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Issue 35
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Automation Update is an engaging, editorially led publication & directory giving the reader news and updates on new products and services to our ever Progressing industry.
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Automation Update - 3
Commander ID 300, the new Leroy-Somer integrated drive Leroy-Somer has announced the launch of Commander ID300, a new integrated drive for the control of IMfinity® induction motors. This decentralized system brings together performance and reliability, offering customized solutions for process, manufacturing and intralogistics applications. With the transition to Industry 4.0 under way, production is evolving in an increasingly complex and demanding environment. Consequently, companies require more and more quality, risk management, equipment performance and compliance to standards. Commander ID300 has been designed to meet these strategic challenges, offering strong dynamic performance and outstanding efficiency levels. The decentralized configuration offers greater flexibility in machine and plant design. Other advantages include space saving, as no cabinet is required, lower overall costs due to the elimination of cables between drive and motor, lower power losses and reduced emission interference… Benefitting from IMfinity® motor’s proven mechanical construction, Commander ID300 is extremely robust. This robustness is strengthened by the use of latest generation electronic components for power and control. To offer a high level of the system performance, the auto calibration and drive setup are carried out at the factory, including optimized starting torque, high dynamics on fast transient load and operation at constant torque using flux vector control across the entire speed range.
system classification IES2 (EN 61800-9-2), enhancing energy savings. The drive also features a low power standby mode for applications with significant periods of idleness. Safety remains paramount: to protect users and minimize machine operation downtime, the Commander ID302 variant integrates onboard safety functions for compliance with the h i g h e s t s a f e t y standards SIL3 (Safety Integrity Level 3) and PLe (Performance Level e). The motor is also protected against overloads thanks to thermal protection. On top of this, the optional brake card enables full control of the brake sequencing and power supply. Commander ID300 has been designed on a modular concept: the wide choice of options and adaptations enables configuration in line with machine architecture.
For an advanced control of the machine, Commander ID300 is provided with features that add value to the application and simplify the system management: onboard PLC, fieldbus communication, extra input/output or preset configurations such as a pump program for pressure regulation (constant pressure / variable flow).
The system can also be combined with an FFB brake for dynamic braking and /or gears from the multiposition 3000 range, ensuring maximum adaptability.
Commander ID300 offers energy efficiency standards higher than
For instance, time can be saved during installation thanks to the
4 - Automation Update
Due to its large selection of features and options, Commander ID300 is an “easy-to-use” solution, ensuring quick and smooth operation.
multiple mechanical adaptations and connections that can be made at the factory. Also, to facilitate setup, configuration and diagnostics, the system delivers intuitive setup and pre-configured settings which are application dependent. Designed for industrial environments as standard, the Commander ID300 all-in-one drive solution is part of the Express Availability offer, the premium Leroy-Somer Service which ensures rapid delivery while minimizing spare and stock requirements.
Motioncompass provides engineering expertise 24 hours a day Portescap is pleased to announce a new motor selector tool, MotionCompass™ – a web-based application that facilitates choosing a motor based on your application needs. MotionCompass will provide you with recommendations for our brushless DC and brush DC coreless products that best fit your needs, including all relevant data and performance curves. We invite you to register and set up an account with MotionCompass.
Portescap From medical devices to various industrial applications that save, improve, and enhance lives, Portescap offers miniature motor technologies to solve the motion needs of a spectrum of end markets. We serve our customers through breadth of innovative product technologies encompassing brushless DC, brush DC, can stack motors, disc magnet motors and stepper linear actuators to optimize application performance. Discover more: www.portescap.com
Automation Update - 5
Advantech ADAM Series of I/O Modules Advantech Remote I/O Modules Advantech is a global leader in data acquisition I/O module design and manufacturing, offering complete stand-alone data acquisition modules which are broadly used in industrial applications, such as facility monitoring, environment monitoring, and industrial process control. Advantech distributed I/O modules are categorized into two families, Ethernet I/O (ADAM-6000 series) and RS-485 I/O (ADAM-4000 series), which are subdivided into Analog I/O and Digital I/O modules with some of them supporting modbus communication protocol.
Ethernet I/O Modules In the past, integrating automation and enterprise systems required changing the entire architecture of the control system. Nowadays, Advantech ADAM-6000 accomplishes this integration easily through the latest internet technology, so that it can remotely monitor the device status more flexibly.
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Advantech’s ADAM-6000 modules are empowered by Peer-to-Peer (P2P) and Graphic Condition Logic (GCL), and can perform as standalone products for measurement, control and automation. With Advantech’s P2P and GCL technology, no additional controllers or programming is needed. With the easy-to-use and intuitive graphic utility, system configurations can be done in an extremely short time. The members of ADAM-6000 series include Communication Controllers, Analog Input/Output Modules and Digital Input/Output Modules.
Profinet I/O Modules Advantech offers the ADAM-6100 series of Industrial PROFINET modules. Equipped with the PROFINET protocol, ADAM6100PN series also allows daisy chain connections, making it possible to transfer data much faster during process control and other industrial automation applications.
Please visit Advantech new estore to see more.
£2.59
CorDEX Announces Launch DIGITHERM Digital
The CorDEX DIGITHERM are the most advanced, intrinsically safe portable digital imaging cameras yet. 8 - Automation Update
of All New TOUGHPIX Imaging Camera Series
C
orDEX have announced the release of the all new TOUGHPIX DIGITHERM camera series, comprising of a world’s first – an intrinsically safe combined 5mega pixel digital camera and onboard thermal imager. Offering ground-breaking affordability in exchange for an impressive array of features, the TOUGHPIX DIGITHERM series sets a new industry standard for delivering a compact and lightweight, yet rugged, digital imaging camera. The new cameras allow users to quickly detect issues, conduct accurate measurements and document findings for remedial action. The TOUGHPIX DIGITHERM cameras feature a rich set of new hardware, software and technical specifications designed from the ground up to set the highest standard in the industry. Manufactured from lightweight but tough, aircraft grade aluminium, every single component in the TOUGHPIX DIGITHERM has been selected with one goal in mind – quality that’s built to last. Douglas Walker, Research Director said “CorDEX have pioneered an intrinsically safe dual mode radiometric camera. DIGITHERM provides digital and thermal imaging in a compact tough package with a low entry cost. The high resolution visual image combined with the capable 80x60 IR image opens up many application areas. Problem hot spots are easily made visible and located accurately in tough environments.” With its industry leading, 5 megapixel visual sensor, motorised automatic focus and ultrabright LED flash, TOUGHPIX DIGITHERM takes crystal clear, high resolution digital images in broad daylight a swell as darker environments. Not only this, but the cameras include a thermal imaging camera, meaning its duel functionality is the perfect hybrid for any situation. Additionally,
the cameras offer adaptive thermal blending, WIFI, onboard analysis tools, a removable memory card and removable battery. Tony Holliday, CEO confirmed CorDEX had gone back to its roots “CorDEX made a name for itself by introducing the first ATEX certified digital camera with flash almost ten years ago. Today, with the launch of TOUGHPIX DIGITHERM, CorDEX has again set the bar not only providing a ground up developed
digital imaging camera, but a camera more resembling mainstream compact cameras with the additional benefits of a rugged Intrinsically Safe design, plus onboard thermal imager.” The TOUGHPIX DIGITHERM series is available through select distributors and directly from CorDEX Instruments. To buy the TOUGHPIX DIGITHERM or to learn more about the series, please visit www.cord-ex.com. Automation Update - 9
Cryogenic technology brings rocket science to screwdrivers ‘It’s not rocket science,’ people often say when describing how easily a problem might be solved. But cryogenic, ice hardening technology, used by NASA and other space agencies to develop rocket fuel, is now being used to manufacture stainless steel screwdrivers. Previously, stainless steel hard enough for industrial or construction applications has been too brittle for everyday use. Bahco design engineers have overcome this by using cryogenic technology, giving their stainless steel screwdrivers and torsion bits superb hardness and durability. Electricians, electrical engineers and technicians working within the automation industry will probably be aware that using a conventional steel screwdriver to drive stainless steel screws can leave traces of ‘foreign’ debris on the screws and other fasteners. This contamination causes them to oxidize and create extraneous rust, which is not only unsightly but, more importantly, can lead to serious corrosion and a threat to hygiene and safety if left untreated. The only effective solution is to ensure that non-rusting stainless steel screws are driven by stainless steel screwdrivers, which can also be used when driving non-stainless
10 - Automation Update
steel screws. Renowned for its hygienic qualities and ease of cleaning, stainless steel is widely used in ‘clean rooms,’ in the food manufacturing and pharmaceutical industries, within hotels and restaurants and in the automotive, aerospace, oil and gas business sectors. Stainless steel’s resistance to all weather conditions, corrosion and antacids also make it suitable for use offshore. Using stainless steel screwdrivers cuts costs by reducing the frequency of replacing worn tools. Their introduction is timely as the use of stainless steel screws has grown by almost 70 per cent over the past few years. “This technical achievement provides further evidence of Bahco’s market leading innovation,” says Mark Haywood, who leads the Bahco team in the UK. “The breakthrough offers significant benefits to electricians, electrical engineers and other technicians required to work in any ‘clean’ environment where corrosion must be avoided.” Bahco’s stainless steel screwdriver range features round blades made from high performance alloy stainless steel. They are now available from all good trade counters, along with a range of ¼” stainless steel torsion bits, with a choice of slotted, Phillips®, Pozidriv® and Torx® heads. For further details or technical information visit www.bahco.com
Profile Technology
Conveyor Technology
Linear Motion
Factory Equipment
Modules and Much More
Pallet Handling Systems Modular. Compatible. Versatile.
mk Profile systems limited a company of the mk Technology Group Unit 2·Wolds Farm Business Park Kinoulton Lane·Kinoulton·Nottinghamshire, NG12 3EQ Phone +44 (0)1949 823751·Fax +44 (0)1949 81270 www.mkprofiles.co.uk·info@mkprofiles.co.uk
RockStar ModuPlug ®
More freedom – Less effort RockStar® ModuPlug is setting new standards combining power, signals and data in one connector and is the platform for future, innovative modular connectivity solutions Industrial applications are becoming increasingly complex. The demands being made of the connectivity used are growing at the same time. Functionality in the smallest of installation spaces, safe installation and a fast retrofitting process are just some of the product properties being called for. RockStar® ModuPlug addresses these demands by enabling the flexible combination of all the necessary functions for power, signal and data transmission in a single applicationspecific interface. New and more compact inserts allow for a significantly increased functional density compared to previous solutions. Half the pitch size, twice the module slots Up until now, there were two standard module widths for heavy-duty connectors: ‘Single 1.0’ and ‘Double 2.0’. Weidmuller have broken away from this standard, and are creating new dimensions with the intermediate sizes of ‘Half 0.5’ and ‘Single Plus 1.5’. Four different module widths make for unprecedented levels of flexibility and allow for the construction of particularly space-saving connector solutions. The modules reduce the amount of space required and cut costs when compared with fixed-pole inserts and other modular plug-in connector systems. The sophisticated frames and modules can be installed with extreme ease and integrated into HDC enclosures with the IP65 and IP68 protection classes. You can even use the RockStar® ModuPlug to supplement existing applications without any need to make system adjustments. More and Less - Discover your freedom with RockStar® ModuPlug
12 - Automation Update
More power – Less weight Users of the RockStar® ModuPlug have the option of either using more functional modules within the same installation space or having the same functions as before but with a smaller frame and housing. In addition to space savings, the latter option also helps to achieve weight savings, making it particularly suitable for applications in the fields of railway engineering and wind energy. More signals – Less space - transfer more signals with the same enclosure dimensions: Thanks to a higher contact density – 36 signal contacts at a rated voltage of 250 V, the double module HD36 achieves 50 percent more contacts in the same space as the market standard. More data – Less limits - A new level of data transfer Two Cat.6A cables each with 10 Gbits can now be integrated in a single module. The use of standard M12 connector technology achieves optimal EMC values and the 360˚ shield connection offers maximum protection against external interference. More options – Less costs - save installation space, weight and costs: you can choose between four different module widths. The halved pitch size allows twice the number of module slots in the frame, plus the reduced pitch separation allows more functionality in the same space. More convenience – Less risk The innovative design of RockStar® ModuPlug offers assembly and disassembly without tools. A fixed locking position provides stability for faster and easier assembly. Incorrect connection is avoided through a unique coding system. In addition, there’s less wiring work required thanks to the ability to connect two PE cables of up to 10 mm².
RockStar® ModuPlug in use: Machinery High performance in the smallest of spaces with RockStar® ModuPlug The challenges in machine construction are numerous: flexible machine units need to be networked. In robotics, space is limited to a bare minimum. On production lines, processing of very high data volumes must be ensured. With RockStar® ModuPlug, you can transmit more signals in less space saving on connector costs. Transportation Reliable jumper cables with RockStar® ModuPlug are a durable solution for secure data and signal transmission within the train. In transport engineering, increasing amounts of data and signals need to be transferred reliably. Special air-conditioned containers place exacting demands on power transmission. More functionality in the same area enables space and weight saving. Weidmuller’s slim 100 A modules ensure high power transmission with a low space requirement. Energy - Efficient and secure with RockStar® ModuPlug Wind turbines have to be operated efficiently, reliably and with low maintenance. Measurement data should be transferred using as little space as possible. The high-speed data module can accommodate megabit and gigabit data inserts. It offers transfer rates of up to 10 Gbits in the smallest of installation spaces. Product selection guide. You can find the right product quickly and accurately our product configurator. You can also visit the Weidmuller website at www.weidmuller.co.uk or call them on 0845 094 2006.
More freedom - Less effort RockStar® ModuPlug is setting new standards Let’s connect. Across all industries, the requirements placed on functionality are becoming more extensive and complex. RockStar® ModuPlug sets new standards. The modular connector system solves space problems by offering increased functionality with a reduced installation space. And all this with more convenient installation. Discover your freedom with RockStar® ModuPlug. Sales: 0845 094 2006 Tech: 0845 094 2007 Email: marketing@weidmuller.co.uk www.weidmueller.com/moduplug
Monitoring and networking in harsh environments made possible with PROCENTEC ComBricks HE+ PROCENTEC ComBricks has proven itself as the number one permanent monitoring tool for PROFIBUS networks for years. In addition to the ComBricks family, PROCENTEC recently launched the new robust ComBricks HE+, the perfect solution for use in harsh environments, making PROCENTEC ComBricks applicable in an even wider range of solutions. PROCENTEC ComBricks unites network components and offers permanent monitoring with industry leading features. It enables users to remotely monitor PROFIBUS installations from anywhere in the world and gives advance warning of any potential system faults, acting as a virtual maintenance professional. ComBricks is a unique modular platform able to carry repeater and modules on a backplane. It is the only product with an integrated oscilloscope for permanent PROFIBUS monitoring. The use of PROCENTEC ComBricks makes it possible to collect and store network diagnostic data to identify even intermittent network faults, which are usually the most difficult to diagnose and rectify. Based on a set of personalized criteria, it gives an easy to interpret notification that can then be acted upon before a failure occurs. The system works with an integrated web browser which gives secure access to the units via a web connection.
Harsh environments The newest member of the successful ComBricks family is ComBricks HE+. Because of its robust stainless steel housing, the device is ideal for the use in industrial, marine, and extreme conditions. It is ILAC-MRA vibration approved, which means the device is resistant to vibrations that may occur when the unit is used on trains, planes, boats and trucks. Furthermore, the device allows for a better temperature dissipation. In comparison with the first ComBricks systems, no separate backplane is needed. ComBricks HE+ is based on an internal backplane, up to two scope repeater modules can be added next to the head station, locked together with a metal clamp.
PROCENTEC Atlas The ComBricks system is the perfect solution for monitoring PROFIBUS networks. Recently, PROCENTEC launched a monitoring solution for Industrial Ethernet networks as well: PROCENTEC Atlas. This tool is perfect for preventing unexpected and expensive downtime in complex factory networks. Are you interested in these innovative solutions? For more information, check out procentec.com. Or visit PROCENTEC at the SPS Nuremburg trade fair from November 28th until November 30th in Hall 10.0, stand 530. 14 - Automation Update
Newest innovations The new PROCENTEC ComBricks HE+ Is your PROFIBUS network located in a harsh environment with for instance high temperatures or vibrations and do you need 24/7 monitoring of your network? The ComBricks HE+ is a robust device, which makes it ideal for these harsh environments. The system unites network components with permanent monitoring and ProfiTrace.
Our vision on the future, PROCENTEC Atlas Driven by the need for high performance, integration between factory installations and IT-systems, there has been a growing acceptance of Industrial Ethernet within industrial automation. With this, system complexity will continue to increase. Our Atlas products are a perfect solution for diagnostics in your network, preventing you from unexpected and expensive downtime.
@PROCENTECNetherlands
@PROCENTEC
@PROCENTEC
@PROCENTEC
Industry 4.0 and its Relevance to Compressed Air Systems The smart factory is on the horizon and the technologies to implement it are available today. So, what has all this to do with compressed air systems? BOGE’s Mark Whitmore explains. In a recent survey of its customers, one UK industrial services company found that, there is a clear differentiation between believing in the potential of Industry 4.0 and actually implementing it. Industry 4.0 is all about socalled ‘smart factories’ and while ‘smart’ manufacturing is carried out in these facilities, ‘there’s still a need for those traditional vital resources – compressed air being one of them. So, what’s needed to make compressed air system technology ‘Industry 4.0-ready’? Well, networking, internet connectivity and artificial intelligence for starters. Modern compressor control systems have a large number of networked features that enable one machine to act as the master for a wider network while coordinating the operation of multiple machines via a fieldbus. Meanwhile, built-in internet links allow operations and maintenance staff to monitor overall system performance remotely using a web browser or mobile app. These features are provided as standard in all BOGE air compressor control systems, but for larger, more complex systems, the company has developed a new generation of networked controllers called airtelligence provis 2.0. This continually and automatically monitors a compressed air system, anticipates changes in demand and operates proactively to activate the optimum combination of compressors and other components to fulfil that demand. The German drinks manufacturer, Nordbrand Nordhausen is currently using this system on three frequency-controlled type SF 60 BLUEKAT catalytic compressors to determine its total network volume and trends, initiating appropriate machine start-ups ahead of predicted demand peaks in order to maximise efficiency. BOGE compressor installations can be connected to the internet allowing them to share operating data with the 16 - Automation Update
company’s analytics centre in Germany. Some 70 sensor measurements per second are assessed by ‘learning’ algorithms that establish the plant’s normal operating conditions. Any excursion from the norm is immediately detected by the analytics centre staff. BOGE is also making use of augmented reality spectacles that provide on-site maintenance staff with the virtual support of remote experts. Industry 4.0 uses a wide range of monitoring and reporting tools, allowing system operators to see and understand energy consumption, system reliability and available capacity at the touch of a button. Machines connected to BOGE’s analysis system, for example, are given an annual report detailing the cost of compressed air system production, how demand varies over time and how the operating efficiency of the system is influenced by those demand variations. The approaches described above are not tomorrow’s technology; they are real product and service offerings, driven by Industry 4.0, and are available today. BOGE has embraced Industry 4.0, and that makes it all the easier for the compressed air user to build it into their own manufacturing operations too.
Tooling up for Engineering Improvement
Modern techniques have made the process of commissioning a manufacturing tool easier and more cost-effective. Jeff Kiernan, Commercial Director at Dawson Shanahan, explains. Efficient manufacturing relies on high quality tooling. The tooling determines everything, from the speed at which parts are made to the repeatability of manufacture in high volume production – and, ultimately, the quality of the finished part. Effective tooling design requires a deep understanding of the conditions that a tool will encounter during machining or cold forming. This informs the way the tool is built and the materials used, as well as potential modifications to process criteria. The designer must consider many factors, including: tolerances in the finished part; mechanical strength and rigidity; cutting tool strength; sacrificial or weak links; machine tool speed, feed and size; and disposal of swarf or other waste.
‘correct’ tooling can be engineered first time. For example, DEFORM simulates deformation and die stress analysis – banishing iterative processes, and ensuring that a die is ‘right first time’ when it is cut.
Cost confusion Software has also made it easier for engineers to assess the time, labour and materials required to produce individual tool sets. Historically, there has been confusion over tooling cost, and how it is charged to each customer. Because there were no standard definitions to guide cost calculations, suppliers adopted a variety of practices to calculate the cost of developing tooling.
Dawson Shanahan’s approach is to work with each customer, explaining how costs are calculated and then finding the solution that works best for both parties. This might be a one-off charge, or an agreement to amortise the cost of tooling across the lifetime of the project. A critical step is always to consider how the cost of both tooling and the overall project can best be reduced, while ensuring that part quality and delivery deadlines are unaffected. It is usually better to invest slightly more in the tooling if this significantly reduces part costs. This is especially relevant in high volume projects. For instance, although tooling for precision cold forming is more costly than that for conventional CNC machining, cold forming is usually more cost-effective: it is faster, uses less material, and produces a higher quality component that needs minimal postprocessing. As a result, part costs are lower, while less waste is generated and less energy used. Tooling may seem just one part of the manufacturing process, but approaching it in a measured, scientific way can reap huge benefits.
Powerful computer-aided design and modelling software has helped to streamline this process in recent years, while other software has helped to reduce tooling costs.
Managing misconception Tooling is usually considered an expensive process, but this is a misconception. Modern techniques have cut the cost of conventional tooling for CNC machining and precision cold forming. In the past, cost and time delays often occurred because tooling development was largely an iterative process – with improvements made through a series of prototype stages. While this methodology remains, software tools – such as SolidWorks and DEFORM – allow tool design, analysis and testing to be done on-screen rather than in the tool room, so the
Automation Update - 17
Verifying the Quality of Component Marking Marking, identification and traceability specialist Pryor’s Alastair Morris asks: are you doing enough to verify the quality of your marks?
M
achine readable codes contribute to the maintenance of part quality, allowing accurate, timely identification of parts that need to be diverted from the line. Once a part is with the end-user, these codes also simplify the tracking of failures and matching of genuine replacement parts, or help resolve warranty issues and liability claims. Most modern component marking standards use two-dimensional Data Matrix codes applied to the part using a variety of marking techniques. These marked codes are effectively error correctable, which means they can still be read even when damaged or partially obscured by dirt. Only by verifying the quality of the code straight after marking, do you know that you have the full redundancy available to you. Marking is regulated by certain standards, the terms of which demand some form of mark verification process which must be embedded into a manufacturer’s production and quality assurance operations. The simplest approach to verification involves machine reading, and while this matches the speed of modern high-speed production processes, it is subject to variations in lighting and the environment in the vicinity of the reader. Failure to ensure that product markings are fully compliant with established standards creates two kinds of problems: customer rejected parts if noncompliance is detected and the likelihood that poor quality marks will become completely unreadable following even minor levels of degradation en route from part supplier to customer. Pryor offers a solution to these verification challenges in the form of a dedicated verification system called VeriSmart 2.0, which can be integrated with the marking equipment, or located at 18 - Automation Update
some suitable point on the production line. VeriSmart operates on a similar principle to conventional code reading systems, but instead of a dot matrix reader they use a high resolution imaging camera in combination with a controllable lighting arrangement. In addition to checking that the correct data has been marked on the part, these systems also ensure that the size, shape and position of the code dots are compliant with the standards. And they can do all that within the cycle time of a machine operating at speeds of up to two parts per second. Today’s leading verification systems can also verify the quality of humanreadable codes, such as serial numbers or automotive VIN codes. The latest
systems can be fully integrated with a manufacturer’s ERP or MES system, checking each marked character against manufacturing records and providing an accurate quality score. VeriSmart 2.0 software can identify common marking issues such as shot peened dots becoming too large or too small relative the cell size of the mark, sending a request to an operator or controller to adjust the punch pressure accordingly - essentially condition monitoring for the marking equipment. So, while the modern verification system helps manufacturers to comply with marking standards, it also provides an excellent way to gain real time quality control over the marking equipment itself.
Fieldbus modules:
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more robust, more control Reliability needs reliable connections
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www.io-link.ifm ifm Telephone (020) 8213 1111
Profile Technology
Conveyor Technology
Linear Motion
Factory Equipment
Flexible modular solutions from mk! Compatible standard modules from mk simplify your production and maximise efficiency. Technology from mk provides the ideal solution for plant and special machinery engineering.
mk Profile Systems Limited a company of the mk Technology Group
Unit 2·Wolds Farm Business Park Kinoulton Lane·Kinoulton·Nottinghamshire, NG12 3EQ Phone +44 (0)1949 823751·Fax +44 (0)1949 81270 www.mkprofiles.co.uk·info@mkprofiles.co.uk