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ON THE COVER
WHAT'S NEW IN PROCESS TECHNOLOGY OCTOBER 2012
CONTENTS
Telemecanique Sensors is a world-class global brand offering a comprehensive range of products with over 25,000 types of sensors, including limit switches, pressure sensors, proximity sensors, encoders and safety sensors. In addition, Telemecanique provides state-of-
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The power factor effect How reactive and nonlinear loads affect energy efficiency
many PLC manufacturers.
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New products
Manufacturing sensors and factory automation
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Hot products online
Sensors is well known for its high-quality
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Choosing the ideal conveyor for your food product
The correct decision depends on the application and the whole operational and lifecycle cost
the-art RFID systems that are compatible with
products for more than 90 years, Telemecanique products and superior performance, providing all the right agency approvals. Telemecanique Sensors understands the importance of staying competitive in today’s
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Evolution in motion
manufacturing environment. That is why it is
The machine automation controller
increasing R&D investment, developing new
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As I see it The future of the IC&A industry sectors
and innovative products that have a positive impact on production, while at the same time establishing global adaptation centres to enable a fast response and quick delivery of customised sensor products designed to meet customer needs. Telemecanique’s aim is to simplify installations, allowing customers to focus on what is important, improving their plant and machine performance. A dedicated team of sensor application specialists works with customers to recommend the right solution, the first time. Telemecanique provides logistics designed to meet the specific needs of its customers, with a worldwide supply chain and a network of local distribution. Its commitment is to ensure it is a reliable supplier and partner to your business. Connect with the experts! Schneider Electric Aust Pty Limited www.tesensors.com/au
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THE POWER FACTOR EFFECT Š iStockphoto.com/TERADAT SANTIVIVUT
HOW REACTIVE AND NONLINEAR LOADS AFFECT ENERGY EFFICIENCY Glenn Johnson, Editor
Technology such as variable speed drives allow us to save energy from motor applications, but electrical energy efficiency is not just about speed control. Non-unity power factor loads and harmonic distortion increase energy losses in the power distribution network and increase infrastructure costs.
4 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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T
he effect on power network infrastructure of non-unity power factor loads and harmonics has been increasing in recent years. Previously these loads were mostly linear (direct connected motors) and with minimal harmonic distortion, but the increase in the use of inverter drives in industry and other forms of commercial and domestic electronics in the form of fluorescent lighting and switchmode power supplies for electronic equipment such as computers has led to a sharp increase in harmonic distortion, and a decrease in energy efficiency. This article is intended as a ‘refresher’ on non-unity power factor loads, both linear and nonlinear, and why they are detrimental to energy efficiency goals.
Power factor In an AC electrical circuit, the power factor is defined as the ratio of the real power reaching the load to the apparent power in the circuit and is a dimensionless number between 0 and 1. Real power is the capacity of the circuit to perform work (for example, the capacity of it to be converted to rotational motion in a motor), while apparent power is the simple product of the current and voltage in the circuit (simple Ohm’s law). The causes of the difference between real and apparent power are: • the phase shift between current and voltage caused by a reactive (non-resistive) load; • the non-fundamental harmonics (distortion) caused by nonlinear loads such as rectifiers and inverters. Both of these causes result in energy flowing in the circuit which is not used to do useful work at the load, but which is nevertheless consumed from the power supply grid. In other words, a load with a low power factor (closer to 0) draws more current from the supply than a load with a high power factor (close to or equal to 1) for the same amount of useful power transferred. The resulting higher current results in higher voltage drops in the circuit and higher costs of delivery (such as larger cable), and usually results in larger electricity charges to the consumer.
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Linear loads In a purely resistive circuit (such as a simple filament lamp load), the current waveform is undistorted and in phase with the voltage supply (phase angle φ = 0° - see Figure 1). In this case the apparent power and real power are the same and all the energy is transferred to the load (with the exception of a small voltage drop and power loss in the cables delivering the current). When reactive loads such as capacitors or inductors are present, energy stored in the load results in a phase shift between the current and voltage waveforms (φ ≠ 0° - see Figure 2). The energy stored in the load is returned to the grid in each cycle after a delay. This stored energy is not producing useful work, and its flow is therefore referred to as reactive power. In the case of a purely sinusoidal waveform as shown in Figures 1 and 2, the relationship between apparent power, real power and reactive power is a vector triangle such that:
where: S = complex power (|S| = apparent power) in volt-amperes (VA) P = real power in Watts (W) Q = reactive power in volt-amperes reactive (VAR) The power factor is the ratio of the real power to the apparent power, and since this is a vector triangle (phasor) relationship, the power factor is equal to the cosine of the phase shift between current and voltage, |cos φ|, and:
This type of linear power factor, arising only from the difference in phase between the current and voltage, is also known as displacement power factor, to differentiate it from the power factor produced by nonlinear loads as described below. Real-world loads consume both real and reactive power, but only the real power delivers work. For example, if a 1 kW load
OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5
Energy Efficiency
Figure 1: A purely resistive load (ϕ=0°) results in a unity power factor and all the power is delivered to the load.
has an equally resistive and reactive component and results in a phase angle of 40° (Figure 3), then the power factor will be cos φ = 0.8 and the apparent power will be 1.41 kVA. The additional apparent power must be produced and delivered by the supply and results in larger distribution losses.
Linear power factor correction The most common type of real loads in industry are inductive, usually motors or other types of electromagnetic actuator. Inductive loads, storing energy in a magnetic field, cause the current waveform to lag the voltage waveform. This can be offset by the use of a purely capacitive load in parallel with the inductive load, since the capacitor (storing energy in an electric field in its dielectric) causes the current waveform to lead the voltage waveform. Sizing the capacitive reactance to match the inductive reactance of the real load will cancel it out and reduce or eliminate the reactive power consumed by returning the power factor to 1. All this is fine while the load is operating. If the motor is switched off, then the capacitors need to also be removed from the circuit so they do not consume reactive power themselves. In the case where power factor correction is applied across a
Figure 2: A purely reactive load (ϕ=90°) results in a zero power factor and no real power delivered to the load.
system of loads (such as multiple motors), then the amount of correction needs to be switched/adjusted as the loads go on- and offline. Incorrect power factor correction in such a system can result in resonance in the electrical network and instability. In large sites, such as steel mills, other techniques are often used to provide dynamic power factor correction, such as synchronous condenser systems and static VAR compensators, but these are beyond the scope of this article.
Nonlinear loads Loads that involve frequent switching produce harmonics that are multiples of the power system frequency. Switchmode power supplies, fluorescent lighting, welding machines and arc furnaces commonly cause these kinds of disturbances, but the most common source of these harmonics in industry today is variable speed drives(VSDs). VSDs use a rectifier to switch the waveforms on each phase of the supply to produce a DC output for conversion to a variable frequency output via an inverter. VSDs are generally seen as beneficial from a power factor perspective, because they increase the displacement power factor that would normally be produced by a motor to almost unity (typically 0.95). In a typical three-phase rectifier, the
6 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
diodes (or thyristors) switch on and pass current only when the voltage across them exceeds their switching threshold, and don’t conduct when it is reversed. In the case of thyristors, their switching can be further delayed by controlling when they are triggered. The resulting current in the supply for a single phase resembles the graph of Figure 4, for a single cycle of the supply voltage. This results in the harmonics shown in Figure 5, where the harmonics at 5, 7, 11 and 13 times the mains frequency are significant. These harmonics do not produce work in the end load being driven by the VSD, but still produce energy loss in the supply network. Since the desired current is a pure sinusoid, the other harmonics present in the supply current go to make up what is known as harmonic distortion. Total harmonic distortion (THD) is defined as the ratio of the sum of the power in the non-fundamental harmonics to the power in the fundamental. Since power is proportional to the square of current (I2Z), then the total current harmonic distortion is:
Where the harmonic currents are RMS values.
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Energy Efficiency
Figure 4: Current waveform of one phase of a three-phase rectifier relative to a single cycle of the supply.
Figure 3: A real reactive load may typically result in a phase shift of ϕ=40° (PF ~ 0.8) and requires a larger peak current to deliver the same real power compared to the resistive load of Figure 1.
Figure 5: The harmonics produced by the waveform of Figure 4. The THD in this case is nearly 90%.
We can define then distortion power factor as:
THD by as much as 50% on load. Even so, a typical ‘passively filtered’ VSD can still cause a THD of up to 50%.
In other words, the distortion power factor is the ratio of the fundamental current to the total phase current and is like displacement power factor, a number between 0 and 1. The total power factor can therefore be defined as the displacement PF multiplied by the distortion PF:
Active harmonic correction
Nonlinear power factor correction Passive harmonic correction The graph in Figure 4 represents the theoretical current waveform produced by a simple three-phase diode rectifier, and the spectrum of Figure 5 shows a THD of nearly 90%! In practice, a real VSD produces even more ‘spikey’ current waveforms in the supply, when under a real load. On the other hand, VSDs contain filtering capacitors after the rectifier and often line inductors before and/or after the rectifier, which have the effect of ‘softening’ the waveform of Figure 4 and reducing the harmonics of Figure 5, reducing the
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Many drive companies are now producing active harmonic filters (active PFC) to make the drive appear purely resistive and without harmonic distortion, as viewed by the supply grid. Active filters are wired in parallel (shunt) with the supply input of the drive system and actively change the waveshape of the supply current. They work by electronically detecting and measuring the harmonic currents created by the nonlinear load and then synthesising and injecting a current that negates the distortion, virtually eliminating the harmonics. The cost of doing this, of course, is much higher than with passive correction, and it should be noted that active correction must be provided in addition to passive correction, not instead of it. This is because the passive correction serves to reduce the intensity of the distortion and lower the amount of distortion energy the active filter must manage.
real-world applications, multiple loads across the supply can result in unbalanced phases, and non-zero neutral current, at various frequencies. This often results in other harmonics (such as the third, sixth and ninth harmonics in Figure 5) becoming more significant in the supply current. One of the benefits of an active filter is that it can be applied across multiple nonlinear loads, and even if the loading is unbalanced, then the active filter can be used to ‘rebalance’ the supply current.
Always seek expert advice I hope this article has served as a basic reminder of how energy efficiency can be negatively affected by some of the very technologies (such as VSDs) that we apply to save energy. Of course, every application and situation will be unique, and if you are considering passive or active power factor correction or filtering, then you are best advised to seek the advice of your power system and drive vendor to decide on the appropriate technology for your PFC needs.
Unbalanced loads In a normal, single motor application, the phase loads should be balanced, so that the neutral current is zero. However, in
Glenn Johnson BE (Hons) MA is the Editor of 'What's New in Process Technology' and www.processonline.com.au
OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7
NEW PRODUCTS
POSITIVE DISPLACEMENT FLOW METERS The Trimec Flow Products Multipulse range of positive displacement flow meters offers a high level of accuracy and repeatability. These precision meters are used for flow rate measurement in flow monitoring and control applications and for totalising in dispensing and batching. Multipulse meters are suitable for use with a wide range of clean liquids including viscous lubricants, chemicals, food bases and non-conductive low-viscosity solvents, either pumped or gravity fed. The MP Series flow meters are selected based on flow range, pressure, temperature, material compatibility and functionality. The flow meters are manufactured in several materials, such as aluminium, stainless steel and UPVC (SAP) depending on the measured product. The flow meters are available as blind meters with pulse output or with integral or remote totalisers, flow rate displays or preset batch controllers, and outputs can be interfaced to most electronic displays or instrumentation. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/Q722
COMPACT SAFETY RELAY The PNOZcompact safety relays monitor the basic functions of emergency stop or safety gate, providing maximum safety up to Performance Level (PL) e or SIL3. PNOZcompact is equipped with fixed, integrated push-in spring terminals, which enable simple, quick installation without the use of tools. With a compact width of 22.5 mm, it also saves space in the control cabinet. As the first safety relay in the range, the PNOZ c1 features a block diagram with a connection example printed on the side of the unit, which guarantees rapid installation and provides visual support when servicing. This helps to reduce machine downtimes. More detailed information is available via the QR code printed on the device, which provides direct access to online content with the latest technical information on the product. The functional safety relay enables dual-channel wiring with detection of shorts across contacts, which permits either manual or automatic reset. PNOZcompact has a 24 VDC supply voltage. Operating voltage and switch status is displayed via LED, guaranteeing rapid diagnostics. Pilz Australia Industrial Automation LP Contact info and more items like this at wf.net.au/R155
FLOW SWITCH The Series V4 Flotect flow switch operates automatically to protect equipment and pipeline systems against damage from reduction or loss of flow. A magnetically actuated switching design gives good performance, and there are no bellows, springs or seals to fail. Instead, a free-swinging vane attracts a magnet within the solid metal switch body, actuating a snap switch by means of a simple lever arm. The V4 Flotect switch features a leak-proof, explosion-proof (IECEx and ATEX) body machined from bar stock and weatherproof to IP65. There is a choice of custom vane calibrated for the application, and it can be used in pipes from 38 mm up. It installs directly and easily into a pipeline with a thredolet, tee or flange, and the electrical assembly can be easily replaced without removing the unit from installation. The pressure rating is 69 bar with the brass body and 138 bar with the 316 SS body. Applications include protecting pumps, motors and other equipment against low or no flow; controlling the sequential operation of pumps; automatically starting auxiliary pumps and engines; stopping liquid-cooled engines, machines and processing when coolant flow is interrupted; shutting down burners when the airflow through heating coils fails; and controlling dampers according to flow. Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/Q721
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HOT PRODUCTS
ON WWW.PROCESSONLINE.COM.AU THIS MONTH DEVELOPMENT SYSTEM National Instruments has introduced NI LabVIEW 2012, the latest version of its system design software for engineers and scientists. National Instruments Australia
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LED OPEN FRAME MONITOR sign enables flexible and customised face plates for easy re-engineering and it is suitable for any embedded application. Advantech Australia Pty Ltd
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10 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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The open front bezel de-
SERVOMOTORS PMCtendo SZ servomotors are characterised by quiet operation and high process quality due to low cogging torques. Pilz Australia Industrial Automation LP
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Domino iTech
A tried&true way to LEAN your labelling and coding operations.
Domino introduces iTech: Common parts, software and control pads for all coding technologies. Today’s business is about LEAN operations, process improvement and achieving 100% quality. The new Domino iTech range allows users to control multiple technologies from a single touch point, and provides maintenance staff access to common parts for all equipment. Achieving LEANER operations, Domino’s iTech range allows the use of common parts, software and control pads for continuous ink jet, laser, thermal ink jet, thermal transfer overprint and print and apply technology.
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NEW PRODUCTS
DRY-RUNNING COMPRESSOR RANGE Kaeser has introduced a range of dry-running rotary screw compressors, the CSG-2 series. Available with drive powers ranging from 37 to 90 kW, these two-stage machines provide free air deliveries from 4.8 to 12.7 m³/min for pressures between 4 and 10 bar (g). Together with the existing DSG-2 and FSG-2 series, Kaeser’s dry-runner range covers free air deliveries from 4.8 to 50 m³/min, or even or 51.8 m³/min with variable speed control. CSG-2 systems are suitable for applications where dry compression is required. Users can choose between air- and water-cooled versions and also have the option of SFC variable speed control for applications with fluctuating air demand. The air-cooled systems are designed for use in ambient temperatures up to 45°C. Each unit contains a quality, two-stage compressor airend. The rotors are equipped with Ultra Coat, which can withstand temperatures up to 300°C. The coating is also abrasion-proof. Kaeser claims its dry-running rotary screw compressors consume no more energy after years of use than when first commissioned. The PC-based Sigma Control 2 internal controller combines multiple control modes, a timer and base load sequencing to provide energy savings. The system provides flexibility through its numerous interfaces and plug-in communication modules, enabling easy connection to master control systems, computer networks and/or remote diagnostics and monitoring systems, such as Kaeser’s teleservice facility. CSG-2 systems have a large display, SD card slot and RFID reader. They are powered by IE3 premium-efficiency motors and have PT100 sensors for measuring and monitoring motor winding temperature, which enables maximum motor switching frequency and reduces idling periods. Kaeser Compressors Australia Contact info and more items like this at wf.net.au/Q834
COMPUTER FOR POWER SUBSTATIONS The Moxa DA-685 is a 19″ 2U rackmount computer tailored for substation applications, featuring many communication ports and precision timing capabilities. The DA-685 series computers feature the Intel Atom D510 processor, a fanless design, PTP v2 and EMC Level 4 certification. They feature an Intel Atom D510 1.66 GHz processor with a DDR2 SODIMM socket supporting DDR2 667 RAM up to 2 GB. Communication ports include 10/100/1000 Mbps ethernet, two RS232/422/485 serial ports (DB9 male), six RS485 serial ports (terminal block), two USB 2.0 ports for high-speed peripherals, a CompactFlash socket for storage expansion and a SATA interface for hard disk drive expansion. Madison Technologies Contact info and more items like this at wf.net.au/R406
12 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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PLANT PERFOMANCE SOFTWARE ExperTune has expanded the functionality of its PlantTriage software with the CompareMap tool, designed to focus operator attention on changing plant conditions. The tool highlights the biggest changes in plant performance and provides drill-down into corrective actions. The CompareMap approach compares the plant performance from two periods of time. Performance improvements and deterioration are both instantly highlighted. Operators can immediately focus on important changes in the plant. For example, a shift operator can quickly see what has changed since their last shift. The high-level plant graphic is based on Tree Map technology. Tree Maps were developed by the University of Maryland, as a way to visualise large amounts of data. Applied to real-time process control data, Tree Maps have been used to provide a snapshot to pinpoint trouble spots in plant performance. CompareMap is flexible, allowing more in-depth analysis by process engineers and control engineers. Over 80 aspects of plant performance can be monitored. These performance measures include production, quality, reliability and cost-related parameters. CompareMap is included with all PlantTriage systems, version 10.1 and higher. Existing PlantTriage users receive the features at no charge, as part of their software maintenance agreement. Daesim Technologies Pty Ltd Contact info and more items like this at wf.net.au/Q844
CONDUCTIVITY SENSOR Mettler Toledo Process Analytics Division has introduced the Thornton UniCond conductivity sensor with inline calibration capability. Enhanced sensor electronics allow calibration using an accessory UniCond calibrator without removing the sensor from the process. This is a critical factor in pharmaceutical water compliance, microelectronics fabrication, power generation, pure water and steam applications. The UniCond calibrator is a digital conductivity system that meets USP <645> and EP requirements. It provides NIST-traceable resistances for all ranges of UniCond measuring circuit. A major advantage of the sensor is its ultra-wide conductivity measurement range, from ultrapure water to seawater with one sensor. Stainless steel sanitary sensors have measurement ranges from 0.02 to 2000 ÂľS/cm total range with Âą1% system accuracy to meet pharmaceutical water requirements. The sensor may be used with Thornton M300ISM or M800 multiparameter transmitters, which enable the use of two or four digital sensor inputs for continuous measurement of ozone, dissolved oxygen, conductivity, pH and total organic carbon. Mettler Toledo Contact info and more items like this at wf.net.au/R083
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OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13
NEW PRODUCTS
DAQ SYSTEM National Instruments has announced the latest stand-alone NI CompactDAQ system, a highperformance embedded measurement and logging platform with a built-in, dual-core Intel processor for running data acquisition, online analysis and logging software. The NI CompactDAQ system features an Intel Core i7 dual-core processor, 2 GB RAM and 32 GB nonvolatile storage to allow the running of high-performance, mixed-measurement tests while logging data directly to the system, removing the need for an external PC. It is also fully compatible with LabVIEW 2012. The 8-slot chassis offers more than 50 C Series I/O module options - users can mix and match a variety of I/O and sensor types, including AI, AO, DIO and CAN to create custom measurement and logging systems. USB, ethernet and serial ports allow users to connect USB and ethernet NI CompactDAQ devices, including the NI cDAQ9184 ethernet chassis, to expand the number of module slots for large-channel-count applications or to integrate other devices, such as a camera or GPS device. Data can be streamed to disk at up to 30 MBps, allowing users to simultaneously stream continuous measurements with sample rates up to 1 MSps per channel. National Instruments Australia Contact info and more items like this at wf.net.au/R077
WIRELESS GATEWAY WITH ETHERNET/IP Emerson has introduced a Smart Wireless Gateway with native EtherNet/IP output, providing ease of integration and enhanced security functionality. Currently, PLC users requiring EtherNet/IP must purchase a converter from a third-party provider to add wireless to their systems. Using a converter can increase the time it takes to establish and run the wireless network, while adding cost and hardware
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violations without having to make
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expensive site visits. The remote analyser solution comprises AirMagnet WiFi Analyser PRO 10.0, AirMagnet Spectrum XT 3.5.1 and AirMagnet Series Sensors. Sensors can be deployed to remote sites and then be monitored via WiFi Analyser PRO or Spectrum XT at a control site. Fluke Networks Contact info and more items like this at wf.net.au/R152
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NEW White Papers
now available online! Advanced pressure diagnostics provide valuable insight into your process Advanced pressure diagnostic technology provides a means for early detection of abnormal situations in a process environment and enables the user to proactively respond to changes in the process, troubleshoot and prevent future shutdowns. Find out how it can help prevent abnormal situations in your plant.
CERTIFIED SAFETY ENCODER PCA’s Fraba Posital division has announced the addition of a certified safety encoder to its OCD series of absolute shaft encoders. The encoders offer increased personnel safety, minimal risk of machines malfunctioning and reduced costs, the company claims. In addition to creating a safer environment, the transmission of ‘Safety Position’ eliminates the need to install two separate encoders, and the complex development of validation monitoring logic in the PLC. The encoders fulfil the requirements of IEC 61508, EN 62061 (SIL CL3) and EN ISO 13849 (performance level e). Operated with protective extra low voltage (PELV), they are suitable for use in drive technology, lift applications, mobile machines, construction machinery,
Global networks for M2M M2M has a relatively short history, having been around since 2000 when it became apparent that communication between machines carrying out similar functions would be a good idea. It has since broadened into communication between dissimilar devices, examples being medicine and mining. This eBook explains more about this technology.
cranes and machine tools. The OCD encoders use a proven optoelectronic method to measure absolute position values. The single-turn sensor provides a resolution of up to 16 bit/revolution (0.05°) and the multiturn unit registers a maximum of 16,384 revolutions (14 bit), thereby covering an overall measuring range of 30 bit. The encoders have two functional devices within the one physical housing. Plant Control & Automation
Power quality eBook
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With equipment and energy costs rising, it’s hard to stress enough the importance of power quality. Power quality issues can hamper production processes, damage costly equipment and lower productivity. This eBook features articles on power quality challenges, managing and reporting problems, improving efficiencies and reducing costs. Download now.
Flammable gas detection technology: selection and application tips Gas detection technology should always be chosen based on the hazard faced. Selecting the right technology and applying it correctly will prevent injuries, save lives and save money in the long term. This white paper provides insightful selection and application tips - download now to ensure you are prepared.
HIGH-PRESSURE RELIEF VALVES Emerson Process Management has expanded its overpressure protection range with additional sizes for the EZH, EZR and FL series relief valves and backpressure regulators. Pilot-operated relief valves and backpressure regulators are used for overpressure protection in natural gas systems to protect pipelines and gas processing equipment downstream of the regulator. The EZH is now offered in 1″ through 4″ sizes, the EZR is available in 1″ to 8″ sizes and the FL is available in 1″ to 10″ sizes. The Types EZH, EZR and FL are used in applications requiring high capacity and low pressure build-up. Typical applications would be city gate stations, large capacity distribution systems and power plant feeds. The EZH, EZR and FL series offer bubble tight shut-off, durable construction, versatility, precise pressure control, a common
For these and more White Paper downloads, visit www.processonline.com.au/white_papers
body platform and long life. Emerson Process Management Contact info and more items like this at wf.net.au/Q913
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NEW PRODUCTS
HYDRAULIC COUPLINGS Gates now offers a flexible solution that is compatible with a broad range of wire-braid hydraulic hose. GlobalSpiral ferrules are a money-saving solution for those who crimp their own assemblies in the field or in the shop and, due to remoteness of location, costassociated inventory limitations, or both, may not have access to a full inventory of couplings for both wire-braid and spiral-wire hoses. Six GlobalSpiral ferrules will do the job of 143 wire-braid couplings. The Gates GlobalSpiral couplings are claimed to reduce costs and simplify operations as they are compatible with wire-braid and spiral-wire hydraulic hose assemblies. This line of couplings will give those who crimp their own assemblies the ability to assemble them
DOUBLE BLOCK AND BLEED VALVE Noshok has announced the 3070 Series double block and bleed valve with redundant isolation valves and a dedicated vent valve to ensure additional safety in hazardous media applications. The Noshok 3070 Series has a 700 bar hard seat pressure
not only with Gates spiral-wire line of hoses, but with their full line of wire-braided hoses as well. These durable, two-piece couplings have been designed and validated with Gates’ production hoses in order to offer the optimal hose/coupling interface across all sizes and hose/coupling types. Validation testing has been conducted in accordance with SAE J517 specifications and requirements. ‘Bite the wire’ crimp design improves coupling retention and blow-off prevention and the machined Full-Torque Nut technology eliminates damaged couplings and leaks due to over-torquing.
rating at 95°C. The block valve isolates the downstream process
Gates Australia Pty Ltd
fluids, while the bleed valve exhausts upstream fluids, enabling
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instruments to be removed without disturbing the permanent piping installation on the bottom. The 1/4″ NPT vent plug is located 90° to the left and may be removed and replaced with exhaust piping to direct the fluids or gases to a safe location. All Noshok valves are 100% helium leak tested to 1 x 10-4 mL/s and a blow-out proof stem provides a secondary stem seal in the full open position. An FKM O-ring seal and a PTFE backup ring below the stem threads protect from corrosion and galling, while a PTFE or Grafoil packing is optional. All stems are made from 316 stainless steel and all stem threads are rolled for strength and ease of operation. There is a one-piece bonnet with a metal-to-metal seal to the valve body below the bonnet threads and a slotted spring pin prevents accidental bonnet loosening. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/R067
ULTRASONIC LEVEL CONTROLLERS Siemens has released a series of ultrasonic controllers with 1 mm measuring accuracy. The Sitrans LUT400 series controllers are compact, single-point, long-range ultrasonic controllers for continuous level or volume measurement of liquids, slurries and solids. Importantly, they deliver high accuracy monitoring of open channel flow. They are also suited to key applications such as wet wells, reservoirs, flumes/weirs, chemical storage, liquid storage, hoppers, crusher bins and dry solids storage. The Sitrans LUT400 comes in three different models to match the application, level of performance and functionality required. The LUT420 level controller measures the level or volume of liquids, slurries and solids, and conducts basic pump control functions and basic data-logging capabilities. The LUT430 is a level, volume, pump and flow controller. It includes all the features of the LUT420 plus a full suite of advanced pump control and alarm functionality, open channel flow monitoring, and has basic flow data-logging capabilities. The Sitrans LUT440 is a high-accuracy OCM. It includes all the features of the LUT430 and provides an accurate of ±1 mm within 3 m. It has a full suite of advanced control functions as well as enhanced flow-logging capabilities. Siemens Ltd Contact info and more items like this at wf.net.au/R148
18 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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To complement our existing solution, we’ve introduced the all new Modicon X80 drop. This cost effective offer is based on the Modicon M340 form factor, which now enables you to develop robust systems with a very compact footprint. As an integral part of Schneider Electric’s ‘PlantStruxure’ methodology, QEIO supports today’s remote I/O architecture requirements, as well as being scalable and flexible enough to adapt to future installation modifications. © 2012 Schneider Electric. All Rights Reserved. Schneider Electric and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. www.schneider-electric.com.au CLIPCOM 25305
© iStockphoto.com/David Gomez
CHOOSING THE IDEAL CONVEYOR FOR YOUR FOOD PRODUCT
Materials handling
Should you use a traditional belt conveyor, or a vibratory or horizontal motion conveyor for moving your food products? Each has its pros and cons, and the lowest cost to implement many not necessarily mean the lowest total cost of ownership.
M
any food processors and packers have traditionally relied on belt conveyors to transport bulk and packaged product on their production lines, in part because low capital costs make these conveyors seem so affordable. However, when ongoing maintenance and sanitation costs are factored in, the affordability equation shifts in favour of other conveyor types. Add performance issues like gentle handling and throughput into the analysis and each food product and application points to its own ideal conveying solution. In this article, we will explore the types of conveyor systems that are suitable for foods - belt conveyors, vibratory conveyors and horizontal motion conveyors - highlighting the strengths and weaknesses of each. We will consider a variety of products including fresh-cut and processed fruits and vegetables, potato products, salty and savoury snack foods, meats, seafood and other food products as well as a range of applications from simple conveying to dewatering, fines removal and more. The goal is to help food processors and packers identify the most effective conveying solutions for their specific applications.
Belt conveyors Belt conveyors typically offer the lowest initial capital cost of all the conveying solutions, which contributes greatly to their popularity. But such a simple cost analysis is short-sighted because high maintenance and sanitation costs cause the total cost of ownership of a belt conveyor to quickly rise. Although the initial price tag for vibratory conveyors and horizontal motion conveyors is often $8000 to $10,0001 higher than that of belt conveyors, the larger upfront cost is quickly recovered because it can cost $30002 a year more to maintain and clean a belt conveyor. Keep a conveyor in operation for more than three years and the vibratory or horizontal motion shakers usually cost less. Although a total cost of ownership analysis indicates that vibratory and horizontal motion conveyors are less expensive than belt conveyors in the long run, there are food applications that are best served with belt conveyors, warranting their use despite the higher cost. These applications include the following: • Belt conveyors are ideal for achieving significant changes in elevation. Vibratory shakers are effective if the required incline angle is 10 degrees or less, but beyond 10 degrees, a belt conveyor is needed. • Using conveyors to store large volumes of material is often best handled with a specialised belt conveyor called a ‘storeveyor’, while horizontal motion conveyors are perfect for many mediumcapacity storage applications. • Conveying packaged product can be achieved effectively with either a belt conveyor or a vibratory shaker. The sanitation advantage of a vibratory shaker is less of a factor with packaged product, making a belt conveyor appropriate in this application. With a range of plastic, fabric and metal belt materials as well as conveyor geometries, belt conveyors can be designed for many food applications. However, high maintenance costs and sanitation challenges often make vibratory shakers and horizontal motion conveyors preferred solutions.
www.ProcessOnline.com.au
Vibratory shakers There are two main types of vibratory conveying systems - true natural frequency conveyors with mechanical drives and electromagnetic conveyors with electromagnetic drives. Both use frame-mounted drives and spring-arm assemblies to distribute energy to the conveyor bed, producing a diagonal, harmonic motion that moves product forward. Traditional vibratory conveyors that use mechanical drives produce a high-amplitude, low-frequency movement. Electromagnetic shakers allow lower conveying pan amplitudes at higher frequencies that can be varied, which make them ideal for lines that handle a wide variety of products or lines that require precise metering. Compared to belt conveyors, vibratory conveyors are inherently cleaner with stainless steel product zones and no belt-to-pulley/gear laminations. They also reduce maintenance, which results in a lower total cost of ownership over the life of the conveyor. Some newer vibratory shakers take low maintenance to the next level with drive systems that eliminate the need to lubricate or change oil. In addition to these across-the-board benefits, there are specific applications that do particularly well with vibratory conveyors, as follows: • Vibratory conveyors are ideal for dewatering, as the vibration releases the bond between surface moisture and product. Furthermore, the water can be easily collected from a vibratory shaker, which allows a processor to recycle it. This dewatering application is ideal for a wide variety of potato products and produce such as green beans, carrots, leafy greens and some fruits such as strawberries and blueberries. • Vibratory conveyors work well for product distribution on processing lines and packaging lines because gates can be easily opened and closed to divert product to multiple points. • Depending on the product, vibratory conveyors can work effectively for sizing. A multideck shaker is fitted with screens that allow product of a particular size to drop to the lower level. An operator can quickly swap the screen to change the size. If the product is prone to blinding, another type of vibratory conveyor - a diverging bar grader - may be ideal. • Leafy greens are conveyed more effectively with vibratory shakers than with horizontal motion shakers because the product actually absorbs the energy of the shaker so the slight vertical lift of the vibratory conveyor helps move the product forward. • For hand-sorting wine grapes and a wide range of other products, vibratory conveyors offer an adjustable speed control to display product evenly for thorough inspection. • Fines removal is handled well with either a vibratory conveyor or rotary-style sliver sizer remover. The rotary-style remover is perfect for many round products such as tomatoes, where slivershaped fines are created during the cutting process. • Electromagnetic shakers that start and stop quickly are often ideal for scale feed applications where accurate metering to scales greatly enhances scale and bagger performance. Vibratory conveyors with mechanical drives and horizontal motion conveyors can also be used effectively in many scale feed applications, depending on the product.
OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 21
Materials handling
TO DETERMINE THE TOTAL COST OF THE CONVEYOR SYSTEM, START WITH THE INITIAL CAPITAL COST PLUS THE COST OF INSTALLATION AND ADD THE PROJECTED ANNUAL MAINTENANCE AND SANITATION COSTS OVER THE ANTICIPATED LIFE OF THE EQUIPMENT.
• Feeding a cutter or slicer, where product orientation and singulating improves the effectiveness of the operation, is handled best with vibratory shakers.
Horizontal motion shakers Horizontal motion conveyors offer the gentlest handling and the easiest sanitation of all conveyors types, while the lower maintenance requirements lead to a lower total cost of ownership than belt conveyors. A few of the applications in which horizontal shakers are ideal, include the following: • Horizontal motion conveyors are often ideal for seasoned and coated products. The gentle handling reduces the loss of seasonings or coatings and the horizontal motion produces a continuous self-cleaning action that prevents the build-up of the seasonings and coatings. • The sliding action of horizontal motion conveyors prevents mixing and size separation, making this conveyor ideal for premixed blends. • Horizontal motion conveyors are perfect for some delicate products when high throughput is not important. Whole potatoes, which bruise easily, and many snack foods are handled well with horizontal motion when they are not loaded too deep into the conveyor bed. This gentle handling advantage must be considered on a productby-product basis because many seemingly delicate products such as blueberries are handled well with vibratory conveyors and other products like leafy greens are actually handled better with vibratory conveyors. • For foods that are not delicate, especially products that have no flat sides to scuff along the bed of a conveyor, like baby whole carrots or nuts, horizontal motion conveyors work well. For these products, the throughput that can be achieved with higher-speed vibratory shakers can be matched on horizontal motion shakers by increasing the depth of the product flow. • Unlike vibratory conveyors, some horizontal motion conveyors can reverse product flow, which increases the flexibility of the line and provides some storage capacity. • Although the noise of a horizontal motion conveyor drive is similar to that of the traditional vibratory conveyor drive, some products such as frozen meat, poultry or seafood that would make a drumming noise on vibratory shakers will run more quietly on horizontal motion shakers. That said, electromagnetic drives are the most quiet of all, so if product drumming is not an issue, an electromagnetic vibratory shaker will be the quietest solution.
22 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
• Because horizontal motion conveyors can be heavily loaded, they provide some bulk storage capacity on the production line when conveying product in which damage may not be a factor.
Conclusion To select the ideal conveyor for each situation, food processors and packers should take into account a wide variety of factors from cost to performance issues. To determine the total cost of the conveyor system, start with the initial capital cost plus the cost of installation and add the projected annual maintenance and sanitation costs over the anticipated life of the equipment. Such a long-term view highlights the relative affordability of vibratory and horizontal motion shakers over belt conveyors. Selecting equipment that lasts longer also saves the time it takes to make subsequent purchase decisions and install replacement equipment. Beyond costs, the strengths and weaknesses of each conveyor type should be considered as well as the specific applications in which one particular type of conveyor excels. The benefits of each type of conveyor must be judged on a product-by-product basis. To help navigate this complicated analysis, processors and packers should consider working with an equipment supplier that offers expertise in the food processing industry and provides a full range of conveying solutions to choose from. With a deep and broad knowledge base, such a supplier can be a valuable resource in identifying the ideal conveying solutions that create competitive advantages by improving the performance on the production line.
Notes 1. For a conveyor that is 60 cm wide and 4.5 m long, a typical belt conveyor might cost $12,000 to $16,000 while the cost for a comparable vibratory or horizontal motion shaker is closer to $20,000 to $25,000. 2. For a detailed breakdown of ongoing maintenance and sanitation costs, go to http://www.key.net/files/products/fresh-cut-solutions.pdf; see the table titled Yearly Operating Cost Comparison on page three. Key Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/R481
www.ProcessOnline.com.au
MATERIALS HANDLING
PRODUCTS
LAYER PICKING ROBOT Dematic’s 4-axis layer picking robot has a Qubiqa vacuum gripper head that provides versatility in product handling. It can accommodate most pallet stacking patterns, even those with a hole in the middle, and is capable of handling cartons, cases, bags, sacks, cans and bottles. Dematic claims the layer picker’s software enables the system to operate at efficiency rates of up to 150% and eliminate as much as 80% of manual handling. The robot has the company’s FreePick Maximiser software that cross-matches orders and pairs those with compatible order profiles. This can enable up to 50% of goods to be distributed without being handled, the company claims. The system also has reduced forklift operation and improved transport utilisation. According to the company, the system provides good pallet build quality, less product damage and fewer returns.
Dematic Pty Ltd Contact info and more items like this at wf.net.au/Q514
Schenck Process ramps up its investment in bulk handling
weighing
feeding
screening
automation
Following the acquisition of Redler, the next phase of Schenck’s bulk handling growth strategy is the recent purchase of Mac Process and Clyde Process. Schenck Process Australia Pty Ltd Ground Floor 65 Epping Road North Ryde NSW 2113, Australia T 1300 551 645 Australia wide T + 61 2 9886 6800 sales@schenckprocess.com.au www.schenckprocess.com.au
www.ProcessOnline.com.au
OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 23
MATERIALS HANDLING
PRODUCTS
VIBRATORY FEEDER CONTROLLER Enmin’s digital frequency controllers assist users to find the correct resonance frequency to ‘tune’ electromagnetic vibratory feeders. Electromagnetic vibratory feeders suffer from the inherent problem of repetition of build since they all are a combination of a machined base and a fabricated tray or bowl - the latter being the problem since no two will ever be exactly the same. The result of this condition lies in tuning the electromagnetic feeder to achieve the best possible conveying rate. Traditionally, springs would be altered or weights added to the system to compensate.
MATERIALS HANDLING ROBOT Adept Technology has introduced the Adept Viper s1700D, a 6-axis robot designed for material handling, machine tending, packaging, cutting and assembly. The robot features Adept ACE software, which deploys the robot through a user-friendly interface. The ethernet TCP/IP capability allows the robot to be controlled through a PC, PLC or controller. The FQIN model can be used to service vibratory feeders from 4 to 15 A. Operating from a standard single-phase power supply, the simple push-button operation quickly searches for the resonance frequency; and combined with amplitude adjustment, the vibratory feeder is able to be tuned to its maximum potential. Many other features are available as standard with the Enmin FQIN, such as password protection which denies access to unauthorised personnel, connections for operational feedback load sensors and delay start and stop functions. The digital readout display program provides a host of messages for the ease of operation, fault finding and operating conditions. The FQIN is built to IP55 standard and complies with European CE standards for electromagnetic compatibility.
Self-diagnostics enable proactive monitoring and quick troubleshooting. Offering a reach of 1.7 m and a payload capacity of 20 kg, the Viper is interchangeable with other Adept robots and controllers, which can ease deployment, support and maintenance, including parts availability. The robot works with the Adept SmartController CX that offers scalability and support for IEEE 1394-based digital I/O and general motion expansion modules as well as Fast
Enmin Pty Ltd
Ethernet and DeviceNet.
Contact info and more items like this at wf.net.au/R219
Adept Technology International Ltd Contact info and more items like this at wf.net.au/R218
RFID CONTROLLER The Balluff BIS-V RFID controller is a compact evaluation unit that enables the simultaneous connection of up to four read/write heads. Both HF (13.56 MHz) in accordance with ISO 15693 and ISO 14443 and LF (125 kHz) read heads can be connected on the front with plug connectors and are automatically detected. It also allows IO-Link capable sensors or actuators to also be directly connected. The controller fulfils all requirements for an industry-ready version (IP67, metal housing) and is equipped with Profibus interface and with USB as the service interface to the PC. There are many typical application areas for the combination of RFID controllers and sensors. For identification tasks for material flow control in production systems, the user can profit from the low hardware usage and the low installation costs in areas like conveyor systems in mechanical engineering, assembly lines, electric suspension systems or in the intralogistics field. Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/R535
24 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
www.ProcessOnline.com.au
MATERIALS HANDLING
PRODUCTS
PE PACKAGING SYSTEM The latest in tna’s vertical form fill and seal (VFFS) robag range is the tna robagFXIS 3ci Series for polyethylene (PE) packaging. Designed with performance, simplicity and flexibility in mind, the range features a rotary impulse sealing jaw system for the efficient packaging of fresh or frozen vegetables, salads, ready-to-eat fruit and prewrapped candies at bagging speeds of up to 150 bpm. The latest addition to the robag 3ci packaging line, the series ensures more precise temperature control, maximum uptime and an extended lifespan. Greater efficiency is also achieved through rapid former changes using tna’s ‘auto connect’ and ‘unload assist’ features. Also, product-in-seal-detection (PISD) software monitors product in the seal and jaw area and adjusts the bagger’s speed accordingly, to both optimise speed and reduce waste. The series can be added to existing packaging lines and fully integrated with tna weighers, metal detectors, date coders and conveyors for a comprehensive and efficient packaging line. TNA Australia Pty Ltd Contact info and more items like this at wf.net.au/R223
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OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 25
Red robots in the red house Germany’s Black Forest has long been famous for its natural beauty, clean water and clean air. It also has a tradition of precision workmanship going back many centuries, with products such as its clocks being famous the world over. The Rothaus brewery, maker of the famous Tannenzäpfle beer, uses four ABB robots in handling and packaging. High up in the Black Forest in south-west Germany sits the 221-yearold Rothaus (‘red house’) brewery. The beer brewed there has long since achieved a cult status among German beer drinkers, and the brewery’s distinctive beer bottles, with their foil cladding and label showing a German Fräulein, are known throughout Germany, and beyond. The Rothaus State Brewery was founded in 1791 by monks from the nearby St Blasien monastery. Enough spring water and wood was available near the red house, above the picturesque village of Grafenhausen, to adequately supply the water- and energy-intensive beer operation. After the monastery was dissolved, ownership passed to the Grand Duchy of Baden in 1806. Later, it was taken over by the state, in whose ownership it remains. The famous stylised Fräulein figure, essentially unchanged since the 1960s, has been dubbed Birgit Kraft, from the local pronunciation of “Bier gibt Kraft” (beer gives you strength). With an annual production of 840,000 hectolitres, the Badische Staatsbrauerei Rothaus AG is now one of the biggest in the BadenWürttemberg region. Despite being over two centuries old, the brewery is nowadays equipped with the latest in modern technology, including four ABB robots that handle the beer kegs and cases. On the production floor, an ABB robot can be seen bending gracefully forward and gripping a stainless steel beer keg gently but firmly around its mid-section, then smoothly rotating 90° and carefully placing it, inverted, in the packing area. For many years, keg handling was done by hand; then, later, by an elaborate gantry unit. Now, two identical ABB IRB 6640 robots perform the task, like clockwork and with much less fuss. The special Foundry Plus 2 robot variant is suited to conditions in the brewery. One jockeys the empty, not yet cleaned, stainless steel kegs from a wooden palette onto a conveyor belt. A good 10 minutes later, its partner neatly stacks the now thoroughly cleaned and filled kegs. The two robots are painted the fiery Rothaus RAL 3000 red, like all other moving equipment in the brewery.
26 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
“They couldn’t be more reliable and low-maintenance,” reports Robert Jäger, who is in charge of the beer-filling operation, “and in comparison to the earlier gantry unit they take up a lot less room, too.” The IRB 6640 comes in different arm lengths and handling capacities. The robot can bend backwards fully, providing a large working range while permitting it to fit into space-restricted production lines. Typical application areas are materials handling, machine tending and spot welding. The robot is also available with different options for different working environments, such as Foundry Plus 2, Foundry Prime 2 and Clean Room. The maximum payload is 235kg, which makes the robot suitable for many heavy materials handling applications such as those at the Rothaus brewery. IRB 6640 runs the second generation of TrueMove and QuickMove from ABB. This gives the robot highly accurate motion, which translates into less time for programming as well as a better process result. This software also supervises internal robot loads, meaning reduced risk of overload and longer robot lifetime. However, only 10% of the Rothaus beer ends up in kegs; the rest goes into the attractive bottles so loved by beer drinkers up and down the country. Of the bottled beer, one in every eight is sold in a six-pack - and here again, an ABB robot has a hand in passing around the beer. Since 2005, an IRB 6640 robot has been assisting the automated packing machine in which a 24-bottle crate is repacked into four six-packs. The IRB 6640’s strong beer-lifting arm can effortlessly move its 142 kg load onto a conveyor belt. The beer crates come tied together, for safety during transport, in a four-crate-wide, two-crate-deep configuration. Removing the safety band is the job of the fourth member of the ABB robot team: the small IRB 140. Despite its rather diminutive size compared with its colleagues, it is very capable nonetheless. Project leader Ralf Krieger is also pleased with the ABB products, saying “Like the two robots in the filling area, these two were also brought into service really quickly.” These are words that the ABB team members like to hear - maybe they will celebrate them by clinking together some of those attractive foil-topped bottles.
ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/R249
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Do-More PLC - H2 Series CPU Modules Do-more PLCs use proven DirectLOGIC PLC DL205 hardware for a flexible control platform
Download the FREE Do-More PLC Programming Software www.automationdirect.com.au
New! ... Easier control implementation with the latest in PLC technology! ... and with FREE PLC programming software Do-more PLCs - H2 Series Two CPU modules are available with Do-more H2 Series PLCs: the H2-DM1 and H2-DM1E. Both CPU modules are programmed using the Do-more Designer programming software. NOTE: Existing DirectLOGIC DL205 CPU modules (D2- 230, D2-240, D2-250(-1) and D2-260) cannot utilize Do-more Designer PLC programming software.
Features - Do-more CPUs 192k words total memory 64k words ladder (flash memory) 128k words user data memory (SRAM with battery backup) Ladder programming, Real time clock/calendar Two or three built-in communications ports: RS-232 port - supports programming, K-sequence slave, MODBUS RTU master/slave and ASCII IN/OUT USB port - supports programming Ethernet port (H2-DM1E) - supports programming, TCP/IP, UDP/IP and Modbus/TCP Bumpless run-time editing Up to 2000 PID loops Back-up battery included Do-more CPU modules require the Do-more Designer programming software (free online download, or on CD for a nominal fee) User manual H2-DM-M is available as a free download, or you may purchase a hard copy separately
H2-CTRIO and New!..H2-CTRIO2 Counter I/O Modules The H2-CTRIO and H2-CTRIO2 Counter I/O modules are designed to accept high-speed pulse input signals for counting or timing applications. These modules also provide high-speed pulse output signals for servo/stepper motor control, monitoring and alarming as well as other discrete control functions. The CTRIO and CTRIO2 modules offer greater flexibility for applications which call for precise counting or timing based on input events or for high speed control output applications. They can also be used for applications that call for a combination of both high-speed input and high-speed output control functions. The CTRIO and CTRIO2 modules have their own microprocessors and operate asynchronously with respect to the CPU. Therefore, the response time of the on-board outputs is based on the module's scan time, not the CPU's scan time.
Free Programming Software
The Do-more Designer software represents a clean break from the past (DirectSOFT)*. We listened to our customers to create a powerful, easy-to-use programming environment with all the features you expect from modern PLC programming software: • Flexible program management supports a mix of stage and ladder logic for a best-of-both-worlds approach that simplifies your code and makestroubleshooting easier.The Do-more Designer software includes a hyper-accurate simulator, a “virtual PLC” on your PC. It’s actually the very same code that executes inside the Do-more CPU!
TECHNOLOGY THAT MAKES YOUR JOB EASIER
www.automationdirect.com.au
Australia Wide: 1-800-6330405 New Zealand: 0-800-6330405 Asia Pacific: 61-7-55874222 E: sales@automationdirect.com.au Fax: 61-7-55252053
NEW PRODUCTS
HMI/SCADA SOFTWARE InduSoft has released InduSoft Web Studio v7.1, which offers enhanced interface capabilities for use on a variety of smartphones and tablets, as well as revision control and intuitive project management. InduSoft Web Studio v7.1 provides an enhanced Studio Mobile Access (SMA) client that works with any HTML.5 web browser to display alarms,
IP69K LINEAR MOTORS
trends and critical tag values. It also adds easy-to-use widgets (gauges,
LinMot has released a series of stainless steel linear motors with
switches and text boxes) to monitor and interact with process values (tags)
an IP69K protection rating.
on any current browser, including those found on iPad, iPhone (iOS Safari) and on Android phones and tablets.
The technology of linear direct drives together with the smooth and hygienic design is suited to applications in food, pharmaceuti-
Alarms and other information can be sent via multimedia formats, such
cal, packaging machines and many other industrial applications.
as a PDF, to an email account, a printer or a smartphone in real time or as
These stainless steel motors from LinMot are suitable for
historical data. InduSoft v7.1 connects to any SQL database including, but
replacing pneumatic systems and belt-driven and ball screw
not limited to, MS SQL, MySQL, Sybase, Oracle, MS Access and ERP/MES
linear systems in food processing machines, especially in very
systems such as SAP. It also easily connects to Excel and other popular PC-
harsh or aseptic environments. LinMot systems are claimed
based programs. InduSoft v7.1 provides a built-in interface for display of trends,
to reduce system complexity, energy and maintenance costs,
alarms, events, grids and other objects without requiring SQL programming.
therefore increasing machine uptime and machine throughput.
The InduSoft Collaboration Tool and Application Lifecycle Management
Linear direct drives allow the machine designer to develop very
option is available for an additional licence. It enables users to compare any
compact solutions, as no servomotor or gear head is required.
configuration file, as well as merge changes from multiple developers. This
The one IP69K-rated connector is directly mounted on the motor
option also offers support for source control and interaction via Microsoft’s
and only one cable between linear motor and servo controller is
Team Foundation Server for life cycle management.
required, further simplifying installation time and commissioning.
Dominion Electronics
Motion Technologies Pty Ltd
Contact info and more items like this at wf.net.au/Q627
Contact info and more items like this at wf.net.au/R113
HD2717/8 SERIES OF HUMIDITY TRANSMITTERS CONTOLLERS & LOGGERS
■ Measures
Temp, Rh, dew Point, Wet Bulb, Absolute Humidity & more.
■ Interchangeable
probes with pre-calibration (fixed type & remote mounting).
■ Analogue
(mA & V) & digital (RS232/RS485) outputs with 3 relay control outputs.
■ Logger
version with date stamping & 9,000 sample memory.
■ Up
to 180°C working range & large backlight display for easy set-up.
DIGITAL POSITIONERS Bürkert’s digital positioners have zero air bleed and consumption at rest, drawing air only when the pneumatic device moves. Traditional positioners bleed high air volumes, with one positioner reporting 540 L/h consumption at low pilot-pressure. The zero-bleed positioners are said to reduce compressed air use dramatically, saving money and power and promoting ecofriendly processing. The Types 8792 Positioner and 8793 Positioner-Process Controller suit rotary and linear process valves, as well as virtually any pneumatically controlled instrument including valves, cylinders and dampers. The positioners are available for direct or remote mount, all with IP65/67 housings for robust service in challenging environments. Using the company’s piloting technology to deliver high precision, the digital positioners are able to control to up to 150 L/min for both spring return and double-acting actuators. This represents a significant jump on traditional positioner flow rates, giving far wider scope of use. Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/R175
28 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
www.ProcessOnline.com.au
Registration NOW OPEN — Early bird closes 31 October 2012
4–5 December 2012
2012
Melbourne Convention Centre, Australia
NEW
Free e All da xhibition ye qualifi ntry to ed* profes s pre-re ionals with gistrat ion
In conjunction with the ARCIA Industry Gala Dinner
Utilities | Government | Enterprise | Transportation | Public Safety
The Future of Professional Mobile Radio in Australia Now in it’s 6th year … With a sharp focus on industry end users and their needs, as well as the application of currently available technologies now and into the future, this year’s conference offers two solid days of learning and an exhibition where you will find everything you’re looking for.
Don’t miss out, Register Today! Speakers include: Prof. Hugh Bradlow – Chief Technology Officer, Telstra Chris Chapman – Chairman and CEO, Australian Communications and Media Authority Peter Clemons – Managing Director, Quixoticity Alvin D’Mello, Data Communications System Manager, QR National Doug Booth – Project Director, Country Fire Authority Dietmar Schoeps – Director, Funkwerk Security Communications Marta Fontecha – Transport Area Manager, Teltronic Des Bahr – CEO, APCO Australasia Industry & Technology Focus: • • • •
Public Safety • Mining • Utilities • Transport •
Networks and Infrastructure Spectrum Planning Training & Education SCADA/M2M
Plus papers and comparisons on Tetra, P25, dPMR, DMR and much more ...
Registration Open – secure your place today. Keep up to date, join the RadioComms Connect LinkedIn group today Event partner:
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Magazine partner: In association with: Supporting associations & media organisations:
WFevents, a division of Westwick-Farrow Media - ABN: 22 152 305 336
((( www.radiocommsconnect.com.au ))) *conditions apply, see online registration for details.
NEW PRODUCTS
The ORing IPS-3082GC-24V managed industrial ethernet switch pro-
PRESSURE SENSOR WITH IO-LINK
vides advanced network control and security management including
ifm efector’s robust pressure sensor
SNMP v1/v2c/v3, IGMP v2/v3 and STP/RSTP/MSTP.
now communicates all data flexibly
ETHERNET SWITCH
The IPS-3082GC-24V supports ethernet redun-
via switching outputs or IO-Link 1.1.
dancy protocols, ORing and O-Chain, with recovery
Process data and diagnostic infor-
time of less than 10 ms with up to 250 nodes, for
mation are transmitted easily using
network security and reliability. It also provides a
a standard cable. Also, parameter
‘Green Power Schedule’ allowing the user to set
setting of this PN7-type pressure
the desired power accordingly, effectively eliminat-
sensor also uses the IO-Link com-
ing energy wastage.
munication technology. An IO-Link
The IPS-3082GC-24V comes with eight integrated
master saves the parameters of the
ports with PoE (PSE) function and 2 GB combo
connected sensor and transmits them when the sensor is replaced by a
ports with an IP31 grade rugged aluminium housing.
device of the same type. This eliminates the need for a new parameter
This switch has an extended temperature range of
setting. If the IO-Link function is not used, then the pressure sensor op-
-40 to +75°C. The plug-and-play design and fault
erates as before, with two switching outputs (SIO mode) or a switching
relay alarm function for auto notifications make the switch a
output and a diagnostic output.
user-friendly device and easy to implement in industrial applications.
Additionally, the sensor has high switch point accuracy and switch-
The IPS-3082GC-24V includes Power Boost, which supports wide-
ing frequency, as well as being robust. The overload-protected ceramic
range 12-36 VDC power inputs and generates 50 VDC PSE power
measuring cell withstands more than 100 million switching cycles, the
output per port. Each port provides 15.4 W for applications such as
company claims. Versions with pressure ranges between -1 and
IP surveillance and wireless access points.
600 bar are available.
ICP Electronics Australia Pty Ltd
ifm efector pty ltd
Contact info and more items like this at wf.net.au/R407
Contact info and more items like this at wf.net.au/Q832
EtherNet/IP ENABLING PROCESS DEVICE INEGRATION ON STANDARD, UNMODIFIED ETHERNET. Enhance your control loops with the same unmodified Ethernet network you use for information sharing and Automation Control. Multi-variable process measurements like mass or volume flow can now be simply managed when integrated into a single network environment. Rockwell Automation and its partner Endress+Hauser have been driving these developments so that you can take standard, unmodified Ethernet and do extraordinary things. See something extraordinary at: www.apac.rockwellautomation.com/ethernetip/WNIPTAUD
EIP_wnipt_half-pg_oct12.indd 1
30 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
30-Jul-12 2:53:47 PM
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NEW PRODUCTS
SERIAL TO WIRELESS DEVICE SERVERS Moxa has released the NPort W2150A/W2250A Series RS-232/422/485 to wireless IEEE 802.11a/b/g device servers. The NPort W2150A/W2250A series allows secure data access with WEP/ WPA/WPA2/802.1x encryption, consumes only 2.4 W of power and supports wide-temperature operation for environments ranging from -40 to 75°C, making them suitable for use in industrial automation such as warehouse AGV and CNC applications. Moxa’s Fast Roaming technology increases the roaming speed to unify AP channels and reduce handover times to less than 500 ms. The series also offers 3-in-1 surge protection, which includes level 3 (2 kV) power line surge protection and level 2 surge protection for serial and ethernet ports. The series is designed to continue operating if the wireless connection is temporarily disconnected. If the wireless connection is restraining, or if the connection fails, serial data transmissions from the serial device will be queued in the built-in port buffer with over 10 MB of storage. As soon as the wireless connection returns to normal, the data stored in the buffer will be sent to its destination. Madison Technologies Contact info and more items like this at wf.net.au/Q837
DUAL-PORT ETHERNET/IP I/O ADAPTERS The Allen-Bradley Flex I/O dual-port EtherNet/IP adapters are designed to help OEMs connect machines to their end customers’ IT infrastructures using a single network. With the dual ports, users can also leverage the adapter to display diagnostics via a web browser, helping reduce troubleshooting and downtime. These EtherNet/IP adapters support a device-level ring (DLR) topology, which provides robust network infrastructure and fast recovery time, while keeping implementation cost down. DLR infrastructures are connected at the end device versus the switch. With no need for unnecessary switches and cabling, users can reduce design time and simplify implementation. The ring also adds a measure of redundancy that is very effective when a connection fails - as a single network failure, such as a cable break, will not lead to the failure of the other devices in the ring. A DLR network can recover in less than 3 ms for a 50-node system. During this time, the connection between the programmable automation controller and the I/O device is not interrupted. The adapters also support the daisy-chain topology for applications that involve devices located long distances from CPU subsystems. The adapters (1794-AENTR and 1794-AENTRXT for extreme environments) are compatible with RSLogix 5000 programming software version 16 and higher and RSLinx version 2.58 and higher. The adapters also can connect up to eight Flex I/O modules. Rockwell Automation Australia Contact info and more items like this at wf.net.au/Q744
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OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 31
NEW PRODUCTS
HIGH-SPEED I/O MODULES The Allen-Bradley ControlLogix 24 VDC I/O modules, used with the ControlLogix 5570 family of PACs, are designed to improve total system response time (SRT) through new hardware technology and peer-to-peer communication capabilities that reduce the time it takes for modules to communicate with the controller. Since SRT equates to the time required for input module response, controller processing and output module response, reducing I/O latency results in higher machine speeds. For further performance improvement, the modules also function in peer-to-peer mode, bypassing the controller by establishing in-chassis connections that allow I/O modules to communicate directly with each
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other. Shifting task management to the I/O modules can relieve a controller of the overhead required to process and direct I/O modules, helping improve reliability in program execution and throughput. In peer-to-peer mode, input to output response time can be less than 100 µs. The peer-to-peer capabilities are suitable for applications with fast detect-energise sequences, such as high-speed parts rejection.
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EMBEDDED SYSTEM The TANK-720-QM67 is a high-performance fanless embedded system featuring the second-generation Intel mobile Core i7/i5/i3 and Celeron processor. It features onboard 2 GB DDR3 memory and a DDR3 SO-DIMM slot supporting storage for up to 10 GB. An advanced Intel HD graphics card supports H.264/AVC-MPEG2/VC1, DirectX 10.1 and OpenGL 3.0. This embedded system also features fully integrated I/O and a Wi-Fi module to support dual-band 2.4/5 GHz 802.11a/b/g/n 3T3R MIMO technology. This ensures an uninterrupted wireless connection and provides up to 450 Mbps operational bandwidth. The system adopts dual-combo (SFP fibre/RJ-45) Gigabit LAN, which
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is designed for long-distance networking. It is used in long-distance network environments where an ethernet cable would be unable to provide adequate coverage. ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/R120
32 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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NEW PRODUCTS
LOW-CONTACT GRIPPER The OGGB low-contact gripper from Festo is an alternative to suction cups for handling highly sensitive solar cells and other fragile workpieces. The gripper transports thin, flexible workpieces quietly and economically, but also reliably and quickly, with the help of the Bernoulli principle. Compressed air is accelerated to supersonic speed through a tiny gap. This produces a powerful vacuum on the underside of the gripper. The Bernoulli suction cup picks the wafer up gently and holds it reliably. The necessary vacuum can be controlled by means of the operating pressure. The maximum lift height can also be precisely adjusted in this way. This is especially important when handling sensitive workpieces such as solar cells so that the wafers are reliably handled with the same settings at all times. The wafers rest on inserts made from POM, PEEK or stainless steel depending on the application. A further advantage compared with conventional suction cups is the fact that no dirt (like the silicon dust produced when a wafer breaks) can get into the system. That means that no costly filter systems are required. Festo Pty Ltd Contact info and more items like this at wf.net.au/R415
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OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33
NEW PRODUCTS
FANLESS WATERPROOF PANEL PC Interworld Electronics’ APC-3591 stainless steel fanless waterproof panel PC is sealed to IP65 specifications on all sides. All external I/O, including the DC power input, serial, ethernet and USB ports have waterproof sealed connectors. The PC combines an embedded PC and a 15″ 350 cd/m2 LCD in a thin IP65 stainless steel enclosure measuring 399 x 324 x 72 mm. The panel PC supports Intel Core 2 Duo 1.66 or 2.26 GHz processors and up to 4 GB of 800/1066 MHz DDR3 memory. The 15″ LCD provides a maximum resolution of 1024 x 768 pixels and is available with an optional analog resistive touch screen. External I/O includes two USB 2.0 ports, two COM ports, one RJ45 LAN port and one audio line-out connector. Its wide range DC input (11 to 32 VDC) allows the PC to be powered from most DC sources. The PC is suitable for industrial process control, medical and marine environments. Interworld Electronics & Computer Industries
COMPONENTS Contact info and more items like this at wf.net.au/Q833
CONTROL COMPONENTS Control Components
CORIOLIS MASS FLOW METER Bronkhorst Cori-Tech of The Netherlands has released an option for its mini Cori-Flow series mass flow meters for low flow rates. The compact flow meters, operating via the Coriolis principle, are now available with IECEx and ATEX approval II 2G Ex d IIB T6 for
Control Components Pressure
CONTROL COMPONENTS Control Because Components REsOURCE BOOMs
are finite…switching to Neo-Dyn makes good sense
use in hazardous areas. The instrument is built into a rugged enclosure with separated compartment for the electronics. The flow meters, suitable for both liquid and gas flow applications, cover flow rates from 0.1 g/h to 30 kg/h and can be used in systems with pipeline pressures up to 140 bar (2000 psi). The design of the miniature Coriolis sensor features short response time and high accuracy, irrespective of changing operating conditions with regard to pressure, temperature, density, conductivity and viscosity. Mini Cori-Flow mass flow meters offer integrated PID control for close-coupled
ITT Neo-DyN INDusTrIal swITches:
• Pressure • Vacuum • Differential Pressure • Temperature
control valves or pumps, thus constituting compact Coriolis mass flow control loops. The instruments offer
• IECEx certified flameproof switches
both analog and RS232 communication, optional fieldbus interfaces
• Internal / External adjustment. Tamperproof versions also
and additional functions such as alarms, totaliser (to measure fluid
• Range of pressure set-points – vacuum to heavy hydraulic
consumption) and batch dosing. The mass flow meters feature
• High cycle life & over pressure rating
fluid temperature and density as secondary digital outputs. As an
• Rugged construction for stability – avoids re-calibration
option, the Coriolis flow meter can be equipped with a heater to
TAKE CONTROL
CCEZY.COM.AU 02 9542 8977
34 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
prevent condensation or solidification inside the instrument. Applications can be found in process control systems in food, chemical and petrochemical plants. Anri Instruments & Controls Pty Ltd Contact info and more items like this at wf.net.au/R309
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NEW PRODUCTS
MULTICOLOUR INDICATORS The Banner Engineering EZ-Light S18L general-purpose indicators are designed to provide a simple and cost-effective indication solution. The indicator is capable of standalone use on a machine or enclosed in a panel, with no enclosure required, making it suitable for a variety of applications in manufacturing and factory automation. The S18L features up to three independent colours in one unit and multiple colours to choose from for customcoloured indication. The S18L general-purpose indicators are available for mounting with a variety of brackets, including right-angle with curved slot, swivel with tilt and pan movement, flat and right-angle with articulation slots. Offering an operating range of -40 to +50°C and a durable, IP69K-rated housing, the S18L can be used in harsh washdown environments. The S18L indicators are available in green, red, yellow, blue, white, orange, turquoise, violet, sky blue and magenta. Daylight-visible models are also available for areas with high levels of ambient light. To avoid false indication, the indicators’ face appears grey when off.
RUGGEDISED KEYBOARDS Cortron’s Model 121 Series keyboard/ pointing devices are built to withstand the most hostile and demanding industrial and military environments. The Model 121 Series is virtually impervious to contaminants found in harsh applications, both indoors and in the field. Vital electronics and switch bearing surfaces are sealed for long-term protection against water, beverages, dust, dirt and many chemicals. Sugar-based beverages can be left to dry without causing damage to components. There are over 300 variations available and all versions in the 121 Model Series come with features which include sealed, spill/dustproof construction; all-metal enclosure with welded seams; full-travel, solid state switches; durable long-life key legends; durable exterior finish; and ergonomic key sculptures. Optional features for the Model 121 Series include electric (I/O) interfaces, backlighting, electromagnetic protection, panel mounting and rackmount kits.
Micromax Pty Ltd
Metromatics Pty Ltd
Contact info and more items like this at wf.net.au/Q829
Contact info and more items like this at wf.net.au/Q896
More of our 2012 panels Competence: dedicated electrical, network, & mechanical project teams at our Sydney Systemhaus Capability: experience on the largest control system projects in the country (call for reference sites) Quality: full QA, with our Sydney Systemhaus ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions’ Call on Bürkert to build your panels!
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OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 35
EVOLUTION IN MOTION THE MACHINE AUTOMATION CONTROLLER
The machine automation controller (MAC) is the latest stage in the evolution of the automation controller, meeting machine control needs more effectively than previous controller solutions.
T
o paraphrase Albert Einstein, the opportunity for development is directly related to the potential for value. This is particularly relevant to technological development, where market forces establish need and value, and then science and engineering are applied to meet them. Look at the use of machine control hardware for automation. During the past 50 years there has been a powerful and dramatic development of controllers: distributed control systems (DCSs), programmable logic controllers (PLCs), industrial PCs (IPCs) and programmable automation controllers (PACs) (Figure 1). The explosion of industrial applications continues to challenge the functionality of those controllers, fostering further innovation. The need to combine the capabilities of traditional process/discrete industrial control has led to adaptations or extensions of existing technology. The efforts to evolve resulted in underperforming machine automation due to limitations in architecture and a lack of cross-discipline expertise. Today we see the emergence of a new controller type: a machine automation controller (MAC). An MAC resolves the integration of
36 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
control technologies without sacrificing performance. Only after painstaking development from the ground up - specifically for highspeed, multiaxis motion control, vision and logic - has the MAC emerged. Let’s revisit how this point was reached. The industrial controls market split into two distinct segments: process - where pressure, temperature and flow were paramount; and discrete - where sequencing, count and timing were the key metrics. PLCs dominated the discrete market, while DCSs led the process market. Customers were well-served. As machinery advanced, technologies converged and the PAC was developed to address the overlapping of process and discrete markets. The PAC incorporated the fundamental capabilities of a small DCS and a PLC with the addition of low axis-count motion control. The PACs provided redundant processors, single database, function block language, high speed logic, component architecture and online programming (Figure 2). While PACs cost less than traditional distributed control systems, and also integrate motion and logic into a single controller, they encounter limitations when applied to high-speed motion with
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© iStockphoto.com/ Alexey Dudoladov
Automation
AN MAC RESOLVES THE INTEGRATION OF CONTROL TECHNOLOGIES WITHOUT SACRIFICING PERFORMANCE.
multiple axes. Motion control continued to be implemented with a separate network and performance issues were tackled by adding processors. This meant additional code for controller sequencing, which resulted in inefficiencies in system synchronisation. Inevitably, machine performance was compromised.
System synchronisation in such a system occurs when the user application program coordinates with the motion scheduler, the network servo drives, and ultimately controls the motor shafts. With each motor shaft synchronised with each other, what is true for two axes is true for nine, 17 or even 64 axes. There are many 8-axis and 16-axis controllers on the market, but if there is a need to expand the coordination of motion beyond that number of axes, another motion module is typically added. However, this is where many controllers fall short, because the application requires synchronisation across the expansion modules, through to the network, and back to the application program into the motion scheduler. To best approximate the intended motion profile, the controller must be deterministic to accurately coordinate all axes in the system. All this points back to the main driver: in order to increase throughput, the system requires the axes to remain synchronised with great repeatability to guarantee higher performance of throughput, yield and uptime (see Figures 3, 4 and 5). In achieving this, lower yields will result and the system may require shutdown to make adjustments. Uptime is not necessarily just a factor of the equipment itself; it’s also a factor of the production process. If motion is not accurately controlled to match the process, when speeds are increased the result is bad parts as the machine goes slightly out of control. This clearly impacts uptime because upstream and downstream processes need to be readjusted as well. Enter a new category of controller called a machine automation controller, where the most important attribute is motion performance. A true MAC can handle applications that require a high level of synchronisation and determinism, as it integrates multiple technologies stretching across the boundaries of motion, vision, logic and I/O without sacrificing performance. An MAC features an advanced real-time scheduler to manage motion, network and the user application updates at the same time to ensure perfect synchronisation. An MAC such as Omron Industrial Automation’s NJ Series is capable of updating all three in the same scan.
The emergence of the MAC
Convergence
Manufacturing demands performance in terms of throughput, yield and uptime: the overall equipment efficiency (OEE) model. Moreover, manufacturers are always pushing for greater accuracy and lower cost while maintaining quality and safety. These factors are the key drivers. Increasingly, manufacturing also requires moving product automatically during setup or production. This calls for a system that centres on motion and relies on it to be fast and accurate. If a controller has not been designed around motion, it may have inherent architectural barriers to performance when used to increase OEE. Consequently, machine manufacturers are forced to coordinate and synchronise the controller across technological boundaries such as motion, vision, logic and safety.
The revolutionary step is to purposely design an MAC to integrate multiple specialised controllers with exacting system synchronisation to deliver high performance throughput on a single controller. Consider the MAC advantages in a simple application such as a vision guided, Cartesian pick-and-place robot (Figure 6). There are two parts: the setup and actual production. The coordinate system of the camera must match with the coordinate system of the Cartesian robot. To get the camera data to the controller in a coherent form, a lot of time is spent developing the protocol. Previously, this might have taken the combined efforts of an articulated-arm robot manufacturer, a third-party vision system engineer and a PLC vendor. There could be three different systems
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OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 37
Automation
PAC
SERVO Drive
Motion Controller
PLC ()
I/O
MultiDiscipline System Redundancy
Circa 1991
I/O
SERVO Drive
()
Motion Network
Network
PAC
Motion Controller
PLC Discrete
Circa 2001 MAC
()
SERVO Drive
MAC
Multi Discipline: Motion at the core
I/O
Built-in machine network
System Synchronisation: <1 microsecond network jitter Single Controller High axis count 32 axes <1 millisecond
Circa 2011 Figure 1: Controller historical development.
Figure 2: PACs, PLCs, motion controllers and MACs.
from three different companies using three different technologies. At this point there would be three engineers in a room, taking them weeks to figure out how the systems can communicate with each other for commissioning. By design, an MAC allows these technologies to converge together so protocol development can be completed in a matter of hours. On the performance side, the use of a real-time network enables the passing of vision data to the motion system without losing a scan. This is only possible if vision and motion are on the same network. As another challenge, machine builders want to adjust servo parameters on the fly. This added functionality can create performance loss as the whole system gets overloaded with a high number of axes moving a high speed with full synchronisation. In the absence of an MAC, achieving this with non-MAC controllers require additional CPUs.
Where MACs are best used
The new performance benchmark Todayâ&#x20AC;&#x2122;s benchmark to qualify for the MAC category is processing 32 axes and updating in one millisecond. There were many earlier attempts to create a multidisciplinary controller, PACs being the most prominent. There were attempts to apply them to process control, cell control and machine control; but the PAC had to have an extensive operating system. Also, for truly high-speed motion control, the controller and configuration required many CPUs, since the performance of motion control will drop as the number of axes increases.
38 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
The market for the MAC is where the motion market, the vision market and the PLC market have commonality. Companies have different types of controls and control systems. In their higher-end controls, they may have a deep need for higher-end performance: motion, vision, functional safety and I/O together. But they also want to program their lower-level machines in the same language. They want to re-use the same libraries in scalable systems and not develop twice. Code re-use helps amortise the engineering investment over a wide range of projects into the future. Imagine yoghurt packs travelling on a conveyor. They get inspected, checked, picked up by a series of delta robots, put in boxes, lined up in cartons and so forth. Before the MAC, a typical line like this would have many controllers that would have to be coordinated - the vision controller, the robot controller, the motion controller and, on top, the PLC that sequenced all of them. This is a typical application where customers have been asking for one controller and one software application to know what is happening on the production line from vision inspection to pickand-place to synchronisation of the robot with the conveyor to packing and palletising at the end of the line. An MAC meets these requirements, streamlining operations by reducing the amount of equipment and integration traditionally required when different systems were cobbled together.
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Automation
Desired motion control profile Expected motion profile
Figure 3: Problem - control cycle time not fast enough to approximate the desired profile.
Figure 5: MAC solution - faster cycle times with system synchronisation allows for closer profile execution without delay.
In the packaging industry, machines for packing, wrapping, cartoning and palletising use a certain amount of robot functionality combining vision and motion, and a great amount of axis synchronisation. These represent the successes where early MACs have been applied. Further applications may include intelligent controllers that can handle multiaxis synchronisation at the heart of machine operations. An example of this use is an application involving soft material cutting or 2D cutting - be it wood, plywood, glass, stone or industrial textiles - where a certain amount of path or pattern execution functionality is needed, as well as handling and positioning. It is multiaxis control, but not requiring the extremely high functionality of typical CNC controllers.
Conclusion “Every great and deep difficulty bears in itself its own solution,” said Niels Bohr, Einstein’s contemporary and peer. “It forces us to change our thinking in order to find it.” Controller inefficiencies that were exposed by machine innovation caused the new thinking that led to the development of machine automation controllers. Now that MACs have emerged as a revolutionary solution, further machine development incorporating their advances will continue evolving, with motion at the core and with the creation of value as its ultimate work. Today, with MAC, the potential for value is being realised to a higher degree than ever before.
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Network Delay
Network Delay
Figure 4: Attempted solution - increase profile generation cycle time, but network or backplane delays cause loss of system synchronisation resulting in profile execution delays.
Figure 6: Application - a vision-guided Cartesian pick-and-place robot.
A condensed history of industrial control (1961- 2012) Where we are today could hardly have been imagined in the early 1960s. Consider the following developments that demonstrate how far we’ve advanced in the past five decades: • Mechanics gave way to relays, which gave way to microprocessors and low voltage differential signalling and expansive power distribution, which is now harnessed for inverter, servo and robot control. • On/off and open/closed status moved first to mechanical time, then electronic time, then distributed electronic time, and now to GPS time. • Visible gears became virtual elements that are defined as electronic axes. • Information has gone from pen and paper to an iPad displaying a SQL database query pulled from a server in the cloud. • Custom became proprietary; proprietary became open. • Communication media and connections overcame physical barriers: Hardwired copper >> bus systems >> point-topoint serial ports >> multiport networks >> digital networks >> gigabit speeds on fibre >> wireless industrial control architectures were initially distributed, then centralised, then distributed over digital networks, then highly distributed. Omron Electronics Pty Ltd Contact info and more items like this at wf.net.au/R479
OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 39
NEW PRODUCTS
MOTION CONTROLLER Adlink Technology has released the PCI-8254/PCI-8258 advanced motion controllers, that provide servo updates up to 20 kHz through a hardware-based PID-FF control loop and second-order filters, time-deterministic trajectory and velocity planning, comprehensive application functions, and powerful easy-to-use diagnostic and control utilities. Hardware-based PID-FF closed-loop control, coupled with a powerful filter capability, overcomes the effects of generated noise and significantly eliminates mechanical resonance for high-speed and precision-enhanced point-to-point applications in the semiconductor industry. The program download function can execute up to eight individual tasks simultaneously, guaranteeing control performance in real time, and conserving CPU resources and costs. The device also provides multidimensional interpolation, as in 3D linear/circular/spiral interpolation, ideally suited for contouring applications in manufacturing industries, such as laser engraving/cutting, glue dispensing and others. The device is also equipped with MotionCreatorPro 2, a Windows-based application development software package. More applicable time-domain and frequency-domain diagnostic tools are integrated into this utility for auto-tuning, frequency response analysis, as well as motion and I/O data sampling. A set-up wizard shortens the system installation and evaluation time, and allows monitoring of onboard DSP and I/O consumption via a system diagnostic page. Sampling pages and graphic tools deliver real-time motion and I/O status and conduct further motion flow analysis. The controller supports Windows XP and Windows 7 (32-bit) operating systems. In addition, 32 additional onboard digital I/O channels (16 DI and 16 DO) can save the expense of a full DI/O card. ADLINK Technology Inc Contact info and more items like this at wf.net.au/R402
PRESSURE CALIBRATORS FOR EX APPLICATIONS The Martel BetaGauge 311A-EX (single-sensor) and 321A-EX (dualsensor) pressure calibrators have hazardous area approvals that include IECEx and ATEX certification for worldwide use. In addition to the approval to safely use the calibrators in hazardous areas without hot work permits, the EX versions include a ClearBrite graphic LCD with intense backlight for a crisp and easily read black-on-white display. The familiar Martel 3-key user interface is supported by a multimode operating system that allows a range of operations from simple measurements to complex calibration applications such as natural gas custody transfer calibration. The calibrators are available in the userâ&#x20AC;&#x2122;s choice of 25 available pressure ranges from 2.5 kPa to 68 MPa in compound, gauge, differential and absolute modes. The user can choose from 19 built-in engineering units and specify up to two custom units at the time of order. The ability to measure up to 24 mA DC means these calibrators can perform a complete calibration on a pressure transmitter in the field. Accuracy on most ranges is Âą0.025% FS, over a wide variety of ambient temperature conditions. Applications include natural gas flow computer calibration, multivariable transmitter calibration, calibration of all types of process pressure instrumentation, and flow and level transmitters that use pressure-inferred measurement techniques. The calibrators also offer special features for the testing of pressure switches commonly used in safety instrumented systems and other control and monitoring applications. Zedflo Australia Contact info and more items like this at wf.net.au/R247
40 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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NEW PRODUCTS
SIGNAL INPUT BOARD FOR 8619 TRANSMITTER/ CONTROLLER The modular multichannel MultiCell 8619 is designed with standard functions and extension modules to customise the transmitter/controller to specific application needs and connected sensors. An extension module has been released as a signal input board that can be used for direct connection of two additional digital input flow sensors and two additional analog input measurement devices. The signal input board features two 4-20 mA signal inputs for any type of transmitter with a suitable signal, such as pressure, level or water chemistry parameters including turbidity, oxygen, free chlorine and ozone. These analog inputs can be locally altered to 0-5 V or 0-10 V inputs.
A NEW compact machine control platform that has it all.
The board is also equipped with two digital NPN and PNP transistor inputs for the connection of transmitters with frequency output, such as flow transmitters. Alternatively, the digital inputs can be used as contact inputs to trigger selected functions of the 8619. The Type 8619 transmitter is delivered precommissioned, with the user parameterising inputs, and selecting scaling and units as required. All standard units for pressure, temperature, flow rate and many other types of measurements are available. In addition, a free text for a physical unit of a measurement value, such as ‘Brom ppm’, can be defined. Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/Q827
AIR AMPLIFIERS Exair’s super air amplifiers and adjustable air amplifiers provide a fast, quiet, efficient way to move large volumes of air for the transport of smoke, fumes or light materials as well as for venting, cooling, drying and cleaning. The company’s air amplifiers have now also been certified as meeting the rigorous safety, health
The NEW Allen-Bradley midrange control platform equipped with Allen-Bradley® products from Rockwell Automation provides all the control you need and at a competitive price. • CompactLogix control platform provides scalability from 2-16 axes of motion • Standardisation of platform simplifies design, operation and maintenance • EtherNet/IP connectivity for network standardisation and enhanced data management • Integrated Motion and drives over EtherNet/IP
Find out more at www.scalabletechnology.asia/WNIPTAS
and environmental standards of the European Union in order to attain the CE mark. Using no electricity or moving parts, these air amplifiers are able to transform a small amount of compressed air into a high-volume, high-velocity output that is up to 25 times their consumption rate.
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The design maintains a constant, high-velocity outlet flow across the entire cross-sectional area. Output is easily adjusted and both the vacuum and discharge ends can be ducted, making them also suitable for drawing fresh air from another location to ventilate confined areas, or moving smoke and fumes away. Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/R119
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OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 41
NEW
CORIOLIS MASS FLOWMETER
PRODUCTS
The Optimass 6400 is a twin bent tube Coriolis mass flowmeter designed to meet standard liquid and gas applications in the chemical and petrochemical, oil, gas, pharmaceutical, food and beverage, and energy industries.
VISION SENSOR
The product features advanced entrained gas management
ifm efector’s O2V vision sensor is designed for packaging, production
(EGM). In the past, gas entrainments in liquid media presented
and quality control, and checks objects for presence, size, position
a challenge for mass flowmeters because the relative movement
or completeness.
between gas and fluid dampens the amplitude of the measuring
Standard vision sensors check components by means of defined
tube. This dampening leads to inconsistent sensor amplitudes,
contours, whereas the O2V vision sensor compares by means of
which interfere with the electronics’ ability to determine the actual
variable features. Instead of a defined contour, the user determines
resonant frequency. With EGM, the flowmeter is able to follow and
relative features used by the sensor to assess an object or a scene.
correct for the varying amplitudes. This is achieved for entrained
Within adjustable tolerances the sensor determines characteristics
gas up to 100% of volume and continues to present an actual read-
such as the area of an object (number of pixels), the inner and
ing, together with an indication or configurable alarm for the user.
outer object size of irregular
Compliant to NAMUR standard installation lengths, the product
object geometry, roundness or
is available in sizes DN 08-250 and covers high temperatures
compactness or the number of
up to 400°C, as well as cryogenic applications down to -200°C.
available holes. Additionally, the
It also handles pressures up to 200 bar (2900 psi).
grey-scale values can also be used for assessment.
These specifications, together with the feature of EGM and custody
A number of evaluation pa-
transfer approvals for both liquids
rameters enable a range of ap-
(OIML R-117-1/MI005) and gases
plications. Thirty-two scenes with
(OIML R137/MI002), make the product
up to 24 different models can
suitable for process industries and spe-
be saved in the unit. Parameters
cialist applications
can be set via the menu-guided
supercritical gas-
parameter setting software.
es in terminal or
like LNG, CNG or
The O2V can be used as a
storage/bunker-
stand-alone system: camera,
ing, along with
illumination and evaluation are
custody transfer
integrated into a compact metal
applications. The Optimass
housing with an IP67 protecting
6400 is available in stainless
rating. An operating temperature range of -10 to 60°C enables a range
steel 316L, Hastelloy C22 and
of applications. An ethernet interface is used for image transmission
Duplex steel UNS S31803.
and connection to the controller.
Krohne Australia
ifm efector pty ltd
Contact info and more items like this at wf.net.au/R434
Contact info and more items like this at wf.net.au/R429
42 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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NEW PRODUCTS
ANALOG OUTPUT ENCODERS The AS/AM58A analog output encoders from Lika Electronic of Italy are supplied in an industrystandard 58 mm flange diameter housing with IP67 protection (IP65 on shaft side) in both hollow (Ø 14, 15 mm) and solid (Ø 6, 8, 9.52, 10, 11, 12 mm) shaft versions. New circuitry allows for a more compact housing and a slim profile (48 mm deep). A wide variety of mounting configurations is available for a quick, safe and low-cost installation. The AS/AM58A encoders offer a 12-bit resolution in single-turn and up to 16,384 turns in the multiturn
LASER SCANNER
version for an overall 65,536 count. The improved hardware and software architecture provides an enhanced
The TiM300 laser scanner has
range of voltage and current output including 0-5 V, 0-10 V, -5 to +5 V, -10 to +10 V, 0-20 mA, 4-20 mA
a range of 2 m and is suitable
and 0-24 mA. Complementary and zero-setting inputs are supplied standard along with a fault output to
for applications such as collision
warn against circuit interruption (current output versions only). Another feature is the optional Teach-In func-
prevention and reversing protec-
tion, which includes two Start-Stop buttons located on the external enclosure designed to easily program
tion on mini-AGVs and mobile
the setting of the initial (start) and the final (stop) position.
platforms or monitoring projections
Control Devices Australia
and occupancy on storage and
Contact info and more items like this at wf.net.au/R424
retrieval devices. The scanner has a compact and robust metal housing, a scanning angle of 270°, integrated teachin function and four switching outputs. Power consumption is below 4 W. The device operates with an infrared transmitter light and gives good detection capability, even
SOLUTION BASED...
RISK FREE.
with black surfaces with just 10% object reflectivity. Suspension monorails can be reliably distanced even in curves, the
OUT OF THIS WORLD
IND USTRIAL & EMBED D ED PCs
TRANSPORT MINING DEFENCE FOOD PROCESSING DIGITAL SIGNAGE AND MORE...
company claims; the drive paths of autonomous vehicles (as well as the vehicle itself) can also be monitored laterally; and doubledepth shelves can be checked
PANEL PCs HMI CONTROLLERS FANLESS BOX PCs RACK MOUNT SYSTEMS
for occupancy as well as for any projections. The TiM300 offers up to 16 triple field sets in the form of signalling, warning and stop fields. They permit vehicles to react to the position and distance of detected objects depending on both the current situation and in advance. Four switching outputs are available for this purpose. The SOPAS interface from Sick is claimed to offer comprehensive programming for which the TiM300 aid is also available. Sick Pty Ltd Contact info and more items like this at wf.net.au/R427
www.ProcessOnline.com.au
555
93 7
95 T 03
has a USB interface. An alignment
CALL US!
OR VISIT OUR WEBSITE!
www.ieci.com.au
OCTOBER 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 43
NEW PRODUCTS
SENSOR SWITCH FOR FILL-LEVEL DETECTION Baumer claims its LBFS switch is a reliable alternative to vibratory level switches. The LBFS sensor can detect the levels of viscous or dry materials and can be fitted on tanks or pipes in any desired position. The sensor is insensitive to flow, turbulence, bubbles, foaming and suspended solids and its compact, smooth sensor head resists media adhesion, even with sticky media. The company says the sensor’s short response time enables rapid fill-level detection and accurate, reliable fill-level compliance. The level switch can detect media levels in tanks, vessels and pipes. It can also be used for overflow prevention, pump protection against dry running and media separation with oil/water mixtures. It is suitable for a range of application areas, including domestic water, wastewater, HVAC filters, hydraulic systems, oil and gas, bioenergy, wood pellets, grain mills, rail transport and pump systems. The sensor is housed in a compact, sturdy and corrosion-resistant stainless steel enclosure. It can be installed easily using Teflon tape sealing. Configuration is facilitated by the PC-based FlexProgrammer 9701. A short response time of 0.2 s means the level switch operates reliably even with fast filling processes. The device has a rated operating temperature range of -40 to +115°C. The LBFS operates on the frequency sweep principle using a highfrequency signal emitted by the sensor which experiences a phase shift in the sensed medium. When this sensor encounters a medium having a dielectric constant outside the defined range, an electronic signal is triggered. The sensor’s good sensitivity over a large measuring range for dielectric constants from 1.5 to over 100 enables limit detection with a range of powders, granulates and liquids,
SELF-CONTAINED WIRELESS PHOTOELECTRIC SENSORS The Banner Engineering SureCross Q45 is a self-contained, wireless standard photoelectric sensor solution designed for control and monitoring applications. When traditional solutions are significantly more costly due to infrastructure requirements - complexities of cables, conduits and installation - operators can quickly integrate a scalable, wireless sensor network to improve efficiency by monitoring and coordinating multiple machines and processes. The sensor provides a turnkey wireless photoelectric solution. Proprietary power management delivers extended battery life up to five years on two replaceable AA lithium batteries, depending on sensor and application. The sensor is capable of long-range communication up to 1 km (line-of-sight) and multiple I/O can be achieved with support for a wireless network of up to 47 Q45 sensors per gateway. It is claimed to provide deterministic PLC-level reliability, and has built-in, site-survey capabilities. The case provides robust, IP67/NEMA 6P protection against liquids and debris common to industrial environments. The sensor is suitable for many applications, including cable replacement, moving applications, remote applications and productivity solutions. To meet diverse application requirements, models are available in polarised retroreflective, convergent visible, remote device interface and fibre optic. Micromax Pty Ltd Contact info and more items like this at wf.net.au/R311
and even difficult substances such as polyamide granulates and paper. Transtech Electronic Control Contact info and more items like this at wf.net.au/R425
44 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289)
I
THE FUTURE OF THE IC&A INDUSTRY SECTORS
t seems virtually self-evident that ever-increasing sophistication in advanced technologies underpins and acts as the driving force behind almost every area of human endeavour that derives from invention, design, production and manufacturing. Likewise, I think that the common thread which binds this myriad of technologies is their dependence on ever more advanced instrumentation and control systems as well as, increasingly, on automation to ensure that all those diverse end products are all able to function safely and deliver what they are designed for. Instrumentation, control systems and automation (IC&A) industries directly or indirectly employ or engage people in almost all key activities within any modern economy. IC&A is integral to mining, oil, gas, telecommunications, electronics, aerospace, automotive, transportation, pharmaceutical, medicine, chemical, agribusiness - and the list goes on. It also includes, of course, the TAFEs and universities that teach and prepare students for employment in those areas. And it also has a huge flow-on effect on many other industry sectors in all those thousands of socalled ‘para’ IC&A product and services areas. So when I look at the big picture that includes all the incredibly diverse areas of IC&A employment in Australia, I see a potentially positive outlook for the future. I cannot see the march of technology petering out - our natural resources as well as our amazingly clever and innovative people across all areas of industry and manufacturing seem adept at ensuring that Australia will continue to do well. Furthermore, we know from the history of past economic ‘revolutions’ (agrarian, industrial, scientific and so on), that this twenty-first century’s technological ‘revolution’ will also demand more and more skilled specialists to progress and manage the inevitable acceleration of even newer technologies. On the other hand, history also demonstrates that as change occurs, it is accompanied by the decay and disappearance of many existing areas of employment as they are ousted by newer technologies and ways of doing things. We are already witnessing in areas of IC&A, the obsolescence of what were, not so many years ago, novel and exciting innovations. There are, unfortunately, winners and losers when change happens.
Change itself takes on different forms. It can be dramatic, gradual or possibly evolutionary, depending on the industry sector concerned. The deciding factors in determining future viability will include: • Preparation of current and future employees for change • Development of long-term policies and planning • The ability to marshal leading-edge technologies and innovative solutions to specific problems I want to conclude, therefore, by posing a number of questions that I believe have bearing on the future of IC&A in Australia: Are Australian TAFEs and universities equipped to be able to provide current and future students with world’s best education in areas of IC&A to ensure they can succeed in a globalised and increasingly competitive environment? Or are they reactive and always playing ‘catch-up’ to emerging needs? With the globalisation of companies and employment opportunities offshore, are there sufficient opportunities for our IC&A employees, graduates and apprentices to find work and develop careers within Australia? Are there sufficient incentives for Australian companies to invest in R&D, particularly in areas of cutting-edge technologies that will ensure their long-term viability and competitiveness? Are Australian politicians sufficiently aware of the importance of the IC&A contributions to our country’s wealth creation potential? I hope these issues will generate discussion and debate about matters of national importance to the IC&A sectors. Brett Simpson has spent 18 years in the plastics, petrochemical and petroleum industry. Having a BEng (Electrical) with Honours and a Masters of Business Technology, he has worked in a variety of senior engineering roles in the electrical, instrument and process control fields. Brett is currently working for Caltex Australia, and he is also the Federal President of the Institute of Instrumentation, Control & Automation Australia (IICA).
46 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2012
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List (A) Job Function 1 Management - Corporate/General 2 Management - Manufacturing/ Engineering/Specialist 3 Engineer - Electrical 4 Engineer - Electronics 5 Engineer - Process 6 Engineer - Project 7 Purchasing/Procurement 8 Technician - Maintenance/Service 9 Technician - IT 10 Technical Officer 11 Scientific Officer - R&D 12 Scientific Officer - QA 13 Consultant 14 Contractor/Tradesperson 15 OHS/EHS 16 Education/Training 17 Student-Undergraduate/Apprentice 18 Analyst 19 Sales/Marketing
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