear motor
pressure—in stroke lengths from fractions of an inch
approach. The capital cost of linear motors typically
to 10 ft. Additionally, because pneumatics use air as
far exceeds simple pneumatics. However, the longer a
controldesign.com
CD1411_37_41_FEATURE2.indd 37
November 2014 Control Design
37
11/3/14 11:26 AM
MACHINE INPUT
pneumatic system is in service, the
Langro: The choice to use pneu-
higher the cost. Maintenance costs
matics, hydraulics or electrics
climb, and air leaks add to the cost.
really should come down to the
On the other hand, pneumatic
application requirements. What
systems are generally easier to
are you trying to move? How fast
troubleshoot. This is especially
do you need to do it? What type
important when the knowledge
of accuracy and repeatability is
pool in a maintenance department
required? Are you planning to run
is decreasing due to attrition. A
multiple products that will require
linear motor, likely involving a VFD
constant changeover? What are
and motion logic, needs main-
the environmental consider-
tenance staff skilled in motion
ations? Based on these factors,
control programming. We pick the
you start to see which options
solutions that fit the application. A
offer the most viable solution.
pneumatic ram is a good choice for
Pneumatics is a great choice for a
an on-deck hawser winch brake.
It’s relatively compact for the force
exerted and is easy to maintain
and quite robust. For the remote
actuator bank, running it via a
common fieldbus protocol such as
FESTO
Ethernet/IP or Profinet is the only
way to go. Pulling many conductors for traditional central control
is more costly than pulling a single
case erector where the motion is
Ethernet cable. The fieldbus hard-
highly repetitive and the motion
ware is very reliable and using a
requirements are not high preci-
device level ring gives redundancy
sion. In contrast, a wafer inspec-
for even more robustness.
tion process in the semiconductor
Nobles: The primary reasons for
industry involves variable posi-
using pneumatics are simplicity,
tions and requires high accura-
compressed air availability and
cies and repeatability, making an
experience. We are seeing interest
electrical-type motion solution
in conversion to electric actuators,
more suitable for this application.
but this trend hasn’t been vast.
Savela: Pneumatics excels in
Can you talk about the types of
applications that require the ap-
machines or applications you’re using
plication of precise amounts of
pneumatics for?
pressure or force, yet those that
Marks: We use pneumatics for the
also benefit from the compliance
majority of our applications in the
of the air medium. Using electric
plant. They include automated
motors in such applications would
material handling, parts position-
cost more and be more difficult to
ing for welding, paint application
implement. In addition, holding
and bolt and fastener tightening.
a load in a pneumatic system can
We do this with end-of-arm tool-
consume less energy, possibly
ing on robots, dedicated clamp-
zero, in a closed system, which
ing and positioning equipment,
isn’t possible with an electric mo-
paint application bells and guns,
tor, unless an expensive braking
and handheld fastener tightening
scheme is implemented.
torque guns.
38
CD1411_37_41_FEATURE2.indd 38
Control Design November 2014
controldesign.com
11/3/14 11:26 AM
Nobles: Womack is using pneu-
is also found in gas box panels
manufacturing applications
matics in several industries. We
in the semiconductor industry.
include material handling equip-
have applications on packaging,
A common use of pneumatics
ment such as conveyor diverters
well service, food processing
is in the packaging of products.
and pick-and-place equipment.
and utility service equipment, to
Pneumatics can be found in just
Savela: Fluid power applica-
name a few.
about every machine that forms,
tions in general benefit from
Langro: Pneumatics are used
fills or seals.
the medium’s ability to be used
in just about every industry
Scherzinger: As a manufacturer,
when pressure or force must be
that’s involved in high- and even
our components—actuators,
controlled in an application, and,
low-volume manufacturing. For
valves, fittings, manifolds, FRLs—
within these application types,
example, diverse industries such
are used on a tremendously wide
pneumatics excels when the
as the automotive, semiconduc-
variety of machines designed for
application can benefit from a
tor, pharmaceutical and food and
many applications. The applica-
degree of compliance. Because air
beverage all have use for pneu-
tions range from agricultural
is much more compressible than
matics in their various applica-
equipment and transportation
hydraulic fluid, pneumatics can
tions. Pneumatics can be found
vehicles, which need to withstand
have an advantage in applications
in the clamping and stamping of
harsh outdoor environments, to
where force control is required,
sheet metal parts in an automo-
food processing and packaging
but which also need to have some
tive press shop, the lifting and
equipment exposed to corrosive
give when an actuator and a work
transferring of wafers, and the
washdown chemicals and medical
piece come together. Pneumatics
coating of tablets in the phar-
devices that require a high degree
are also especially useful in ap-
maceutical industry. Pneumatics
of precision. Common in-plant
plications where the load can be
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CD1411_37_41_FEATURE2.indd 39
11/3/14 11:27 AM
MACHINE INPUT
subject to unknown shocks, bend-
without damaging the logs, even
benefits. Spare parts are both less
ing applications where a force
as log surface profiles are rapidly
expensive and simpler to install;
must be applied to the load to do
changing, can be accomplished
they are typically plug-and-play,
the work and force-backing appli-
better using pneumatics than
requiring minimal training and
cations where the load must have
other technologies.
no parameter setup. These advantages come with a tradeoff. These
an accurate known force applied
to it, such as a metal riveting
How does a pneumatic solution
simpler pneumatic systems are
application. Consider a press roll
compare to an integrated linear mo-
not as precise in their positioning
that is used to hold down lengths
tor package, when considering cost,
or motion control as an electro-
of logs as they are fed into a
footprint and plug-and-play?
mechanical system. While it is
piece of sawmill equipment such
Marks: Pneumatics are cheaper
true that a pneumatic system can
as a planer, edger or bandmill.
and simpler than linear motor
be designed to be very precise,
Controlling the press rolls means
packages from both an engineer-
this would eliminate many of the
holding logs tightly without dam-
ing and maintenance perspec-
benefits of using pneumatics.
aging them so as to not destroy
tive. From an engineering view,
Savela: Pneumatics can handle
valuable timber. Logs can be mov-
PLC-controlled pneumatics are
high-cycle force applications that
ing as fast as 2,000 board ft/min,
typically easier to design than a
would degrade electromechani-
and the press rolls may need to
motor, requiring less PLC code,
cal solutions in a short period
sustain a force of up to 1,800 lb in
simpler position sensing, less
of time. An electromechanical
order to maximize productivity.
complicated motion control, and
solution may be more appropri-
Adaptation of press roll position-
less costly components. Mainte-
ate for applications which require
ing to maintain desired force
nance enjoys many of the same
speeds greater than about 40in./
CD1411_eWON_HHP.pdf
1
10/21/14
10:50 AM
HMI
PLC
CD1411_37_41_FEATURE2.indd 40
11/3/14 11:27 AM
and can place less weight on the
in., but most electromechanical
moving actuator than a motor
solutions will not be able to match
would. In applications that must
the life of a pneumatic solution
apply and hold a given amount
in a force control application. In
of force on an object, pneumatic
general, although they’re typi-
systems have the advantage of
cally fine for applications that do
being able to do so with lower
position control, linear electric
energy consumption than electric
motors aren’t good for controlling
motors, even linear ones. From
force. Coupled with a proportional
the perspective of ease of use, a
valve and precise transducers, a
pneumatic system incorporating
motor package and can be operat-
closed-loop motion controller can
a motion controller with special
ed with a simple electrical signal
attain the same level of position-
support for fluid power control
from a PLC output. An integrated
ing accuracy as a linear motor,
can be very easy to set up.
linear motor could be five times
while also controlling pressure/
Nobles: Pneumatic solutions tend
the product cost and requires
force to a high degree of accu-
to be more cost-effective and
more advanced programming to
racy. Assuming that the pump,
have a smaller footprint than a
get the same positioning function.
valve and control system can be
competitive linear motor package.
What a linear motor package can
mounted away from the actuator,
The plug-and-play aspect of these
offer over pneumatics is flex-
but not too far away, a pneumatic
systems is comparable.
ibility, enabling the machine to
solution can have a very small
Langro: Pneumatics is typically
be easily reconfigured to handle
footprint at the actuator site
a lower-cost option than a linear
different products.
FESTO
sec or accuracies better than 0.005
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CD1411_37_41_FEATURE2.indd 41
11/3/14 11:27 AM
TECHFLASH
Leslie Gordon
•
lgordon@putman.net
ECAD: Simple or Complex?
DEPENDING ON THE application, you might use a
might undergo with regard to fluid or process compo-
standalone electrical software program when placing
nents because everything is contained inside of one proj-
components in a panel or designing a wire harness. On
ect database,” says Paul Goleniak, professional services
the other hand, there are those who swear it’s better to
senior consultant at ePlan.
use programs that are integrated into computer-aided
design (CAD) software—that is, perform electrical design
For example, Advanced Machine & Tool (AMT, www.
amt-corp.com), which builds coils and winding equip-
and CAD mechanical design in parallel in an electrical
ment used in the production of electric motors, genera-
CAD (ECAD) package.
tors and alternators, found using ePlan solutions simpli-
On one end of the spectrum in terms of use is Radica
fied product development steps like device tagging, wire
Software’s (radicasoftware.com) Electra E7. “Electra is a
numbering and machine design standardization. “EPlan
plug-in for Microsoft Visio, so it requires very little train-
tags devices and numbers wires automatically, generates
ing,” says Radica founder and CEO Thomas Yip.
error-free diagrams and BOMs, archives standard cir-
According to Steve Sandberg, controls and applica-
cuitry so we can reuse it from project to project and inte-
tions engineer at Vickers-Warnick (vickers-warnick.com),
grates fluid schematics into the overall project, eliminat-
Electra is simpler to use than full-blown CAD, but it has
ing errors with device naming and missed components,”
plenty of capability for the job at hand. “For example,
says AMT electrical engineer Mark Lohrman. “This saved
a panel layout function places dimensioned virtual
us about 23 to 28 work hours on one project alone.”
At the far end of the spectrum, some users
even enter the finite element analysis
(FEA) realm to make sure that panel
components don’t overheat.
components on a virtual backplane,” he says. “A library
Meanwhile, AutoCAD Electrical works with 3D CAD,
says Lee Hollingworth, senior product manager for
AutoCAD at Autodesk (www.autodesk.com). “True,
mechanical and electrical are different disciplines, but
most applications require that electrical components be
positioned on mechanical structures,” says Hollingworth.
At Siemens Energy (www.siemens.com), Todd Hall,
of pre-existing components reflect the sizes of their real-
manager of the drafting and design department, says,
world counterparts, which helps you develop a layout
“We have one engineer dedicated to mechanical, while
that allows for proper component spacing. Electra also
six individuals focus mostly on electrical. They can all
has intelligent functions that eliminate the need to per-
share designs using Autodesk Vault CAD data manage-
form manual operations. For instance, the PLC generator
ment software. We create our schematics and layout in
makes a usable component in about two minutes. You
AutoCAD Electrical, along with a mechanical model in
can directly attach wires to the component, and version
Inventor CAD software. In one project, we exported the
E7 makes them look even better. Also, when you assign
wires from electrical into the Inventor model, which gave
a wire number to a wire, that relationship is stored in a
us a 3D wire-linked capability that, along with some soft-
database. Connect that wire to any other wire and both
ware I built, created a wire list for the shop floor, where
wires will then share the same name, which saves lots
the wires will be cut to length, prints the wires with data
of time tracking down wire naming issues. Also, you can
telling where they’ll go and places loads on each end.
drop a terminal symbol (small circle) on any wire. After
This has turned what used to be an eight-hour panel
completing a drawing, a special feature shows you a list
job into a four-hour task because the wire personnel are
of all the wires that have a terminal symbol. This can
handed all the information they need to know up front.”
then be used to create a terminal block for your panels.”
A different approach comes from ePlan Software &
Finally, at the far end of the spectrum, some users
even enter the finite element analysis (FEA) realm to
Services (www.eplanusa.com). Its Pro Panel computer-
make sure that panel components don’t overheat, adds
aided engineering (CAE) software builds 3D assemblies
Goleniak of ePlan. Rittal, a sister company that provides a
that show the electrical and fluid configuration of control
variety of different panels at ePlan’s data portal, also sup-
cabinets, and Electric P8 is for documenting and man-
plies software, Rittal Therm, that allows users to input
aging automation projects, and it allows exchange of
data from the parts mounted inside the panel and per-
engineering data from other project areas.
form a calculation on the heat consumption in the panel.
“Users don’t have to worry about having multiple
projects out there for all the different functionalities they
42
Control Design November 2014
CD1411_42_TECHFLASH.indd 42
EPlan and Pro Panel can also perform calculations on the
panel components when the bill of materials is created.
controldesign.com
11/3/14 11:30 AM
cdroundup@putman.net
PRODUCT ROUNDUP
Take Control of Control Software
Current Approaches Automate Automation
INCREASING DEMANDS ON the time and resources
ANALYZE THIS
of today’s engineers mean that modern control
Zenon Analyzer 2.20 is reporting
software should be designed with efficiency in mind.
and analysis software for industri-
“Trends in the industry lean toward the ability to au-
al automation applications. An SQL
tomate the automation software, providing engineers
connector lets users connect data-
the tools to programmatically change the software
bases from third parties and use
configuration of a machine, including the actual PLC
the data for reporting and analysis. The software has
code. This enables an OEM to automatically configure
new report templates such as the Sankey diagram, a
the machine controller’s code to match the machine’s
requirement for energy data management systems in
actual I/O layout or to modify the software configu-
accordance with ISO 50001.
ration based on the company’s orderable machine
Copa-Data USA; 609/385-0846; www.copadata.com
options, without requiring the efforts of a controls
engineer,” says Daymon Thompson, TwinCAT product
specialist, Beckhoff Automation.
The resulting better use of engineers’ time boosts
PLC PROJECT PLANNING
EPlan Platform 2.4 provides PLC
their productivity and gives them the freedom to
project planning in graphical over-
focus on more valuable activities such as R&D and
views. Navigation options acceler-
developing next-generation machine concepts, con-
ate project planning, even in large
tinues Thompson. “These capabilities come with the
projects. Extended support for IEC
need to archive and control the source code of the
81346 and IEC 61355 through structuring principles and
machines. Modern PC-based control software makes
reference designations provides users a basis for inno-
use of widely used and available source control tools
vative design methods.
such as Git, SVN or even Microsoft Team Foundation
ePlan Software & Service; 248/945-9204; www.eplanusa.com
Server. This means engineering teams have access
to a wider range of valuable programming tools. In
this way, the automation technology (AT) and IT/
COLLECT MAINTENANCE DATA
computer science arenas are unified so the best-suited
SILStat v2 software helps users evaluate risks posed
programming tool can be deployed depending on each
by hazardous situations by collecting and analyzing
individual task.”
operation and maintenance data. A standalone (Lite)
and server-based (Site) option are available.
CONTROLS
PROGRAMMING
exida; 215/453-1720; www.exida.com
Automation Interface in TwinCAT 3
CONTROLS SCADA
allows the remote
Proficy HMI/SCADA - Cimplicity software
control of Twin-
precisely monitors and controls every
CAT PC-based
aspect of a user’s SCADA environment,
real-time control
equipment and resources. Version 9.0
systems, support-
lets users improve structured databases
ing the external
quickly and easily, enabling real-time
control of almost all off-line and on-line functions.
operation intelligence and providing the right informa-
Automation Interface consists of a large number of
tion, anytime, anywhere. Features include improved
programming routines available in the software’s API
configuration capabilities, better interaction with new,
in the form of classes and methods. Users can gener-
richer protocols and an improved operator experience
ate, change and save TwinCAT projects in a standard
with reduced alarm noise. Long point names allow 256
and flexible manner in conjunction with a source
characters for building a structured database quickly.
code database, if desired.
Proficy Historian for SCADA is included in the release.
Beckhoff; 877/894-6228; www.beckhoffautomation.com
GE Intelligent Platforms; 800/433-2682; www.ge-ip.com
controldesign.com
CD1411_43_45_ROUNDUP.indd 43
November 2014 Control Design
43
11/3/14 11:59 AM
PRODUCT ROUNDUP
trial version is available on the
company’s website.
Yokogawa Corporation;
800/888-6400; www.yokogawa.com
SCADA SOFTWARE
ANALYZES ROOT CAUSE
Idea Studio SCADA software
PlantTriage Control Loop Moni-
helps operators and developers be
toring software uses a special
productive in a short time with
method called Automated Deter-
an architecture that pre-inte-
mination of Root Cause, which
grates all core SCADA compo-
BIG FOR MACS
is central to assessing a control
nents with one installation. Users
Sysmac Studio software integrates
loop by locating the original root
can configure redundant servers,
configuration, programming,
cause of upsets. The method
distributed historians, mobile ac-
simulation and monitoring to set
determines the most likely root
cess or communication with any
up, program, debug and maintain
cause using a big-data technique
combination of I/O. The software
NJ-Series machine automation
that gathers real-time data from
provides a simple drag-and-drop
controllers (MACs) and EtherCAT
hundreds or thousands of con-
interface for creating professional
slaves. Machine and motion pro-
trollers and correlates it.
displays. Operators can create
gramming is based on IEC 61131-3
Metso ExperTune; 262/369-7711;
and save their own trends.
and PLCopen function blocks for
www.expertune.com
Trihedral; 800/463-2783;
motion control. It offers a 3D simu-
www.trihedral.com
lation environment to develop and
test off-line motion profiles.
Omron Automation & Safety;
866/88-omron;
www.omron247.com
PROGRAMS PACS
MANAGES FIELD DEVICES
PAC Project 9.4 is an upgrade to
FieldMate Versatile Device
PAC Project, a software suite that
Management Wizard R3.01 is
provides control programming,
software for configuring, adjust-
BUILD IT
HMI development, OPC connec-
ing and managing a wide variety
Automation Builder provides an in-
tivity and database integration.
of field devices used in factories
tegrated development environment
PAC Project 9.4 adds support for
and other production sites. The
for control and motion systems
HART protocol SNAP I/O mod-
software includes functions that
based on PLCs, safety PLCs, robot-
ules, logs HMI data to ODBC data-
facilitate the management of
ics, motion control and related
bases and uses Unicode (UTF-16)
memos, photos and videos, as
automation components. This re-
in the HMI to support many
well as automatically generate
duces software complexity by com-
additional languages.
reports. It runs on PCs, includ-
bining all of the tools required for
Opto 22; 951/695-3000; www.
ing tablet PCs, that have either
configuring, programming, debug-
opto22.com
Windows 7 or Windows 8.1. A
ging and maintaining automation
44
CD1411_43_45_ROUNDUP.indd 44
Control Design November 2014
controldesign.com
11/3/14 11:59 AM
projects from a common intuitive
independently adjust the poll rate
latest mobile platforms for iOS and
interface. It includes RobotStudio
for each I/O rack (slave). Ethernet
Android for dashboards for remote
tool for simulating and program-
slaves can be configured as “criti-
monitoring and system control.
ming industrial robot applications,
cal” I/O, so the CPU will drop out
National Instruments; 800/453-6202;
Mint WorkBench tool and pre-built
of run mode if that I/O rack or GS
www.ni.com
and tested libraries for controlling
drive disconnects for some reason.
devices connected via fieldbuses,
Diagnostic functions are included.
networks or the Web.
AutomationDirect; 800/633-0405;
ABB; 262/780-3000; www.abb.com/plc
www.automationdirect.com/
do-more-plcs
DEPLOY CONTROL
Portico software
lets users deploy
FOLLOW THE RIGHT PATH
a network portal
Generate G-code motion programs
for remote
directly from CAD drawings by im-
visualization,
porting vector-based drawing files
SERVICE UPDATES
interaction
into CADFusion to see the result-
With Service Pack for CoDeSys
and control of
ing tool path graphically. Automat-
v.3.5, users make better use of
other computers on the factory
ic and manual shape reordering
screen space by automatically
floor. Using Ethernet and remote
options allow for optimal tool and
hiding windows that aren’t re-
frame buffering (RFB), it extends
processing paths. The software
quired. Dialogues are simplified,
the transmission of video signals
allows user-defined initialization,
drag-and-drop support is ex-
beyond the limits of VGA or DVI,
process shutdown and shuttering
tended, online displays standard-
and does it without the need for
commands (laser on/off).
ized and the program displays in
repeater hardware and cables. Its
Aerotech; 412/967-6854;
graphic editors are more intui-
control arbitration mechanism
www.aerotech.com
tive. Motion and CNC character-
ensures that only one client has
istics of the system have been
control of the server computer at
extended by new transforma-
any given time.
tions, as well as drivers for CAN
Phoenix Contact; 800/322-3225;
and EtherCAT drives.
www.phoenixcontact.com
3S-Smart Software Solutions; +49831-54031-17; www.codesys.com
MORE
HARDWARE
SUPPORT
GOOD TO SHARE
LabView 2013
version control, support for shared
includes native
projects via modularization and
support for the
simple object-oriented program-
newest hardware from vendors
ming. It comes with an interface
such as ARM and Xilinx, as well as
to Eplan Electric P8, which allows
a suite of code management, docu-
ECAD projects and the hardware
MORE SUPPORT
mentation and review tools. New
configuration to be synchronized.
Do-more PLC supports Ethernet
tools integrate with a software
A smart editor uses function
I/O directly from the Ethernet port
engineering process, including
libraries and sections of code that
on the CPU. Connected racks and
a new Subversion plug-in from
have already been programmed.
drives are auto-discovered, and
Viewpoint Systems and a new tool
B&R Industrial Automation;
all connected Ethernet I/O points
from Wirebird Labs. It enables
770/772-0400;
use native addressing. Users can
users to deliver systems on the
www.br-automation.com
controldesign.com
CD1411_43_45_ROUNDUP.indd 45
Automation Studio 4 has trueto-life architecture modeling,
November 2014 Control Design
45
11/3/14 11:59 AM
SPECMATE
Hank Hogan •
contributing editor •
hank@hankhogan.com
2 Views of Machine Vision
by Hank Hogan, contributing editor
FOR MACHINE VISION, basic differences are blurring
first global shutter CMOS sensor in early 2014. That
and on the verge of disappearing. As a result, a long-
development is particularly important to the machine
running battle may soon end, and machine builders
vision market, according to Michael Gibbons, director
will then have one less choice to worry about.
of sales and marketing for Point Grey Research (www.
Fundamentally, machine vision cameras can be
classified into two camps. On one hand are charge
coupled devices (CCDs). The alternative vision sensors
ptgrey.com). The company makes products with both
CCD and CMOS vision sensors.
CMOS has traditionally used a rolling shutter that
are built using complementary metal-oxide-semi-
sequentially exposes each line of pixels in the sen-
conductor (CMOS), the same technology that powers
sor. Thus, not all parts of a scene would be captured
computer chips. The two have long been locked in a
at the same instant in time, and so objects moving
struggle, which looks to be ending.
fast enough could be blurred. With a global shutter,
“Just in the past year, it’s become pretty clear that
on the other hand, the entire sensor is exposed at
CMOS is going to be the dominant one,” says Vineet
the same time, eliminating a source of image distor-
Aggarwal, when discussing the future of the two
tion. Hence, the growing availability of global-shut-
technologies in industrial machine vision applica-
ter CMOS sensors means the technology is better
tions. Aggarwal is senior group manager for embed-
suited for a wider range of machine vision applica-
ded systems products at National Instruments (www.
tions, Gibbons explains.
ni.com). The company works with many different
vendors of machine vision cameras.
Also important to the growing use of the newer
sensor technology is that most digital-grade consumer cameras use CMOS sensors. As a result of
The instances in an industrial setting
where light levels are low enough to
make CCD sensors strongly preferred
over their CMOS counterparts could
be rare.
this, CMOS is the target of the bulk of research and
development spending.
That R&D work exploits a key characteristic of
CMOS sensors—the light-to-electron converting
silicon sits adjacent to circuitry. This means that
individual pixels can be read out in a largely parallel fashion, which makes the vision sensor capable
of a faster frame rate. Another consequence is that
Both CCD and CMOS sensors are silicon-based, and
analog-to-digital converters can be built in, allow-
both convert incoming photons into electrons. Of
ing features such as integrated gain, offset and dark
the two, CCD is the older technology. It was the only
level adjustment. This makes it less expensive to
game in town from the mid-1970s until the mid-1990s,
integrate the sensor into a vision system and poten-
which is when the first commercial CMOS sensors
tially reduces overall cost, according to Roszkowski.
appeared. One result of this technological headstart is
Because CMOS sensor technology is both newer
that CCD sensors were traditionally considered higher
and evolving more rapidly, machine vision applica-
quality, which was defined by two key attributes.
tions can benefit from such features as high dynam-
“One of these was better signal-to-noise ratio, and
ic range, variable trigger modes, light control output,
the other was a lower number of dead pixels, or pixels
windowing and on-chip image scaling, as well as
that don’t respond to light. But CMOS has improved
the ability to exclude everything outside of multiple
greatly in the past few years and has closed the gap to
regions of interest.
the point where the two are almost interchangeable
However, it’s not quite time just yet to abandon
for most applications,” says Rick Roszkowski, senior
CCD in all machine vision applications. For one thing,
director of marketing for the vision products business
the vision technology found in consumer cameras is
unit of Cognex (www.cognex.com), which offers both
close to but not exactly the same as that in industrial
CCD and CMOS sensors in its products.
applications, which means machine vision cameras
An indication that CMOS vision sensors have
are not following precisely the consumer device cost
gained parity is the fact that Japan’s Sony, which has
curve. One reason is that consumer cameras squeeze
traditionally only produced CCD sensors, released its
a lot of pixels into a tiny chip, which means each
46
Control Design November 2014
CD1411_46_47_SPECMATE.indd 46
controldesign.com
11/3/14 12:01 PM
United States Postal Service
Statement of Ownership,
Management, and Circulation
1.
2.
3.
4.
5.
6.
7.
pixel is small, perhaps 1.5 microns (µm) across. A
machine vision camera has much larger pixels that
are typically 4.5 µm in size. The advantage of bigger
pixels is they collect more light, but the downside is
the sensor chips are larger and therefore more costly
for an equivalent number of pixels.
What’s more, CCD still offers advantages in certain applications. Because every pixel on the chip
is read by the same electronics per tap or output
channel, no pixel-to-pixel variations are introduced
by the readout circuitry itself. Also, since there’s
no circuitry in the way, nearly the entire surface of
the sensor can collect light. The result is generally
greater sensitivity, and that leads to the only circumstances where the older technology might still
be preferred over the newer.
“There’s only one reason to go CCD over CMOS—
low light levels. In all other situations, CMOS offers
greater speed and equivalent sensitivity, while
benefiting from advances in consumer camera technology,” says Joachim Linkemann, senior product
manager at Basler (www.baslerweb.com). Like the
Publication Title: Control Design
Publication Number: 1094-3366
Filing Date: 9/30/14
Issue Frequency: Monthly
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13. Publication Title: Control Design
14. Issue Date for Circulation Data Below: September 2014.
other camera manufacturers, Basler uses both CCD
15. Extent and Nature of Circulation:
No.copies
12 months
No.copies
single issue
and CMOS sensors in its products.
a. Total number of copies (net press run)
33,095
32,939
b. P aid and/or requested circulation (1) Paid/requested outside-county mail
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30,834
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c. Total paid and/or requested circulation
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1,439
117
150
e. Total Non-requested Distribution
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Thanks to this greater sensitivity, CCD sensors
are still preferred for scientific applications, such
(2) Paid in-county subscriptions
stated on form 3541
as those in astronomy and the life sciences. Both
typically involve a photon-poor source and so need
to get the most out of any light that arrives. While
(3) Sales through dealers and carriers,
street vendors, counter sales, and
other non-usps paid distribution
industrial users typically don’t face the same issues,
(4) O
ther classes mailed through the usps
there can be cases where light levels are low and
CCD sensors are a better solution.
On the other hand, good lighting is almost always
(1) Outside-county as stated on form 3541
critical to machine vision success. Hence, the in-
(2) In-county as stated on form 3541
stances in an industrial setting where light levels
(3) O ther classes mailed through the usps
are low enough to make CCD sensors strongly pre-
(4) C
opies Distributed Outside the Mail
(Include Pickup stands, Trade shows,
Showrooms and Other Sources)
ferred over their CMOS counterparts could be rare.
However, even this low-light advantage is in
jeopardy. Roszkowski reports changes are underway
that promise to improve CMOS sensors in this area.
“CMOS is moving to back-illuminated designs, which
would allow them to be much more sensitive than
current CMOS devices in the near future,” he says.
This approach puts the light sensing material on
the back side of the chip while the circuitry stays
on the front. Consequently, there is no decrease of
incoming light arising from shadows cast by metal
traces, transistors or other circuit components.
controldesign.com CD1411_46_47_SPECMATE.indd 47
November 2014 Control Design
47
g. Copies Not Distributed
805
554
h. Total
33,095
32,939
i. Percent Paid and/or Requested Circulation
95.60%
95.09%
16. Publication of Statement of Ownership. Publication required.
Will be printed in the November 2014 issue of this publication.
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and Title of Editor, Publisher, Business Manager, or Owner
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11/3/14 12:01 PM
REAL ANSWERS
controldesign@putman.net
Give Your HMI an Ergonomic Tune-Up
OUR MULTI-MACHINE WORKSTATIONS haven’t
user interface along with a central and sometimes
changed much beyond the sophistication of the HMI
singular point of data feedback.
software and better tactile input methods. The opera-
DAN DIGIOA, marketing manager,
tors now spend more time at the workstation and less
EAO, www.eao.com
time patrolling the machines with clipboards since
we have much more operational data feedback at the
Ergonomic Outlook
HMI. We need an ergonomic tune-up to make sure the
It’s important to take
operators are safely paying attention to the increased
the time to do an
amount of operating data without being too comfort-
ergonomic tune-up.
able to be attentive. Any experiences to share?
Ergonomics plays
ANSWERS
an important role in
health, safety and
productivity. Technological advances have over-
Mixed Technologies
loaded operators with information, and their scope
This can be best accomplished by employing a
of responsibility is ever expanding. Many operators
mixed-technologies approach along with ergonomic
work long hours in less-than-ideal conditions. Well-
design principles when creating an optimal user
designed control rooms balance productivity with
interface. By utilizing and implementing a design
ergonomics, and a key component is the operator
which incorporates all forms of human-machine
console. The console is the bridge that connects the
interface (HMI), a complete and consolidated user
operator to the technology, and therefore, has a sig-
experience can be accomplished.
nificant impact on performance.
HMI systems have to be designed with the user and
Sit/stand consoles are a great choice for an er-
application environment in mind. You first have to
gonomic upgrade. Recent studies have shown that
define the operational and functional requirements.
too much sitting can be detrimental to your health.
This can encompass durability requirements and en-
Movement throughout the day is important to main-
vironmental stresses including exposure to moisture,
taining good health.
vandalism, temperature extremes, cleaning agents
Alternating between sitting and standing is a
and general rough use. Operator feedback is critical
healthy activity that increases energy and reduces
to capture end-user attention and to ensure overall
fatigue. Sit/stand consoles also provide adjustability
effectiveness and efficiency. Understanding the ap-
to meet the needs of each individual operator.
plication can dictate the degree of HMI complexity.
The ergonomic standards outlined in ISO 11064
And regulatory standards must be considered to meet
are a good reference for any ergonomic initiative. ISO
industry criteria.
11064 standards are designed to improve efficiency
All of these aspects influence the design of the
and reduce human error in the control room. A good
interface in order to capture user attention and to
ergonomics program translates into significant ROI in
ensure safe operation. This is why a mixed-technolo-
terms of reduced healthcare costs, increased produc-
gies approach is best. Not one single technology has
tivity and fewer errors. Beyond the numbers, ergo-
the ability to provide an all-encompassing solution.
nomics can improve the quality of life for workers.
Once the application and user requirements are
Operators who are more comfortable and better able
defined, a mixture of push buttons, cursor controls,
to do their jobs find more satisfaction in their jobs,
keyboards, touch technologies and interactive dis-
which improves the morale of the organization.
plays can interface with industrial computers to in-
BRENT LEIMER, marketing manager,
form, alert and efficiently update the user of machin-
Winsted, www.winsted.com
ery functions. Use of illumination techniques such
as ring, halo or animation combined with audible
Machinery Visibility
alerts capture end user attention in both an aestheti-
As your question points out, even with sophisticated
cally pleasing, modern appearance and forthrightly
output from software, visibility to machinery is still
effective manner. The mixing and matching of com-
key. In fact, lean manufacturing techniques have led
ponents and technologies allow for a consolidated
to a shift in the use of control enclosures to allow
48
Control Design November 2014
CD1411_48_49_REALANSWERS.indd 48
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11/3/14 12:03 PM
visual contact between operations and cells. Luck-
every 10 or 15 minutes, so I think that we have freed
ily, there are a variety of HMI enclosure systems
up the operator to focus on the process and the prod-
available beyond traditional, static workstations to
uct, rather than boring him so much that he becomes
help you create a solution specific to your business’s
inattentive. As interface designers, we gather and
needs. Great examples of this are vertical motion and
present more and more data, and our challenge is to
suspension systems, which allow operators to reposi-
crunch the data and present it as simplified choices
tion equipment as necessary throughout their shifts.
the operator can make quickly, rather than flooding
Look for a system that allows for multiple combina-
his screen with distracting raw data and expecting
tions of components for innovative system solutions
him to analyze it. My goal is to always reduce the
for any work environment. For even more flexibility,
amount of data and choices and operations in any
you may want to investigate industrial tablets, which
given sequence an operator will have to make. For
blend all of the benefits of modern technology with
every decision or step of manual workflow that you
the ability to patrol machinery as you would with a
can remove for an operator, you exponentially reduce
traditional clipboard. Ultimately, there are more HMI
the possible outcomes and effectively reduce risk by
enclosure systems out there than ever which can be
the same factor.
tailored to fit your application.
STEVE MEREDITH, reliability electrical coordinator,
EMILY DELOZIER,
Corod Division at Weatherford, www.weatherford.com
global product manager for large and HMI enclosure systems,
Pentair, www.pentairprotect.com
Operator Evolution
It sounds like the right direction—machine data
Operator Ergonomics
processing evolution—but operator evolution may
HMIs are available as free-standing operator stations,
be a concern. As more data is collected, the machine
console stations or pedestal or support arm systems.
should process more data, so the operator has to
Depending on the application and available floor
process less data. The direction of less human depen-
space, appropriate solutions can be selected. Systems
dency in the process equals less human error and risk,
are available in aluminum, mild steel and stainless
and greater safety, reliability and repeatability. But at
steel to address differing application, environment
the same time, operator evolution must take place to
and aesthetic requirements.
guide the operator to perform new tasks with the new
Many users are transitioning to the support arm
with enclosure solution because it can be safely
time that was freed up by machine evolution.
Excitingly and interestingly, machine data collec-
moved in and out of the workplace when program-
tion will eventually evolve to collecting data about
ming or data acquisition has been completed. Sup-
the human operators, too, so as to further reduce
port arm systems provide options for vertical motion,
human error and increase safety. The human motion/
swinging motion and swiveling to move the HMI
gesture sensing on games such as Xbox will be incor-
enclosure into the most ergonomic position for the
porated; later, even health vitals and retina scans will
operator to access. Considerations for operator er-
be incorporated. So the machine may sound an alarm
gonomic use, safety, floor space, environmental per-
if my human operator has fallen asleep, is drunk, is
formance, weight load, heat management, aesthetics
sick or is in the wrong place at the wrong time, that
and cost should all be considered when selecting the
is, for the few machines in that distant future that
correct HMI solution.
still require a human to operate them.
GREG QUICK, product manager, wallmounts and HMI,
DON FITCHETT, president,
Rittal, www.rittal.us
Business Industrial Network, www.bin95.com
The following responses to the question were posted on
Autonomy
LinkedIn.
I believe automation today is and should move toward
autonomous automation, where whole facilities can
Data Flood
be run from a central SCADA position with multiple
An interesting quandary you envision. Most process-
monitors observing multiple machines and maybe
es I have worked with still involve regular operator
even multiple facility locations, simultaneously.
interaction to load parts and/or renewable supplies
and provide regular quality checks, some as often as
controldesign.com CD1411_48_49_REALANSWERS.indd 49
MONTY BASS, engineering & maintenance manager,
Exide Technologies, www.exide.com
November 2014 Control Design
49
11/3/14 12:03 PM
PRODUCT SHOWCASE
controldesign@putman.net
SMALL SENSORS
45° increments to change the pivot angle without
Photoelectric sensors in the BOS
swapping the head of the unit. The device is compat-
6K series are 31.5x19.5x10.8 mm,
ible with multiple motors and can be interchanged
suitable for tight spaces in com-
with common pneumatic pivot units equipped with
pact machines. The series includes
125, 160 or 200 mm cylinders.
diffuse, through-beam, reflection
De-Sta-Co; 888/337-8226; www.destaco.com
light and analog distance sensors, each with the flexibility to be
configured for light/dark switch-
ALIGNS MACHINE SHAFTS
ing. They feature a tough and durable plastic housing
RS5 laser and sensor unit
with abrasion-resistant laser inscription. The sensors
for machine shaft align-
are IP 67- and IP 69K-rated, and the lens surface
ment can measure over
meets PMMA and Ecolab approvals.
spans of 10 m. It moni-
Baluff; 800/543-8390; www.balluff.com
tors horizontal and vertical machine corrections
at the same time, with the sensor at any rotational
LOOKS AHEAD
shaft position, and takes hundreds of measurement
Power PMAC controller
readings during shaft rotation to ensure repeatable
features a 2 GB program
results. The RS5 laser and sensor unit is waterproof,
buffer, advanced control
shockproof and dustproof.
functions including a
Ludeca; 305/591-8935; www.ludeca.com
look-ahead function that
algorithmically evaluates
trajectories in advance
IOS CONTROLLER APP
of their execution, improved servo tuning functions
Nanospark machine
and application-specific parameters. With Cam-
interface input and
Sculptor software, the controller supports table-
output controller man-
based electronic cams that develop customized,
ages attached equipment
cyclic optimal trajectories for motors.
through the touch-screen
Delta Tau Data Systems; 818/717-5656; www.deltatau.com
display of an iOS app. The interface lets users remotely turn off a machine through text messaging.
The controller includes digital and analog inputs and
SOFT TOUCH SWITCHES
outputs. The app is free on iTunes.
KSH tactile switches are
Nanospark; 715/318-1059; www.nanospark.com
RoHS-compliant, single-pole,
single-throw (SPST), top-actuwith a soft touch tactile feel.
MINIATURE OPTICAL
ENCODER
In a range of operating force ratings (1.6, 2.0, 2.5,
Atom non-contact,
3.0 and 3.5 N) with a travel distance of 1.3 mm, the
optical, linear and
switches have an operational life of 200,000 cycles
rotary incremental
(up to 3.0 N operating force) and an operating range
encoder has a readhead
of -40 to 90 °C.
of 6.7x12.7x20.5 mm and
C&K Components; 617/969.3700; www.ck-components.com
provides analog speeds to 20 m/s (29,000 rpm on a 17-
ated, surface-mount devices
mm disc) and digital resolutions to 1 nm when used
with the company’s interpolation electronics. The
NO MORE PNEUCS
readhead includes a set-up LED and an auto-calibra-
Using a worm gear instead of a
tion routine. Options include linear and rotary (angle)
pneumatic toggle, 98W electric
scales in stainless steel and glass. The encoder is
pivot unit can rotate its arms 360°.
CE-approved.
The pivot lets users adjust the saddle arm mount in
Renishaw; 847/286-9953; www.renishaw.com
50
Control Design November 2014
CD1411_50_53_SHOWCASE.indd 50
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CONTROLLER SUPPORTS
ETHERNET/IP
Productivity3000 controller now
supports the ODVA’s EtherNet/IP
as a standard protocol. Through
COMPACT LINEAR STAGES
its embedded Ethernet port, the
MTN Series of linear stages have an all-steel con-
P3-550 CPU can support Ether-
struction, high stiffness and load capacity, and
Net/IP configurable as a scanner
thermal stability in a compact, low profile design.
or adapter (or both simultaneously). The P3-550 CPU
The units have travel lengths of 300 mm and can
can communicate to devices using either explicit
withstand 1,000 N of load, as well as a high axial
messaging or implicit “I/O” messaging. To assist
load capacity of up to 200 N. The drive mechanism
with implementation, diagnostic tags are available
features a precision-ground, lead screw and preci-
to help determine which layer of the protocol may be
sion-lapped nut. The series comes with dc or stepper
preventing successful communications.
motors. Vacuum-compatible versions down to 10-6
AutomationDirect; 800/633-0405; www.automationdirect.com
hPa are also available.
Newport; 949/863-3144; www.newport.com
DETECT CLOGGED PUMP
INTAKE AND MORE
APT Series Power Transducers are available in 24
Vac/dc, 120 Vac or 240 Vac
power supply options. The
transducers produce 4-20 mA, 0-5 Vdc or 0-10 Vdc
PYROMETRY IMAGING
output that can help users monitor and report power
ISR 6-TI advanced pyrometer uses a built-in video
usage so they can take proactive corrective action
camera with infrared filter to improve manufacturing
when power rises or falls to abnormal levels. The
processes in metals, glass and other heat-dependent
transducers can also detect dry runs from clogged
manufacturing industries. The system operates in a
pump intake or discharge lines and monitor impeller
short wavelengths (around 1 μm) for accurate and reli-
cavitation and bearing wear. They are housed in a
able temperature measurements between 700 and 1,800
compact DIN-mounted case.
°C. The analog video output signal is converted to USB
NK Technologies; 800/959-4014; www.nktechnologies.com
and fed to a PC using the company’s special software.
LumaSense Technologies; 800/631-0176;
www.lumasenseinc.com
MULTI-HEAD CAMERA
FASTCAM Multi, a
flexible, multi-head
VFD TALKS IN WORDS
camera system,
PowerGate 66 IP66 / NEMA 4 vari-
is tethered to a
able-frequency drive (VFD) comes
remote processor
housed in a custom made NEMA 4
with cable lengths
enclosure for use in harsh
of 16 ft. (5m) or 33 ft. (10m). The small, sealed
environments. The VFD
camera heads provide 1280 x 1024 pixels resolution
includes a unique keypad
at 4,800 fps and 720 HD (1,280 x 720 pixels) to 6,000
and display where the LCD
fps. The camera processor is separate from the
shows information in words, rather than number-
camera heads, ensuring that data is safely retained
based codes. To simplify programming, the keypad
in the processor in case the camera heads or cables
has 10 buttons laid out similarly to a pocket calculator.
are damaged or destroyed during the capture of an
Mitsubishi Electric Automation; 847/478-2100;
explosive event.
us.mitsubishielectric.com/fa/en
Photron; 858/395-8618; www.photron.com
controldesign.com
CD1411_50_53_SHOWCASE.indd 51
November 2014 Control Design
51
11/3/14 12:16 PM
PRODUCT SHOWCASE
controldesign@putman.net
MINI VSD
PROFINET I/O DEVICE GATEWAY
CFW100 Mini Drive is a single-phase
PLX31-EIP-PND EtherNet/IP to Pro-
variable speed drive (VSD) designed
finet I/O device (slave) gateway can
to handle 150% overload for 60 sec-
be used for PLC-to-PLC interlocking,
onds at 50° C ambient temperature
as a SCADA interface or for data
rating. The unit has power ranges
concentration. The EtherNet/IP driver
of 1/4 , 1/3 , 3/4 and 1 hp at 230 Vac with
supports multiple I/O connections
single-phase in and 1.5, 2.6 and 4.2
and lets users prioritize data trans-
A three-phase output. It features built-in DIN rail
fers by setting different update rates
mounting, detachable fan for easy maintenance and
for control and diagnostic data. This
plug-in modules for communication and I/O options.
lets users send low-priority data at
WEG Electric; 678/249-2022; www.weg.net
slower rates.
ProSoft Technology; 661/716-5287;
www.prosoft-technology.com
SCRATCH-PROOF HMIS
IndraControl V HMIs have a
scratch-proof aluminum front
RUGGED FLAT PANEL COMPUTER
and thermally hardened glass
SeaPAC R9-8.4 combines a power-
displays. They feature high
ful RISC-based embedded com-
shock and vibration resis-
puter with a bright 8.4 in. TFT
tance. The anti-reflecting,
LCD to create a wide-temperature,
projective-capacitive touch display supports single as
ruggedized, flat-panel computer
well as multi-touch operation. The units are IP65-rated.
for a variety of HMI and con-
Bosch Rexroth; 800/739-7684; www.boschrexroth-us.com
trol applications. Featuring LED
backlight technology, the system has an operating
temperature range of -30 to 70°C with no heaters or
NATIVE MODBUS COMMUNICATOR
cooling fans required.
UA Modbus gateway can connect to any
Sealevel Systems; 864/843-4343; www.sealevel.com
device that uses the standard Modbus
protocol both over serial or Ethernet
connections on one side and makes it
PNEUMATIC INTELLIGENCE
securely available to OPC UA clients on
IntelliSense technology platform
the other side via OPC UA over Ethernet.
combines sensors, cylin-
OPC UA provides many features Modbus
ders and software
lacks including security, reliability and data
to deliver real-time
modeling. The unit can operate in extreme tempera-
performance data
tures and dusty environments.
that helps users to
MatrikonOPC; 877/628-7456; www.MatrikonOPC.com
be proactive about
maintenance and
system optimization.
RODLESS LINEAR ACTUATORS
The system’s intel-
High Moment Rodless (HMR) electromechanical
ligence is embedded inside the sensor interface
linear actuator series comes in 085-, 110-, 150-, 180-
module (SIM), a remote monitoring device connect-
and 240-mm frame sizes and precision ball screw or
ed to sensors attached to the company’s cylinders
high-efficiency timing belt drive train options. Units
using pneumatic fittings. Users receive operational
feature a load capacity of up to 26,600 N.
insights about cylinder condition, cycle time, pres-
They work in an ambient temperature
sure (to one hundredth of a psi) and temperatures
range of -30 to 80 °C.
(down to a hundredth of a degree). The system also
Parker Electromechanical
delivers up-to-date condition information that pre-
Automation; 800/358-9068;
dicts when a cylinder will fail.
www.parkermotion.com
Bimba Manufacturing; 708/534-8544; www.bimba.com
52
Control Design November 2014
CD1411_50_53_SHOWCASE.indd 52
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11/3/14 12:16 PM
is the only magazine exclusively
dedicated to the original equipment
manufacturing (OEM) market for
instrumentation and controls—the
largest market for industrial controls.
GALVO SCANNER
The Nmark AGV-HPO open-frame galvo scanner is designed to attain
single-digit, micron-level accuracy over the field of view. Its optical feedback technology improves thermal stability,
and it offers resolution of greater than 24 bits when
1501 E. Woodfield Rd., Suite 400N
Schaumburg, Illinois 60173
630/467-1300
Fax: 630/467-1124
used with Aerotech’s Nmark CLS controller. Multiple
input apertures and mirror coatings support a variety of laser wavelengths, and its open-frame design
is designed to reduce cost and allow for more flexible
PUBLISHING TEAM
laser beam delivery. Right-side and left-side aperture options
GROUP PUBLISHER & VP, CONTENT
for side-by-side parallel processing are available. The AGV-HPO
KEITH LARSON klarson@putman.net
family is available with 10, 14, 20, and 30 mm input apertures and
DIRECTOR OF CIRCULATION
can be equipped with an F-Theta or telecentric lens directly from Aerotech. Mirror coat-
JACK JONES jjones@putman.net
ings for a wide range of UV, visible, IR, and CO2 wavelengths are supported.
Aerotech; 412/963-7470. www.aerotech.com
SALES TEAM
northeastern and mid-atlantic regional manager
DAVE FISHER dfisher@putman.net
ROTARY SENSORS
508/543-5172 Fax: 508/543-3061
The Vert-X 32E Series of programmable rotary angle sen-
24 Cannon Forge Dr.
Foxboro, Massachusetts 02035
sors are touchless magnetic angle sensors with a permanent
MIDWESTERN AND SOUTHERN REGIONAL MANAGER
magnet that can be secured to a rotating shaft, so that there
GREG ZAMIN gzamin@putman.net
is no direct mechanical linkage between the shaft and the
630/551-2500 Fax: 630/467-1124
measuring system, and therefore no wear. Output provided
1501 E. Woodfield Rd., Suite 400N
is CANopen Interface. Vert-X 32E Series is CiA-certified se-
Schaumburg, Illinois 60173
rial communications output and supports real-time control. The Vert-X 32E Series can
WESTERN REGIONAL MANAGER
be programmed through a programming device connected between the sensor and a
LAURA MARTINEZ lmartinez@putman.net
computer’s USB port and software called EasyAdapt, which runs on Windows PCs. Users
310/607-0125 Fax: 310/607-0168
can select from six default setups or use one as a starting point and customize it. Output
218 Virginia, Suite 4, El Segundo,
characteristics including custom characteristic curve, angle range, zero point and curve,
California 90245
as well as gradient-direction versus direction of rotation, can be programmed.
DIGITAL SALES SPECIALIST
Novotechnik; 508/485-2244; www.novotechnik.com
JEANNE FREEDLAND
jfreedland@putman.net
805/773-4299 Fax: 805/773-0451
AD INDEX
Adalet . . . . . . . . . . . . . . .
Allied Electronics. . . . . . . .
ARC Advisory Group. . . . . .
AutomationDirect. . . . . . . .
AVG Automation . . . . . . . .
B&R Industrial Automation .
Balluff . . . . . . . . . . . . . . .
Beckhoff Automation . . . . .
Bimba . . . . . . . . . . . . . . .
Daisy Data Displays . . . . . .
DataForth . . . . . . . . . . . . .
Endress+Hauser . . . . . . . .
eWon . . . . . . . . . . . . . . . .
Harting . . . . . . . . . . . . . . .
IDEC . . . . . . . . . . . . . . . .
ITS Enclosures . . . . . . . . .
INSIDE SALES SPECIALIST
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24
POLLY DICKSON pdickson@putman.net
Maple Systems . . . . . . . . . . . . . . . . 22
630/467-1300 Fax: 630/467-1124
Matrox Imaging . . . . . . . . . . . . . . . . .21
Opto22. . . . . . . . . . . . . . . . . . . . . . 29
EXECUTIVE STAFF
Otek . . . . . . . . . . . . . . . . . . . . . . . . 39
president & ceo
Pepperl+Fuchs . . . . . . . . . . . . . .12, 13
JOHN M. CAPPELLETTI
Phoenix Contact . . . . . . . . . . . . . . . . 3
cfo
Pro-Face America . . . . . . . . . . . . . . 23
RICK KASPER
Telemecanique Sensors . . . . . . . . . . . 7
vp, circulation
TRC Electronics. . . . . . . . . . . . . . . . 35
JERRY CLARK
vp, creative services, production
Triangle Research . . . . . . . . . . . . . . 32
STEVE HERNER
Unitronics . . . . . . . . . . . . . . . . . . . . 30
Wago . . . . . . . . . . . . . . . . . . . . . . . . 8
REPRINTS
WebCom Communications . . . . . . . . .41
FOSTER REPRINTS www.fosterprinting.com
WEG Electric . . . . . . . . . . . . . . . . . .31
JILL KALETHA
Yaskawa America . . . . . . . . . . . . . . . 55
jillk@fosterprinting.com
866-879-9144 ext. 168
controldesign.com
CD1411_50_53_SHOWCASE.indd 53
November 2014 Control Design
53
11/3/14 12:16 PM
OEM INSIGHT
Geoffrey Peckham • info@clarionsafety.com
Machinery Safety Labels Matter—Part II
This two-part column can be read in its entirety at www.controldesign.com/articles/2014/the-importance-of-machinery-safety-labels.
LAST MONTH, I began to share what I believe
Tool #3: Global Warnings That Use Symbols
are some key best practices and tools that shape
Many machinery manufacturers sell their products
the current state of the art for product safety label
worldwide, and, when this is the case, compliance
design. We discussed Tool #1: Standards. We’ll finish
with global standards is required. The ANSI Z535.4 and
that discussion with two additional tools.
ISO 3864-2 product safety label standards and the EU
machinery directive emphasize using well-designed
Tool #2: Risk Assessment
symbols on machinery safety labels, so information
From an engineering perspective, your job is to iden-
can be conveyed across language barriers. Adding
tify potential hazards and then determine if they need
symbols also increases your labels’ noticeability. The
to be designed out, guarded or warned about. From a
use of symbols to convey safety is becoming common-
legal perspective, your job is to define which hazards
place worldwide, and not taking advantage of this new
are “reasonably foreseeable” and “reasonable” ways
visual language risks making your product’s safety
to mitigate risks associated with hazards that can’t
labels obsolete and noncompliant with local, regional
be designed out. Here is where risk assessment comes
and international codes.
Note that sometimes
into play.
symbols alone can’t con-
We should expect that
a product is designed
vey complex safety mes-
with safety in mind. At
sages. In these cases, text
its most basic level, risk
is often still used. When
assessment involves con-
shipping to non-English
sidering the probability
speaking countries, the
and severity of outcomes
trend today is to translate
that can result from
the text into the language
potentially hazardous
of the country in which
situations. After identify-
the machine is sold.
ing the potential hazards
Digital print technology
makes this solution much
related to your product at
every point in its lifecycle, you then consider various
strategies to eliminate or reduce the risk of people
more cost-effective and efficient than in the past.
The safety labels on your products are one of its
most visible components. If they don’t meet cur-
Making sure your product safety signs
and labels are up-to-date is an important
task for every engineer responsible for a
machine’s design.
rent standards, if they’re not designed as the result
of a risk assessment and if they don’t incorporate
well-designed graphical symbols, then your company
risks litigation and nonconformance with market
requirements. Most importantly, you might be putting those who interact with your machinery at risk.
interacting with these hazards. The best practice,
Making sure your product safety signs and labels are
risk-assessment standards that exist today (ANSI Z10,
up-to-date is an important task for every engineer
ANSI B11, ISO 31000 and ISO 31010) give you a process
responsible for a machine’s design. I hope the above
to use to quantify and reduce risks. Using these
information has helped to set your company on the
standards as the basis for a formalized risk assess-
right path to revise its warnings.
ment process not only will help you develop better
safety labels and a safer product, they will also give
Geoffrey Peckham chairs the ANSI Z535 Committee for
you documentation that will help you show the world
Safety Signs and Colors and the U.S. Technical Advisory
that you’re a safety-conscious company that uses the
Group to ISO Technical Committee 145—Graphical Symbols.
latest standards-based technology to reduce risks.
He is a member of the U.S. Technical Advisory Group to ISO
This will be highly important should you be involved
Project Committee 283—Occupational Health and Safety
in product liability litigation down the road.
Management Systems.
54
Control Design November 2014
CD1411_54_OEMINSIGHT.indd 54
controldesign.com
11/3/14 12:19 PM
20 MILLION INVERTERS
10 MILLION SERVOS
300,000 ROBOTS
Yaskawa. Proven. Worldwide.
Nobody enjoys a larger installed base of inverters,
servos and robots around the world than Yaskawa.
Our experienced engineers, proven technology and
unsurpassed quality can
all be combined to give proven solutions in which
you can have total confidence.
In a recent internal study of 100,000 servo motors
shipped, Yaskawa found that only 7 were returned
for warranty repair. To put that in perspective, a
typical out-of-box failure rate goal for manufacturers
of brushless servo motors is 0.5% (or 500 failures
per 100,000 motors shipped).
No matter how you add it up, nobody equals Yaskawa.
Call us today.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
©2014 Yaskawa America Inc.
CD1411_FPA.indd 55
For more info:
http://Ez.com/yai693
11/4/14 10:55 AM
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AIR PREP
CONTROL VALVES
NITRA pneumatic air prep devices’ modular design allows for
stand-alone applications as well as easy field assembly for
combining components.
Manual or electrically controlled, NITRA’s directional control
solenoid valve selection offers capacity and form factor
flexibility to meet your system configuration needs.
•
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Filters
Regulators
Lubricators
Combination filter/regulators
• Poppet and spool valve styles
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push-pull and foot pedal
valves
• Manual shut-off relief valves
• Soft-start/dump valves
• Modular assembly brackets
• Process (pipeline)
• Compact modular
• Manifolds, silencers, cables,
connectors
• Position switches
CYLINDERS
TUBING AND FITTINGS
NITRA pneumatic cylinders are interchangeable with many
other brands, offering styles for various application
requirements in popular bore sizes and stroke lengths.
Wide array of choices, including:
• Bulkhead unions
• Union straight, reducers,
Tee, elbow, Y
• Manual hand valves
• Meter-in and -out flow control
• Dual-rod guided
• All stainless round body style
• Position switches
• Non-repairable round
body style
• Compact (pancake style)
• NFPA heavy-duty, standard
and cushioned-end styles
• Quick-disconnect straight
and swivel hose couplings
• Brass adapter fittings
• Nylon and polyurethane
straight and coiled tubing
Many fitting styles also available in stainless steel
CHECK OUT OUR PRICES
Pneumatics
AutomationDirect
NITRA
McMaster-Carr
Grainger
MSC
Solenoid Valve
5-port, 2-pos, 1/4” NPT
$28.50
AVS-5312-24D
$84.10
$115.40
$87.35
Filter/Regulator Comb.
1/4” NPT, gauge, bracket
$30.50
AFR-3233
---
$138.55
4ZK92
$115.47
Air cylinder, nose mount
3/4” bore, 1” stroke
$12.50
$16.33
6498K141
---
$21.62
Nylon tubing
1/4” OD, black, 100 ft.
$17.50
$68.00 1
---
$84.65
NB-4-035-0100-P
A12010SN
N14BLK100
6124K513
3JCN6
5097T411
84470475
42007401
36696458
Research, price, buy at:
www.automationdirect.com/
pneumatic-parts
1) Sold by foot, price shown for 100 feet
All prices are U.S. published prices. Many other part numbers are available from all vendors. Automationdirect prices are from April 2014 Price List. McMaster-Carr prices are from www.mcmaster.com 2/20/2014.
Grainger prices are from www.grainger.com 2/20/2014 MSC prices are from www.mscdirect.com 2/20/2014. Prices subject to change without notice.
Order Today, Ships Today!
* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.
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the #1 value in automation
11/4/14 10:55 AM