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THE SMART FACTORY: AN OVERVIEW Author: Milton D’SILVA

The smart factory is still a work in progress, but the building blocks are already in place. A report.

couple of years ago, a technocrat from a leading automation vendor, chatting on the side-lines of an industry event made an interesting observation. “A factory manufactures products, but that is not the purpose of the factory,” he said. “The purpose of a factory is to make profits.” Implicit in this assertion is the role technology plays in making those profits. It started with the very first Industrial Revolution in the mid-18th century powered by steam, and continues with the Industry 4.0, the fourth version – unleashed by the Internet and facilitated by cyber physical systems in the new millennium.

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Each of these revolutions brought in tremendous advantages in terms of transportation, telecommunications, access to raw materials, exploration of resources, etc., and led to large scale manufacturing of industrial and consumer goods, gadgets and appliances for everyday use. However, by now, most of these advantages have been exploited to the hilt, and production efficiency in some sectors has reached in the higher 90s in terms of percentage. Yet today, more than at any other time in human history, manufacturers are under constant pressure to produce higher quality products in lesser time at lower prices, and to suit individual requirements as well. With margins shrinking, the only way to squeeze profits is to further increase efficiencies, reduce errors, anticipate failure of equipment and eliminate breakdown altogether. Welcome to the Smart Factory era, made possible by the bouquet of emerging technologies now available to the industry in quest of still higher efficiencies.

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5G plays a central role in the Bosch vision for the factory of the future. Picture: Bosch

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ABB’s smart factory module demonstrated at Hannover Messe 2019. Picture: Hannover Messe

What exactly is a Smart Factory? In simple terms it is a place for smart manufacturing where machines, already automated to a great extent – and increasingly intelligent robots – are linked together by smart devices through the Industrial Internet of Things (IIoT). This in turn facilitates self-learning and adaption, improving the processes through advanced automation and selfoptimisation, with seamless end-to-end connectivity and data analytics. The resultant benefits are not just in terms of efficient production, but also the streamlining of all related functions like supply chain logistics and pre- and postproduction processes, to make it sustainable. The secret to unlocking this potential is hidden in the data generated by these processes. According to an IBM report, an average factory generates 1TB of production data each day, of which over 99% is not analysed. The information hidden in this data, the analysis of which is beyond human capabilities and needs technologies like artificial intelligence and machine learning, holds the key to greater operational efficiencies.

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The smart factory does not necessarily have to be built from scratch. Existing facilities can be transformed into smart factories, provided there are investments made to put a few things in place. These include a proper network infrastructure, smart controllers, analytics software with integrated information systems including IoT, cloud computing, Big Data and technology using artificial intelligence. Above all, this needs skilled manpower and the preparedness to adapt to new technologies.

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The smart factory is still a work in progress, but the building blocks are already in place. However, there are gaps to be filled – while Artificial Intelligence plays a key role in data analytics, 5G is the go to technology for connectivity – and a lot remains to be done in both these areas. So what is the status of the smart factory and its implementation from the perspective of the leading vendors of technologies for the smart factory? Presented here is a snapshot of 5 leading vendors and their technologies. ABB and its Ability A custom-made wristwatch assembled within three minutes. That is what ABB demonstrated at Hannover Messe 2019 at the smart factory module on display at its booth, using three of its key technologies – the YuMi collaborative robot performing precision assembly operations; the SuperTrak flexible transport system ensuring timely movement of parts; and the ABB Ability Connected Services monitoring health and performance. ABB launched the Ability™ technology platform in 2017, bringing together a number of its digital products, solutions and services under one umbrella. The ABB Ability platform today offers more than 220 digital solutions, which enable enterprises to increase productivity and improve safety at lower costs. The ABB factory at Heidelberg in Germany is a classic example of a smart factory, a showcase of ABB’s cutting edge technology as well as manufacturing prowess. One of the oldest plants of the ABB group, it manufactures miniature circuit breakers (MCBs), a common but critical safety device used in electrical installations, available in many different variants. The MCB effectively breaks the circuit in case of overload and other faults, protecting the installation from fire and damage. The Heidelberg plant is a demonstrator for smart manufacturing – of how the

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factory of tomorrow looks like. It is equipped with seven types of ABB robots, all interconnected on the ABB Ability platform, the digitalisation increasing their productivity. The transformation has increased the plant efficiency to handle 3 times as many product variants as before, adding to a whopping 6000 variants now, also improving quality of the products. Predictive maintenance practices have led to accurate delivery schedules and better in-plant material handling. The Ability platform leverages intelligence gathered from ABB’s vast global installed base of over 70 million connected devices and 70,000 control systems. This not only helps customers optimise operations, but ABB also uses the insights to develop new business models. Bosch goes beyond Mobility Bosch, the renowned provider of vehicle technologies and mobility solutions, now offers Industry 4.0 technologies for smart factories. With the focus on automation, digitalisation,

Bosch’s Blaichach plant in Germany, specialised in manufacturing ABS and ESP systems for automobiles, is a smart factory working on the Nexeed platform. This brings all the benefits of the connected plant for both new and existing machinery, as Nexeed is an open system, where it is easy to retrofit IoT devices on legacy production lines. The Blaichach plant employs 3000 associates as Bosch calls them, and produce 6.7 million ABS/ESP safety systems. The transformation has made it possible for Bosch to increase productivity at its ABS/ESP manufacturing facilities worldwide by almost 24 per cent.

Bosch smart factory working on the Nexeed platform. Picture: Bosch

For Bosch, these initiatives of integrating Industry 4.0 technologies in the smart factory is paying off with the company having earned more than Euro 1.5 billion with Industry 4.0 applications in the last 5 years. By 2022, Bosch has ambitious plans to generate annual sales of over a billion euros with Industry 4.0.

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AI and IoT, the idea is to boost productivity, quality and safety. As a leading user and provider of Industry 4.0 solutions, Bosch follows the ’3S’ strategy – using sensors, software and services. These are channelised through its software platform Nexeed, on which reside a variety of ’Source-Make-Deliver’ solutions for continuous optimisation – from procurement (source) through production (make) to the end customer (deliver). Nexeed includes tools like predictive maintenance, cockpit charts, traceability and tracking solutions, manufacturing execution, maintenance support, autonomous transport systems, intralogistics – all connected. Nexeed is ideal for larger enterprises that have

deployed Industry 4.0 solutions, companies that have global production network and plants at multiple locations. But Bosch also offers solutions to SMEs in smaller packages, introducing to them the benefits of Industry 4.0, especially when they do not have in-house digital expertise.

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Rockwell Automation and The Connected Enterprise Rockwell Automation believes the world needs to become a smarter place and offers solutions to that end through The Connected Enterprise, where products become smarter, people become smarter, and their decisions become smarter. The 117-year-old company is a major provider of industrial automation and information technology products with global sales of USD 6.69 bn for 2019. The company conducts signature events like the annual Automation Fair in the US and the region specific TechED events at other global locations to connect with and educate customers about the latest developments in the field. The hardware offering of Rockwell Automation comprises thousands of Allen-Bradley products, the software comprises numerous software suites under the FactoryTalk banner. The Connected Enterprise is a platform that brings these smart solutions together for the benefit of discrete manufacturing as well as process industries, bringing them tangible benefits like faster time to market for manufactured products, improved asset utilisation, lower total cost of ownership, and more effective enterprise risk management. That these are all tried and tested solutions is borne out by the fact that Rockwell Automation uses them in its own manufacturing facilities as part of its digitalisation transformation journey. The Connected Enterprise, according to the company, is a five-step journey: identify a desired business outcome; get an outside perspective; assemble the team; implement a pilot program; and scale for expansion. For companies who adopt the platform for their digital transformation, the outcome, based on use cases, leads to: productivity increases of 4â&#x20AC;&#x201C;5% per year; waste reductions that result in hundreds of thousands of dollars in savings; faster time to market, which includes plants that become operational in weeks instead of months; quality improvements that result in defects being cut in half; and up to 98% on-time delivery.

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In 2017, Rockwell Automation opened its EMEA Customer Center for The Connected Enterprise in Karlsruhe, Germany, offering customers and visitors the opportunity to receive tailored advice on smart factory subjects combined with a 360-degree view of The Connected Enterprise.

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The Rockwell Automation EMEA Customer Center at Karlsruhe, Germany. Picture: Rockwell Automation

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Schneider Electric builds the EcoStruxure Schneider Electric, the leader in the digital transformation of energy management and automation, traces its origins to 1836. It is a European multinational company with operations in over 100 countries and 2019 revenue of Euro 27 billion. Since 1980, the company has grown phenomenally through a series of acquisitions, shedding its traditional steel business in favour of electricity and related technologies. Having reinvented itself for the digital era in the new millennium, the company launched its IoT enabled EcoStruxure platform for digital transformation, with sector specific suites covering not just industries, but also homes, buildings, data centres, energy and infrastructure. EcoStruxure for Industry is the Schneider Electric IIoT platform that is open, interoperable, and ready for smart manufacturing, at every level from Connected Products to Edge Control and Apps, Analytics and Services. It is the digital backbone connecting best-in-class operational technology (OT) solutions with the latest in IT technology to unlock trapped value in operations and leverage the true potential of the Internet of Things. With integrated software, it improves productivity, efficiency, sustainability, and cybersecurity for plants and machine builders. Benefits include up to 80% reduction in engineering costs and time; up to 75% savings in maintenance cost; and up to 50% reduction in carbon footprint. Schneider Electric executives often say ’we eat our own food’, which means the smart technologies the company offers to the industry are implemented in its own plants first. The company has launched several Smart Factories around the globe in countries like France, USA, Mexico, China, India, Indonesia, and the Philippines. These are central to its Tailored Sustainable Connected 4.0 supply chain digital transformation where it leverages digitisation across its supply chain operations to deliver end-to-end integration and visibility to enhance its performance. The World Economic Forum has designated the Schneider Electric facilities in Le Vaudreuil in France, and Batam in Indonesia, as Advanced 4th Industrial Revolution (4IR) Lighthouses. The company has set for itself a target of 100 smart factories for 2020, and the same technologies are available for any company looking for similar transformation.

The Schneider Electric smart factory at Le Vaudreuil in France. Picture: Schneider Electric

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Siemens and its MindSphere Established in 1847, Siemens is the German multinational corporation and the largest industrial manufacturing company in Europe with a global footprint, with 2019 revenue of around Euro 87 billion. With its main business verticals of Industry, Energy, Healthcare and Infrastructure, Siemens today has the domain expertise and digital knowhow to generate performance improvements across the entire value chain through digital transformation. This is achieved with its two main solutions: MindSphere – a cloud-based, open IoT operating system; and Digital Twin – the virtual representation of products and production. Launched in 2016, MindSphere today connects an estimated 1.3 million devices and more than 1,000 customers. Global automobile

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The Siemens Smart Factory at Amberg, Bavaria. Picture: Siemens

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giant Volkswagen uses MindSphere in its cloud network, connecting machinery and equipment at more than 120 of its plants. This data is used to improve productivity and efficiency across plants and production lines. What MindSphere does essentially are 4 things: connect assets and upload data to the cloud; collect, monitor, and analyse data in real-time; gain insights that improve efficiency and profitability; and take advantage of apps and solutions that solve real problems. Like other major vendors, Siemens too has an excellent example of the Smart Factory in its Amberg plant in Bavaria, which has deployed the MindSphere system as well as executed the digital twin. Spread over 100,000 sq.ft, the Amberg plant manufactures a mix of 1200 products, which means on an average there are 350 production changeovers per day! The plant produces 17 million Simatic components per year, and about 50 million items of process and product data are evaluated and used for optimisation! In the process of the smooth running of the plant, Siemens uses other ground-breaking technologies like artificial intelligence, machine learning and Industrial Edge computing. The results of the transformation are evident in the figures – a 13-fold rise in production since the plant started operations in 1989, without any additional manpower or expansion. Summing up According to a market research report on global smart factory industry posted by Reportlinker recently, the global market for Smart Factory is estimated at US$136.4 billion in the year 2020. This is projected to reach a revised size of US$218.4 billion by 2027. The expected additional value for manufacturing industry due to productivity gains in smart factories by 2023 is expected to be between US$1.5 to 2.2 trillion, according to the Capgemini Research Institute’s estimates, published in its report ’Smart factories @ scale’. This indicates the potential gains of smart factory for the manufacturing world. An important question that rises from these developments is the human role in the factory of the future with the spectre of massive unemployment caused by digitalisation. But Prof Martin Ruskowski, Chairman of the Executive Board at SmartFactory-KL, the manufacturer-independent demonstrator and research platform based in Germany, does not agree. According to him, “Humans will and must be able to change every decision made by a machine. We will retain responsibility for what happens in the production processes. Machines and artificial intelligence cannot and should not take this away!”

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DELTA CONTROLS, A DELTA GROUP COMPANY, WINS THE 2020 GLOBAL BUILDING AUTOMATION SYSTEMS COMPANY OF THE YEAR AWARD BY FROST & SULLIVAN Delta, a global leader in power and thermal management solutions, announced Delta Controls, Inc., a Delta Group company and provider of cutting-edge building automation systems, has won Frost & Sullivan’s 2020 Global Building Automation Systems Company of the Year Award.

he honor by the prestigious market research firm recognizes Delta Controls’ ability to provide superior value to worldwide customers with its industryleading technologies that offer a full suite of smart features and functionality, as well as with its best-in-class technical support. Delta Controls’ signature O3 Sensor Hub 2.0, an innovative system integrating multiple sensors and IoT interfaces to enable next-generation smart and energyefficient buildings, served as a key factor in receiving the Frost & Sullivan award. “Delta Controls exemplifies superior best practices in bestof-breed technology offerings and innovative solutions because it incorporates a convergence of technologies with a dedicated customer service partnership experience,” said Neha Tatikota, an industry analyst for energy and environment at Frost & Sullivan.

“Winning this award is a testament to the hard work, spirit and dedication that shines across our organization every day,” said John Nicholls, president of Delta Controls. “Our guiding philosophy is to ‘do it right,’ which fuels our ambition to develop only the most innovative solutions.” Surrey, Canada-based Delta Controls was acquired by Delta Electronics in 2016 to strengthen the company’s building automation capabilities and expand its portfolio of critical smart infrastructure solutions.

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Mr. Bill Lo, general manager of Delta’s Building Automation Business Group, said, “We are extremely proud of Delta Controls’ passion in always pushing the envelope. They are a tremendously valued part of Delta – enabling us to collectively create a more energy-efficient built environment for a smarter and greener future.”

as a highly cost-effective installation”. The hub utilizes sensor fusion technology for superior room control and to optimize occupant comfort. The ceiling-mounted device observes its environment and reports interior temperature, occupancy, humidity, lighting, heating and cooling – while serving as a connectivity platform for sensing air quality, ventilation, window contact and shade positions. It also supports multiple protocols that allow for integration with nearly any system, including native BACnet, MQTT and REST API for third-party integration and BLE API for custom app development.

https://deltacontrols.com/es

Frost & Sullivan called the IoT-enabled O3 Sensor Hub 2.0 “revolutionary,” before concluding “it is beneficial not just for building owners, managers, and occupants, but also accepted by architects, installers, and consultant community 27 | Industry EMEA | November 2020

CO N S U M E R E L E C T R O N I C S

MONTH’S PRODUCT

VIEWSONIC LAUNCHES NEW, ALL-IN-ONE DIRECT VIEW LED DISPLAYS WITH SIZES OF UP TO 216”

Elegant design, user-friendly, and seamless viewing experience.

iewSonic is introducing its latest All-in-One Direct View LED Displays, a brand-new addition to the large-size presentation display sector. Different from traditional LED displays, these new displays integrate display, image stitching, power supply, and control systems into one device that offers easy installation, operation, and maintenance. The elegant design of the All-in-One Direct View LED Display elevates the seamless viewing experience and easily merges with the surrounding environment in spaces such as lobbies, auditoriums, boardrooms, and conference rooms.

“As a leading visual solution provider, we are pioneering new trends in the LED projector and presentation display markets and moving the development of LED technology forward by achieving this new milestone in LED displays,” said Dean Tsai, the Head of the Projector & LED Display Business Unit of ViewSonic. “We created a whole new product category, and market sector with All-in-One Direct View LED Displays, which come in sizes of up to 216”. The complete product line-up delivers large-sized presentation displays for a wide array of usage scenarios and proves that we remain at the cutting edge of innovative applications in the display world.”

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Traditional large-size display solutions still have many limitations. LCD video walls have many LCD panels that are difficult to install, calibrate, and maintain. The panels are heavy with thick bezels, which can result in problematic image grids. Also, the size of a single LCD panel has a limitation of 98”. Although traditional LED displays constitute a significant improvement over LCD solutions and do not come with image grid issues, they still use separated systems for display, power supply, image stitching, and control, making them too large and difficult to maintain and operate.

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The brand-new ViewSonic All-in-One Direct View LED Display resolves all the pain points of traditional largesized displays by providing innovative LED technology and integrating different systems into one device. Moreover, it supports wireless presentation and can operate as a large interactive display through being coupled with ViewSonic’s ViewBoard or touch monitor. Overall, ViewSonic’s All-in-One Direct View LED Display delivers a fantastic visual experience, and harmoniously blends in with its surroundings due to its elegant design. Because of its all-in-one design, it features easy installation, operation, and maintenance with a low total cost of ownership in the long run.

User-Friendly For easy installation, operation, and maintenance, multiple pre-assembled and pre-calibrated panels eliminate the need for a complicated setup process. The pioneering modular design with wall mount or optional aluminum alloy floor stand allows for easy installation that is time and labor efficient: the installation can be completed by two people in just two hours. One power button provides easy operation, and there is a wide selection of instantly accessible I/O ports. The system supports swappable modules, control systems, and 100% full front-maintenance using an electric vacuum suction tool. www.viewsonicglobal.com

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Fantastic Visuals For the magnificent viewing experience, the All-in-One Direct View LED display is available in four different sizes—108”, 135”, 163”, and 216”. It has a stunning and vivid 120% Rec.709 wide color gamut and up to 600 nits of brightness with eight levels of adjustment. Therefore, users can fine tune the brightness based on the environment.

style. The super-slim bezel of only 10 mm provides an even more immersive viewing experience.

Elegant Design Achieving a natural and perfect merger with the surrounding environment, the ultra-thin and lightweight display features a thickness of only 35 mm. It’s as thin as a mural on a wall and blends in harmoniously with almost any interior design 27 | Industry EMEA | November 2020

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VIEWSONIC’S VIEWBOARD IFP70 SERIES RECEIVES MICROSOFT WINDOWS COLLABORATION DISPLAYS CERTIFICATION

ViewSonic announces that its ViewBoard IFP70 Interactive Display series has been certified by Microsoft as Windows Collaboration Displays (WCD).

mong displays certified by WCD, the IFP70 series is the only one with a display size up to 86 inches. The ViewBoard IFP70 series is certified as an ideal USB-C one-cable solution, offering a superior touch and writing experience, delivering high-quality video for conferencing, and is Microsoft Azure IoT-certified to make workspaces smarter.

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“The ViewBoard IFP70 series is ViewSonic’s line of collaboration solutions, which are specially designed to provide enterprises with easy-to-use, next-generation conferencing capabilities,” says Monica Sun, Director of the Large Format Display Business Unit at ViewSonic. “We are happy it was recognized by Microsoft as a certified Windows Collaboration Display and believe it will allow for advanced collaboration, and better work efficiency and productivity.”

Certified WCD solution for better efficiency and productivity The ViewBoard IFP70 series makes use of a single USB-C cable that supports A/V, data, Ethernet, and power delivery, ensuring that every meeting or presentation gets started quickly and without a hitch. Meanwhile, it offers Windows Ink functionality in Microsoft 365 to let users take better notes during meetings. Adjust the line thickness by varying pressure on the screen with the included all-in-one smart pen that works for not only annotation but also presentation. The ViewBoard IFP70 series is embedded with comprehensive conferencing features, including a wideangle camera lens, a six-array mic, and 2.1 stereo speakers. In addition, the ViewBoard has the ability to automatically switch between the functionality of an external PC and the IFP70 while running Microsoft Windows and video conferencing. Microsoft Azure IoT certification means the ViewBoard IFP70 series helps make the workspaces smarter through a myriad of capabilities including built-in sensors that detect and measure the attendees, room temperature, humidity, and ambient light. These insights provide office managers with

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the data they need to optimize workspaces for employees and to improve upon energy efficiency by detailing energy consumption and cost breakdowns. Beyond WCD - advanced Bring Your Own Device (BYOD) experience ViewSonic provides advanced wireless presentation display (WPD) tools to make presentations, meetings, and workshops more interactive and collaborative to unleash the power of BYOD. With myViewBoard Display even a firsttime user can share content from his or her device wirelessly without the need for dongles. In addition, the contentsharing app ViewBoard Cast provides complete sharing and collaboration functions to meet a variety of different meeting scenarios.

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In addition, myViewBoard Manager allows for efficient remote management of multiple displays in the same or in different offices. With Manager, IT administrators can power on/off, restart, and adjust the volume of their ViewSonic devices. Administrators now have the ability to control devices remotely and even display content and emergency broadcasts, all from a single dashboard. An added value to the WPD solution is that these can be grouped and remotely updated, making it even easier to install software on several groups of devices simultaneously. www.viewsonicglobal.com 27 | Industry EMEA | November 2020

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VIEWSONIC SMART LED PROJECTORS ARE THE GO-TO SOLUTION FOR BIG-SCREEN HOME ENTERTAINMENT

ViewSonic LED Projectors Grew 30% in the First Half of 2020.

iewSonic Corp., a leading global provider of visual solutions, announced its LED projector sales grew 30% in the first half 2020 (Note 1), which is a new milestone for ViewSonic in LED projection. ViewSonic entered the LED projector segment in 2017 and became one of the world’s top three LED projector brands within three years. It boasted the fastest growth amongst the top five brands in the overall projector market in 2019 and continued its strong sales performance in the first half of 2020 with year over year growth of 30%.

“LED technology has now progressed to a point where it is an ideal audiovisual solution for all the activities consumers partake in at home. ViewSonic’s mission is to deliver a feast for the senses at home,” said Dean Tsai, Head of Projector BU at ViewSonic. “As an innovator and leader in LED projector technology, ViewSonic is combining its advantages in LED know-how, and consumer insights to bring new smart LED projectors to market. We are focused on redefining lifestyleoriented, all-inclusive solutions, from mobile, outdoor, to home. We want to light the way for more people to enjoy a new flexible big-screen audio-visual experience in their daily lives.”

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ViewSonic LED projectors’ achievements can be attributed to the continued innovation of product development. ViewSonic began to focus on LED projector development three years ago when the technology had advanced to an ideal level, aiming to offer consumers a more versatile option. By combining great visuals and audio into a single, portable projector the M1 was born. Today ViewSonic provides a full line-up of smart LED projectors for a wide range of applications, including the flagship X series for premium home entertainment with enhanced smart functionality and the portable M series for an exciting on27 | Industry EMEA | November 2020

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the-move lifestyle, such as the featherlight, 300-gram M1 mini Plus smart pocket cinema projector. More than just a device, ViewSonic smart LED projectors are an audio-visual solution. ViewSonic smart LED projectors combine the latest audio-visual technologies with smart integrated functionality and can connect with mobile devices, home networks, and content services for a seamless viewing experience. Through four main features – audiovisual excellence, smart capabilities, user-centric design, and eco-friendliness, ViewSonic smart LED projectors are differentiated to deliver a new enhanced audio-visual experience for home entertainment.

Smart Capabilities The smart features include wireless content casting from users’ smart devices via 5GHz Wi-Fi, and intuitive touch control via their mobile devices as an alternative remote

User-Centric Design ViewSonic places emphasis on user-centric designs to offer consumers the perfect balance of form and functionality. By creating humanised, lifestyle-oriented products, ViewSonic has won iF Design Awards for three consecutive years from 2018 to 2020. Eco-Friendliness ViewSonic smart LED projectors are more eco-friendly alternatives to other projector types, free from the toxic mercury found in traditional projector lamps and consume significantly less power for improved efficiency. LEDs are also a more durable light source than traditional lamps, offering a lifespan of up to 30,000 hours. As a result, it reduces the total cost of ownership.

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Audiovisual Excellence ViewSonic smart LED projectors deliver true-to-life colours by proprietary Cinema SuperColor+ Technology with 125% Rec.709, and a new level of brightness with industry-leading second-generation LED technology. To complement their stunning visuals, all ViewSonic smart LED projectors incorporate professional audio customised by Harman Kardon or JBL. From hardware design to rounds of audio tuning, each projector has its own customisation to best fit each scenario.

control. Bluetooth connectivity allows users to broadcast audio from mobile devices with the projectors’ Harman Kardon speakers, or connect to external Bluetooth headphones to immerse yourself in big-screen fun. Convenient voice control via Amazon Alexa or Google Assistant, and USB Type-C connectivity offer a fun twist on streaming for direct projection from phones, tablets, or gaming consoles.

www.viewsonicglobal.com Note 1: Source: Futuresource Q2’ 20 World Projector Market Track. The market share is assessed by the sales volume. 27 | Industry EMEA | November 2020

ELECTRONICS

ELECTRONIC ASSEMBLIES WITHOUT PCBS

Laser direct structuring (LDS) is a special success story. For almost 20 years, it has been possible to apply electronic conductor paths directly onto plastic parts during series production.

DS enables the production of electronic assemblies with flexible geometric shapes. This process enables electronic products (such as smart phones, sensors or medical devices) to become even smaller and more powerful. Automated manufacturing processes also make this process more economically attractive.

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There is less and less space available for electronic assemblies, so solutions are needed which replace conventional printed circuit boards. LDS enables further miniaturisation and makes increasingly complex geometric designs possible. This is a stable and reliable process that has established itself in quality-critical sectors such as medical technology or safety-relevant components for the automotive industry.

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The LDS process enables three-dimensional assemblies Direct laser structuring enables 3D-MID (Mechatronic Integrated Devices) assemblies to be produced. When using 3D-MID, electronic components can be fitted directly onto a three-dimensional base body, without circuit boards or connecting cables. The base body is manufactured using an injection moulding process, whereby the thermoplastic material has a non-conductive, inorganic additive. The additives in the material are â&#x20AC;&#x153;activatedâ&#x20AC;? by direct laser structuring so that the plastic material can accommodate the electrical conductor paths. The laser beam writes the areas intended for the conductor paths and creates a microrough structure. The released metal particles form the nuclei for the subsequent chemical metallisation. In this way, the electrical conductor paths are applied to the areas marked by the laser. The other areas of the three-dimensional base body remain unchanged. The plastic component can then be assembled in standard SMD processes similar to a conventional PCB. It is also suitable for soldering in a reflow oven.

Laser Direct Structuring (LDS) - The structure of the conductor path is applied using the LDS process. LDS enables electronic assemblies to be made in flexible geometric shapes. Smart phones, hearing aids and smart watches are becoming smaller and more powerful thanks to this process.

Dirk Rettschlag HARTING AG - Project Manager & IE MID

Versatile application of laser technology HARTING 3D-MID AG is the largest supplier of 3D-MID components outside of Asia. HARTING uses highperformance laser systems for the LDS process, with three lasers working in parallel, each offset by 45 degrees. Thanks to an additional axis of rotation, components can be processed by the laser simultaneously from all sides (360 degrees). This technology enables flexible geometric shapes, such as reflector shells or LED lights, to be made. Despite the minimal conductor path thickness of 16 to 20 μm, the conductor paths are still suitable for demanding automotive components or for applications with currents up to 10 A – for example for heating coils in cameras which are used to prevent the optics from fogging up.

The production of prototypes using LDS is also easier compared to conventional processes. HARTING can produce the plastic base body using LDS-compatible material and 3D printing. Injection moulding can also be used with inexpensive prototype tools.

• The working area of the laser has been enlarged from 160 x 160 x 80 mm to 200 mm x 200 mm x 80 mm, thus enabling a higher packing density and the processing of even larger components. • The working speed of the laser can be doubled to 4 m/s by optimising the servo units and mirrors which guide the laser beam, thereby significantly reducing the processing time. • The improvement of the optics enables the use of a laser with a diameter of 100 μm and a laser with a fine focus of 50 μm for processing even smaller structures. HARTING is the only 3D-MID manufacturer in the world that has a laser system with three fine focus optics of 50 μm. Even smaller conductor path gaps can be achieved thanks to this fine focus laser. Thus, many conductor paths can be created on the same component and a higher packing density can be implemented. This is used for safety technology, among other things, because the closely spaced and intertwined conductors are capable of triggering safety alarms from even the smallest physical interference.

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Frequent changes during the electronics development phase or new components with modified dimensions can lead to costly adjustments during conventional PCB production. The laser layout, in contrast, can be adapted very flexibly by using the parameters of the laser’s control software. No changes in the injection moulding are required for this.

New trends in the LDS process Several aspects of LDS technology have been improved and further developed over the past few years.

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Dimensioning and positioning - Minimum distances between the conductor paths (a): 50 – 150 μm. Minimum width of the conductor paths (b): 50 – 150 μm. Radius (r): 0.2 mm

Advances in materials and economics Only specially selected thermoplastics are certified for the LDS process; these are available from stock. The process can be further improved with customer-specific adjustments to the plastic material: • HARTING uses a process which adds LDS additives to noncertified materials to make them MID-compatible. • Specific RAL or Pantone colours can be achieved with MID plastics by using colour pigments and special LDS additives. • By selecting suitable additives, special RF characteristics can also be implemented, depending on the frequency range.

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To further improve the cost-effectiveness of the manufacturing process, HARTING relies on automated robotic systems. The LDS laser system is equipped with a rotary indexing table so that a component can be inserted or removed while another component is still being processed. The in-feed and unloading procedures are automated by HARTING using robotics. This increases throughput and autonomy, while also enabling integration into automated production processes. An additional automation step is provided during the injection moulding process. Here, too, a robot takes over the removal of the injection moulded parts. 27 | Industry EMEA | November 2020

The use of robotics also improves the precise reproducibility of the processes and, thus, overall product quality. More growth for 3D-MID HARTING reports increased demand for MID projects and has further expanded the 3D-MID division by investing in machinery and by acquiring a competitor’s business. Innovative in-house products are also contributing to further growth. HARTING has developed a solution based on 3D-MID technology which replaces flexible PCBs with a component carrier. Instead of using a flex-PCB, the component carrier can be fitted directly with electronic components, thus saving up to two thirds of the cost. About HARTING 3D-MID www.harting.com/3D-MID

Component carrier - Electronic components â&#x20AC;&#x201C; such as LEDs, ICs, photodiodes and sensors â&#x20AC;&#x201C; can be attached directly onto the component carrier. The assembled component carriers can then be processed as standard SMD components.

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Security caps for payment terminals - The 3D-MID caps protect the electronics from unauthorized access both mechanically and electronically. A highly precise meandering structure detects every access, no matter how small, and consequently prevents theft.

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H VA C

CARRIER AQUASNAP® AIR-COOLED SCROLL CHILLER RANGE NOW AVAILABLE IN R-32 VERSION

The AquaSnap units are now available with R-32 refrigerant.

Carrier AquaSnap® scroll chiller range is now available with R-32 refrigerant, which improves performance and reduces direct greenhouse gas emissions by up to 80%, compared to the previous range using R-410A refrigerant.

he innovative air-cooled range meets requirements for the European F-Gas phase-down of HFC refrigerants and Ecodesign requirements for 2021. Carrier, a world leader in high-technology heating, airconditioning and refrigeration solutions, is a part of Carrier Global Corporation (NYSE: CARR), a leading global provider of innovative heating, ventilating and air-conditioning (HVAC), refrigeration, fire, security and building automation technologies.

Carrier selected R-32 refrigerant, which has a low global warming potential (GWP) of 675, for use in commercial scroll chiller ranges. R-32 has a GWP that is two thirds less than the GWP of the current R-410A version and this change, combined with a significant system refrigerant charge reduction – up to 30% – allows for an exceptional 80% reduction in direct greenhouse gas emissions. The AquaSnap range reaches an outstanding Seasonal Energy Efficiency Ratio (SEER12/7) of up to 5.33 and a Seasonal Coefficient of Performance (SCOP) of up to 3.77. The range covers capacities from 40 kW to 940 kW.

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“Carrier’s AquaSnap range with R-32 refrigerant allows our customers to anticipate compliance to Ecodesign 2021 requirements while supporting the next phase down steps of the European F-Gas regulation for HFC,” said Didier Genois, Vice President, Carrier HVAC-Commercial, Europe. “The range also provides customers with best-in-class performance in heating and cooling conditions.”

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The AquaSnap with R-32 refrigerant can meet the needs of a wide scope of applications. The range covers an extended operating map, up to 48 degrees Celsius outdoor air temperature, and features Carrier’s best-in class technologies for maximum efficiency in all conditions, including: • M ultiple scroll compressors able to match load requirements. • Brazed asymmetric plate heat exchangers with true dualcircuit design for high performance in both full- and partialload conditions. • Smart energy monitoring function providing real time capacity provided and energy consumption measurement. • Greenspeed® intelligence on premium versions: variablespeed fans and variable-speed pumps. www.carrier.com MORE INFORMATION

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I N T R A LO G I S T I C S

NEW “INTELLIGENT GUIDED VEHICLE” (IGV): AUTONOMOUS COUNTERBALANCED FORKLIFT IS GUIDED BY SWARM INTELLIGENCE

After the “ONE” comes the “OCF”: AGILOX expands their line of intelligent guided vehicles by introducing a new autonomous omnidirectional counterbalanced forklift, operating with swarm intelligence. In doing so, AGILOX has entered a new area of application: classic intralogistics in inbound/outbound warehousing and storage.

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ith the ONE, AGILOX’s ultralight, high-efficiency forklift product line, the company has reshaped the concept of AGVs. The fleets operate without a central control system, meaning the vehicles navigate the production facility or warehouse in a truly autonomous fashion. The exceptionally compact AGILOX IGVs organize their routes according to the decentralized principles of swarm intelligence, making them much more flexible than traditional AGVs. Additionally, programming or “teaching” the vehicles becomes significantly easier, while central software programs including maintenance, updates, etc. are rendered obsolete—an innovation that lowers operating costs.

AGILOX is now expanding its range of IGVs to include the OCF—an abbreviation for “Omnidirectional Counterbalanced Forklift”. While the ONE is equipped with a scissor lift to function as a load handling device (and thus transports the load within the vehicle contour), the OCF is designed according to the principles of the counterbalanced forklift. Hence, it can pick up pallets, lattice boxes, and other load carriers with a maximum weight of 1500 kg (3300 lbs), transport them to the destination, and set them down at a height of up to 1600 mm (63 in). AGILOX’s intelligent and cost-saving IGV concept opens up new application areas. While the ONE vehicles are mainly used for material supply in production, the OCF enables classic intralogistics tasks in incoming and outgoing goods, order picking and storage, as well as in production— provided that the transport is pallet-bound. Just like the ONE, the OCF uses an omnidirectional drive concept. It can therefore also drive sideways through narrow aisles, turn on the spot, and maneuver in the tightest of

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spaces. The same lithium-ion (LiFePO4) battery technology ensures short charging and long operating times - just three minutes of charging allows for up to one hour of operating time.

the first OCFs set to be delivered to customers in the first quarter of 2021. https://agilox.net/en

The IGV fleets can be connected to customer software systems (LVR, ERP, WMS, MES, etc.) via an open API interface. An optional IO box enables the integration of external infrastructure, such as rolling gates and stationary conveyor systems, in the intelligent control system. An analytics module provides the user with all relevant operating data and KPIs. Dipl.-Ing. (FH) Franz Humer, M.A. Co-Founder and CEO of AGILOX, notes “The OCF is a logical addition to round out our product portfolio. With it, we open up opportunities in storage and order picking technology, and thus, a large market in which the IGVs can showcase their advantages over both AGVs and man-operated forklifts.”

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The combined operation of the ONE and OCF in a “swarm” also provides a great advantage. For instance, while the smaller vehicles carry out delivery services to assembly workstations or tend to e-Kanban shelves, the OCF can, using the same control system and WiFi infrastructure, take over pallet transport. The OCF pilot series has already been successfully tested in Vorchdorf, Austria. Series production will begin shortly, with 27 | Industry EMEA | November 2020

I N T R A LO G I S T I C S

2200 SERIES MODULAR BELT CONVEYOR NOW BEING BUILT AT DORNER EUROPE’S JÜLICH, GERMANY, LOCATION; FASTER DELIVERY THROUGHOUT REGION Dorner GmbH continues product expansion by adding the 2200 Series Modular Belt Conveyor to its portfolio of conveyor platforms being manufactured in Jülich, Germany. Dorner (http:// www.dornerconveyors.com) is an industry leader in the design, application, manufacturing and integration of precision industrial and sanitary conveyor systems.

he 2200 Series Modular Belt is ideal for small to medium part handling within the automation, packaging, assembling, metalworking and general manufacturing industries. The conveyor comes with features and benefits that make it ideal for a variety of conveying applications, including: • Ladder-style, open-frame design that allows better airflow through the frame for cooling, water and chemical drainage applications • Sleek, narrow profile for positioning under machinery and in other tight spaces where other conveyors wouldn’t fit • Universal T-slot compatible with industry standard hardware for attaching accessories and guiding fast and simple

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The 2200 Series Modular Belt joins the 2200 Series LPZ as the second major conveyor platform this year being manufactured from Dorner’s Jülich, Germany, location. Now building three versions of the 2200 Series in Germany enables customers throughout Europe and the Middle East to take delivery of their equipment faster than ever before.

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Features and specifications of the 2200 Series Modular Belt conveyor include: • Loads up to 68 kg • Belt speeds up to 76 m/min • Belt widths: 76 mm to 610 mm • Conveyor lengths: 457 mm to 9,144 mm • Micro pitch (general purpose) belt option • Metalworking belt option • 12 mm diameter integral drive shaft • Fully encapsulated in frame belt return For more information on Dorner’s 2200 Series Modular Belt conveyors being manufactured in Germany, visit www.dornerconveyors.com Connect with Dorner on Facebook at https://www.facebook.com/Dornereurope/ Subscribe to Dorner on YouTube at https://www.youtube.com/channel/UCJbrRugp agWittxmW1lq5A Follow Dorner on LinkedIn at https://www.linkedin.com/company/dornergmbh/

SOFTING ENHANCES EDGECONNECTOR SIEMENS

edgeConnector Siemens supports innovative industrial edge solutions

Softing Industrial releases version v1.20 of edgeConnector Siemens. The software module is based on container technology and connects Siemens controllers with industrial IoT applications. In addition to SIMATIC S7-1200 and S7-1500, the new version also supports SIMATIC S7-300/400 controllers.

dgeConnector Siemens enables access to SIMATIC S71200 and S7-1500 data including optimized data blocks. Version v1.20 additionally supports SIMATIC S7300/400 controllers. Client applications have access to data via the interoperability standard OPC UA. The product can be configured locally via a built-in web interface, or remotely via a REST interface. It seamlessly integrates with Azure IoT Edge and AWS IoT Greengrass and is made available via online repositories such as Docker Hub.

edgeConnector Siemens can be tested for free. It is currently evaluated by customers in the automotive, aerospace and food & beverage industry. Further information can be found on the product website. https://data-intelligence.softing.com/products/edgeconnector-docker/datafeed-edgeconnector-siemens/ MORE INFORMATION

Users benefit from flexible deployment and ease of use which comes with virtualization and container technology. Valuable process and machine data are made available for innovative IoT applications without any changes to controller or automation network configuration. Advanced security features such as the management of access right for individual client applications increase the security of the entire solution.

“edgeConnector Siemens is the first strategic expansion of our dataFEED product family to include virtualization and container technology”, says Wolfgang Wende, Senior VP Sales at Softing Industrial. It leverages Softing’s extensive experience with brownfield connectivity and OPC UA technology and makes it available for new and highly efficient IoT solution architectures.”

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SEEQ CLOSES SERIES B FUNDING AND ADDS CISCO INVESTMENTS AS NEW INVESTOR AS GROWTH ACCELERATES

Cisco Investments joins Saudi Aramco Energy Ventures, Altira Group, Chevron Technology Ventures, and Next47 to fund Seeq product and market expansion.

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eeq Corporation, a leader in manufacturing and Industrial Internet of Things (IIoT) advanced analytics software, announced today that is has closed its Series B expansion with an investment from Cisco Investments, as well as existing investors. Renewed participation comes from Saudi Aramco Energy Ventures, Altira Group, Chevron Technology Ventures, Second Avenue Partners, Next47, the venture group for Siemens Inc, and other existing investors. This round of investment will enable Seeq to further the growth of its business which was recently recognized by Inc Magazine as #261 on their 2020 list of the Fastest Growing Companies, an improvement from 2019 when Seeq was ranked #369.

Seeq enables engineers and scientists in process manufacturing organizations to rapidly analyze, predict, collaborate, and share insights to improve production outcomes. Seeq customers include companies in the oil and gas, pharmaceutical, chemical, energy, mining, food and beverage, and other process industries. This funding will accelerate Seeq’s expansion of development, sales and marketing resources, and help increase the company’s presence in international markets. “We are pleased to close our Series B funding efforts with the support of Cisco to enable manufacturing organizations to make data-driven decisions,” says Steve Sliwa, CEO and co-founder of Seeq. “With Seeq, ‘data rich but information poor’ is in the past as customers can spend 80 or 90 percent of their time delivering business value instead of in data access, preparation, and calculations.” “Cisco Investments is excited to support Seeq in their journey to bring advanced data science capabilities to customers to accelerate operational and business outcomes,” said Amit Chaturvedy, senior director, Corporate Development and Cisco Investments. “Seeq’s strong value proposition for the

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NEWS

industrial market aligns well with Cisco’s focus on IoT and digital transformation of businesses.” Upon closing, the Series B expansion for Seeq will increase capitalization by approximately $30 million, which is in addition to previous Series B funding led by Altira Group and Saudi Aramco Energy Ventures, bringing the total investment in Seeq since its inception to approximately $65 million. Seeq’s comprehensive set of applications for analyzing and sharing insights on process manufacturing data includes Workbench for easy to use advanced analytics, Organizer for publishing reports and dashboards, and Data Lab for accessing Python libraries.

On Azure, Seeq has been available in the Azure Marketplace since 2018 and was recently recognized as a 2020 Microsoft Energy Partner of the Year Finalist. Support for Azure services includes Azure Synapse, Azure Data Lake, Azure Data Explorer, Azure Time Series Insights, Azure Notebooks for machine learning integration, and Power Automate. In addition to cloud partnerships, Seeq connects to an extensive set of automation vendor data storage platforms for on premise engagements including OSIsoft, Siemens, GE, Honeywell, Emerson Automation Solutions, Inductive Automation, AVEVA, AspenTech, Yokogawa, and others. www.seeq.com

Seeq is available worldwide through a global partner network of system integrators, which provides training and resale support for Seeq in over 40 countries, in addition to its direct sales organization in North America and Europe. MORE INFORMATION

Seeq’s rapid growth is being fueled in part by its partnerships and commitment to cloud-based computing. Seeq is available in the AWS marketplace, is an AWS Industrial Competency Partner, and supports many data storage services, including Amazon Redshift, S3, plus machine learning in SageMaker, and other services.

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VOLKSWAGEN INTEGRATES NEWEST EPLAN AND RITTAL SOLUTIONS

Andreas Bamberg: “The additional 3D functionality from Eplan Pro Panel makes it possible to directly derive manufacturing information for automated control cabinet and switchgear system engineering,” says Eplan Strategic Account Manager Andreas Bamberg.

Markus Hülsmann: Global Key Account Manager Automotive Markus Hülsmann at Rittal says: “The current release of the VASS V6 library delivers fully integrated reference control cabinets in 3D based on the new Rittal VX25 control cabinet system.”

VASS Standard: now expanded with 3D functionality and state-of-the-art control cabinet technology.

olkswagen has recently released the sixth generation of its VASS (Volkswagen Audi Seat Skoda) Standard, which includes an update to Eplan Version 2.9. The standard – used in production plants for models on the MEB platform – has also been expanded with 3D functionality in switchgear system engineering and with data for bidirectional exchange with PLC project planning tools. The new VX25 control cabinet system from Rittal has additionally been integrated into the standard.

Volkswagen’s decision to start providing its suppliers with 3D data based on Eplan Pro Panel in the VASS standard libraries means that the complete digital twins of control cabinets and the installed components can be depicted. Previously, only 2D representations from Eplan Electric P8 were included in the standard. For suppliers, this creates the foundation for entering into and expanding automated manufacturing steps in control cabinet and switchgear system engineering: from mechanical NC machining to automated terminal assembly to wire processing and wiring support. Companies benefit from the fully developed design templates provided by Volkswagen that can be used as a basis for faster and higher-quality system engineering, manufacturing and commissioning.

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Uniform plant system documentation Eplan Strategic Account Manager Andreas Bamberg explains: “The additional 3D functionality from Eplan Pro Panel makes it possible to directly derive manufacturing information for automated control cabinet and switchgear system engineering. Engineering offices further benefit from the integrated collision check and thermal power dissipation considerations for components, enabling 27 | Industry EMEA | November 2020

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Daniel Gräser: “This expansion of the VASS Standard with the newest aspects of Eplan’s engineering software and Rittal’s state-of-the-art system technology means we’re ideally supporting our suppliers in realising digital and automated manufacturing processes,” says Daniel Gräser in the Division for Manufacturing Automation and Digital Production at Volkswagen.

optimised component placement in the cabinet and a more energy-efficient design for Rittal climate control systems.” An extra benefit: the addition of key control technology information to the device and project data enables completely bi-directional data exchange between Eplan (hardware engineering) and the Siemens TIA Portal (software project planning) using the AML interface. “This considerably reduces the efforts required in engineering and for system planning since the PLC hardware structures, pre-defined inputs and outputs and bus topologies can be imported directly from Eplan, not to mention the exact port wiring,” Bamberg says. During plant system operations and for later modifications or expansions, the information from TIA Portal can be fed back into the Eplan Project. This ensures uniform, error-free plant system documentation “as built” and shorter entry processes for integration into digital production management.

and Rittal’s state-of-the-art system technology means we’re ideally supporting our suppliers in realising digital and automated manufacturing processes. At the same time, we are also adding an important component along the path we’ve started towards the digital factory.” After all, the digital twin of the control cabinet as part of the production process is an essential foundation for fully digital operating and maintenance processes of the future. International service support Since 2018, Eplan has been offering a three-day VASS V6 Training for suppliers in English and German. It lays the international foundation for successful project planning according to this standard. Along with regular dates in Germany, initial trainings have also been conducted in the US and in China. www.eplan-software.com

State-of-the-art control cabinet technology Rittal, with its large control cabinets and small enclosures, has been a part of Volkswagen’s corporate standard for years, just like Eplan. As Global Key Account Manager Automotive Markus Hülsmann at Rittal says: “The current release of the VASS V6 library delivers fully integrated reference control cabinets in 3D based on the new Rittal VX25 control cabinet system.”It also includes fully integrated enclosure accessories and ten variants of the AirSTREAM mounting frame from the company Friedrich Lütze, which can be selected directly from a list of accessories and placed as a complete macro. Hülsmann continues, “This considerably reduces the work required in engineering since the components can start being placed directly in the cabinet after just a few clicks.” Future VASS releases will include libraries expansions with the Rittal AX and KS enclosures and the respective sample assemblies. Associated enclosure macros in 3D are already available in Eplan Data Portal and can be used when designing with Pro Panel.

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The goal: digital manufacturing Automobile production is becoming increasingly challenging, including ever shorter start-up times, individualised design efforts, new control technologies and high demands on maintenance and repair to name just a few. Volkswagen is diligently working on further developing automation standards, which are then passed down to the company’s suppliers. Daniel Gräser in the Division for Manufacturing Automation and Digital Production at Volkswagen says, “This expansion of the VASS Standard with the newest aspects of Eplan’s engineering software 27 | Industry EMEA | November 2020

MEASUREMENT

HOW THERMAL TECHNOLOGIES IMPROVE FACILITY SECURITY AND WORKFORCE SAFETY

Blind spots in surveillance coverage, incompatible video and access control systems, lack of adequate perimeter measures—these are common issues that facility directors must address with their security teams. At the end of the day, facility executives need technology that accomplish more with less— that expand situational awareness, overall system functionality, and real-time response capabilities while generating cost-savings.

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y leveraging technology like thermal imaging, this is possible. Security directors who want to improve facility management—specifically 24/7 monitoring for heightened security and elevated skin temperature frontline screening for entry control—should consider incorporating thermal cameras into their next security upgrade or new installation project.

Leveling Up your Security with Thermal By using thermal security cameras, facility directors can better protect their property and tenants from external threats. Backed by decades of successful deployment in the government and defense sector for reconnaissance, thermal imaging is a trusted technology. New innovations have expanded the use cases for thermal cameras and made them widely available to commercial and industrial facilities. Today, corporate offices, manufacturing plants and healthcare campuses all use thermal cameras as a core component of their security strategy. Thermal security cameras perform in adverse conditions where standard surveillance cameras cannot. Visual cameras require a light source, and thus, additional infrastructure, to produce an image. If there’s no light, there’s no video. Because thermal cameras measure infrared radiation, or heat, they do not need illumination to produce imagery. In fact, thermal cameras can see in total darkness as well

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as in rain, smoke, and light fog. They truly enable 24/7 surveillance. Further, thermal cameras yield high-contrast imagery, which not only enhances video analytics performance, but also situational awareness. For example, a security operator viewing a thermal camera feed can easily spot a trespasser attempting to camouflage in the foliage at night by alerting the operator of body heat on premise. Thermal cameras also enable alarm validation. While motion sensors, laser detectors and fiber optic cables need another technology to visually verify the alert, thermal cameras already provide this function. With onboard analytics, thermal cameras detect objects, classify whether itâ&#x20AC;&#x2122;s a human, animal or vehicle, and provide video clips for remote operators to assess the alert. Consequently, thermal cameras minimize unnecessary dispatch of guards or police for false positives, saving valuable time, money and resource for facilities.

Streamlining Entry Control with Temperature Screening Facility executives can also improve their access and entry control security procedures by using radiometric thermal cameras for temperature screening. COVID-19, classified as a global pandemic in March 2020, has permanently changed how facility directors build security and environmental, health and safety (EHS) plans. Now, facility directors are prioritizing protocols and technologies that minimize both the risk of exposure as well as the spread of infectious diseases among employees, visitors and contractors. Temperature checks have become one of the most widely adopted as a key component of frontline screening practices across facilities. In fact, General Motors plants and the Pentagon Visiting Center are notable examples of critical facilities deploying radiometric thermal cameras for skin temperature screening.

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In the event of a true alarm, thermal cameras enable superior suspect tracking. Upon receiving an intrusion alert, a long-range pan-tilt thermal camera can widely monitor the area and scan the property. The camera can then follow the movements of an intruder, and if equipped with both thermal and optical sensors, provide both thermal and color video of the person. With this data, a security officer can ascertain the threat level and determine whether the person is an employee who forgot their ID or an unauthorized person trespassing on private property. It is

important to note that thermal cameras cannot detect a specific individual or their personal information, rather they classify whether the object is a human and then further analysis is required through of the use of visual cameras for identification. For these reasons, facility directors, especially those managing large campuses or properties, should consider deploying thermal cameras to maximize their intrusion detection capabilities for stronger overall security.

Radiometric thermal cameras for skin temperature screenings allow for a non-contact, frontline diagnostic 27 | Industry EMEA | November 2020

tool that enables high throughput. These thermal cameras specifically measure skin surface temperature at the inner corner of the eye, the region medially adjacent to the inner canthus, which is known to be the best measurement spot. The most reliable thermal cameras yield accuracies of ±0.3 °C (0.5 °F) over a temperature measurement range of 15 °C to 45 °C (59 °F to 113 °F). Available in a handheld, tripod-mounted or fixed-mount form factor, elevated skin temperature thermal cameras are deployed inside entryways, immediately screening people as they walk into the facility. These cameras scan a person up to one to two meters (or three to six feet) away. Premium thermal cameras can scan individuals in two seconds or less. Thermal cameras are intended for use as an adjunct to clinical procedures in the screening of skin surface temperature. Upon detection of an elevated skin temperature, a person must then undergo a secondary screening where a medical device can determine whether the person has an actual fever or should partake in virus specific testing. By implementing these screening procedures, facility directors ensure a faster, non-invasive method to quickly detect possible signs of infection before an individual enters a populous area. This minimizes the risk of communal spread of viruses among employees in the workplace, which ultimately increases workforce health, safety and peace of mind.

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Today, a total security solution designed to detect both physical threats as well as environmental and health hazards is one that includes thermal cameras for elevated skin temperature screening. Facility managers can strengthen their risk management plans by proactively expanding their security systems to include these solutions. Many physical security solutions are already in place at key entry points as well as additional checkpoints, such as indoor surveillance cameras, visitor management and access control. Implementing screening stations with specific radiometric thermal cameras is a logical integration at these locations.

Choosing the Right Solution for your Facility While thermal cameras for perimeter protection and elevated skin temperature screening are valuable components to the overall security system, facility directors need to know that not all thermal is created equal. Thermal cameras need to be carefully researched and evaluated before deployment. Here are a few best practices for choosing the right thermal camera for your facility and application. 1. Define Your Application: A thermal camera made for long-range perimeter monitoring functions differently than a thermal camera built for elevated skin temperature screening. Make sure to choose a camera designed for your specific use case. 2. Know the Distinguishing Characteristics: Be aware of which technological features separate high-performing cameras from low-end options. For perimeter thermal cameras, resolution, detection range and integration capabilities matter. For elevated skin temperature screening cameras, resolution, sensitivity, accuracy and stability are critical. 3. Check for Certifications: Select a thermal camera with proven interoperability. Consider one that is ONVIFcompliant to ensure integration with the overall security system and chosen video management software. Additionally, for elevated skin temperature cameras, consider one that has a 510 (k) filing (K033967) with the U.S. Federal and Drug Administration as well as one that supports other screening standards such as ISO/TR 13154:2017 and IEC 80601-2-59:2017. 4. Work with Experienced Partners: Work with a system integrator who is knowledgeable in thermal. Choose thermal cameras from manufacturers with a solid track record of success for both security and elevated skin temperature screening deployments. Leverage guidebooks, site planning tools and online trainings that these experienced manufacturers have to offer to maximize performance. www.flir.com.br/instruments/public-safety/environmenthealth-and-safety/

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MEASUREMENT

COGNEX LAUNCHES NEW ITEM DETECTION SYSTEM 3D-A1000

Virtual showroom tour of new Customer Experience Center provides an exclusive glance on new and yet to be released solutions.

ognex Corporation, the leader in industrial machine vision, introduces the 3D-A1000 Item Detection System. A motion-capable smart camera, the 3DA1000 can identify the presence or absence of objects with unmatched accuracy on all types of sorters traveling at production line speeds. This product release extends the existing 3D-A1000 platform into new applications for helping retail and logistics customers reduce delivery errors, improve throughput, and increase fulfillment efficiency.

Unlike conventional methods, the 3D-A1000 uses patented 3D Symbolic Light technology to freeze motion with a single image. The system gathers precise 3D and 2D information without the need for an encoder, allowing detection of low contrast objects while avoiding tray hygiene issues. Embedded processing then uses Cognex vision tools to provide detailed inspections of trays and objects. The 3DA1000 is factory calibrated and can be installed in less than 15 minutes.

“As consumers increasingly expect reliable and fast delivery, retailers need to ensure the right products get to the right customers on time, every time”, said Carl Gerst, Cognex Senior Vice President. The 3D-A1000 Item Detection System is a powerful, turnkey solution for detailed inspections in sorting that hasn’t been available until now.”

www.cognex.com

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MEASUREMENT

FLIR INTRODUCES ELARA FR-345-EST FOR RAPID AND ACCURATE ELEVATED SKIN TEMPERATURE SCREENING

Features an Automatic On-Edge Guide to the Inner-Canthus for Improved Temperature Reading Accuracy and People Flow Through Screening Checkpoints.

s employees continue returning to the office, travelers start flying again, fans slowly return to stadiums, technology that focuses on maintaining health and safety in semi-public and private venues remains crucial to slowing the spread of COVID-19.

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In response, FLIR Systems today announced the FLIR Elara FR-345-EST, a fixed-mount radiometric thermal security camera that measures elevated skin temperature (EST) accurately without contact or the need for a reference temperature source. This system provides a safe and effective environment at high-traffic airports, stadiums, commercial buildings, and manufacturing facilities to quickly asses skin temperature at access control points. The Elara FR-345-EST automatically guides to the part of the body that most closely correlates to core body temperature: the inner-canthus—or the inner eye of a human face— without sacrificing accuracy or the ability to maintain social distancing guidelines.

The Elara FR-345-EST camera can serve as a stand-alone system without the need for desktop software or as part of a broader access control program designed to improve people flow for elevated skin temperature screening while simultaneously improving the accuracy of finding the inner-canthus, balancing the needs of personal safety and convenience. It also integrates with a variety of third-party video management systems (VMS), including FLIR United VMS, to enable fast integration within the existing security infrastructure to avoid adding risk to network IT security. Improved Speed and Accuracy Through the use of integrated algorithms and a convolutional neural network (CNN), as individuals pass through the screening process the interactive on-screen prompts assist with eyewear identification, proper pose, positioning, and head orientation. This enables the camera’s on-edge artificial intelligence to automatically locate and measure the temperature at the inner canthus within an accuracy of +/- 0.5°C (+/- 0.9°F). The improved AI capabilities with the on-camera software also improves the screening assessment time to an average of one-second-per-individual after the subject

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is in a stationary position in front of the camera and once eyewear has been removed, helping to keep lines of workers, spectators, guests, students and patients moving and to eliminate any potential crowding at checkpoints*. The self-screening operation provides instant go/no-go feedback and the adaptive alarm threshold feature can be used to minimize false alarms to account for natural body temperature fluctuations throughout the day.

*For the most accurate temperature readings, FLIR EST cameras detect heat and do not require any saving personally identifiable information during the screening process. **FLIR EST screening solutions should be considered as one component of a broader health and safety screening program. FLIR EST cameras are not medical devices and a second screening by a medical profession is always recommended.

The ElaraÂ FR-345-EST reduces setup time and calibration while improving real-time operator decision-making with on-edge analytics. Now the user has the ability to simply self-start by connecting the camera to a smart monitor with a web browser to view a live user interface. While the camera removes the need for a dedicated operator specific to EST frontline screening**, integrators, customers and their staff can still expect a seamless user experience.

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The camera can also be customized to meet specific integrator or customer needs. In addition, FLIR offers extended training and support for customers and users to properly setup, operate and maintain the system. The ElaraÂ FR-345-EST is available globally starting today through authorized dealers, with shipments expected to begin in Q4. www.flir.com/fr-345-est 27 | Industry EMEA | November 2020

MEASUREMENT

IDS EXTENDS ENSENSO N 3D CAMERA SERIES

Ensenso N40 et N45 : un poids réduit grâce au boîtier en plastique renforcé de fibres.

New design and improved electronics: Ensenso N40/N45 3D cameras are compact, lightweight and collaborative.

he Ensenso N-Series is a compact and robust 3D camera system designed specifically for 3D applications in robotics and automated series production. Thanks to IP65/67 protection, it is also wellsuited for use in harsher environments. The camera family is now being expanded by the new N40 and N45 models. They feature a novel design both inside and outside. Lightweight and with rounded edges, they open up new application possibilities, for example in collaborative robotics.

The housing of the new Ensenso N40/N45 3D cameras is made of fibre-reinforced plastic – resulting in the lightest stereo vision cameras with Gigabit Ethernet in the IDS product range. When mounted on a robot arm, for example, this means less stress on the robot mechanics. The cameras also minimise the risk of injury thanks to their rounded edges. As a result, they also excel in collaborative use with human colleagues. Furthermore, the housing meets the requirements of protection class IP65/67 and is effectively protected against dirt, dust and water spray.

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Electronics have also been revised for the new 3D cameras: The improved infrared projector enables higher light output and has an optimised heat management. This results, among other things, in better data quality or higher clock rates. The projector is optionally available with blue illumination in the visible range (465 nm) or with infrared illumination (850 nm). The new models each include two monochrome CMOS sensors (global shutter, 1280 x 1024 pixels) and are equipped with screwable GPIO connectors for trigger and flash. Power-over-Ethernet allows data transfer and power supply to be realised even over long cable distances. The 27 | Industry EMEA | November 2020

NEWS

Ensenso selector on the IDS website helps customers to choose the right camera model. A new stereo matching process, which is available as standard for all models when using the Ensenso SDK 3.0, also ensures particularly detailed point clouds. “PatchMatch” works extremely effectively with a large distance range at different object distances and without significant effects on the execution speed of the algorithm. This benefits, for example, applications in which large volumes are to be captured in the shortest possible time. https://en.ids-imaging.com/ensenso-3d-camera-n-series. html

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27 | Industry EMEA | November 2020

MEASUREMENT

IDS TO OFFER 20.35 MP IMX541 SENSOR FROM THE PREGIUS S SERIES FROM SEPTEMBER

Fourth generation of Sony CMOS sensors - uEye SE sets new standards with Pregius S IDS Imaging Development Systems GmbH

Setting standards: uEye SE cameras with fourth-generation Sony Pregius sensor.

DS integrates the high-performance, extremely highresolution sensor IMX541 from the Pregius S series into the versatile uEye SE camera family. Thanks to its compact 1.1" format, the 20.35 MP CMOS sensor is compatible with C-mount lenses. The industrial cameras feature a practical USB3 Vision interface, deliver 20 fps and will be available from September either as board-level models or with a robust metal housing.

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Pregius S – the fourth generation of extremely powerful CMOS image sensors from Sony – makes BSI (“Back Side Illuminated”) technology available for the first time in global shutter sensors. The benefits are smaller pixels (only 2.74 µm, which allows a significantly higher pixel density), higher resolution and also improved quantum efficiency and sensitivity. The new camera models deliver outstanding image quality that leaves nothing to be desired even in demanding machine vision applications such as surface inspections, detailed image evaluation in medical technology or use in the traffic sector. Anyone who values high-resolution images – for example to detect even the smallest material defects – will hardly be able to overlook these sensors in the future.

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The compact industrial cameras are therefore also a sensible alternative to cameras with similar high-resolution, but large-format sensors, for which F-mount lenses are usually required. With the uEye SE models, C-mount lenses can be used – which means considerable cost savings. Thanks to the USB3 Vision interface, the cameras are also uncompromisingly Vision Standards-compliant and can therefore be used comfortably with IDS peak, for example. The free SDK is characterized by an easy-to-use programming interface developed by IDS. Users no longer need to work directly with GenTL and GenAPI. Convenience classes help to reduce programming effort and thus minimize potential sources of error. https://en.ids-imaging.com/news-article/ueye-se-sonyimx541.html

MECHANICS

SAVE TIME AND BOOST PRODUCTIVITY WITH THE NEW SECO ASSISTANT APP BY SECO TOOLS

Seco Assistant puts the product information and tools you really need at your fingertips without the need for internet searches or catalog research, even when you are offline.

eco Assistant’s machining calculator gives you turning, milling and holemaking data for any brand including feeds, speeds and material removal rates. The Tool Comparison function gives you Seco tool recommendations and alternatives to other manufacturers’ inserts, while the Suggest function helps you find the right tooling option and cutting strategies for specific jobs. You can search for products by item, number, designation or grade or simply scan the code on the packaging.

The app is developed for maximum convenience and ease of use, with a small download size and a clean, clear interface. Crucially, if you don’t have an internet connection you can also search for Seco products or use the data calculators offline. Seco Assistant streamlines the daily machining experience, combining vital information and tools with the smoothest of user experiences. With easy to navigate practical tools, it puts the information you really need at your fingertips. Scan the QR-code or go to your app store to download Seco Assistant. www.secotools.com MORE INFORMATION

27 | Industry EMEA | November 2020

NEWS

NEW-GENERATION BULLET TRAIN RELIES ON NSK BEARINGS

The NSK cylindrical roller bearings used on the small gears (left) and large gears (right) in the N700S gearbox provide longer life and reduced maintenance requirements.

High-performance bearings from NSK are now operational in the newly developed N700S Shinkansen (bullet train), which from 1 July 2020 began service on the Tokaido Shinkansen line between Tokyo and Osaka. The N700S marks the start of a new era, being the first completely new Shinkansen design from the Central Japan Railway Company in 13 years. NSK bearings underpin the train’s no-compromise focus on safety, stability, comfort and environmental performance.

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earings for railway applications contribute directly to safe operation and travel. High reliability is key, as is the ability to support elevated speeds, improved energy efficiency and reduced maintenance requirements. The demands placed on railway bearings are especially apparent in bullet trains, which transport large numbers of passengers at high speeds over long distances. Applications of this type call for highly efficient and durable bearings, along with meticulous quality control in all production processes.

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The ’S’ suffix of the new-generation N700S bullet train stands for “Supreme”, signifying the progression in design, technology and comfort. High-performance bearings from NSK can be found in the gearbox, axle and traction motor assemblies. Regarding the gearbox, the N700S is the first Shinkansen to replace helical gears with herringbone gears, which offer increased reliability and lower noise output. Gearbox bearings are subject to intense shocks and vibration, so exhibiting a long operational life under these conditions is a priority. NSK has been supplying tapered roller bearings for helical gears in bullet trains for decades. Drawing on this experience, the company has designed a special flanged cylindrical roller bearing for the N700S’s herringbone gears that delivers longer life, lower heat generation and reduced maintenance compared with the previous generation product.

NEWS Positions of NSK cylindrical roller bearings for small gear (1) and large gear (2) on the new herringbone gear type (right) - as compared with a conventional helical gear (left)

Further benefits of the gearbox bearings used on the N700S include improved seizure resistance, which has been achieved by optimising the design of areas that do not contact the flange face. In addition, a high-strength machined brass cage optimised with NSKâ&#x20AC;&#x2122;s proprietary R-pocket technology reduces internal stress in the cage structure.

sectors help create products that bring about notable advances in this important industry. www.nskeurope.com

For the axles, the NSK double-row tapered roller bearings used in the previous Shinkansen have been further improved to deliver even higher reliability and reduce maintenance costs. Lower heat generation leading to longer life is a particular attribute. Concerning the N700Sâ&#x20AC;&#x2122;s traction motors, NSK cylindrical roller bearings and deep groove ball bearings feature outer rings that are plasma-sprayed with a ceramic coating. This coating increases reliability by preventing any opportunity for electrolytic corrosion, an unwanted effect that occurs due to the transfer of electrical current through the inside of uninsulated bearings. MORE INFORMATION

NSK has been supporting the advancement of the global railway industry since the company first became involved with the sector in 1932. Bearings from NSK are trusted for their world-class safety, high-speed performance, high reliability and efficiency. Today, the companyâ&#x20AC;&#x2122;s products are used by high-speed rail operators throughout Europe. Close ties with partners in the European OEM and aftermarket 27 | Industry EMEA | November 2020

PLANT SAFETY

HOW CAN A RADIO CONTROLLED FIRE DOOR SYSTEM HELP YOUR FLAT OR RESIDENTIAL BUILDING COMPLY WITH THE FIRE SAFETY BILL 2020?

Currently progressing its way through Parliament, the Fire Safety Bill 2020 proposes fundamental changes to the Regulatory Reform (Fire Safety) Order 2005.

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he changes will action the recommendations identified by the Grenfell Tower public inquiry and the Dame Judith Hackett review which found current building and fire safety regulations needed a “major reform” in order to prioritise and protect resident’s safety. In conjunction with the Building Safety Bill, which overhauls legislation around building construction methods and materials, the Fire Safety Reform represents a landmark change to current fire safety legislation. Lord Greenhalgh, Building Safety and Fire Minister, said: “These are the biggest changes to building safety legislation for nearly 40 years, and they will raise standards across the industry and ensure building owners have nowhere to hide if they break the rules”.

The reform will provide clearer accountability to those responsible for high rise buildings, increase sanctions to deter non-compliance and amplify the voices of residents raising concerns. Read the Draft Building Safety Bill: www.gov.uk/ government/publications/draft-building-safety-bill

What does the Fire Safety Bill 2020 mean for fire door safety? The bill will impact any managed residential blocks in England, Wales and Northern Ireland where the main use of the building is sleeping, such as; blocks of flats, student accommodation, hotels and hostels. Buildings will be required to identify an “accountable person” in each premises who will be responsible for the implementation of fire safety measures. These measures are likely to include carrying out risk assessments, ensuring fire-fighting and fire-detection equipment is supplied and establishing fire safety drills and emergency routes. In additional to this, the “accountable person” will also be

27 | Industry EMEA | November 2020

make heavy fire doors cumbersome, presenting significant obstacles to the young, elderly or disabled. In residential settings, such as student accommodation or care homes where isolation, access or ventilation can be a problem, residents often risk fire door integrity by using wedges to prop open bedroom and flat entrance doors. Wedging open of a fire door prevents it from functioning effectively; risking lives, prosecutions, significant fines and voided insurance policies. A BS EN1155 standard hold-open, free-swing door closer removes many of the risks associated with standard self-closing devices ensuring that heavy fire doors feel lightweight, easy to move and can be held open at any angle whilst closing in the event of a fire. The BS 7273-4:2015 code of practice specifically relates to the operation of fire protection measures and the actuation of release mechanisms for doors. There are three actuation types for door devices in different settings; critical, standard and indirect. Critical actuation (Category A) is the highest level of protection available, ensuring that self-closing devices are fail-safe to any potential fault and can actuate within two minutes of power failure. Category A devices are required when holding open any fire door which forms part of the stair enclosure in a residential building. From November 2020, flat entrance fire doors will also be required to use Category A devices. Which radio-controlled systems comply with Category A of BS7273 -4? Salamander offers the only wire-free system of radio controlled fire door holders and closers which complies with Category A of BS7273-4.

responsible for carrying out and keeping record of regular inspections of flat entrance fire doors, as well any doors adjacent to common areas or escape routes from multioccupied residential buildings. Previously the responsibility of non-communal fire doors was not a legal obligation of building owners or managers, who were able to satisfy legal requirements by asking residents to carry out their own inspection and reporting back any problems. The lack of clarity around responsibility for flat entrance fire doors often resulted in essential maintenance and repairs not being carried out. Why are fire doors important? Fire doors are an essential measure in preventing the spread of flames, smoke and toxic fumes should a fire occur. A fire door allows the fire to be compartmentalised, delaying the time it takes to spread from one area to another.

The Salamander door closer is suitable for most fire doors, holding them open at any desired position, while the Salamander door holder is designed for doors where standard closers are already in place. The system uses innovative, wire-free, magnetic technology to safely hold open fire doors and release them upon activation of the fire alarm. Currently, there is nothing to protect leaseholders and building owners from the cost of bringing existing buildings up to standard when the Fire Safety Bill 2020 is passed. As the wireless Salamander system can be retrofitted to existing buildings, it offers the same benefits as a hard-wired system whilst saving time, installation costs and disruption to a building’s fabric or occupants. MORE INFORMATION

A standard fire door should meet the FD30s standard, which provides up to 30 minutes of protection and should be fitted with a self-closing device. This not only protects the other areas within the building or block, but provides essential time for evacuation.

Each Salamander device connects wirelessly to a mainspowered controller unit, which is connected to the building’s existing fire alarm system. One controller unit can manage up to 99 fire door closers or fire door holders. All products in the Salamander range are battery-powered, wire-free and offer two-way communication between controller and device, allowing the “accountable person” to easily manage and oversee any faults within the building.

www.geofire.co.uk/salamander-radio-controlled-fire-doorsystem/

How can a radio controlled fire door system help? Building regulations dictate that fire doors must be fitted with a BS EN 1154: 1997 standard self-closing device in order to ensure fire doors “swing-shut” after use. These devices can 27 | Industry EMEA | November 2020

PLANT SAFETY

TECHNOLOGY REPORT

Leuze’s detection expert – the DRT 25C – reliably meets the high requirements of packaging machines for confectionery and baked goods with innovative reference technology.

One for everything - DRT 25C dynamic reference diffuse sensor with innovative CAT technology.

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ith the DRT 25C dynamic reference diffuse sensor, Leuze has brought a new operating principle to the market in the area of optical sensors. At the heart of the invention is the innovative CAT technology, which transforms a simple diffuse sensor into a highly intelligent device. This can be seen in the DRT 25C’s clever mode of operation: it is taught in on a reference surface at the press of a button which allows it to reliably detect nearly every object – independent of shape, color and surface structure. The reference surface can be a machine wall, a piece of sheet metal, or even a vibrating, moving conveyor belt. This makes the sensor particularly well suited for use in packaging systems, especially in the area of confectionery and baked goods. No readjustment is necessary when changing objects.

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Leuze developed its first optical sensor almost 60 years ago. Numerous technological milestones and innovations have followed since then. The more than 1,200 Sensor People worldwide view themselves as forerunners for their customers. Leuze has registered more than 200 patents in the last 10 years alone. This all with the goal of ensuring the lasting success of their customers in an industry that is ever evolving. Not only do the Sensor People have decades of experience but also in-depth application know-how in their specific focus industries. One of these is the packaging industry, which, with throughputs of several hundred thousand products per day and finely tuned process steps, places extremely high demands on the optical sensors. Clear-glass retro-reflective photoelectric sensors require less maintenance through smart tracking. Thanks to line-shaped light spots, laser diffuse sensors detect objects – no matter how complex – on their front edge. Extremely powerful through-beam photoelectric sensors detect the chocolate bar in its outer packaging with completely harmless infrared light. The intelligent CAT technology, which the new DRT 25C dynamic reference diffuse sensor uses, continues the idea of the clever sensor.

The DRT 25C reliably detects the front edges of the objects, ensuring smooth processes and no machine downtime. The wide scanning range detects all types of products, even those with complex geometries. From transparent to high-gloss: The reference technology enables the detection of packaging with a wide range of colors and transparency as a “deviation” from the conveyor belt surface.

CAT technology: Contrast Adaptive Teach This market requirement led to the development of the CAT technology at Leuze. CAT stands for Contrast Adaptive Teach. The underlying idea is simple: if the object can change at any

time, use its environment instead as a constant reference surface. In packaging systems, this is the conveyor belt. This serves as a teachable reference. Once the sensor has been taught the contrast information of the conveyor belt, it only needs to be intelligent enough to adapt this knowledge to a possible change of environment. This is precisely what CAT technology does. Operating principle of dynamic reference diffuse sensors The new DRT 25C dynamic reference diffuse sensor uses the CAT technology in a new operating principle: it learns the signal parameters of the conveyor belt at the press of a button and stores them as the “standard zero.” Every object that is transported on the conveyor belt now generates a signal. If this deviates from the zero state, the DRT 25C reliably detects the object as a “deviation from the reference.” The performance of the device is optimized through the choice of teach level. There is, for example, a teach routine

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Our goal: detection on a running conveyor belt Packaging and the objects to be packaged vary widely in color, shape and surface structure: flat, glossy, transparent, with gaps or holes – the entire spectrum. As a result, they are not so easy to detect. However, that is the task of optical sensors in packaging systems. The challenge in object detection is in detecting as quickly and reliably as possible and ideally directly from above. At the same time, the working environment poses a challenge as well: the objects that are to be detected are usually on conveyor belts that move and vibrate and which may become soiled or wet. The sensor solutions currently on the market have so far only been able to perform this task to a limited extent. Thus, there was a need for precisely such an intelligent model.

27 | Industry EMEA | November 2020

PLANT SAFETY

The DRT 25C works with the conveyor belt surface as a dynamic reference for the detection of objects. This is how the sensor reliably detects all objects that do not correspond to the belt surface, even in the case of contamination and vibration of the conveyor belt.

The teach button is used to teach-in the belt surface during the initial setup of the sensor. This means no additional setup time is required when changing products or packaging materials.

for conveyor belts that become heavily soiled over time. Another teach level exists especially for the detection of very flat or even transparent objects. Once the sensor has been “taught,” no additional settings or readjustments are necessary. Not even if the object is changed, as the sensor operates together with the conveyor belt as a reference.

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Reliable detection increases the throughput If, for example, a chocolate bar is not reliably detected, a failure quickly occurs in the subsequent, precisely cycled packaging, which must then first be removed and cleaned. The more reliably the sensor detects the product, the less frequent unplanned maintenance needs to be performed. Herein lies the strength of the DRT 25C dynamic reference diffuse sensor, which operates reliably even with difficult shapes and surfaces. This increases the machine throughput, the production quantity and avoids downtime. Because no adjustment work needs to be performed on the sensor when changing products or changing the packaging materials, setup time is also reduced, further increasing output quantities. Up to now, a format change – such as from the classic 100 g bar of chocolate to a mini chocolate cube – meant that sensors had to be readjusted. However, because the DRT 25C uses the conveyor belt as a reference, this is no longer necessary. Even if the color, height or contour of the packaging changes, no settings need to be made at all on the dynamic reference diffuse sensor.

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The all-rounder based on CAT technology The DRT25C dynamic reference diffuse sensor represents a new operating principle that is based on the new intelligent CAT technology. It thereby sets new technological standards on the market and is another milestone in the innovation history of Leuze. Once again as forerunners, the Sensor People thereby precisely meet their customers’ requirements for reliable detection and make them successful in an industry that is ever evolving. After all, the success of their customers is their aspiration and goal. Reduced downtimes, increased machine throughput as well as higher production quantities, all with maximum flexibility without readjustment when changing objects – that means increased cost effectiveness for their customers. www.leuze.com/drt25c

S M A R T FA C TO R Y

EMERSON LAUNCHES UNIQUE HEAT STAKING TECHNOLOGY TO MEET GROWING DEMAND FOR COMPLEX PLASTIC PARTS

The Branson GPX platform, with its unique heat-staking technology, provides greater design freedom by enabling highquality joins and superior aesthetics in a range of challenging applications.

Branson™ GPX platform provides greater design freedom by enabling high-quality joins and superior aesthetics in a range of challenging applications

merson has introduced new heat staking technology designed to give manufacturers greater design freedom by enabling them to join more complex, delicate and sensitive components to plastic moldings. Using a unique pulse staking technology that optimizes the heat staking process, the Branson GPX platform produces high-quality joins, superior product aesthetics and energy savings in increasingly challenging applications.

The Branson GPX platform uses PulseStaker technology to provide instantaneous heating and cooling, with adjustable cycle times for optimized, low energy heat staking. The process creates no particulates or burn marks, and enables more delicate and sensitive parts, such as those with

The advanced technology is suitable for all heat staking applications, including those with thermoplastic materials and metalized coated parts. A wide range of heat staking tip designs, which can be adapted to meet any stake welding requirement, and the ability to stake multiple points simultaneously provide manufacturers with greater design freedom. “The automotive, electronics and medical industries require more complex, delicate and sensitive components to be joined to plastic moldings,” said Priyank Kishor, global product manager for Branson products at Emerson’s Automation Solutions business. “The unique heat staking process that the Branson GPX platform provides helps to meet this demand and offers manufacturers a broad range of benefits, such as superior product aesthetics and reduced energy use.”

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Electronics, automotive and medical device manufacturers must produce more creative designs to meet rapidly changing market demand. This has led to an increase in challenging heat staking applications involving parts with more complex 3D geometries, closely aligned features and fragile or heat-sensitive components, such as soldered components or sensors, and using a greater number of blended, glass-reinforced, chromed and metallicized plastics.

embedded electronics, to be joined with consistently highperformance finishes.

https://www.emerson.com/en-us/news/automation/20-09branson-gpx-platform 27 | Industry EMEA | November 2020

S M A R T FA C TO R Y

EWON DATAMAILBOX – REMOTE ACCESS TO MACHINE DATA JUST GOT A LOT EASIER!

HMS Networks now launches Ewon® DataMailbox, a secure freemium cloud-based solution allowing machine builders and factory owners to easily access data from their machines anywhere in the world. What is Ewon DataMailbox? DataMailbox is an online data buffer that enables easy retrieval of data from machines. It is a part of the Ewon Talk2M cloud service.

How it works The Ewon routers Cosy and Flexy connect to a remote machine and send data via Ethernet or cellular connection to the Talk2M cloud. The DataMailbox is a part of Talk2M allowing application developers to easily retrieve historical data from multiple Ewon gateways using a simple API call. The results Customers can collect data from multiple machines anywhere in the world in a highly secure process in order to analyze this data at their convenience. This allows for big data analytics and dashboards for predictive maintenance and operational intelligence.

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A fast and secure way to enable access to machine data It is possible to set up a data connection in a couple of hours, no matter how complex the IT environment is, and also scale up when necessary. Users can add machines to the process in a couple of clicks. With the DataMailbox as a data buffer, users will avoid losing data, no matter how many sites they are collecting from as 27 | Industry EMEA | November 2020

NEWS

data is automatically stored and forwarded if the internet connection is down. Users also always have access to a clean historical dataset for analytics applications. Freemium The DataMailbox is a freemium service within the Ewon Talk2M cloud, meaning that customers can utilize it for free for an unlimited time. By moving to the Pro version, customers get covered by a unique Service Level Agreement and can process even more data. The Freemium approach and ease of access in no way compromises the security as Ewon solutions are trendsetters in cybersecurity.

Available now via a network of partners To help customers maximize the power of their data, Ewon has established a robust ecosystem of 2000 experienced partners, ready to quickly create efficient and integrated solutions based upon customer needs. For more information, visit www.ewon.biz and the knowledge base articles at www.ewon.biz/support

By adding this innovative service to its range of hardware, Ewon proposes an easy and scalable integrated solution to collect and process data from an unlimited number of sites, allowing customers to increase their efficiency.

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“In a time when it is risky and expensive to allow people into factories, it is our duty to provide customers with an easy, secure and scalable solution to collect data from several sites, allowing users to improve their efficiency”, says Francis Vander Ghinst, General Manager of HMS’s Business Unit Ewon.

27 | Industry EMEA | November 2020

S M A R T FA C TO R Y

MOVING TO THE EDGE

Industrial companies face an ever-changing landscape of operational challenges. A process plant or manufacturing facility deals with a complex set of variables that can affect machine or production performance. As one problem or bottleneck is solved, another seems to appear. For many years, plant operations teams have been using DCS, PLC, SCADA and MES technology as the tools to improve automation, alarms, analysis and reporting. However, as automation approaches the machine level gaps still remain, leaving islands of information that could support improved business decision-making still inaccessible.

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he recent emergence of IndustryÂ 4.0 and advancements in electronic components have helped those traditional tool sets become a lot smarter by adding cloud connectivity, cybersecurity and distributed processing power, amongst other things. This new convergence of technology has created an opportunity when it comes to problem-solving functionality, operational insight and the implementation of new techniques, in an emerging industrial automation space called â&#x20AC;&#x153;the edgeâ&#x20AC;?.

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Edge computing Powerful computers have now merged with the CPU of a traditional industrial automation control system to provide 2-in-1 devices that are physically the size of a book. This means that the same device that controls your machine or process has an onboard, cloud-capable computer to provide new on-machine functionality. While control systems have historically been connected to computers, these were generally separate workstations or servers that were most likely located in an office far from the machine. This perpetuated the concept of an office IT network that is separate from the OT (operations technology) plant floor network. However, a combined computing and control device provides companies with

NEWS

new opportunities for storage, analysis, processing power and cloud connectivity right at the machine, or edge. Smarter control Companies with a computer running at the edge can benefit by controlling their machine or process in a smarter way. Traditional PLC/DCS have some limitations in programming languages, but a computer provides more powerful computing and processing functionality. Advanced algorithms can be processed on the computer side of the edge controller box and passed back to the realtime control system to provide an extra smart control loop. This enables a new form of advanced processing power in a tiny form factor.

Reduced complexity With a computer inside the edge-enabled controller box, companies donâ&#x20AC;&#x2122;t have to buy an external computer to see whatâ&#x20AC;&#x2122;s going on in a machine. Peripherals can simply be

Cloud connectivity Implementing a cloud strategy is no longer complex. Using an edge-enabled control system, the automation system on your machine can be easily connected to a cloud storage service in just a few minutes. This new generation of control products has taken away any mystery that existed in getting this done, so instead of thinking about how to connect, you can instead consider what to connect. The ability to connect a machine status to the outside world enables new business models through connectivity to remote fleet, corporate, expert or market data. Connecting machines and processes to the cloud offers companies a number of potential opportunities and benefits. For example, one of the easiest ways to identify an improvement opportunity is to compare similar assets from different locations and to benchmark their performance. An under-performing asset is easy to identify using basic KPIs, and raising its performance level can bring quick improvement.

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Simplified local data storage The computer side of the edge-enabled controller box enables a local data historian to be run for storage of the real-time data that is generated on the PLC side of the box. This provides the flexibility of local machine data that could be analysed right at the source or connected to a plant-wide historian server for centralised storage if that is preferred. Of course, local storage will help with better execution of machine learning and optimisation algorithms.

connected to the ports available on the controller box. Connecting a local display is as easy as plugging in a cable. This simplifies the computer requirements across the plant and gives users hardened industrial devices that provide maximum reliability. A single edge controller device can control a machine, connect to a cloud storage service, store data, run complex algorithms, get real-time visibility and provide a platform for real-time decision-making.

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NEWS

Daniel Coetzee, EMEA Commercial Director in Industrial Automation and Control Solutions, Emerson

Collecting data from sensors on a machine provides a long-term picture of its performance against the original design theory. Determining real-world failure modes and thresholds can then help to improve future designs and brings competitive advantages for the OEM. Sensor data can also be used to build a digital history of performance and machine health. Algorithms can then be developed that use real-time sensor data to create alerts for domain experts located anywhere in the world should performance deviate from optimum levels or equipment health degrade. Having self-diagnosed machine health or status, edge controllers can connect to a cloud solution that uses GPS and geofencing to alert an appropriately skilled technician closest to site to repair the problem as quickly as possible. Edge controllers can help to enhance multi-organisation collaboration, such as manufacturers and raw material suppliers. The opportunity to connect to third parties’ systems such as off-site supply chain systems, as well the onsite MES or ERP, provides an easy means of digital collaboration between different organisations, ensuring transparency and greater efficiency. As well as data being sent to the cloud, it can also be received. A cloud-based algorithm can collect data from multiple sites and use powerful centralised processing to run the master algorithm of the company. The result can send data to a controller that can improve production or reduce costs. An example of this could be a cloud algorithm checking live energy tariffs and sending a message to the controller to run pumps or motors when the energy price is low. By combining some of these functionalities, new business models emerge. OEMs can create new value for their customers by offering new types of service agreements. Raw material suppliers can differentiate themselves by accepting stricter contractual terms with their customers as a result of effective real-time business critical information. Automation system integrators can expand their businesses by offering new and differentiated cloud-based services. Industrial plant monitoring centres could become a new industry as more and more machines get connected. https://www.emerson.com/en-us/automation/controland-safety-systems/programmable-automation-controlsystems/edge-devices-software

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https://www.emerson.com/en-us/automation/controland-safety-systems/programmable-automation-controlsystems/programmable-automation-controllers

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Emerson’s PACSystems RX3i CPL410 Edge Controller provides real-time deterministic control, analysis and visualisation of data at the machine level and connectivity to the IT and cloud level.

S M A R T FA C TO R Y

ADVANTECH LAUNCHES SLIM AND POWERFUL DS-082 4K DIGITAL SIGNAGE PLAYER Advantech a global leader in providing embedded platforms across vertical markets, is excited to announce the launch of DS-082, the powerful yet slim 4K digital signage solution for four displays.

his powerful 4K signage system delivers a high-impact visual experience across multiple displays powered by AMD Ryzen V1000/R1000 processors and integrated with AMD VEGA Graphics. DS-082 comes in an ultra slim profile of just 19mm with fanless and cable-free design that allows for easy installation behind the displays while saving on space. It can simultaneously drive four/three UHD (4K)/ FHD (1080P) displays via HDMI; delivering seamless and smooth content flows across digital menu boards, selfordering systems, retail applications, queuing systems, and multi-media kiosks.

Remote Digital Signage Network Management Advantech DS-082 is integrated with both WISE-PaaS/ SignageCMS multimedia content management software and WISE-PaaS/DeviceOn remote device management software for easy signage network management. WISEPaaS/SignageCMS allows users to easily edit content layout, schedule, and dispatch programs. An up-to-date scheduling function is also available to allow real-time information and advertising campaign management. DS-082 incorporates WISE-PaaS/DeviceOn IoT device management software to monitor signage devices in real-time, make maintenance easier, and reduce the need for costly on-site support. Moreover, WISE-PaaS/DeviceOn provides a McAfee whitelist security function to ensure on-screen content is secured while Acronis tools recover essential data and make backups. As a result, DS-082 helps simplify digital signage network management while reducing total cost of ownership and time-to-market. MORE INFORMATION

High-Impact Visual Experience Across Multiple Displays Measuring only 19 mm in profile with a small 18 x 19 cm footprint, DS-082 is the world’s slimmest digital signage player powered by the latest AMD Ryzen V1000/R1000 processors supporting four display outputs in UHD/FHD resolutions. This thin and powerful signage player is sleek enough to fit in just about anywhere with the performance features necessary to deliver compelling dynamic graphics and video advertising in 4K resolution. DS-082 is designed to be fanless and cableless to ensure solid system reliability and easy maintenance. For secure installation mounting, DS-082 offers a bracket that supports wall mount, VESA, and DIN-rail mounting. In terms of cost/performance ratio, functionality, and connectivity, DS-082 provides an economical, super-

compact, and powerful computing platform that empowers all kinds of digital signage projects.

http://www.advantech.com/applied-computing-systems/ digital_signage/

27 | Industry EMEA | November 2020

S M A R T FA C TO R Y

AN INNOVATION WITH ADDED VALUE – THE PP20H PRESSURE SENSOR WITH IO-LINK WINS THE INNOVATIONS SHOWCASE AWARD

At the Process Expo in Chicago, a panel of experts from the food processing industry selected the PP20H pressure sensor as the winner of the Innovations Showcase Award in the dairy product category.

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he pressure sensor prevailed among the 17 finalists due to its condensate-resistant silicon measuring cell, exceptional precision across the entire temperature range, and IO-Link interface. “An IO-Link interface is the latest trend in the sector and we have incorporated this technology in our PP20H,” says Baschar Al Hammoud, product manager for pressure sensors. However, in true Baumer style, the company did not settle for that without offering its customers extra benefit – in addition to the digital IO-Link interface, the PP20H also offers an additional analog output. Baschar Al Hammoud explains, “With this combination, the PP20H offers users more flexibility than any other pressure sensor.”

27 | Industry EMEA | November 2020

This way, during commissioning of the sensor, users can benefit from all IO-Link advantages, which considerably simplify sensor parameterization while still allowing process control by the sensor via the 4 ... 20 mA analog output. Furthermore, the IO-Link makes it possible to call up additional process data such as the pressure of the measurement cell or the temperatures of the pressure sensor and the microchip in the central processing unit. Access to this information allows for interesting investigations: for example, whether an unusual temperature rise has occurred in a container, which may indicate a defect or faulty dosage of the ingredients in a tank. As high temperatures may decrease the service life of the sensor or other system components, this may indicate the need for preventive maintenance – one of the promises of Industry 4.0. Of course, the PP20H series offers all the advantages of IO-Link, such as quick parameterization during operation and prior to installation. Even more, a new sensor easily learns the parameters of the old sensor via the master and is immediately ready for operation upon installation. For Baschar Al Hammoud, this is only the first step: “We are planning additional functions based on IO-Link.”

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The PP20H also exceeds all standards also in terms of robustness. Its measurement cell is completely sealed even during relative pressure measurement. This prevents the entrance of warm and humid ambient air, which may precipitate with low process temperatures. This is the case, for example, in milk or ice cream processing. At the same time, the sensor must be somehow â&#x20AC;&#x153;openâ&#x20AC;? to the surroundings because the sensor will also determine the difference to the ambient temperature. The Baumer engineers devised a unique technical solution for this challenge â&#x20AC;&#x201C; they placed a barometric pressure sensor in the back of the housing that can measure the reference pressure of the environment via an opening. This way, the actual silicon measurement cell in the front remains hermetically sealed. The PP20H is therefore not only suitable for CIP (Clean in Place) and SIP (Sterilization in Place) processes, but also for sudden changes in process media temperatures. www.baumer.com/pp20h

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27 | Industry EMEA | November 2020