AUTOMATION & DRIVES
VOL 08 | APR-MAY 2015 www.AandD24.in
INDUSTRial INTERNET OF THINGS
Connectivity & collaboration FOCUS Chemical & process industry P. 46 MANAGEMENT Industry perspective P. 29
A&D - Interview Marc Jarrault WWW.AandD24.IN
Managing Director, LAPP India
(p.44)
In association with Advt
APR-MAY 2015 I VOLUME 08
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
A U T O M AT I O N & D R I V E S
Turning workplaces into safer places.
Safety for Man and Machine. Extensive product portfolio and customised solutions – certified and developed to global standards. Expertise stretching back 70 years. Safety products manufactured at Pune, India. From component manufacturer to industry oriented solution provider.
Safety light curtains
Safety switches
Magnetic sensors
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E-mail: siplmarketing@schmersal.com
Solenoid Interlock
Pull wire switches
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Turning workplaces into safer places.
Safety for Man and Machine. Extensive product portfolio and customised solutions – certified and developed to global standards. Expertise stretching back 70 years. Safety products manufactured at Pune, India. From component manufacturer to industry oriented solution provider.
Safety light curtains
Safety switches
Magnetic sensors
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E-mail: siplmarketing@schmersal.com
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Meistermacher. Made in Germany.
Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding.
German champion with Borussia Dortmund 2002 English champion with Arsenal London 2004
The first pro goalkeeper with headed goal qualities
© 2015 SCHUNK GmbH & Co. KG
Jens Lehmann, legendary German goalkeeper
Rainer Scholl, Master – Gripping System Components
The world’s first gripper with multi-tooth guidance PGN-plus, universal gripper from SCHUNK
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Intelligent Drivesystems, Worldwide Services
MAKING IN INDIA SINCE A DECADE – NORD DRIVESYSTEMS Q Reliable Q Versatile Q Global
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Q Strong bearings Q Low noise Q High corrosion protection
The
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Wide power range – Versatile system solutions – High system efficiency
www.nord.com NORD DRIVESYSTEMS Pvt.Ltd. 282/2, 283/2, plot no. 15, Village Mann, Taluka Mulshi Adj.Hinjewadi MIDC-II, Pune- 411057 Maharashtra INDIA Toll Free No. 1800 200 2042 India@nord.com, www.nord.com Member of the NORD DRIVESYSTEMS GROUP
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Automation for a Changing World
Delta Human Machine Interface DOP-B Series One Touch Gives You Limitless Possibilities Delta's HMI offers fast and convenient control of manufacturing automation through a user-friendly graphical interface. Products features rapid downloads and uploads, user-defined graphics libraries, a powerful ARM-based CPU, and flexible user-defined protocols. Thereby it meets customer needs, satisfies a variety of applications, provides multiple functions and creates the ultimate in FA equipment. Delta's extensive product offerings in Industrial Automation provides total solution for machine control and automation.
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For more information please mail us at automation@delta.co.in
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www.deltaelectronicsindia.com
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Unbeatable Control,
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Lowering cost, increasing productivity, and shortening design times are just some of the challenges industrial engineers face. The graphical system design approach combines productive software and reconfigurable I/O (RIO) hardware to help you meet these challenges. This off-the-shelf platform, customizable to solve any control and monitoring application, integrates motion, vision, and I/O with a single software development environment to build complex industrial systems faster.
NI LabVIEW system design software offers ultimate flexibility through FPGA programming, simplifies code reuse, and helps you program the way you think–graphically.
>> Accelerate your productivity at ni.com/industrial-control-platform NI Systems (India) Private Limited Phone: 1800 103 9449 (Toll Free) Email: ni.india@ni.com Š2012 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 07926
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E D I TO R I A L
‘Just enough’ information Industry is always in need of technological quantum leaps and frugal innovations, not just in products but also in processes, in order to generate sustainable growth. Sharpening the technological edge has become a key priority for manufacturing companies, and so is the case for, automation service providers, in order to fulfil varying customer demands. In this scenario, `just enough’ solutions for the right applications are called for, which ensure that skills are rightly & consistently adapted to the growing demands of technological progress and globalisation. Hence, the decisive challenge for economies, companies and educational institutes becomes achieving a knowledge-based lead so as to keep abreast of advanced technology developments. At this juncture, I am happy to present you the 7th Anniversary issue of A&D India, providing `just enough’ information, through an interesting mix of articles which talk on not just the technology developments but also the industry and market trends, management perspectives, new products, and also solutions to your problems. We would like to take this opportunity to thank our readers, advertisers and associates for their trust and confidence in the magazine. Their valuable support and acceptance of our product has given us the strength and this has made us bring out the magazine, issue after issue, bursting with positive energy. With this, we are now gearing up to give you the reassurance of our constant efforts to provide you with the apt information that will help you raise your competency level and stay ahead of the competition. Best wishes from all of us at A&D India!
HIGH PRECISION LASER SCANNER for profile and gap measurement Compact design with integral controller For high speed, high precision measurements Comprehensive software included Easy set up using predefined measurement programs Choice of interfaces for direct connection to PLC
EDITORIAL ADVISORY BOARD
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net
Vijay Srinivasan Partner, Effectus Consulting LLP Anup Wadhwa Director – AIA (Automation Industry Association) P V Sivaram MD – B&R Automation Member – AIA Anant Maheshwari President Honeywell India
Blue laser scanner for red-hot glowing and organic objects
Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Raj Singh Rathee Managing Director Kuka Robotics India
Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant
Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants
Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
A & D I n d i a | A p r- M a y 2 0 1 5
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Phone +91 20 267 410 09 www.micro-epsilon.in/scan 3
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CONTENTS
Market
Management
Focus
INDUSTRY PERSPECTIVE
08
NEWS
INDUSTRY PERSPECTIVE 30
12
Chemical & Process Industry
“AUTOMATION SYSTEMS ARE EVOLVING
“PRIME CHALLENGE FOR COPPER IS
CONTINUOUSLY�
SUBSTITUTION�
Interview with PV Sivaram, Managing Director, B&R Automation India
Interview with Sanjeev Ranjan, Managing Director, International Copper Association India
31
46
ADVANCED PROCESS CONTROL
An article on the various benefits derived by Advanced Process Control system to improve plant profitability & productivity
“INDIAN INDUSTRY IS MENTALLY READY WITH THE GLOBAL TREND�
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Interview with Deepak Aran, Director, Contrinex Automation India
“READY TO MOVE TOWARDS SMART MANUFACTURING‌â€?
Interview with Simon Chang, Senior Vice President & General Manager - Industrial Automation Business Group, Delta Electronics 16
“BALANCING PRODUCT & PRICE ‌â€?
32
ENTRY TICKET TO GLOBAL AUTOMATION�
Interview with Umesh Sakle, Country Manager, Hilscher India 34
Interview with Chetan TA, Country Manager, Murrelektronik India MARKET TRENDS 18
“MULTI-NETWORK CONNECTIVITY IS AN
CRITICAL�
Interview with Sagar Jeevan Bhosale, Managing Director, Schmersal India
IMPORTANT�
ON MODI WAVES
Interview with Prakash Rao, Director, JUMO India 38
42
Interview with Sudarshan Srinivasan, Managing Director, Vega India Level & Pressure Measurement INTERVIEW
“AUTOMATION IS AN ANSWER TO 44
ECONOMIC VIABILITY�
Interview with Ravi Agarwal, Director—Sales, South-East Asia, Pepperl+Fuchs
“INDIAN COMPANIES ARE ADOPTING GLOBAL BEST PRACTICES�
“GLOBALISATION HAS MADE AUTOMATION
AUTOMATION MARKET SET TO RIDE HIGH
The article discusses the current scenario of the Indian automation market and how the recent slowdown has made the manufacturing companies rethink the strategies
“AUTOMATION SOLUTIONS HAVE BECOME
MORE INTELLIGENT�
Interview with Bipin Jirge, Managing Director, ifm electronic India 36
40
“FIELD DEVICES ARE BECOMING MORE &
“EMPHASISING ON AN EFFECTIVE LEAN MANAGEMENT�
Interview with Marc Jarrualt, Managing Director, LAPP India
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CONTENTS
Advt
Technology
Cover Story 24
CONNECTIVITY & COLLABORATION
A read into how Industrial Internet of Things with advanced computing and analytics, offers new opportunities to improve reliability of industrial assets, enabling operators to progress towards no unplanned downtime
SAFETY & INTEGRATION 54
The article briefs on functional safety protection systems and technical measures needed to reduce security risks and maintain productivity 60
360 O LABELLING WITH DIRECT DRIVE
LANGUAGES OF AUTOMATION
The article deals with an automation system that allows control functions to be distributed consistently
GEARS & MOTORS 50
SAFETY & SECURITY FIRST
64
The article deals with labelling batteries that offer high performance without reductions in the price-performance ratio
Cover image courtesy: Shutterstock
New Products 77
ENSURING SAFE PRODUCTION PROCESSES
The article highlights the basic requirements met by the device circuit breakers for high level of production
78
FIELDBUS & NETWORKING 68
CONNECTING COMMUNICATION NETWORKS
The article highlights how b+m surface systems has been benefited by using Hilscher protocol converter
79
MANUFACTURING IT
Market EVENT REPORT 75
DRIVING HIGH-QUALITY AUTOMATION TECHNOLOGIES
A post-event report on SPS Automation India 2015, held in Ahmedabad, Gujarat.
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Process control system; PID controller with FlexBusTM technology; Right-angle gearbox; Lightweight guide system AC output solid state relays; Flexible industrial connectors for switch cabinets; Gateways for measuring devices; Capacitive sensors 8-slot DAQ controllers; Variable speed drives; Detection scanner for field monitoring
DECODING BIO-MEDICAL COMPLEXITY
The feature analyses the various developments happening in 3D printing in the medical field
Columns 05 06 80 80
Editorial Contents Highlights - Next issue Company index
Advt
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MARKET | NEWS
Warehousing Services market driven by Continuous Improvement Strategies To estimate the market size, ARC recently conducted a study on warehousing services, focusing on the market dynamics from an LSP perspective. The study covers the “Top 25” warehousing services suppliers. According to Neelam Singh, Senior Analyst and the principle author of ARC’s Warehousing Services Global Market Research Study, LSPs translate warehousing services into a valuable business proposition by better asset utilisation, offering flexibility, and continuous improvements for their Warehousing Services Market customers. “LSPs report that continuous improvement programs are often mentioned as something potential customers are looking for and almost always include the request for proposal.” It is difficult for the shippers to select an LSP. They often view LSPs as any other service provider, and choose the most cost-effective one. This selection criteria has encouraged providers to suggest cost-effective options, such as multi-client facilities. According to one of the LSP executives, continuous improvement strategies “are table stakes - you have to be able to show you possess a continuous improvement program to
be in the game.” The more value-added services (VAS) the customer assigns to the LSPs, the more specialised the service becomes. Right from simple projects such as relabeling and kitting, all the way up to product preparation (trimming, packing, staging) and point of sale sequencing can be performed by the LSP. As the complexity of the VAS increases, a LSP’s ability to improve margins also increases. LSPs pursue different strategies when it comes to warehouse management systems (WMS). In some cases, they have standardised on a best-of-breed solution; others have standardised on different best-of-breed solutions based on industry; others have their own proprietary WMS, and in many cases, an LSP is willing to implement a best-of-breed WMS specified by the customer. Customers look for the ability to provide visibility to inventory and shipments, advanced BI, and highly intuitive dashboards.
AIA partners with Automation Training Zone for Win India 2015
Analysing global distribution automation market
Win India and Automation Industry Association (AIA), India’s apex industry body recently signed a MoU at the Hannover Messe 2015, announcing AIA to be the official knowledge partner for the Automation Training Zone at Win India 2015, to be held from December 9-11, 2015 at New Delhi. The Automation Training Zone is a two-day skill development and training program designed to support the educational objectives of the Indian government’s “Make in India” initiative. The program addresses the needs of equipment makers and automation users in the food and beverage, automotive, pharmaceuticals, fastmoving consumer goods and consumer durables sectors. The MoU was signed by Anup Wadhwa, Director, Automation Industry Association and Tushar Alekar, Commercial Director, Hannover Milano Fairs India during a seminar on ‘Smart Cities – the Urban Challenge’ at HANNOVER MESSE. “Resonating with Hon’ble Prime Minister Narendra Modi’s ‘Skill India’ initiative, we, along with AIA will train the end user sectors and educated them on the latest technology & automation trends,” said Alekar.
According to a recent survey ‘Analysis of the Global Distribution Automation Market’ from Frost & Sullivan, the market earned revenues of $7.32 billion in 2014 and estimates this to reach $10.33 billion in 2018.“Emerging countries hold significant potential for distribution automation vendors. In India, transmission and distribution loss is estimated at over 20% of produced power, while in Latin America, power The market earned revenues of distribution loss is estimated at over $7.32 billion in 2014 16%. Hence, governments are urging utilities to adopt automation solutions and boost grid efficiency,” said the company’s Energy & Environment analyst. However, the high initial costs of automation solutions restrain uptake. Integration of different types of vendors, including information technology providers, communication network suppliers and hardware suppliers is also crucial to create products that prepare automation companies to meet future demand. Lack of integrated demonstration projects and universal standards are dissuading utilities from investing in distribution automation, so demonstrating the superior operational benefits of these solutions is vital for market growth.
> MORE@CLICK ADI03677 | www.AandD24.in
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> MORE@CLICK ADI03678 | www.AandD24.in
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MARKET | NEWS
Increasing console & operator capabilities Honeywell Process Solutions (HPS) recently launched the UniSim® competency suite, which improves operator competency and helps prepare them faster through realistic training experiences for console & field operators in the process industries, providing comprehensive solution for operator training. The software offers an integrated, robust training experience that will help industrial facilities address a growing shortage of trained operators. “In the near future, many operators at industrial plants in developed countries will retire, while process industries The software offers an integrated, in emerging economies will continue to face robust training experience that will the challenge of critical skill shortages. The help industrial facilities address a expanded UniSim competency suite helps growing shortage of trained operators our customers train its workforce faster in a more realistic environment to drive safe, incident-free, efficient startups & ongoing operations,” said Ali Raza, VP & GM, Honeywell Process Solutions’ Advanced Solutions business. The suite features proven simulation models as well as new technologies including UniSim® Operations, UniSim® Curriculum, UniSim® Tutor, UniSim® Field View as well as UniSim® 3D Connect. > MORE@CLICK ADI03679 | www.AandD24.in
NORD celebrated golden jubilee at Hannover Messe 2015 Hon’ble Prime Minister Narendra Modi and German Chancellor Angela Merkel visited the NORD stand at Hannover Messe 2015. The company celebrated its 50th anniversary this year. The heads of government took note of economical drive units for servo applications. A dynamic racing car simulator, in particular, was of great interest: six intelligently controlled drive axes execute steering Nirmala Sitharaman (Indian Ministry of commands in real time. The latest Commerce & Industry), PL Muthusekkar (MD, generation of distributed frequency NORD India), Ullrich Kuchenmeister (MD, inverters enables extremely dynamic, NORD Drivesystems), Anjela Merkel (German precise control of asynchronous Chancellor), Shri Narendra Modi (PM India), drives. The combination of motor and Jutta Humbert (MD, NORD Drivesystems) inverter conforms to the new, highest system efficiency class IES2 according to the European eco design standard EN 50598-2. Jutta Humbert, MD, NORD Drivesystems Group introduced Modi & Merkel about the company & its journey till date. She also explained how efficiently the company geared motors are running throughout the Rourkela Steel Plant, recently inaugurated by Modi. > MORE@CLICK ADI03680 | www.AandD24.in
Industrial robots break worldwide sales record
KEPL supplies critical application pumps to Reliance
According to Arturo Baroncelli, President, International Federation of Robotics (IFR), Chicago, the global demand for industrial robots in 2014 reached more than 2,00,000 units for the first time. “Strongest drivers of the growth were the automotive industry followed by the electronics industry. Based on the preliminary results of the global statistics on industrial robots, the IFR estimates that about 2,25,000 units were sold in 2014, 27% more than in 2013,” he said. The main impulse by region came from Asia, particularly from China & South Korea. In total, about 1,40,000 units were The international robot sold in Asia, by far the highest volume suppliers delivered about ever recorded. Robot sales to the Americas 40,000 units and to Europe also reached new peak levels. China was again by far the largest market destination for industrial robots in 2014. About 56,000 units were sold, 54% more than in 2013. Thereof, Chinese robot suppliers delivered 16,000 units and the international robot suppliers delivered about 40,000 units.
KEPL has recently shipped the first set 5-stage BB3 pumps to Reliance Industries Limited (RIL) for J3 Project at Jamnagar in Gujarat, India. API 610 standard BB3 pumps are between bearing axially-split case pump. KEPL manufactures process pumps as per API (American Petroleum Institute) standard for high temperature & high pressure application. Its near-centreline mounting design makes it suitable for various refinery applications subjected to the ISO or API criteria for flammable hydrocarbons. The pumping temperatures range for the The pumps are designed to ensure high pump is from 50 C to 2000 C. reliability under high pressure applications Its capacity is upto 2500 cubic metres per hour. “We are delighted to provide our indigenously-developed critical applications to Reliance Industries Limited. The pumps are designed to ensure high reliability under high pressure applications and are very easy to maintain,” said Sanjay Mande, Assistant VP, KEPL. The Jamnagar complex is a fully-integrated facility, with a petroleum refinery complex, an aromatics/petrochemical unit, a power generation plant and a port and terminal complex.
> MORE@CLICK ADI03681 | www.AandD24.in
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NEWS | MARKET
Integrated material management software solution Siemens and thinkstep have recently announced a new integrated material they can react quickly and realise innovation,” said Eric Sterling, Senior VP, management software solution to manage the material lifecycle and Lifecycle Collaboration Software, Siemens PLM Software. streamline material driven product design. The Material property management systems new solution will help manufacturers worldwide have evolved significantly to keep pace with improve product performance and reliability by the growing demand to capture, store and connecting design, engineering, analysis, interrogate material test data. However, compliance and manufacturing to a single these massive volumes of data cannot be source of material information. considered material intelligence unless the The new offering will help reduce errors and lifecycle of the material data is intrinsically will also assist in the re-use of market tested linked with the lifecycle of the product. materials for new products, which is critical in Teamcenter integrated material management a wide variety of industries. It will also assist in provides this missing link between material the re-use of market tested materials for new data and true product intelligence. products, which is critical in a wide variety of Establishing and maintaining integration industries. “With our relationship with thinkstep, between the materials considered for use we are delivering a competitive advantage to This software helps manufacturers worldwide to improve in a product and the product’s bill-ofall of our customers through true material product performance and reliability by connecting design, materials (BOM) is crucial to delivering management intelligence. The new Teamcenter engineering & analysis successful, innovative products. The integrated material management solution Teamcenter integrated material provides a more holistic view of material data for use in all phases of the management solution enables the active management of materials product lifecycle to help improve quality and reduce development cost. The throughout the product lifecycle, from design to production to retirement. > MORE@CLICK ADI03683 | www.AandD24.in new solution gives manufacturers the right information at the right time so
Micro-Epsilon opens new branch in India Micro-Epsilon India has recently unveiled its branch in Pune, from where the other parts of India can be easily reached. The new branch in Pune will primarily service existing and new customers in the region. Trained in Germany, the sales engineers offer customers first-class support, establishing the presence of the company in the emerging Indian market. The company focuses on the implementation of advanced technology into high precision measurement technology for customers in machine building, The Pune branch will service existing automation, automotive design, & new customers in the region electronics manufacturing, and research & development. The diverse product portfolio of the company will have a positive effect on establishing a foothold in the Indian market. The company offers mechanical, electromagnetic and optical sensors, as well as measurement systems for displacement, position, temperature and colour, including a range of Ethernet-capable measurement systems. Alongside Micro-Epsilon China, the Indian subsidiary is the second Asian subsidiary out of 10 foreign representatives of the family-run technology company based in German > MORE@CLICK ADI03684 | www.AandD24.in Ortenburg.
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Rockwell Automation expands device support Rockwell Automation has recently added a new custom-device plug-in capability to its FactoryTalk AssetCentre v6.0 asset-management software. For manufacturers, this connectivity expands monitoring, backup and recovery capabilities for their critical automation-related assets. The software is an asset-management tool that allows manufacturers and industrial operators to centrally manage controllers and other automation-related assets. It archives asset configurations on a regularly scheduled The software is an assetbasis, tracking changes and providing a management tool that allows point of return for faster recovery following manufacturers to centrally an unscheduled downtime event. Archived manage controllers asset configurations can also be saved and used as a “golden copy” configuration, allowing customers to pinpoint exactly what should be running in their automation layer and compare it with what is actually running. “The FactoryTalk AssetCentre software provides extensive access to equipment across an entire automation system. Additionally, plug-in definitions created for one third-party device can be re-used with other devices or even in other automated industrial systems to help speed up commissioning and deployment,” said Mohit Singhai, Product Manager, Rockwell Automation. > MORE@CLICK ADI03685 | www.AandD24.in
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MARKET | INTERVIEW
“Prime challenge for copper is substitution” Sanjeev Ranjan, Managing Director, International Copper Association India, in an interview with Megha Roy, discusses the major initiatives taken by the association to encourage the use of copper in India & developments in the Indian copper industry Though motors are the lifeline of the manufacturing industry in India, penetration of high efficiency motors and premium efficiency motors is low. How does ICA India cater to this barrier? The major barriers in the penetration of high efficiency motors in the Indian market include lack of awareness among motor purchasers regarding the potential for energy and cost savings by using more efficient motors within energy efficient EMDS; company organisational structures that manage their equipment procurement budget separately from operations & maintenance budgets and motors that are often integrated into equipment produced by OEMs before sale to the final end user.
What are the major initiatives undertaken by your association to encourage the use of copper in India? What are the challenges faced in this front? Some initiatives include encouraging safe house wiring practices in building construction sector, creating awareness & imparting education on power quality through Asia Power Quality Initiative Platform, promoting 5 mm microgroove copper tube heat exchangers technology to OEMs and encouraging renewable energy technologies like solar water heaters. The main challenge for copper is substitution, where we advocate its electrical & thermal properties.
How do programs on electrical safety, energy efficiency and sustainability help industrial & commercial electricity users to make the use of motor ‐driven systems more efficient? ICA India has identified some measures, including regulatory measures like working towards adoption of revised standards for motors, ensuring that the original equipment manufacturers adopt IE2 & IE3 motors with their end products and influence purchase guidelines of motors to specify motors conforming to new standards. Supply end measures include adoption of new standards and procurements, while end user measures include creating awareness among them regarding new standards and educating decision makers for purchasing motors on life cycle cost basis. We conduct in-house seminars too.
How can the Indian motor industry match its standards with the latest International Electro technical Commission (IEC) standards? The efficiency of motors depends both on their ratings and efficiency quality, characterised by efficiency classes. In many developing countries, the motor standards are harmonised to international standards. Hence, with the international standard in place, they solve the problem of export barrier. Recently, IEC has published the first edition of IEC 60034-30-1, which provides global harmonisation of energy-efficiency classes of electric motors. It widens the product range covered in the first edition of IEC 60034-30 significantly. The Indian standard harmonised in 2008. In 2011, the Bureau of Indian Standard (BIS) has launched the revised energy efficient motor standards (IS12615:2011), in line with international motor standards (IEC 60034-30).
Can you brief on the latest advances happening in this area to improve the use of copper in existing applications, while creating new applications for copper? In terms of copper die cast rotors technology for induction motors & pumps, electrical efficiency of motors can be improved by replacing the standard aluminum electrical conductor in motor rotor with copper, having a higher electrical conductivity. The use of copper in place of aluminum for conductor bars and end rings of induction motor rotors results in improvements in motor energy efficiency due to a significant reduction in I2R losses. Copper rotor motors are optimum designed for higher efficiencies and with reduced thermal stresses.
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What are the developments expected in the Indian copper industry? Copper will provide the industry a competitive edge by its application and usage in energy efficient motors, power and distribution transformers, wires and cables, to help meet the growing aspirations of India through its applications in heat exchangers of room air conditioners. Copper rotor motors and 5 mm microgroove copper tube based heat exchangers in RACs can be the game changers. ☐ > MORE@CLICK ADI03686 | www.AandD24.in
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MARKET | INTERVIEW
“Ready to move towards smart manufacturing…” …says Simon Chang, Senior Vice President & General Manager, Industrial Automation Business Group, Delta Electronics Taiwan, in an interview with Megha Roy. He also discusses the range of automated products and smart solutions provided by the company Your company has managed to bag the best Taiwan Global Brand for the 4th consecutive year. What do you attribute this success to? For the company’s brand development, in 2010, Delta began with building a brand identity to increase awareness and visibility of the company. We profiled the corporate mission and shared values through a communication program, followed by hardware and software integration to provide customer centric solutions. This led to the enhancement of the unique Delta brand experience. Also, with the launch of our “Smarter Greener Together” brand campaign in 2012, the continuous strengthening of our channel network and service platform, and the initiation of a training program within Delta Group created a unique brand experience based on the company’s brand promise. This, all together, won the praise of our customers and partners across the globe.
have launched the mid-range PLC and PC-based automation controller (PAC), as well as distributed motion control systems. This year, we have launched the SCARA robot solution for a more flexible, efficient and smarter production. For high-speed and stable industrial communication, the company’s industrial Ethernet switches and WLAN AP is the perfect solution for a host of applications. In addition to this, we have developed field devices such as smart sensors, smart meters and machine vision systems. In terms of software, the company provides SCADA (DIAView) and Factory Energy Management System (FEMS, DIAEnergie) too. With a total integration of field devices, controls, communications and intelligent software, our company is ready to move towards the concept of smart manufacturing.
Can you brief on your company’s innovative solutions expected in the coming years in the areas of industrial automation? Can you brief on the recently showcased CNC systems and SCARA Delta has a strong experience & technology in the machine robot solutions during TIMTOS 2015? automation area and has developed solutions for factory At TIMTOS 2015, our company showcased a total of 10 high- automation and process automation. Keeping in mind the end integrated machine tool solutions for high speed tapping future trends of smart & automated manufacturing, our machines, dental milling machines, vertical machine centres, company has also launched SCARA robot solutions and as well as tool turrets solutions. We also demonstrated the will have more industrial robot systems and solutions to latest SCARA robot solution and a 5-axis Cartesian coordinate come in future. With the integration of our automation robotic arm system during the exhibition. solutions and the company’s green products & solutions, we are providing smart solutions in a variety of industries, such In terms of automation solutions, how is your company managing as hybrid energy saving system and full servo system for the complex machine control concepts with the help of latest plastic injection machines, integrated multi-axis servo and technologies, such as smart automation practices? control solutions for robots, integrated drive and control unit Our company has been dedicated to industrial automation for elevators, and energy-saving solutions for high power for nearly twenty years now. As such, we have developed a consumption factories. ☐ > MORE@CLICK ADI03687 | www.AandD24.in broad range of automation products. For high-end control, we
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MARKET | INTERVIEW
“Balancing product and price…” …says Chetan TA, Country Manager, Murrelektronik India, in an interaction with Maria Jerin, while discussing the changing market requirements and the recent developments in the industrial automation segment. Excerpts… What is the present scenario of industrial automation segment in India? What are the challenges and bottlenecks in the industry? Different customers have different applications; some prefer technologies like hardwiring, plug-&-play solution for connection of I/Os while others are already implementing Fieldbus solutions. All these technologies are available in India, so it depends on the needs & preferences of the end customer. Bottlenecks for incorporating new technology has always been the commercial factor but slowly customers have started to believe that in a globalised economy, upgrading their machines to the latest technology is a pre requisite than a USP to compete against global players & hence are adopting to it faster than perhaps a decade ago. How are you aligning your products with the changing market requirements in regards to product development, performance, price, quality, logistics and service? We are convinced that efficient installation, service, maintenance and diagnostic of machines (in regards to reduction of downtime) are important to reduce cost and be more competitive. The awareness of the total cost of ownership of machines or production lines must be created and how to reduce it on a holistic point of view. Hence products with Fieldbus and plug-&-play solutions instead of old conventional hard-wired systems are important coupled with an efficient delivery system that helps customers on saving machine downtime. We are aligning our products along with balanced pricing and post-sales support for the Indian market. Your company has recently introduced the Kanban system to meet the requirements of machine builders. Can you brief us on this? As a first step, ME GmbH is planning to implement the Kanban system in Europe & then at a later stage, depending upon the success & feedback of the customers, plans to implement it across all subsidiaries. With this logistics concept, cables and connectors needed for system installation are always available
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without increasing inventory. The 24/7 maintenance station provides an assortment of spare parts tailored to the special needs of a customer’s machines no matter when the downtime happens. The parts taken out are scanned to avoid the problem of missing inventory. The station is refilled at predetermined intervals based on customer schedules. What is your take on the recent buzzwords IoT and Big Data? What does this mean to automation industry? IoT and Big Data interconnects multiple factories, logistics providers, etc, with each other by a centrally controlled system “backplane” that is capable of synchronising and orchestrating all events throughout the supply chain and giving everyone involved full visibility of what is going on. As Big Data and IoT remakes factories into highly automated plants, goods will achieve greater speeds to market, with stepped up profit for companies. Globally, progressive companies are already investing in IoT-driven systems, which they believe will enable faster responses to changes in consumer demand and product innovation. This potentially opens up greater market opportunities for companies and more options for consumers — which benefits everyone in the value chain. What are the demand trends shaping up in this industry? What are your company’s short, medium and long term plans for the Indian market? With the ‘Make in India’ campaign by the new government gaining lot of traction with foreign & local manufacturers, it’s important for us to be geared up for increase in demand for the products. We are working closely with our distributors to stock the products at regional stocking centers of our partners. As medium term plan, within next 2-3 years we plan to have our own warehouses across different locations in India. As a long term measure, before the year 2020, we plan to have production in India to cater to the domestic market as well as an export hub for ME globally. ☐ > MORE@CLICK ADI03688 | www.AandD24.in
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Remote Management of industrial equipment
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2014-08-18 09:19:31
M OTO R S & D R I V E S | T E C H N O L O G Y
360O LABELLING WITH DIRECT DRIVE In a joint development of motion control solution with integrated labeling controller, Schleuter and Kollmorgen integrated the complete labelling control unit into an intelligent and freely-programmable servo. This article deals with labelling batteries that offer high performance without reductions in the price-performance ratio. According to GKF, more and more mobile electronic devices are firing up the consumption of batteries and rechargeable batteries. It has increased from 116 million in 2008 to 300 million in 2012 in Germany alone. In light of these figures from the German Consumer Research Association, productivity is crucial for cost-efficient production. During a redesign of the system, Schleuter mechanical engineers managed to increase the output of an existing battery labelling machine in China from 600 to 1000 units per minute. This increase was possible, thanks to an automation including motion control that was integrated into the Kollmorgen drive control system.
Battery labelling machine Labels for batteries have two essential functions. Firstly, they convey information such as type designation, power and brand.
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Udo Wildenblanck Key Account Manager Kollmorgen, Ratingen
Secondly, they isolate the aluminium body, thereby preventing short circuits. The outer cover forms the positive pole for Mignon cells in which the negative pole is slid into when assembling. The plastic film material can only isolate the small energy storage device effectively after shrink fitting if the label is applied precisely after the battery has been assembled. This sub-process is critical for the entire manufacturing quality. GU/ BATII-DUO S is the Schleuter system which is today consistently driven by Kollmorgen servo technology. â&#x20AC;&#x153;For us, the use of servo technology for labelling batteries was equivalent to a quantum leap in productivity and precision,â&#x20AC;? emphasises HeinzJĂśrg Fischer, Sales Manager, Schleuter. The automation at the heart of the GU/BATII-DUO S can also be found in an AKD PDMM. Together with Schleuter, Kollmorgen integrated the complete labelling control unit into this intelligent and freelyprogrammable servo controller. With their controller that was
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T E C H N O L O G Y | M OTO R S & D R I V E S
developed in-house based on Power PC architecture, and an operating system that is specially adjusted to it, the device range offers the computing capacity of an IPC as part of a compact drive control unit. The master drive AKD PDMM can control two high-speed labelling machines at the same time with this performance. Moreover, there are still power reserves available for expansion. Furthermore, the AKD PDMM has the task of controlling the feeder beltâ&#x20AC;&#x2122;s drive that ensures that the materials flow through the individual labeling stations of the machine. This axis is implemented electromechanically with a Kollmorgen CARTRIDGE DDR motor. At Schleuter, the synchronous servo motor works as a three-phase rotational direct drive (torque motor) and sits directly on the drive shaft of the roller conveyor. This ensures that it rotates continuously in the direction of the labelling when transporting the battery. By using direct drive technology with CARTRIDGE DDR motors, Schleuter was able to completely dispense with the gear units and bearings that
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had been previously required for the roller conveyor. This saves space, increases ease of maintenance and ensures more precise movements and dynamics due to the reduced dimensions and the absence of gear backlash. As part of the redesign, the rotor was clamped to the drive shaft of the chain belt in the machine and the stator was connected directly to the machine housing.
Precise labelling The six single-phase servo axis are another part of the axis system that is synchronised by EtherCAT, consisting of controllers from the Kollmorgen AKD range and AKM-type synchronous servo motors. They have a total of four tasks. The drive of the infeed starwheel isolates the batteries from the store located above and drives these to the roller conveyor below. Two further axes take over the drive of the first labelling machine and a press-on belt, which presses the label tightly on
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M OTO R S & D R I V E S | T E C H N O L O G Y
I M A G E CO URT ES Y: Kollmorgen
Schleuter saves time when installed with the cable connection technology
to the battery before shrinking. The two processes are repeated PROFINET. The entire system is programmed with the for the second labelling machine. The sixth axis drives an ejector “Kollmorgen Automation Suite” development platform that is that unloads the batteries with production defects after analysis integrated in AKD PDMM servo controllers. On one hand, the by inline high-speed image processing. The total system works servo amplifiers feature a high-performance PLC and Motion under a nominal load with a machine speed of 25.4 m per Control functionality. On the other hand, motion sequences minute. The GU/BATII-DUO S thereby achieves an output of that are synchronised via the Pipe Network proven graphic 1000 units per minute, which corresponds to 17 labelled programming environment are especially quick and easy to batteries per second. Finally, this productivity is also achieved program. In addition, the five standardised languages of the as Schleuter does not run any individual process in the total IEC 61131-3 for the sequential control and the PLCopen Motion system in cycles, but rather they run continuously. Here, the Control functional module for motion control are available. In decision of the Bremen-based company to equip the machines this way, Schleuter and Kollmorgen disclosed all the controller with two cabling units comes into play. These do not work at the data within the engineering project. Thereby all information same time, but alternately. Due to the high production speed, from the system visualisation onwards can be seen and one of the essential tasks of the machine operator is to ensure parameterised. In this way, Schleuter ensures that it does not that there is a supply of labels. So that changing the rolls does require another Engineering Tool. From diagnostics, to not bring everything to a stop, both units are closely synchronised commissioning, through to operation and servicing: The same to each other in terms of the labelling control unit that is system is worked with throughout — including password integrated in the AKD PDMM, so that switching between the protection. “Kollmorgen offers the best technology for this units happens without stoppages or negative effects to the application, says Heinz-Jörg Fischer, Sales Manager, Schleuter. quality. The system even automatically detects up to where on the roller conveyor the batteries have been labelled - and then Conclusion switches over seamlessly. After the switchover, the machine The Schleuter system is a fine model for applications that operator has enough time to equip the empty unit with a new requires computing power, yet costly IPC solutions are ruled roll and get it ready for operation. out due to comparatively low axis numbers. The balancing act starts here. If processes require the precise control of an IPC, High performance through co-engineering then this is condensed as a proportionate cost block for “IPC The machine’s performance cannot be put down to the per axis”. If a compact controller is driven on the DIN rail hardware alone. Rather, it’s the result of distributed intelligence, instead of the more obvious route, the machine performance high computing power, and above all sophisticated software. invariably drops through the limited process resources as a This resulted from close collaboration between Kollmorgen and result of reduced cycle times with the regulation. With the AKD Schleuter. The AKD PDMM supplies the required computing PDMM, Kollmorgen can offer a solution for this application power for this application. Thanks to a processing power of 800 that provides high performance without reductions in the priceMHz. The Siemens PLC is only used for display and formulation performance ratio. ☐ > MORE@CLICK ADI03701 | www.AandD24.in purposes at Schleuter. Data for AKD PDMM is exchanged via
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SAFETY & SECURITY | TECHNOLOGY
Safety & security first Productivity has the highest priority for companies. To ensure productivity a safety system must be integrated in the plant process control system. The article briefs on functional safety protects systems and the technical measures needed to be considered to reduce security risks and maintain productivity As cyber attacks on plants via networks increase, it becomes essential for functional safety and safety-related automation solutions to support cybersecurity. The trend of linking office IT with automation IT in an open network architecture only increases the security risks to plant automation. Functional safety is the basis for any type of process plant, since without mastery of the functional safety risks, operation of the plant is not allowed. In addition to safety, productivity is a crucial factor for the enterprise. To ensure productivity a safety system must be integrated in the plant process control system. However, such integration increases the risk that safety
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Stefan Ditting, Product Manager, HIMA Paul Hildebrandt GmbH s.ditting@hima.com
Thomas Janzer, Product Manager, HIMA Paul Hildebrandt GmbH t.janzer@hima.com
products will be negatively influenced via interfaces and networks. An attack on the integrity of the safety controller also jeopardises the integrity of functional safety. Consequently, the same demanding requirements imposed on functional safety features must also be imposed on the security features of a safety controller.
Integrated solution cannot be easily mastered At first glance, economic reasons can be a persuasive factor for implementing an integrated safety system from the same
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TECHNOLOGY | SAFETY & SECURITY
SILworX protects itself against faulty installation data and manipulation via a CRC (cyclic redundancy check)
company that manufactured the process control system. After all, a uniform system concept and a common bus, as well as a single engineering tool for the standard automation and functionally safe automation, promise several advantages. The advantages of convenience, however, come with disadvantages in the areas of functional safety and security, as anything that a user or the controller can do, an attacker can also do. A larger attack surface is the consequence. With an integrated control system and safety system from a single source, all automated processes and convenience advantages must be critically tested. The more open and integrated a safety controller is, the more effort is required for organisation and security. Security attack vectors in this area include automated processes, such as diagnostic displays, the automatic interaction between engineering tool and controller, and the interaction between the visualisation of the control system and the safety system.
Standards require separate levels of protection To reduce systematic errors, standards IEC 61511-1 (Safety) and IEC 62443-3-3 (Security) require separate levels of protection and autonomy of the operating equipment and protective equipment. By design, an autonomous process control system and a safety system from different manufacturers require different engineering tools, databases, and operating procedures. Such systems from different manufacturers avoid common cause risks and reduce the security risk through diverse technology. Diverse technology also ensures a clear separation of the areas of responsibility and supports the different handling of
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operating equipment and protective devices, in practice. With operating equipment the focus is on daily optimisation, updating, and change; in contrast, risk is reduced when protective equipment is operated rarely, and then only by qualified personnel. Each access to protective equipment constitutes a risk, and changes are only permitted via a management of change process. The international standard IEC 62443-3-3, “Industrial communication networks – Network and system security,” requires compartmentalisation of production networks. To accomplish this, individual zones are determined (enterprise network, control room, safety system, process control system, etc) that are connected via defined transitions (conduits). In accordance with the respective data or protocols that must be exchanged, protection is installed at each conduit in the form of a firewall. For this concept it is strictly required that exchanged data be clearly defined. Appropriate protective measures can only be provided if this structure is known to the user. The forthcoming revision of standard DIN IEC 61511-1, “Functional safety – Safety instrumented systems for the process industry sector,” moves in this direction. It advocates testing, evaluating, and ensuring the independence, diversity, physical separation, and avoids common cause errors between levels of protection. Moreover, it includes the clear statement that a safety system should be physically separated where feasible. Current discussions in standardisation bodies such as NAMUR and DKE likewise address the topic that autonomous secure separation and an appropriately defined conduit are required for mastery of security risks. If there is doubt in this regard, automatic convenience functions must also be
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SAFETY & SECURITY | TECHNOLOGY
The international standard IEC 624433-3 requires compartmentalisation of production networks
deactivated to reduce the complexity and thus the security risks.
Technical measures reduce security risks A safety system must have a variety of security features to harden it against safety-security risks or to reduce the risk in plants. The technical measures affect different areas: PC environment, engineering tool, communication, secure control, safety application. PC environment—avoid common cause errors: The BIOS password is the outermost security layer to protect the PC and the engineering tool of the safety system against unallowed access. In accordance with the basic principle of supporting only that which is required, the operating system environment user guidelines and group guidelines must be set up with reduced access rights. The use of a firewall and antivirus software, further improves the security protection. In this regard an application whitelisting, is indeed more complex in configuration; however, it offers better security protection, particularly against previously unknown malware, than is offered by antivirus software, because only the programs released by the user are allowed to be executed. In order to properly configure the various security measures, the required ports and user rights for the engineering tool must be known. In addition, the engineering software must be compatible with the security software of other manufacturers. Thus, the user can flexibly implement the security products that are prescribed or that are most suitable. The principle of diversity also applies for these levels of protection, as use of products from different manufacturers
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avoids the same type of errors. Engineering tool—comprehensive protective measures: SILworX®, the engineering tool for HIMax, runs on a standard PC with Windows. The software is compatible with all major antivirus protection programs and consequently can be used with the antivirus software that is standardised and released for the respective company. SILworX protects itself against faulty installation data and manipulation via a CRC (cyclic redundancy check) that occurs each time the software is started or code generation takes place. In addition, MD5 checksums for the installation data are available to the user to check the correctness of the installation. SILworX has additional features that promote security. A database file in a HIMA-specific format contains the data for the project generated with SILworX as well as the encrypted user ID and passwords. The function-relevant project parts are additionally protected via a separate CRC so that a change in the project data can also be detected and traced with the available secure code comparer. It is possible to create a project archive automatically each time the controller is loaded. All changes can be traced via this seamless version history. This backup function also permits identification and restoration of the last valid project as part of a recovery procedure. Two-level user management for project access and controller access ensures additional protection. The first level includes the right to access the project data. At this level personalised users can be created with individual user password and assigned to user groups. In the second level the access rights are defined per controller. From among the created user groups the administrator can select which group may access the respective
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SAFETY & SECURITY | TECHNOLOGY
HIMax controller offers several possibilities for secure communication
controller. A individual password is defined in each case. This password can be as complex as desired because it does not need to be known by the user. Advantages of this procedure are that the user knows only his own password, and if there is a change of individual users or their passwords the controller itself is not changed. Thus the security protection is increased, and if there is a change in employees or a password update it is not necessary to make changes in the safety controller. Accesses are recorded in the project log and in the controller diagnostics, which enables easy traceability. Communication—separate levels of protection: The concept of separation is also consistently integrated in HIMA controller systems. For high-level cybersecurity different levels of protection with a virtual or physical separation can be set up for the communication. The HIMax CPU module executes the safety application and can handle communication tasks. Both areas are separated on the CPU through SIL3-certified protection of the memory and of the timing between the communication area and the safety area. If an insecure data transmission is directly connected on the CPU, an integrated firewall ensures a virtual separation because only the protocols and data configured by the user are supported. Invalid or unknown protocol queries or read/write of non-configured address ranges are simply ignored by the controller. For further risk reduction a physically separated communications module can be used. The module has the same security firewall characteristics as the processor module and is connected to the CPU only via the internal system bus. Because the communication module cannot influence the CPU the safe function is physically separated from the nonsecure communication. These features result in stable, robust
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system behavior. Secure control—many protection possibilities: The safetyrelated HIMax controller itself offers several possibilities for secure communication. Physical ports that are not used can be deactivated, and thus an authorised access can be prevented. Moreover, a graduated blocking of controller access is possible. Online changes and the forcing of values can be blocked via system variables. Read-only operation offers additional protection against manipulation. With a key switch at the installation location of the system, the system variables can be written and enabled or disabled via a digital input. If this key is “removed,” the controller in RUN mode allows only reading, regardless of the accesses that occur via the network. Safety application: Last but not least, the safety application itself offers measures for increased security. For example, CRC protection can be used to display program changes in the system and to trigger alarms.
Conclusion There is no safety without security. If a security risk exists via interfaces or integration, the integrity of functional safety is in jeopardy. Security deserves this same high level of attention that is devoted to the topic of safety. Properly structured to be autonomous and as separate as possible to avoid random and systematic errors, the safety controller constitutes the last line of defense. The security standard IEC 62443-3-3 and the forthcoming revision of safety standard IEC 61511-1 support this approach by requiring separate levels of protection. By design, autonomous safety systems reduce security risks through the use of diverse technology. ☐ > MORE@CLICK ADI03702 | www.AandD24.in
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S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y
LANGUAGES OF AUTOMATION Automation of the future demands solutions that can distribute control intelligence and guarantee the necessary networking of multiple control systems. The article deals with an automotion system that allows control functions to be distributed consistently. Until now, automation solutions have often been characterised by independent, standalone functions: safety technology, control technology, visualisation technology and motion control systems are independent systems. The large number of systems and architectures add complexity to the plant control. The larger the automation project and the more extensive the requirements, the more complex it will be for the user to handle. In todayâ&#x20AC;&#x2122;s centrally configured programmable logic controllers (PLC), changes in individual plant sections have far-reaching consequences at control level, because program structures at central points in the control system have to be modified. In terms of flexibility, re-usability and userfriendliness, classic automation architectures with centralised PLC controllers can no longer meet future requirements. Thatâ&#x20AC;&#x2122;s why the automation of the future demands not only solutions that can distribute control intelligence, but also guarantee that the necessary networking of multiple control systems remains easy for the user to handle.
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Centralised view of a distributed system Keeping this in mnd, Pilz developed the automation system PSS 4000. Whereas in classic automation a standalone, centralised control system monitors the plant or machine and processes all the signals, the PSS 4000 allows control functions to be distributed consistently. In detail, the automation system consists of hardware and software components as well as the real-time Ethernet SafetyNET p and various programming editors designed for use in different sectors, with their application-oriented function blocks. The hardware includes control systems of various performance classes. Process or control data, failsafe data and diagnostic information are exchanged and synchronised via Ethernet. For the control function, therefore, it makes no difference where the respective program section is processed. Instead of a centralised control system, the user has a program distributed in runtime within a centralised project. All network subscribers are configured, programmed and diagnosed via this software.
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S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y
The 4-fold safety of automation
This enables simple and standardised handling across the entire project.
Transferring functions to the software The transfer of functions to the software bring users flexibility and scalability, reduces the variety of hardware types and simplifies maintenance and diagnostics on automation solutions. The question as to whether software can be used efficiently depends essentially on the user interface and the available languages – both in terms of human language and programming language. PSS 4000 meets these challenges with the software platform PAS4000. Various editors and blocks are provided, which can be used for automation as well as safety-related tasks. In this system, the tools for configuration, programming, commissioning and operation are closely compatible. The ability of users to use their normal native language is important in terms of acceptance. As a result, the PAS editors in the automation system are available in total of 8 different languages. The diversity of language is not just limited to the menu language but incorporates the whole of the help menu and installation support, as well as the whole system description and safety manual. The diversity of language in this software extends not only to human language but also to programming: that’s because there is a preference for individual programming languages, based on the application area, country or region. One of the editors available to users is the simple, blockbased Program Editor PASmulti. PAS4000 also provides established editors for programming. These include editors for PLC programming (in accordance with EN/IEC 61131-3) for Instruction List (PAS IL) and Structured Text (PAS STL), as well as the new editor for Ladder Diagram (PAS LD). This can be used to create safety-related programs, programs for automation tasks or a combination of the two.
Open for all protocols In addition to the interfaces for man-machine communication, data exchange within the automation project also has an important role to play. The same applies for the more complex and extensive the project, the more important it is to have a standardised language. The system also supports the diversity of language from a technical perspective. The control systems PSSuniversal PLC in the automation system PSS 4000 support the various communication protocols used depending on country and region, for example, the Profibus protocol, which is particularly widespread in Europe; Ethernet/ IP, which is frequently used in the USA and Asia, as well as EtherCAT, CANopen and Modbus TCP. As a result, there is no problem exchanging data with the widest range of third-party control systems – irrespective of the country, region, sector or machine type.
Benefits The increasing challenges faced by automation can be met using systems that can distribute intelligence but at the same time are user-friendly to control. As a result, the cost of engineering, commissioning and maintenance can be significantly reduced. The system’s openness and the wide range of languages make it easier to use in automation projects around the world. If local users can configure their machine in their native language and in their familiar programming environment, it simplifies the learning process and tool handling enormously, as well as increasing acceptance. For machine builders, it brings the additional benefit of using one hardware structure, and a software program that needs generating once only so as to create automation solutions that can be used anywhere in the world. ☐ Courtesy: Pilz > MORE@CLICK ADI03703 | www.AandD24.in
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Ensuring safe production processes To combine availability of electrical systems and energy efficiency, the right power distribution solution must be chosen early during the planning stage. The article highlights the basic requirements met by the device circuit breakers for high level of protection In the chemical & process industries, plant safety must fulfill high demands. Reliability and availability play an important role in the continuous production processes. In order to ensure safety of personnel and to protect the equipment and plant/systems, an over-voltage & short-circuit protection concept complying with the current standards is required. This has now become essential for plant with or without the danger of explosion. Energy efficiency is an increasingly important goal in the planning and operation of systems. Intelligent control concepts and high availability of electrical systems are also becoming more and more important. To combine availability and efficiency, the right power distribution solution must be chosen early on during the planning stage. Generally, AC circuit breakers are used unmindfully even in DC circuits, without analysing the fact that it could lead to
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unwanted breakdown. This breakdown can be prevented by using specific DC circuit breakers or switches. Device protection products must meet two basic requirements: easy installation and reliable, selective shut-off of individual load circuits in the event of a fault. These core prerequisites dictate how the device protection switches are designed and electrically engineered. Phoenix contact device circuit breaker meets such features and has many more essential and diagnostic features.
Device protection switches Device protection switches and circuit breakers are often considered the same, but their functions are very different. According to standard DIN EN 60898-1, circuit breakers are intended for â&#x20AC;&#x153;household installations and similar applications.â&#x20AC;?
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Device protection switches are mainly for protecting against short circuits and overloads
These are primarily used for protecting cables. Device protection switches are mainly for protecting against short circuits and overloads, while also offering cable protection, as described in standard DIN EN 60934. The company has three variants to offer to the industry for short-circuit protection for the control circuits. These include thermal circuit breaker (TCP), for protection against overload; thermo magnetic circuit breaker (TMC), for protection against overload & short-circuit; and electronic circuit breaker, for protection against overload, short-circuit & attenuation. Its features include cable & device protection with pluggable, modular extension and individual adaptation. It is resistant against high inrush currents and has protection of wires & devices in accordance with DIN EN 60934 and UL 1077, 2367. It also features status indication and remote settable.
Modular design Supply voltage is sent from a DC power supply to a distributor through a large cross section. The distributor then distributes the power to various load circuits that have a smaller cross section and are adjusted to the devices to be supplied. Since the load circuits must be configured in different ways, device protection switches must be as modular as possible in their design. The housing concept must allow for connection of protective switches with different rated currents and, if necessary, different tripping characteristics. To ensure easy installation and maintenance circuit breakers are pluggable. This way, the base elements can be installed first, depending on the number of power circuits. The nominal ratings of the individual load circuits are then defined by selecting the appropriate product type and simply plugging the product into the corresponding base element.
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After this step, the different plugs may not be swapped during installation (e.g. in the event of an overload or during maintenance). This is because the individual power circuits are often configured in an application-specific way with different cable cross sections and connected end devices. A practical housing concept should allow for coding between the base component and the plug. The switch is held securely in place, which also ensures flawless operation.
Reliable selective shut-off The most important characteristic during use in an application is the shut-off capacity. The primary task of a device protection switch is to selectively shut off a circuit containing a defective device. Selective shut-off means that the defective load is shut off without impairing the other end devices connected to the power supply. The load can only be shut off if the shut-off conditions have been met.
Conclusion Device protection switches must meet two basic requirements. First, they must be modular in design and easy to install. This minimises installation time and increases flexibility of application. At the same time, switches must be available in electronic as well as thermo-magnetic versions with different tripping characteristics to ensure the best value for money in any application. The goal is always reliable shutoff in the event of a fault, leading to increased system availability. â&#x2DC;? Courtesy: Phoenix Contact > MORE@CLICK ADI03704 | www.AandD24.in
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Connecting communication networks Process control systems are designed on the basis of highly specific goals and requirements. This includes the selection of matching hardware components and connecting them through the most suitable network technology. The application story highlights how b+m surface systems benefited using the Hilscher protocol converter to link totally different communications networks Automation technology is characterised by ongoing technological development. In such a dynamic world it can always happen that a new solution is needed simply because individual components suddenly do not match anymore. The b+m surface systems was confronted with such a situation, when a component supplier was not able to provide the support of modern real time Ethernet protocols. The solution was as simple as effective and came in the form of a protocol converter that even offered a number of additional benefits. The b+m surface systems was founded in 1992 and soon developed into a specialist of application systems for waterbased paint. The company produces key components that includes painting robots, atomisers and paint changing systems.
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Armin P端hringer Area Sales Manager APAC Hilscher
Even the hardware and software components for process automation are developed in-house and tailored to the special requirements of automated paint shops.
Robots in interaction A typical painting system consists of several stations for sequential operation. The process starts with flaming the work piece, followed by the application of several coatings: first a primer, then a base coat and finally a clear coat. Coating itself is done by application robots without any human intervention. These robots are programmed in a way to guarantee application of the required coats with an absolutely even thickness.
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Robots are programmed in a way to guarantee application of the required coats with an absolutely even thickness
Besides an engineering station, several industry PCs are used to control both process technology and material transport technology. They are assigned to each of the application stations for flaming, primer, base coat and clear coat. At process control level, b+m surface systems relies on Beckhoff IPCs, while RH04.0 Bosch-Rexroth robot controllers are employed at field level. Communications between both levels is accomplished via a CAN interface. An integrated CAN/CAN gateway connects the external CAN bus to the IPCs of the internal CAN bus with the individual robot controllers.
Languages and protocols Generally speaking, a process control system is designed on the basis of highly specific goals and requirements. This includes the selection of matching hardware components and connecting them through the most suitable network technology. With the automatic paint application systems of b+m surface systems, this resulted in the use of multiple protocols matching the specific requirements associated to different functions. For example, the PC in the control centre was connected to the paint preparation section via PROFINET, while the connection of the individual field devices within the paint preparation section was realised via a special I/O interface. CANopen was used for real time communication between the PCs in the control room and the individual application robots, while all controllers communicated via Ethernet and TCP/IP.
modern real time Ethernet protocols, such as EtherCAT, PROFINET IO or EtherNet/IP which is the primary standard in the American market. This forced the company to look for an alternative solution. As it turned out, the situation was anything but inopportune, since experience had shown that the existing solution had several disadvantages. For example, the CAN/CAN gateway not only required quite a lot of space in the switching cabinet. It also made it rather difficult to commission a system, since getting the gateway to work required a specialist with detailed knowledge about network configuration. These systems decided to look for an alternative solution, which would neither require high investments nor extensive alterations of the existing system architecture. They ended up with Hilscher from Hattersheim in Germany. Hilscher is specialised in infrastructure components for system automation and has deep knowledge of the different network communication protocols. Therefore, the specialists at the b+m surface systems Hattersheim head office did not take long to find the ideal solution to solve the communications problem.
Mediator in the jungle of protocols
The solution is named netTAP Gateways and is a rather inconspicuous and highly compact component. Unlike the previous gateways it requires only very little space in the switching cabinet. The netTAP is a protocol converter and serves to link totally different communication networks. It was developed after realising that from ERP via process control to field level a wide variety of different network protocols are used. When protocols represent a disadvantage The reason is that at each level there are specific requirements Technical development does not stop. b+m surface systems as far as data volume and transmission speed are concerned. was confronted with this fact in connection with its robot The converter acts as a gateway between two networks. The controllers. Because their painting solutions are used in many device automatically handles the translation between two countries, the company wanted to cover the complete range of different network protocols, thereby allowing a seamless and todayâ&#x20AC;&#x2122;s Ethernet based communications standards. Bosch- transparent flow of information. Rexroth, however, only offered CANopen, but none of the In modern automation technology, netTAP offers a simple 68
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Industrial Automation Solutions
Achieving more flexible machine setting with complete electric motor / axis solutions Maximum productivity demands faster machine changeovers, quickly and repeatable. A complete, matched solution with simple control interfaces and superb set-up and diagnostics. For information on our complete range of innovative electric drives - contact us today!
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F I E L D B U S & N E T W O R K I N G | A P P L I C AT I O N
For the paint application systems of b+m surface systems, netTAP 100-RE-CO is suggested, which is able to link EtherCAT to CANopen, thereby allowing unlimited real time communications between both protocols
way to modernise a system without replacing existing field devices. This is a highly welcome factor for any company wanting to protect its investment while improving system performance. Implementing the converter is very simple and only requires to select the respective protocols via a configuration interface, setting the network parameters and assign the data to both protocols. For this purpose, the converter features a USB interface to allow easy configuration by simply connecting a notebook. For the paint application systems of b+m surface systems, Hilscher suggested its model netTAP 100-RE-CO, which is able to link EtherCAT to CANopen, thereby allowing unlimited real time communications between both protocols. This model is a protocol converter with two terminals and can be configured by simply loading the respective firmware and configuration data. Terminal X2 can be either an Ethernet or a fieldbus interface. Terminal X3 can be a fieldbus, Ethernet or serial interface. Both terminals are located at the front of the unit. In addition, the unit features a USB interface. It allows for example to connect a notebook in order to manage configuration and diagnosis of the device. For this purpose, Hilscher offers its proprietary SYON.net configuration and diagnosis software.
Simple solution with added value Due to a high level of conformity with the CANopen standard, first obstacles during verification of the products were overcome quickly. Since b+m surface systems has been working with the Bosch RH04.0 controller for some time, some of the original functionalities are still being used. In this respect,
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the perfect implementation of the CANopen standard into netTAP 100-RE-CO was of great help. In the end b+m surface systems was highly satisfied with the newly implemented solution. Thanks to netTAP, they did not need to develop a completely new solution but could continue using the existing and well proven hardware and software basis. Another advantage was the fact that the Hilscher protocol converter only required a fraction of the cabinet space when compared to the previous CAN/CAN gateway. In addition, the simplicity of commissioning eliminates the need for any costly training courses for robot programmers, allowing onsite staff to focus on the application itself as well as the overall functionality of the system. The high number of protocols that can be handled makes the solution fit for the future. Since this includes also standards which are preferred in many countries outside Europe, the protocol converter did not only turn out to be an elegant solution for the initial problem, but also paves the way into the future. One added advantage became obvious during practical application. Due to the extremely short latency of the gateway it was possible to speed up communication between robot switching cabinet and control cabinet, which turned out to be another aspect to improve the control of the painting process. As this example shows, keeping up with technical development does not always require a totally new solution. Sometimes, all that is needed is a small and inconspicuous component to link different protocol worlds, simplifying process control and reducing costs at the same time. â&#x2DC;? > MORE@CLICK ADI03705 | www.AandD24.in
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â&#x20AC;&#x153;Reliable instrumentation for the safe and secure operation of your processes.â&#x20AC;?
Self-monitoring level and pressure sensors increase the security of your plant. VEGA sensors use self-monitoring and diagnostic functions to ensure your processes remain safe and reliable. Asset management facilitates preventive maintenance, along with additional memory for process data and event recording for continuous tracking of any changes in the process or to the sensor. This optimizes your plant availability and reduces the overall costs of plant operation and maintenance. www.vega.com/en/chemical.htm
VEGA India Level & Pressure Measurement Pvt. Ltd Senapati Bapat Road, Shivaji Nagar Pune â&#x20AC;&#x201C; 411 016 Phone: +91 20 4148 4148 E-mail: info.in@vega.com www.vega.com/in
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
DECODING BIO-MEDICAL COMPLEXITY 3D printers have been majorly used by the medical industry for usage in medical implants and replica of body part for mock surgery. The feature analyses the various developments happening in 3D printing in the medical field and outlines the various challenges faced in its implementation. Owing to the complexity and durability in the changing demand trends for materials that are used in end products, 3D printers have been able to contribute in bio-medical applications. However, in comparison to more robust and mature CNC technology, it is still more complicated than CNC milling. Though there are free tools for 2.5D milling, when it comes to CAM software for 3D milling, it becomes too expensive and difficult. Designing models in free programmes exported to STL(stereolithography) files is an easy task. With 3D printing, one does not need to worry about tool crashing in
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Sovan Lal Tudu Senior Designer Publish-Industry India sovan.tudu@publish-industry.net
work, thus, making it a better choice for 3D prototyping. Thus, it is rightly referred to as rapid prototyping. 3D printing is also termed as stereo-lithography, layered manufacturing, Additive Manufacturing and solid freeform fabrication. Over the years, there has been a host of developments in the biomedical 3D printing arena. However, much of the development still remains in the research and theoretical stage. There also has been a significant rise in the investment too. Currently, there are a few implantable solutions that are possible from a long-term, mass production perspective.
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T E C H N O L O G Y | M A N U FA C T U R I N G I T
“3D Printing is mostly used in the operation theatre environment to create surgical instruments, which offers innumerable possibilities.” Srinivas Shastry, Technical Director, Altem
Closely emulating human pathology and multi-material 3D printing would create life like models more efficiently and cost-effectively. According to Srinivas Shastry, Technical Director, Altem Technologies, 3D printing is being used synergistically in the most unimaginable ways in the health care industry. “This is because it is playing a vital role in accessing the patients’ pathological conditions with noninvasive procedures.”
“Another challenge is to develop bio safe polymers and get them in the form/shape required for 3D printing.” Swapnil Sansare, CEO, Divide By Zero Tech
Process & application The term 3D printer was a trademark of Stratasys Inc, which, in 1999, allowed it to enter the public domain and become a generic industry term. The basic working integral part of the Stratasys Fused Deposition Modeling, or FDM machines create functional parts by extruding and depositing thermoplastic materials in layers. Here is an introduction to the process & application steps. Process: FDM Technology builds three-dimensional parts by melting and advancing a fine ribbon of plastic through a computer-controlled extrusion head, producing parts that are ready to use. The term fused deposition modeling and its abbreviation to FDM are trademarked by Stratasys Inc. Pre-processing—slicing or sectioning CAD design into layers: Firstly, the FDM process imports a design file, pick options, and create slices (layers). The pre-processing software calculates sections and slices the part design into many layers. Secondly, using the sectioning data, the software then generates “tool paths” or building instructions, which will drive the extrusion head and the job is sent to the 3D printer. Production—the layering process: Two materials enter the extrusion head, one to make the part, and one to support it. Plastic is softened by the use of heat, which are extruded in a ribbon, roughly the size of a human hair. Alternating between part material and support material, the system deposits thin layers. Post-processing—removing disposable support material: After completion of the part, the chamber is opened and the part is removed. Rough finishing is by either washing or stripping away the support material that held the part in place. Application: Considerations in the selection of 3D printer in terms of material, minimum layer thickness and support mechanism, different quality requirement can be met. Three
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“The advantage of performing the mock surgery on the 3D model allows visualising the final result with ease.” Dr Dinesh Kumar S, Associate Professor, JIPMER
levels of equipment, for example L1 (3D printing), L2 (rapid manufacturing for polymers) and L3 (rapid manufacturing for polymers, metals and ceramics) can cater to different material, technology, purpose and location preference. However, the cost also increases in choosing higher level equipment. Already, 3D printers have been used majorly by the medical industry for medical implants and replica of body part for mock surgery. On similar lines, Shastry affirms, “The implants cutting-edge technology offers the possibility of improved outcomes for patients. Currently, there are few implantable solutions that are possible from a long-term, mass production perspective. 3D printing is mostly used in the operation theatre environment to create surgical instruments, which offers innumerable possibilities. The most successful application in the bio medical industry, which is used as a mass manufacturing process yet in a customised manner is for producing the hearing aids. Almost 90% of the hearing aids are being 3D printed worldwide as it offers high level of customisation. The other field where 3D printing is popular is in the field of prosthetics.” Currently, medical, pharmaceutical and food handling equipment have stringent regulations to protect consumers from illness & disease. Regulations include standards such as ISO 10993 and USP Class VI, which classify a material as biocompatible. One such bio-compatible product developed
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I M A G E CO URT ES Y: Stratasys
f o r p ro t o t y p ing art eries
by Stratsys is ABS-M30i, which meets these criteria, so it can As per Shastry, successfully printed and implanted bladders be used for products that come in contact with skin, food and in humans, treating burn victims with the help of 3D printing medications. ABS-M30i blends strength with sterilisation technology are still in the research phase. “The fact that we capability – another criterion for products that come in contact have been able to do these successfully is very reassuring and with our bodies and the things we ingest. gives us a hope for the future”. Adding further on the challenges, There have been several cases where medical science has Swapnil Sansare, CEO, Divide By Zero Technologies, elaborates, joined hands with 3D printing technology to create prosthetic “Converting data from CT scans and MRI scans to printable limbs that might not have been possible a few years ago. data is a challenging job in terms of data preparation. Another According to Dr Dinesh Kumar, Associate Professor, challenge is to develop bio safe polymers and get them in the JIPMER, the advantage of performing the mock surgery on the form/shape required for 3D printing.” 3D model allows visualising the final result with ease. “Also it Highlighting the future outlook and challenges, Kumar familiarises us more intimately than a computer model and avers, “The medical community has generally been very prevents a whole bunch of on-table surprises. The familiarity enthusiastic about this technology. Since medical treatment is with the mock skull allowed us to be more confident and about catering to individuals, rapid prototyping technologies deliberate in our actual surgery reducing not only the time have an undeniable appeal to physicians. As cost is the primary taken but also the tissue trauma.” he added, after successfully roadblock, and as the cost should come down as 3D printers operating a 4-year-old girl child suffering from craniosynostosis: becomes more widespread, I foresee a wider use for this deformed skull, joints between skull bones fuse in an abnormal technology.” formation, leaving open cavities in skull, restricting brain growth. Conclusion
Future outlook & challenges Although the rapid change in the evolution of 3D printing forum from the period of its technological inception is still at a nascent stage, the key challenge lies in the feasibility and costs of such technology. Also, there are no FDA approvals for any such technology as these are still in the research phase. Currently, there are several projects that are working towards creating 3D bio printer and printing tissue cells and human parts. The need to make it commercially feasible and accessible, overcoming adaptability of human body parts is a major concern.
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One of the biggest challenges in this particular sector is the development of a technical foundation through research by industry & academia which needs to be guided by a clear vision of digital revolution in bio-medical application. However, there is no doubt about the advancements in the medical field. The material and technology used in helping 3D printers in bio-medical application, emerging technology trends and innovative solutions to meet customer requirements is still a challenge. FDA approvals along with the government appreciation can harness and appreciate the technological growth in this sector. ☐ > MORE@CLICK ADI03706 | www.AandD24.in
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REPORT | EVENT
Driving high-quality automation technologies Collaborating with the latest automation technology available for the Indian manufacturing industry, SPS Automation India 2015 was an innovative platform for automation, instrumentation, testing and quality control. A post-event reportâ&#x20AC;Ś
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SPS Automation India 2015 was recently held on February 5-7, 2015 at the Mahatma Mandir Convention & Exhibition Centre, Gandhinagar, Ahmedabad. It was supported by the Indian Profibus Profinet Association and laid a firm foundation for accessing high-quality manufacturing technologies for the Indian market, while highlighting the benefits of Profibus and Profinet fieldbus systems. The event was organised by Messe Frankfurt Trade Fairs India with Mesago Messe Frankfurt and PE Schall. The debut edition which was a launch platform for innovations in automation, instrumentation, testing and quality control witnessed over 60 leading industry brands presenting their latest technologies & solutions. With 56 exhibitors, spread over 3,500 sqm of exhibition space, the three-day fair attracted over 2,858 trade visitors. Engaged by the spectrum of technologies at the fair, both exhibitors and attendees agreed that the co-located fairs have the potential to drive high-quality manufacturing technologies in India in the coming years.
Highlights Some key highlights at the fair were one-of-its kind compact power connector by Escha in the worldwide market; Multi-2, a
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new generation safety automation product by Pilz India; MM Sysmac that integrates motion logic control by Omron; a machine that converts mechanical cam to electrical cam by NPS Drive Automation; new range of safety & logistic automation products by SICK India; 3D Poascon â&#x20AC;&#x201D; a laser based photoelectric sensor with advanced functionalities by Baumer Technologies and Econ Ethernet switches by Harting India and others. Partners for the launch edition, Pepperl+Fuchs, introduced their inhouse toy-AGV and 6 point laser dependent anticollision system at the fair. â&#x20AC;&#x153;Every industry is ROI dependent and looks at the profitability of technology. India in particular is moving from being a cost-conscious market to a value-based market with manufacturers ready to invest in automated processes. What will allow automation to achieve its prime level of inception is a smart combination of old processes with cutting-edge new technologies in India. SPS Automation India proved to be an excellent step towards this goal,â&#x20AC;&#x153; said Ravi Agarwal, Director, Pepperl+Fuchs. According to Amir Meghani, Assistant Manager â&#x20AC;&#x201C; Sales, Mitutoyo South Asia, the company met an informed set of customers, who were well informed about trends in measurement technology and quality control. On the other hand, Karan Batra, Head - Plant Operations, Tata Motors, said,
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INDUSTRY SPEAK “Our objective was to make ourselves present in the Gujarat market and SPS Automation India presented an ideal platform. We have attented SPS IPC Drives show in Germany and for the first challenge-laden edition in India, this was really a good start” Dwijen Desai, Manager – Corporate Communications, Omron
“It was a good start for the launch edition of SPS Automation India and our trust in Messe Frankfurt and SPS brand pulls us back for the next edition. The Indian market shows strong potential and we will definitely use the platform next year to our advantage.” Ajay Nair, Assistant Manager – Key Account, SICK India
“We work closely with Nikon, IFM, Mituotoyo for Technology Services, said, “The Indian industry is eyeing implementation of factory & process automation, sensor and opportunities from the Industrial Revolution 4.0 and SPS control technology and visiting SPS Automation India has Automation India is a good platform to educate manufacturing made us reinforce confidence with our suppliers and build professionals about the changing role of technology in the better and more efficient engineering systems for Tata Nano industrial set-up. The launch edition was quite impressive with plant operations.” many major brands present here. It would be good to see more Representatives from electricity generation, transmission Indian participation in the coming years and as one of India’s and distribution company, Torrent Power also visited the fair. foremost automation technology brand we sure look forward Speaking on the show, Divyesh Vagasia, Executive, Engineering to joining next year.“ & Projects, said, “The show is ideal for business discussions on Niraj Shah, Owner, Arihant Satiate, said, “The sessions at new range of products and services and a perfect platform to SPS Automation India were very apt as Indian industries are preview the latest in automation, control and sensor technology focusing on these emerging technologies and it helped to for many of our clean energy projects and power generation provide an in-depth view of these trends from the specialists projects happening across the country.” here. Also, purity of technology is not easily identifiable and it was wonderful to experience such a vast portfolio of automation and quality assurance technologies on one platform. Adding to Concurrent knowledge seminar this, Nishant Shah, Manager-Instrumentation, BASF, said, A seminar featuring presentations & case studies on the “BASF emphasises on matching market requirements with role of automation in manufacturing and process driven green and clean solutions and the sessions on energy-saving industries was conducted during the fair. The seminar on technology by Pepperl+Fuchs in particular held my attention. “Automation - Applications for Manufacturing Competitiveness” We are glad that the organisers selected Gujarat for organising drew interest with inspiring lectures from Pepperl+Fuchs, this international level show and I would definitely like to VIPA, Lenze, Omron and Pilz, thus, giving an insight in the attend the SPS Automation India seminar again next year.“ state of automation in India and an outlook in future tasks and According to Raj Manek, Executive Director & Board chances for the industry. Member of Messe Frankfurt Asia Holding, said, “The successful It also brought together more than 60 experts and industry debut of SPS Automation India, Motek and Control India has professionals, covered a range of topics from sensors, robotics, laid a solid foundation for the coming years and we are certain drives and motors to functional safety developed with the that the events will grow as the finest business arena to access support of AMA Association for Sensors and Measurements, opportunities in Indian market. Moreover, with Gujarat fast Germany. becoming the focal point as a manufacturing and industrial A white paper on the “Reality of adopting technologies and hub, it presents an ideal business destination. Therefore, for trends in India” by Frost & Sullivan was also launched during the next edition in 2016, we will further develop our strategy the seminar, which is in line with the new government’s to target key visitor segments, while bringing smart initiative and highlights the potential demand for goods & manufacturing technologies to the forefront of the Indian services that will drive the manufacturing renaissance. market. ” The next edition of the fair is scheduled on April 7 – 9, 2016 at the Helipad Exhibition and Convention Centre, Gandhinagar, Displaying latest industry trends Gujarat. ☐ A presentation on advancement in robotics in industrial Courtsey: SPS IPC Drives automation was presented by L&T Technology Services. > MORE@CLICK ADI03707 | www.AandD24.in Speaking on the event, Dr Keshab Panda, Chief Executive, L&T
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Process control system B&R has extended the benefits provided by OPC UA for the users of APROL process control system. An OPC UA server and OPC UA client are now available directly on APROL's Linux-based runtime servers to allow open, vendor-independent communication. It now makes it even easier for controllers, HMI panels and SCADA systems from any manufacturer to exchange data within B&R's APROL process control system. OPC UA for APROL process control All APROL variables that make the OPC system UA server available to other OPC UA clients via read or write access can be defined through a simple selection process. All data points that should be linked can be easily selected via integrated browser functionality for the OPC UA client. Important attributes such as read or write access are made available automatically. Motor management and control units, compact OPC controllers and other devices can directly exchange all important operating, service and diagnostic data with the OPC UA client.
PID controller with FlexBus™ technology Red Lion Controls has announced the integration of FlexBus™ technology to its PAX®2C proportional-integral-derivative (PID) controller portfolio. By inserting field installable FlexCard™ modules, users can now populate PAX2C PID controllers in more than 150 configurations to monitor and control multiple application processes on a single display. The company’s advanced Integration of FlexCard™ modules PAX2C modular platform provides an to PAX2C controllers easy upgrade path that enables integrators and panel builders to reduce inventory requirements while increasing application support. The solution is ideal for temperature, flow and pressure control in industries such as packaging, plastic, welding, extrusion and food & beverage. The new FlexCard modules include process input/remote setpoint cards that support input of 0/4 to 20 mA to enable cascade control loops where tighter control is required and heater current monitor cards that provide heater current input and can signal when the heater or heater control devices have failed before damage occurs.
B&R Industrial Automation | Pune Email: shyam.padwal@br-automation.com | Tel: +91-20-4147-8999
Red Lion India | Pune Email: india@redlion.net | Tel: +91-73-5001-1645
> MORE@CLICK ADI03708 | www.AandD24.in
> MORE@CLICK ADI03709 | www.AandD24.in
Right-angle gearbox
Lightweight guide system
Bonfiglioli has introduced the new TQK series - right-angle precision gearbox version. This precision gearbox is complementary to the TQ series and boasts maximum power density, allows for top performance, and offers a space-saving installation solution. Due to its cutting-edge design and stellar performance, it covers a wide area of applications where dynamic, high-speed, and top precision actions are required as well for reverse operations and a high number of starts TQK series and stops. TQK is particularly suitable for dynamic positioning applications for packaging and machine tooling as well for flat-bed machinery for wood working. In addition, it can carry out continuous running applications necessary for printing and paper converting. It provides a maximum power density. It features a versatile design in 5 sizes (060, 070, 090, 130 and 160), ratios from 6 up to 200 thanks to its design based on one and two reduction sizes, all this with a nominal torque from 30-800 Nm.
igus has advanced its guidelok slimline system and now presents the new GLSL-P, which is entirely made of plastic. The guide system for hanging energy chain applications does not require an enclosed channel trough or other elaborate, expensive enclosures and holds the energy chain system as in aisle travels on the railway. Instead, lightweight plastic segments are mounted only every two metres, which saves up to 80% trough costs guidelok slimline P and also weight compared to the previous metal option. Therefore, even faster speeds and (GLSL-P) accelerations can be achieved. Another advantage of the plastic novelty is that vibrations are absorbed better. Two automatically actuated compensators in the segments of the guidelok slimline P fix the e-chain and ensure a quiet, smooth run. If the chain moves in the radius through the segment, the compensator is activated and fixes the energy chain. The innovative locking levers are complemented by open guide rails made of reinforced plastic between the segments, which allows for more dynamics.
Bonfiglioli India | Chennai Email: ameet.rele@bonfiglioli.com | Tel: +91-44-6710-3800
igus (India) | Bangalore Email: harish@igus.in | Tel: +91-80-4512-7809
> MORE@CLICK ADI03710 | www.AandD24.in
> MORE@CLICK ADI03711 | www.AandD24.in
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AC output solid state relays
Flexible industrial connectors for switch cabinets
Crydom has released the new ELS Series of AC output solid state relays. The series includes 8 new models rated at 25 & 50 amp AC. Utilising the company’s proven Solid State Relay technology, the ELS series offer a combination of excellent performance and reliability at an affordable price. It is ideal for use in panels to control a variety of resistive and inductive loads in benign to harsh environment. The series is available on an operating voltage of 48-530 VAC, with a control voltage range of 4-32 VDC including Crydom’s ELS series solid an LED input status indicator and a IP20 state relays touch safe screw terminal configuration. Featuring 4 kV all solid state optical isolation with SCR output, the ELS series is available with either zero voltage turn-on for resistive load applications or instantaneous turn-on for inductive load applications. An output RC snubber network is also available for applications with highly inductive loads or noisy power lines.
Harting is now offering focused product solutions conforming to UL 508 (508 A, 508 C) for “Industrial Control Equipment”. With this solution, distribution lines can be made pluggable and flexible with industrial connectors. According to the standard from Underwriters Laboratories Product solutions conforming (UL), energy inputs and power branches to UL 508 (508 A, 508 C) for switch cabinets in the US and Canada have so far mainly been hard wired. Now the company offers two alternative possibilities. The first option is the use of a completely pre-assembled cable set, in which the proven Han® connectors are employed. These cable sets are listed in the PVVA section of UL 2237 − a standard extension to UL 508. The second alterative was opened by UL on HARTING’s initiative: The “PVVA2” section of UL 2237 lists “recognised components”, which are recognised for use in and on switch cabinets. In tests of short circuit current rating (SCCR) these components consistently reached the quasi standard value of 65 kA for industrial applications using conventional safety elements.
Custom Sensors & Technologies (CST) | Bangalore Email: india@cstsensors.com | Tel: +91-80-4113-2204
HARTING India | Gurgaon Email: abhishek.bimal@HARTING.com | Tel: +91-12-4400-9415
> MORE@CLICK ADI03712 | www.AandD24.in
> MORE@CLICK ADI03713 | www.AandD24.in
Gateways for measuring devices
Capacitive sensors
New gateway from HMS Industrial Networks enables M-Bus data from measuring devices to be monitored from Modbus-TCP networks. M-Bus (Meter-Bus) is a widely used communication standard for measuring devices. It is predominantly used in buildings, for example in electricity meters, gas meters, water meters or other types of consumption meters. By getting data from these measuring devices onto a PLC or SCADA system, users can get a total overview of their Modbus-TCP gateways energy consumption, including building parameters which previously had to be checked separately. The Anybus M-Bus to Modbus TCP gateway decodes M-Bus telegrams and maps meter values to Modbus registers. It is possible to connect up to 20 M-Bus slaves and enable them to communicate on a Modbus-TCP network. The solution can be extended by pairing the M-Bus gateway with an Anybus X-gateway Modbus-TCP, making it is possible to connect M-Bus devices to most industrial networks. Versions are available for CANopen, CC-Link, ControlNet, DeviceNet, EtherCAT, EtherNet/IP, HMS Industrial Networks India | Pune Modbus RTU, PROFIBUS and PROFINET.
With the brand new brochure, Micro-Epsilon has presented numerous possibilities to measure displacement, distance and position using capacitive sensors. Capacitive sensors use a highly stable measurement technique for displacement and distance measurement. These sensors stand out due to their sub-nanometre resolution, unmatched signal stability and a wide temperature range from -270°C to +270°C. In the new catalogue, users will find different series for the respective application: from the compact capaNCDT 6110 to the modular capaNCDT 6200 measurement system and the capaNCDT 6500 New capaNCDT high-performance series. Compactness and catalogue now online user-friendly handling make the capaNCDT 6110 sensor suitable for measuring displacement, distance and position in a diverse range of applications, from test cells to highly automated environments. The modular capaNCDT 6200 controller can be enlarged to a maximum of 4 measurement channels. The capacitive capaNCDT 6500 multi-channel measurement system is designed for maximum resolution providing high accuracy and resolutions to one-hundredths of a nanometre.
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Email: in-sales@hms.se | Tel: +91-20-2563-0211
Micro-Epsilon | Pune Email: pragnesh.mori@micro-epsilon.de | Tel: +91-20-2674-1009
> MORE@CLICK ADI03714 | www.AandD24.in
> MORE@CLICK ADI03715 | www.AandD24.in
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NEWS | TECHNOLOGY
8-slot DAQ controllers
Variable speed drives for food processing
National Instruments has announced the new CompactDAQ 8-slot controller, which expands the CompactDAQ controller offering to meet high-channel count applications in rugged environments. Both the 4-slot and 8-slot CompactDAQ controllers feature an Intel Atom dual-core processor that can run either Windows Embedded 7 or NI Linux Real-Time. By integrating the processor, signal conditioning and I/O into a single CompactDAQ system, engineers can reduce overall system cost and complexity CompactDAQ 4-slot and 8-slot controllers while increasing measurement accuracy. Integrated measurement systems reduce the number of components, connections and wiring needed, which often introduce noise and additional costs, to ensure high-accuracy measurements and cost-optimised systems. By pairing industry-standard OS options with LabVIEW system design software, customers can easily port LabVIEW code from existing measurement systems to these new CompactDAQ controllers. Customers can combine LabVIEW and over 60 sensor-specific I/O modules for CompactDAQ to quickly customise data acquisition systems to meet their application needs.
NORD Drivesystems has distributed drive concepts that meet the typical demands of the food industry. Variable-speed drives with IP66/IP69K ingress protection are suitable for processes that require regular cleaning with high-pressure steam jets. All components are manufactured in-house: gearboxes, smooth-surface motors, and frequency inverters. The nsd tupH antiDrive concepts with corrosion treatment gives the aluminum suitable protection housings a smooth and durable surface. Even blows and scratches do not impair the corrosion resistance. Since no coating is applied but the surface itself is hardened, there can be no pollution of products or process media as for instance with chipping paint. The nsd tupH treatment is approved for food applications according to FDA Title 21 CFR 175.300. The nsd tupH drives have performed in a salty atmosphere for one year. In contrast to painted drives, these units have not corroded. Due to their superior resilience, nsd tupH drives require minimal maintenance and have a long service life.
National Instruments | Bangalore Email: raginee.mamgain@ni.com | Tel: +91-80-4119-0035
Nord Drivesystems | Pune Email: jyoti.mishra@nord.com | Tel: +91-97-6549-0890
> MORE@CLICK ADI03716 | www.AandD24.in
> MORE@CLICK ADI03717 | www.AandD24.in
Detection scanner for field monitoring Pepperl+Fuchs with its Pulse Ranging Technology (PRT) has made the R2000 Detection scanner as the ideal solution for demanding field monitoring applications and assistance systems. Empty bay detection and gap recognition are as easily accomplished as the detection of overhanging and interfering products in high-speed AS/RS applications. Assistance systems for collision avoidance in both automatic guided vehicles or manually controlled forklifts and tuggers are another R2000 Detection 2Dclass of applications where the PRT-enabled R2000 laser scanner Detection offers outstanding features and performance. The speed and performance of the R2000 Detection is due to the revolutionary PRT measurement principle, a true time-of-flight technology based on ultra-short, high-intensity light pulses. As a result, the R2000 Detection offers exceptional ambient light immunity and unparalleled precision, even at long distances. The R2000 Detection, together with all products in the R2000 family, uses a unique rotating measurement head instead of a complex rotating mirror design. This approach provides several important functional enhancements including a wobble-free scan plane and a 360o field of view. Pepperl+Fuchs India | Gurgaon Email: fa-info@in.pepperl-fuchs.com | Tel: +91-12-4389-4000 > MORE@CLICK ADI03718 | www.AandD24.in
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Statement about ownership & other particulars about A&D, as required to be published in the first issue every year after the last day of February 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Monthly 3. Publisher’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 4. Printer’s Name: Shekhar Jitkar Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 5. Editor’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 6. Names & addresses of individuals who own A&D and partners or shareholders holding more than 1% of total capital of publish-industry India Pvt Ltd, 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 Details of the shareholders of publish-industry India Pvt Ltd who are holding more than 1% of the paid up equity share capital of the company as on 20-04-2015: a) publish-industry Verlag GmbH, NymphenburgerStrasse 86, 80636 Munich, Germany b) Kilian Mueller, NymphenburgerStrasse 86, 80636 Munich, Germany I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of my knowledge and belief.
Dated: 20th April 2015 Sd/SHEKHAR JITKAR Signature of the Publisher
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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T
Highlights - Jun/Jul 2015 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net Features Writer Maria Jerin maria.jerin@publish-industry.net
» Power & Energy The global energy industry is undergoing unprecedented changes. Rapid increase in energy consumption in the developing world will be the key driver of growth for the global energy market. Market participants have to start preparing for the oncoming spike in demand. To help companies effectively navigate the market as well as successfully achieve growth objectives, the next issue takes a look at the power and energy industry and gives a take on its current status as well as the future trends.
» Fieldbus & Networks Although fieldbuses have been around for more than ten years, recent years have seen an increase in focus on application of this technology for drives. One of the problems that has impeded the rapid adoption of fieldbus technology has been the lack of standardisation. Several competing alliances were created that all strived to develop an open fieldbus that would establish itself as standard. The result is that today there exist a plethora of standards for open fieldbuses. In the subsequent issue we take a look at some of the standards and recent developments in this sector.
» Test & Measurement Wireless is changing the face of test & measurement equipment at a pace never seen before. The test and measurement industry centers on the production of tools used to analyse, validate, and verify measurements of electronic and mechanical systems. The test and measurement industry creates both general use and highly specialised tools and caters primarily to high-tech industrial, automotive, communications, and medical electronics industries. The forthcoming issue gives an insight into the recent advancements and looks at how beneficial the systems can be to industries.
Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Sovan Lal Tudu (Senior Designer) sovan.tudu@publish-industry.net Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Ph: + 91 - 20 - 6451 5752
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Ajay Kumar Garg Engineering College . . . . . . 33 Altair Engineering India . . . . . . . . . . . . . . . . 21 ARC Advisory Group . . . . . . . . . . . . . . . . 8, 24 B&R Industrial Automation . . .Cover, 6, 7, 30, 77 Beroe Consulting India. . . . . . . . . . . . . . . . . 18 Bonfiglioli. . . . . . . . . . . . . . . . . . . . . . . . . . 77 Chanto Air Hydraulics . . . . . . . . . . . . . . . . . 35 Connectwell Industries . . . . . . . . . . . . . . . . . . 9 Contrinex Automation . . . . . . . . . . . . . . 27, 31 CST Sensors . . . . . . . . . . . . . . . . . . . . 17, 78 DCM Shriram. . . . . . . . . . . . . . . . . . . . . . . 46 Delta India Electronics . . . . . . . . . . . . . . . 3, 14 Eplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Faro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 FestoControls. . . . . . . . . . . . . . . . . . . . . . . 69 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . . 8 Harting . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Hilscher India . . . . . . . . . . . . . . . . . 32, 39, 66
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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page HIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 HMS Industrial Networks . . . . . . . . . . . . 49, 78 Honeywell Process Solutions . . . . . . . . . . . . 10 Hummel Connector Systems . . . . . . Back Cover ICP Das . . . . . . . . . . . . . . . .Back Inside Cover ifm electronic India . . . . . . . . . . . . . . . . 34, 67 igus India. . . . . . . . . . . . . . . . . . . . . . . . 2, 77 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 International Copper Association India . . . . . . 12 International Federation of Robotics . . . . . . . . 10 JUMO. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 KEPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . 50 Kubler Automation . . . . . . . . . . . . . . . . . . . 23 Lapp India . . . . . . . . . . . . . . . . . . . . . . . . . 44 Micro-Epsilon . . . . . . . . . . . . . . . . . 5, 11, 78 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 51 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 63
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Murrelektronik India. . . . . . . . . . . . . . . . 16, 37 National Instruments . . . . . . . . . . . . . . . . 4, 79 NORD Drivesystems . . . . . . . . . . . . . 1, 10, 79 Omron Automation . . . . . . . . . . . . . . . . . . . 13 Pepperl+Fuchs . . . . . . . . . . . . . . . . . . 38, 79 Phoenix Contact . . . . . . . . . . . . . . . . . . 43, 64 Pilz India . . . . . . . . . . . . . . . . . . . . . . . 53, 60 Red Lion Controls. . . . . . . . . . . . . . . . . . . . 77 Renu Electronics. . . . . . . . . . . . . . . . . . . . . 57 Rockwell Automation. . . . . . . . . . . . . . . 11, 15 Schmersal India . . . . . . . . . .Front Gate Fold, 40 Schunk Intec India . . . . . . . . .Front Inside Cover Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPS Automation . . . . . . . . . . . . . . . . . . . . . 75 Stratasys . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Vega India Level and Pressure Measurement 42, 71 WIN INDIA. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `600 AandD.india@publish-industry.net Tel: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.aandd24.in
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