What’s New in Process Technology April 2014 by Westwick-Farrow Media

0414

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY APRIL 2014

CONTENTS

Weidmüller u-remote is our innovative remote I/O concept with IP 20 that focuses purely on user benefits: tailored planning, faster installation, safer start-up and minimised downtimes. This allows considerably improved performance

3D printing as a manufacturing aide

and greater productivity. Reduce the size of your cabinets with u-remote,

New Products

Hot Products online

Drive-based functional safety

As I see it aking a look on the inside T

thanks to the narrow design of 11.5 mm and the need for fewer power-feed modules, due to our dual power paths isolating inputs and outputs. Our u-remote technology also offers tool-free assembly, and delivers higher channel density and extremely flexible design options. The integrated web server capability speeds up maintenance work. It allows users to run diagnoses remotely using any standard browser and without having to install any software. Users can also simulate inputs and force outputs, locally and with ease. Status LEDs on the u-remote module and beside each digital I/O channel enable reliable diagnosis and rapid service. Ordering of the required module is further simplified by there being just one item number per module. This makes planning more flexible, module selection simpler and fewer replacement parts that have to be held in stock. u-remote has a multitude of marking solutions to suit the needs of the application, with connection markers, three module markers per module, or swivel markers. All marking can be exported conveniently to the Weidmüller PrintJet ADVANCED system, which also allows colour printing.

NOW in DIGITAL!

This and many other amazing ideas boost the availability of machines and systems and ensure

Your copy of What's New in Process Technology is now available as an online eMag.

smooth processes too - from planning through

http://www.processonline.com.au/latest_issues

to operation. Our formula: "More Performance. Simplified. u-remote." See more at: www.u-remote.net

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3D PRINTING AS A MANUFACTURING AIDE CUSTOMISE MANUFACTURING JIGS AND TOOLS TO SAVE COST, TIME AND LABOUR Joe Hiemenz, Stratasys, Inc

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The primary reasons that jigs and fixtures are so abundant in manufacturing are that they help to improve quality, decrease cycle time and reduce costs. However, many manufacturers don’t use such tools to their fullest because of the labour, time and cost required to make them.

hen the concept of a custom jig or fixture is expanded to include all manufacturing tools that serve as operational aids, they are even more widespread. They can range from organisational bins and tool holders to templates, guides and gauges. They can include sophisticated robotic end-effectors (grippers) and rudimentary trays, bins and sorters for conveyance and transportation. But the use of such cost-saving utility objects is often limited because making them takes time, labour and money. But now there is an option: additive manufacturing (AM). It is simple and automated; it is fast and inexpensive. It allows more jigs and fixtures to be created and deployed while gaining the ability to optimise their performance.

Overcoming the barrier The cost of creating tools and jigs can be greatly reduced and their production accelerated by taking advantage of additive manufacturing. Even for this single task, additive manufacturing systems offer an easily justified short payback period. But there is an even larger impact on the bottom line - additive manufacturing lowers the threshold for justifying a new tool, which allows you to address unaddressed needs throughout the production process. If you were to look around the manufacturing floor, assembly area and quality control lab, how many new opportunities would you find for a jig or fixture? What would the value be? Could it: • reduce scrap and rework? • decrease direct labour time? • improve process throughput? • improve process control and repeatability?

Often jigs and fixtures, while obviously advantageous, are not currently being used in these operations, because although there is a benefit in having the jig or fixture, the return on investment isn’t large enough to warrant the effort. Since there is never enough time in the day or money in the budget to do everything you would like to do, the decision to build a manufacturing tool puts priority on: • processes that aren’t possible without a jig or fixture • most obvious and urgent needs • largest threats and most likely problems • quickest to implement and produce results • easiest to implement Deciding when and where to use a jig or fixture is no different from any of the other daily decisions we make. Action is taken when value outweighs investment or when the path has little resistance. Additive manufacturing lowers the justification threshold by increasing the ROI and decreasing the obstacles between a great idea and a solution. It does this by simplifying the process, lowering the cost and decreasing lead time. When using fused deposition modelling (FDM) as the additive manufacturing approach to make jigs and fixtures, the process has just three steps: prepare the CAD file, build the tool and post-process it. Unlike conventional fabrication methods, FDM requires little experience and minimal direct labour. In many cases, jigs and fixtures are manufactured with only 15 minutes of hands-on labour. More importantly, they are manufactured with little training on how the process works and no need for prior experience. Combined, this makes

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Additive manufacturing

THE ADDITIVE NATURE OF THE PROCESS GIVES UNMATCHED FREEDOM OF DESIGN - WHAT MAY HAVE BEEN IMPRACTICAL IS NOW REALISTIC AND REASONABLE.

Figure 1: A custom 3D-printed jig in use for manual assembly. FDM an ideal ‘self-serve’ option for jigs and fixtures. For Thogus Products, an injection moulding company in Ohio that specialises in low-volume manufacturing, additive manufacturing is easy and fast. “For one 12-cavity CMM fixture the lead time, if outsourced, was 7 to 10 days. I built it overnight,” says Natalie Williams, quality manager. Manufacturers using FDM 3D printers to create custom manufacturing tools often experience lead time reduction from 40% to 90%. Additive manufacturing also can increase ROI substantially by reducing the cost of a jig or fixture. Typically, companies realise savings of 70 to 90% when compared to outsourced fixtures that are machined or fabricated. For Thogus’s 12-cavity fixture, the savings were 87%. “The machine shop wanted $1500 for the fixture. I made it for less than $200 in materials,” says Williams. Making the tool fabrication process faster and more affordable, additive manufacturing will increase the number of jigs, fixtures and other manufacturing tools, which will improve the bottom line. Additive manufacturing can also optimise manufacturing tool performance. Before additive manufacturing, designs that were sufficient to do the job were acceptable for jigs and fixtures. Due to the expense and effort to redesign and remanufacture them, revisions were reserved only for those that did not work as specified. Although ‘good enough’ may have added a few seconds to an operation or decreased the scrap rate by a small percentage, the savings might not have warranted further investment in the tool. Additive manufacturing changes that thinking. For a few dollars, it can deliver

the next-generation manufacturing tool in time to have it in service the next day. For a tool that has marginal performance, all that is needed is a little time and initiative to redesign it. Doing so may only drive out a few seconds from an assembly operation, for example, but that time adds up. If the fixture makes 500 items per day per worker, a two-second savings reduces direct labour by 70 hours per person per year. For the same part, a 1% reduction in scrap would save 1250 parts per year. The bottom line: additive manufacturing lowers the threshold so that manufactures can put more jigs and fixtures, with optimised designs, into service. This drops more money into your company’s bottom line.

Implementing AM It is important to take materials and dimensional tolerance into account before creating your first 3D CAD model, because while additive manufacturing is ideal for many manufacturing tools, it isn’t right for all of them. Traditionally, jigs and fixtures have been fabricated in metal, so the main consideration for materials is whether plastic will suffice, or whether metal will be a requirement. In many cases, metal may have been just a practical option because it is conducive to milling, turning, bending and fabricating. In this case, additive manufacturing may be an option if plastic is a feasible alternative. With a range of materials to select from, the FDM additive manufacturing process can offer chemical resistance (petroleum, solvents), thermal resistance (up to 200°C) and resilient mechanical properties. Plastic manufacturing tools may also deliver some unexpected advantages.

For example, Thogus uses FDM-made robotic attachments that absorb impact. In the event that the robot arm crashes into an obstacle, the FDM part is likely to isolate the arm from damages, which prevents expensive repairs and downtime. In another example, BMW uses plastic, handheld tools because they are lighter and easier to handle, reducing worker fatigue. When deciding whether to try additive manufacturing on some initial tool-making projects, for dimensional accuracy, pick tools requiring tolerances larger than 0.127 mm. Tighter tolerances are possible, but as a rule, stick with this value when keeping the process simple.

Design for AM The capabilities and limitations of the fabrication methods used can have a strong influence on the design of a jig, fixture or tool. Adhering to design for manufacturability (DFM) rules, they are designed to be practical, keeping cost to a minimum, and with reasonable lead times. These rules don’t apply to additive manufacturing, since they have no bearing on time, cost, quality, performance or practicality. With AM you can throw out the old rules and start with a clean slate and a fresh design. The additive nature of the process gives unmatched freedom of design - what may have been impractical is now realistic and reasonable. Jigs and fixtures can have complex, feature-laden and freeform configurations without adding time and cost. In fact, added complexity may even reduce cost and time. For example, pockets, holes and channels reduce material consumption, build time and total process time, compared with subtractive processes, where they

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Additive manufacturing

MANUFACTURERS USING FDM 3D PRINTERS TO CREATE CUSTOM MANUFACTURING TOOLS OFTEN EXPERIENCE LEAD TIME REDUCTION FROM 40 TO 90%. ADDITIVE MANUFACTURING ALSO CAN INCREASE ROI SUBSTANTIALLY BY REDUCING THE COST OF A JIG OR FIXTURE.

Figure 2: Using FDM, BMW prints jigs and fixtures that would not be possible with conventional machining and fabrication. 3D printing allows them to be easier to use and more functional. increase cost and time. To leverage additive manufacturing, let the function and performance of the jig or fixture dictate the design. Follow the lead of companies like Digital Mechanics AB and BMW. Digital Mechanics capitalised on the freedom of design for a vacuum-assisted robotic gripper. Conventionally made, the gripper had external hoses hanging off it. With additive manufacturing, each finger of the gripper was given an internal vacuum channel that eliminated the hoses. For BMW, freedom of design allows assembly line workers to have a tool that reaches under, behind and inside the rear of the bumper. Manufacturing engineers focused solely on the function, which resulted in an organically shaped bumper-reach tool. Design freedoms can also improve the ergonomics of manufacturing tools. The weight, balance and position of the tool have direct effects on technician comfort, process cycle time and ease of access and storage. To achieve optimal ergonomics, simply design it into your tools. For example, BMW redesigned a badge alignment fixture to improve balance and reduce weight. This reduced worker strain and improved the cycle time for badge attachment. Often, jigs and fixtures are composed of many pieces, so one very simple way to leverage the freedom of design is to consolidate assemblies into a single part. If reproducing an existing tool, start with a redesign that consolidates as many components as possible into one piece. If designing a new item, create it as one piece. Only split off parts when it is advantageous to the operation of the jig or fixture.

Integrating parts into a single component has many advantages: • Eliminate tolerance challenges: Holding tight tolerances is costly. If two mating parts are combined into one, then all costs and concerns about controlling the tolerances of the mating parts are eliminated. • Eliminate assembly time: Assemblies, obviously, must be assembled. This takes time, especially for one-off items like jigs and fixtures, where perfect fits are not guaranteed. • Minimise documentation and overhead: The sum of the parts is less than the whole when it comes to time and cost. Consolidating parts reduces costs for actions such as design, documentation, quoting, ordering and inventory management.

Management No longer consider your jigs, fixtures and other manufacturing tools as assets. Instead, think of them as expenses, and disposable. As assets, jigs and fixtures are stored (inventoried) between uses, they remain in inventory until the product line is retired or they are worn beyond repair. With the time, cost and effort of making manufacturing tools through conventional methods, they are too valuable to be discarded as a disposable item. This approach carries many indirect costs, however. There is cost for the shelf space (warehousing expense); cost to manage and track the inventory; and cost to locate a jig or fixture when needed. For sporadically used tools, these costs can be quite significant. The opposite can be true with additive manufacturing. Often, it takes more to in-

ventory the jigs and fixtures than it does to remake them. So, companies adopt a management approach called digital warehousing where only the digital file is carried in inventory. It may seem unthinkable to scrap a perfectly good manufacturing tool, but for those with infrequent use, this approach reduces cost and labour. Make a fixture when it’s needed. When its job is done, send it off with the scrap material for recycling. Then digitally warehouse its design between uses. This print-on-demand approach is also handy when a replacement is needed for a broken manufacturing tool or duplicates are needed for increased production to meet an unexpected surge in sales.

Conclusion Additive manufacturing can lead to big changes that maximise profits by driving out wasted time and costs from the manufacturing process. For those who aren’t ready to toss out long-established design guidelines, simply replace the usual fabrication processes with additive manufacturing. Either way, the savings on the manufacturing floor and in jig and fixture production will be substantial. If you have a 3D CAD drawing and access to an additive manufacturing machine, you are ready to start making manufacturing tools with as little as 15 minutes of handson labour. Combine the simplicity with typical time and cost reductions of 40 to 90% and you will understand why additive manufacturing spurs companies to make more jigs, fixtures and other manufacturing tools than ever before. Tasman Machinery Pty Ltd Contact info and more items like this at wf.net.au/W470

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NEW PRODUCTS

IR WINDOWS More than 99% of all arc flash incidents

RELOCATABLE SELF-CONTAINED SAFETY SHOWER

occur when a panel door is open,

The EM850 relocatable self-contained safety shower

exposing workers to potentially lethal

with eyewash from Enware Australia features loading/

amounts of energy. The Fluke ClirVu

unloading access for forklift tines or cranes, and is said

CV Series IR windows eliminate the

to already be in use by leading resources, engineering

need to open the panel door to take

and project-management companies in Queensland and

infrared camera readings, and are

Western Australia.

claimed to have an installation time of five minutes or less.

The solar shower uses non-absorbent insulation to insulate its 1350 L tank, eliminating the need for an integrated

The series offers protection for the

cooling system - making it suitable for hot, remote instal-

electricians, engineers and inspectors

lations in places such as Asia, the Middle East and Africa.

who work around high-energy equip-

The shower incorporates a water-storage capacity to

ment. They are torture tested to the

operate both emergency shower and eyewash to international

highest arc blast test ratings and, when

safety standards conforming to both ANSI Z 358.1 2009 and

properly installed, are said to maintain

AS4775-2007 standards.

a panel arc test rating of up to 63 kA.

Designed for service with mining, oil and gas, defence and heavy-industry applications where services are limited, or non-existent, the shower requires no mains power or plumbing connection. The shower incorporates 40 W solar panels with maintenance-free durable batteries as well as dedicated shower and eyewash pumps. It also features a fully stainless steel enclosure to maximise life span and fail-safe operation in harsh environments even in ambient temperatures exceeding 45°C. The system offers immediate response to situations where serious injury can occur if eye and skin accidents are not treated within seconds. An LED display shows water level, battery power and water temperature while the self-monitoring alert system is visible from a distance. Enware Australia Pty Ltd Contact info and more items like this at wf.net.au/V314

OSCILLOSCOPES Emona Instruments has introduced the Micsig Once installed, there is no need

range of handheld oscilloscopes with touch-

to power down or remove panels.

screen technology.

Inspections can be conducted quickly,

With bandwidths ranging from 70 up to

easily and safely, often with little, if

200 MHz, two channels and 1 GSa/s sampling

any, personal protective equipment.

rate, Micsig combine a number of advanced

Installation takes one technician five

features, making them suitable for both labora-

minutes or less. Simply lockout-tag

tory testing or field service applications across

out, punch one hole with a standard

a wide range of industry sectors.

conduit punch without removing the

High-performance features include isolated

panel door, attach and secure the

inputs for safely carrying out floating measure-

cover. The AutoGround feature instantly

ments, a refresh rate of up to 190,000 wfms/s, support for serial bus protocol trigger and decode

grounds the IR window to the metal

(1553B/429/UART/232/485/LIN/CAN/SPI/12C) in both graphic and text modes, and multifunction opera-

enclosure, eliminating the need to

tion including digital oscilloscope, digital multimeter and recorder.

separately ground each metal component of the window. The hinged cover is easily opened

In oscilloscope mode, the units offer a wide range of trigger types, 31 automatic measurements, and maths functions including FFT. Isolated input versions offer up to 1000 V CAT II 600 V CAT III maximum channel floating voltage.

with a quarter-turn latch or key to

Micsig’s touch-screen technology also makes operating the oscilloscopes easier. Users have three

perform infrared inspections. It also

operation modes in touch-screen operation: moving the waveform, zooming in and out and menu op-

protects the window from accidental

tion selection. The units offer a large 5.7″ TFT LCD, which not only provides users with a sharp 640

exterior impact.

x 480 high-resolution display, but also offers a user-selectable indoor (black background) or outdoor

Fluke Australia Pty Ltd Contact info and more items like this at wf.net.au/W482

(white background) display mode, making the models particularly useful in field-service applications. Emona Instruments Pty Ltd Contact info and more items like this at wf.net.au/W485

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OU CAN DO THA

HOT PRODUCTS

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The DFS60I has a resolution of 16 bits and the user can set the zero pulse position and zero pulse width, Sick Pty Ltd

WF.NET.AU/W535 THERMAL IMAGING CAMERA

as well as the voltage level of the output-side interfaces.

The lightweight Flir T390, with a range of -20 to 1200°C, an improved refresh rate and laser locator, is suitable for almost any thermal imaging application. TechRentals

WF.NET.AU/W457

3G SECURITY ROUTERS The mGuard security routers with integrated mobile phone network interface provide integrated security technologies

Phoenix Contact Pty Ltd

IN-LINE DENSITY MONITOR

such as VPN and a built-in firewall.

WF.NET.AU/W587

The Rhotec in-line density monitor continuously measures the density of liquids and can be used to determine the concentration of alcohol, sugar, acids, caustics and other solutions. B-R Controls Pty Ltd

WF.NET.AU/W388

POINT LEVEL SENSORS The LMT point level sensors are now available with extended probe lengths and can monitor the level of virtually any liquid and viscous media or bulk material in storage tanks. ifm efector pty ltd

WF.NET.AU/W518

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NEW PRODUCTS

PUMP DRIVE SOLUTIONS The SK 200E series pump drive system comprises reliable and economical frequency inverters especially tailored to pump applications that precisely adjust power output as required. They are compatible with mains voltages worldwide. NORD configures complete drive systems for various application areas (IP55/IP66, ATEX zone 22/3D). Integrated process and PI controller functions enable the fully automated control of process variables and compensation of disturbances - in stand-alone and mobile applications as well as in complex set-ups with several drives. With two analog inputs, the inverters can directly process sensor data such as pressure or flow rate. Optional signal and power plug connectors facilitate handling and ensure compatibility. A programmable energy-saving function automatically reacts to partial load operation, increasing efficiency and significantly reducing running costs. Operation is straightforward and flexible via control terminals, bus or via an optional potentiometer that enables adjustments directly at the inverter. Up to four operation modes can be stored, saving set-up time; for instance during cleaning cycles or media changes. The customised parameters can be exported to other units via a pluggable storage module, the system bus or ethernet interfaces. With control cabinets no longer required, the decentralised option minimises cabling effort for users, and since the inverter is supplied pre-assembled the effort required during installation is minimal. NORD Drivesystems (Aust) Pty Ltd Contact info and more items like this at wf.net.au/W120

Decouples, monitors and controls

QUINT ORING Active redundancy module for maximum system availability Monitoring with the QUINT ORING: • Output voltage of the power supplies • Wiring up to the redundancy module • Decoupling section • Load current ACB technology doubles the service life of your redundant power supply units. Call us today: 1300 786 411 or visit phoenixcontact.com.au

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NEW PRODUCTS

PROGRAMMABLE TIMER The Novus NT240 programmable digital timer can be easily config-

PRESSURE TRANSMITTER

ured to switch at pre-programmed

The STS ATM/GR robust electronic pressure

time intervals, activating an output

transmitter with both 0-20 and 4-20 mA

according to a predefined mode of

outputs features two independent switching

operation and user-chosen time interval.

contacts that are adjustable across the full

The output is both in relay (SPST) as well

range of the sensor.

as pulsed voltage (5 V, 25 mA) and is switched

The ATM/GR is available with numer-

at pre-programmed intervals according to eleven

ous user-defined configurations to suit

different timing functions. Input types NPN and

the application, and has high long -term

PNP are supported, as well as digital NO/NC contacts.

stability. Its pressure-measuring range is

The front dual 4-digit LED display shows the running time, elapsed time or

100 mbar to 1000 bar with an operating

time remaining, in resolutions from 0.01 s to 99 h, and time counting can be up

temperature range of -25 to 85°C, and a

or down in decimal or h:m:s. Timing accuracy is 0.05% of the displayed time,

process temperature range of -40 to 150°C.

while the time base offers seven scales, from 99.99 s to 9999 h. Power supply is 100 to 240 VAC or DC as well as 24 VDC. Operating environment is 5 to 50°C and 30-80% humidity. The user controls are via a silicone rubber keypad, and the front panel has a protection rating of IP65. Physical

The sensor is available in either stainless steel or titanium, and the switching outputs are potential free up to 48 V, 2 A, 60 W with independently

dimensions of the NT240 are 48 x 48 x 110 mm.

adjustable set points.

Heastern Industries

Automated Control Pty Ltd

Contact info and more items like this at wf.net.au/W521

Contact info and more items like this at wf.net.au/W536

RUPTURE DISC Rupture disc manufacturer Elfab has launched Ferrule Opti-Gard, a reverse-acting disc designed for use in hygienic and aseptic applications. The disc features a 95% operating ratio and 3% tolerance. Available in a variety of sizes, and suitable for a range of burst pressures and temperatures, the design is non-fragmenting and capable of supporting vacuum and back pressures. The disc can be used with tri-clamps and ferrules, and has an uninterrupted surface finish to meet FDA approvals, making it suitable for use in CIP and SIP applications. The design also includes an integral Flo-Tel+ actuator as standard, offering the added benefit of non-invasive, ATEX-approved rupture detection through the Flo-Tel+ system. Elfab Limited www.elfab.com

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NEW PRODUCTS

15 CM TUBULAR CABLE CONVEYOR PORTABLE VIBRATION CALIBRATOR Available to rent, the TMS 9110D portable vibration calibrator is a compact and completely self-contained unit, suitable for electromechanical testing over a wide range of frequencies and amplitudes. This vibration reference source operates with digital closed-loop control, for enhanced stability and accuracy. Applications include: field validation of vibration sensors, proximity probes and vibration monitoring equipment; accelerometer checking; velocity transducer testing; and calibration of data collectors and vibration switches.

Flexicon has expanded its Flexi-Disc line of

The device features a wide frequency range

tubular cable conveyors with the addition of a

of 7 Hz to 10 kHz, an internal memory for

15 cm diameter system, more than doubling

up to 500 records and a USB flash drive

the capacity of the company’s recently intro-

output. Customisable calibration

duced 10 cm diameter conveyor. The conveyor

certificates are compliant with

is intended for the gentle transfer of friable

ISO 17025 and accelerometer

materials including virtually all beans, cere-

calibration is as per ISO 16063-21.

als, coffees, dried fruits, frozen vegetables,

TechRentals Contact info and more items like this at wf.net.au/W146

grains, nuts, beans, pet foods, seeds, snack foods, spices, teas and other fragile/friable food products. Typical non-foods include bulk chemicals, minerals, prills, chopped fibreglass, microspheres, regrind, pellets of all types, tobacco and other fragile products. Low-friction, high-strength polymer discs slide materials gently, quietly and dust free through

VIBRATING FORK LEVEL SWITCHES

smooth stainless steel tubing, which can be

Typically used in challenging or hygienic applications demanding no moving parts

routed horizontally, vertically or at any angle,

or clean-in-place (CIP) fittings, vibrating tuning forks provide a reliable means for

through small holes in walls or ceilings, over

point-level switching. Each fork is trained on site to monitor specific media, ignoring

short or long distances. The system can be

changes in density, viscosity, conductivity, media foaming, tank agitation and vibration.

configured with single or multiple inlets that are

The Sitron V-Tork family of vibrating fork level switches offers a large range of

metered and/or non-metered, and discharges

configuration options including customised insertion length; threaded, flanged or

that are valved or open.

sanitary fittings; relay, transistor or direct switching output; AC,

The cable-disc assembly is pulled through

DC or universal power supply models; and medium- and high-

the tubing circuit by a drive wheel at one end of

temperature models; as well as a range of plug and junction

the circuit, and kept taut by an automatic cable

box terminations.

tensioner at the opposite end of the circuit.

All wetted parts are made from 316 stainless steel,

All housings and ancillary metallic compo-

with a choice of Halar, PFA or epoxy coating, where

nents are of 304 or 316 stainless steel with

required, for corrosive media. To prevent output

continuous welds ground and polished to food,

chatter or false switching, each V-Tork unit has

pharmaceutical or industrial standards. In ad-

an adjustable time delay for response time.

dition to galvanised cable, discs are available

Control Components Pty Ltd

affixed to stainless steel and nylon-encapsulated

Contact info and more items like this at wf.net.au/W203

stainless steel cable for sanitary applications. Wet or dry cleaning accessories can be quickly attached to the cable, while clean-in-place (CIP) accessories allow automated sanitising of the system. Flexicon Corporation (Australia) Pty Ltd Contact info and more items like this at wf.net.au/W034

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NEW PRODUCTS

MULTIPORT VALVES Robolux multiport valves are designed for clean and washdown areas, and can be combined with Burkert’s Element control heads to provide decentralised automation of hygienic processes. Based on diaphragm valve technology, the design of the valves combines independent dual switching functions in a single body, with single diaphragm and actuator. The compact design occupies approximately 50% less space than traditional valve manifolds, and is more easily sterilised. Low internal volume and elimination of dead leg supports faster cleaning and a higher product yield, with the compact construction also streamlining installation and maintenance. The combination of the multiport valves with Element control heads is claimed to present new possibilities for the decentralised automation of hygienic processes. The integration of all automation functions within the control heads allows the valves to be equipped at field level with required automation components, including pilot valves, electrical feedback units and optical status indicators. The control heads also integrate optional fieldbus interfaces, allowing up to 62 valves to be connected to a PLC in series by a single 2-wire line. Typical applications are found in hygienic food and beverage, pharmaceutical and biotechnology processes. Manufacturing applications where dosing chemicals carry a high per-unit cost are also indicated. The valves are said to support such applications with high reliability and repeatability, with an internal and external design that supports purity and sterile process conditions. Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/W542

BULK MATERIAL INTEGRATED SYSTEM NBE has introduced an automated bulk material handling and packaging system built on the NBE integrated construction and controls infrastructure. The complete process sequence, including pallet/base supply, slipsheet pick and placement, bulk material infeed, packaged contents isolated densification, weighing, and finished-package accumulation conveyance, operates on paired, process-specific structural framework chassis with all automation and control functions centralised on a single, menu-driven HMI to enable standardised and system-wide data reporting. The integrated construction provides the basis for reduced total cost of ownership, relative to the common systems integration concept of bolttogether, divergent ‘islands’ of equipment. The slipsheet dispenser magazine can hold up to 1100 kg of sheet. Sensors and automated controls guide the dispenser lift carriage along horizontal and vertical flanged cam rollers to provide highly accurate pick and place of up to 30 slipsheets per hour. The bulk bag filling stage of this bulk packaging system uses a cantilevered fill head/bag hanger carriage design with pneumatic actions to bring the fill head and rear bag hooks to well within the operator’s reach - eliminating the need for the operator to step or lean into the equipment. The 8 GPM hydraulic lift carriage easily and safely lifts bag capacities up to 2000 kg. The hang-weigh system provides valid, accurate and repeatable weighing of the bulk bags to an accuracy of ±0.05% of bag weight, and the bulk bag densification platform uses 3 g of highspeed, low-intensity vibration to settle material in the bag to a dense, stable and safe load. Mercer Technologies Contact info and more items like this at wf.net.au/W483

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CASE STUDY

Researchers develop an autonomous gas leak detection robot

Detection of gas leaks in industrial facilities can not only be dangerous and time-consuming, but it is also susceptible to human error and interpretation. RoboGasInspector was conceived in order to provide a safer, more efficient and more reliable detection solution. As part of the German technology program AUTONOMIK, a consortium of nine companies and research institutes developed a prototype of an autonomous mobile robot for gas leak detection and localisation in large industrial facilities. The consortium came up with a system that is able to perform inspection tasks in industrial facilities without having to access hazardous areas directly - and without requiring any human presence. The robot can be used for routine inspections of facilities or for targeted inspections of specific system parts. The development of innovative monitoring processes that make the most of state-of-the-art measuring and automation technology as well as robotics promises improvement in the reliability, efficiency and cost-effectiveness of inspections. At the same time, it relieves technical personnel of monotonous, time-consuming and labour-intensive tasks. RoboGasInspector was the result of a collaborative research project headed by Dr Andreas Kroll and Dr Ludger Schmidt at the Mechanical Engineering Department of the University of Kassel and subsidised with 2.4 million from the German Federal Ministry of Economics and Technology. Exercising the utmost care wherever toxic or explosive gases are used is absolutely essential, which is why rigorous inspection specifications apply to the chemical industry, biogas facilities and gas suppliers. Usually, preventive inspection programs require personnel to perform time-consuming routine inspection procedures on a daily basis. During these regular inspections, staff members check the system for proper functionality and therefore they usually rely on perceptions and experience without making use of measuring technology. However, there is always a risk of inadvertently overlooking possible sources of danger due to inattention. The development of innovative inspection technologies and focusing the flexibility and performance of human operators on managing the technological systems makes sense not only for economic reasons, but also with regard to relieving humans from repetitive routine tasks and improving inspection coverage. For professors Kroll and Schmidt, a top requirement for the new system was that it should allow for automated, hazardfree inspection and monitoring and that it should be able to respond independently to problems. The RoboGasInspector was demonstrated for the first time in a hall at the University of Kassel and independently completed an inspection route, successfully overcoming obstacles and a ramp in the process. At specified inspection sites it inspected various pipelines and found a methane leak. In the following months, this success was expanded to several square kilometres of large industrial facilities under laboratory

conditions in which environmental factors such as wind and sun as well as confounding factors resulting from system operation were included. The RoboGasInspector consists of three modules: a chaindriven mobile platform, a navigation module and an inspection module, which incorporates a FLIR optical gas imaging camera. The chain-driven platform is equipped with an electric drive and conventional batteries. The navigation module consists of 2D laser scanners (front and back, particularly important for navigation inside buildings) as well as a GPS receiver for outdoor orientation. Continuous comparison of the area to be inspected with a digital map enables the RoboGasInspector to determine its position at any time; obstacles and blocked areas (such as explosive zones) can be noted on this map. “Thanks to its 2D laser scanners, the RoboGasInspector also avoids unexpected objects such as parked cars, pallets, barrels and people,” explained Professor Kroll. “If the RoboGasInspector encounters obstacles, it moves around them or stops until the path is clear again.” The inspection module combines various metrological instruments on a pan-tilt unit, including a remote methane leak detector (RMLD), which is based on an active tunable diode absorption spectroscopy (TDLAS) instrument. It works by means of an infrared laser: when the laser beam hits a surface, it is reflected and its residual intensity is measured. In addition, a FLIR GF320 thermal imaging camera is mounted on the inspection module to visualise the gases and to help to detect gas leaks from a safe distance. To ensure that the RoboGasInspector itself does not pose a risk, it is also equipped with a built-in gas sensor that shuts down the entire system from 10% of the lower explosion limit (LEL) onwards in order to prevent possible danger in a flammable atmosphere. Processing of the measured data and pattern recognition are performed independently by the robot. The RoboGasInspector also carries out the inspection of the specified routes and performs measurements on its own. Despite this, it is continuously in contact with the control room and can be remotely controlled from there if necessary. A video camera is also incorporated in the panand-tilt measuring module for this purpose. However, in normal operating mode, the RoboGasInspector works independently and merely transmits all measured data to the control room via WLAN. The system prototype has impressively demonstrated its use and capability in extensive series of tests. The drive unit, the navigation system and the complementary sensor systems performed well during the tests. However, before deployment in industrial settings, further development is required, and of course legal issues must be clarified prior to deployment in commercial settings. FLIR Systems Australia Pty Ltd Contact info and more items like this at wf.net.au/W529

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NEW PRODUCTS

INTEGRATED PLC AND HMI The Unitronics Vision130 PLC+HMI family are flat fascia PLCs with onboard HMIs. The flat fascia makes these models suitable for the food and pharmaceutical industries. With their IP66/IP65/NEMA4X rating, these units can be used wherever spray/wipe-down applications apply. Models include: V130-J-B1, V130-J-TR20, V130-J-R34, V130-J-TR34, V130-J-TR6, V130-J-RA22, V130-J-TRA22, V130-J-T2, V130-J-T38, V130-J-TA24. The company says their PLC+HMI advantage gives users the opportunity to minimise budget, programming time and wiring. With a wide variety of onboard and expandable I/O options, the units are capable of supporting up to 256 I/O. These configurations include digital and analog inputs and outputs, high-speed I/O, PT100/ thermocouple capabilities, and load cells for weight measurement. The I/O can be mounted locally or remotely, up to 1000 m from the controller. They are also equipped with recipe capabilities, micro SD card memory storage for data logging and backup and complete PLC cloning. Vision130 units can support 24 auto-tuned PID loops to control temperature, level and pressure. The graphic LCD, 2.4″ 128 x 64 pixel operator interface supports over 1024 user-designed screens with 400 images per application, a 20-key keypad, and is able to display trend graphs and a text string library. Internal memory holds 512K of application logic, plus 128K for fonts and 256K for images. Communication options include ethernet, mobile and industrial protocols such as Modbus, DF1 slave, J1939 and CANopen. In addition, the units can be ‘taught’ to communicate via almost any ASCII protocol. Micromax Pty Ltd Contact info and more items like this at wf.net.au/W397

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NEW PRODUCTS

ASSET PERFORMANCE MONITORING SOFTWARE WinCC V7.2 Performance Monitor can provide plant-specific key performance indicators (KPIs) for individual devices, machines and even entire production lines. This includes key

SOUND VELOCITY CONCENTRATION MONITOR The Centec Sonatec inline sound ve-

metrics such as overall equipment efficiency (OEE), MTBF

locity monitor continuously measures

and MTTR. WinCC V7.2 provides performance transparency

the sound velocity of liquids. Centec,

from operator to management level, critical for productivity

a German-based company, designed

improvements to achieve greater competitiveness. With the

the Sonatec for maximum stability and

application environment integrated in WinCC, the applica-

high accuracy. Sonatec can be used in

tion engineer can create the individual formulae for the

chemical, petrochemical, metal processing and pharmaceuti-

performance metrics required. Cyclical or event-triggered

cal plants to determine the concentration of hydrocarbons, acids, alcohol,

calculation results are written to WinCC variables.

caustics, oil emulsions, oil in water and many other liquids. The sound

KPI analysis by maintenance and operations manage-

velocity measurement is measured directly in line, the liquid flowing through

ment can be performed on a WinCC/Web Navigator

a U-shaped fork. Any change in the fluid concentration changes the sound

client or standard WinCC client, inspecting bar charts

velocity. For any given fluid, the correlation between concentration and sound

(performance), progress displays (Gantt) and tabular

velocity can be described by a mathematical polynomial. With decades of

control. Management can also access the KPIs in a

experience and their own laboratory facilities, Centec have the polynomials

more customised web-based report format via a WinCC/

for a large number of liquids. Temperature changes of the measured liquid

Information Server Client. Operators are also kept up to

are automatically compensated for by an internal PT1000 sensor. Sonatec

date on performance while at work, via representation of

displays various units, such as volume %, mass % and °Brix. The Sonatec is

performance figures within the standard WinCC run-time

available with a range of wetted part materials to suit most liquids, including

user interface.

316 stainless steel, Hastelloy, Monel and tantalum. A range of communica-

Siemens Ltd

tion options exist to interface with PLC and DCS systems.

Contact info and more items like this at wf.net.au/W075

B-R Controls Pty Ltd Contact info and more items like this at wf.net.au/W152

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NEW PRODUCTS

SAFETY SWITCH The design of the external cam on the

CONTROL SYSTEM SOFTWARE Kepware Technologies has released KEPServerEX version 5.14, offering liquid electronic flow measurement support, store-and-forward support for data logging, improved support for Siemens S7 PLCs, and performance improvements when used with Allan-Bradley ControlLogix. Kepware now provides liquid electronic flow measurement (EFM) support for the Fisher ROC+ and OMNI flow computer drivers, as well as the EFM Exporter that has been engineered to create liquid CFX files. The version also includes major usability improvements for the Siemens TCP/IP Ethernet

Schmersal AZ300 mechatronic safety switch, in the shape of a Maltese cross, allows the AZ300 to accept the actuator from any of three sides, providing mounting flexibility for either left- or right-hinged doors, or sliding guards.

Driver, including automatic tag generation for S7 300 and S7 400 PLCs. The software also supports packet-size configuration, which allows users to take advantage of the larger packet sizes allowed in ControlLogix controllers Firmware v20 and higher, and the DataLogger plug-in now offers store-and-forward functionality to guarantee delivery of process data to SQL Server. Users with an active support and maintenance agreement may be eligible to upgrade to the most current version of KEPServerEX at no charge. Automation Direct Pty Ltd Contact info and more items like this at wf.net.au/W481 The AZ300 also has integrated an RFID sensor to detect the actuator and indicate a closed guard. This noncontact operating principle limits wear on components, tolerates misalignment and offers the option of individual cod-

SOLUTION BASED...

ing. The basic version of the sensor

RISK FREE.

responds to any AZ300 target actuator; the ‘I1’ version only accepts the coded ID number of the specific target actuator which is configured during the first

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start-up; and the ‘I2’ version allows the teach-in process to be repeated, allowing replacement of a lost or damaged actuator. With continuous internal function tests and monitoring of the safety outputs, the AZ300 can be wired in series without detriment to the safety levels. Diagnostic LEDs on the sensor indicate various errors, misalignment and door open/ closed signalling. For more advanced indication, the AZ300 is also available with serial diagnostics. The AZ300 also offers adjustable latching, which provides a holding force of 25 N or 50 N. Lockout/tagout can be achieved by placing padlocks through the key of the actuator, preventing the guard from closing. The AZ300 meets the requirements

T 03

9593

7555

of Cat 4, Performance Level e or Safety Integrity Level 3; and because of its protection class IP69K, it is also suitable for use in hygiene-sensitive areas.

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Control Logic Pty Ltd Contact info and more items like this at wf.net.au/W394

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NEW PRODUCTS

WIRELESS DEVICE SERVERS Advantech’s Industrial Auto-

COMPACT VOLUME FLOW SENSORS

mation Group has introduced

The PSK AFS compact volume flow sensors from

the EKI-1361 and EKI-1362

Phoenix Contact are based on calorimetric

1- and 2-port RS232/422/485 to 802.11 b/g/n WLAN serial device servers. They have been

measurement and can detect consumption quantities as low as 0.06 Nm3/h. The sensors are also suitable for measur-

designed for use in areas where

ing operational consumption thanks

signal strength and reliability may be af-

to their large measuring range of up

fected. To counteract these issues, they use MIMO 2x2 technology which transmits two signals simultaneously to provide greater efficiency by ensuring they are not jammed by other devices. To further aid reliability, they have a fast roaming design. This

to 700 Nm3/h. In addition to the IO-Link communication system that facilitates intelligent communication between the sensor and

means that when moving from one access point to another where

the controller, the compressed air counters

signal strength can weaken, these switches can quickly switch to a

can also output analog values and digital im-

new access point without degrading the data.

pulses, as well as measuring switching thresholds via

To fit in areas with limited space, they weigh 800 g each, have a

two digital outputs. These versatile options for outputting flow and temperature

small footprint and provide a range of mounting options and antenna

measurement data facilitate a wide range of connections to process and

extensions. In industries where the devices are in fixed positions, they

control systems. The compressed air counters measure the current volume

can have a peer-to-peer connection without using wireless access

flow, the total volume consumed and the temperature of the compressed

points, therefore making it cost-effective in areas that would otherwise

air in the monitored process. The devices offer a value and status display in

need to have a long wired connection.

addition to the numerous configuration and measuring options available via

Advantech Australia Pty Ltd

the IO Link, providing users with an overview directly at the sensor.

Contact info and more items like this at wf.net.au/W591

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/W279

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CASE STUDY

Rockwell and Ampcontrol collaborate on earth leakage safety for VSDs

Medium-voltage (MV) variable speed drives (VSDs) are now widely used in mining applications. However, due to the high-frequency voltage generated by these drives, they can introduce earth leakage currents at frequencies outside the normal power system frequency which may not be detected by traditional earth leakage protection relays. Earth leakage - the leakage from an active circuit to ground - can create safety issues. As a result of this, mining regulators in various states of Australia have requested that special attention be given to installations that use VSDs. AS/NZS 2081:2011 is the relevant standard for electrical protection devices for mines and quarries. This standard specifies the performance requirements for protection devices intended for use with electrical supply networks utilising earth fault current limitation techniques (IT networks). Earth fault current limiting devices are used to minimise the risk of touch and step potential reaching harmful levels due to an earth fault. Special mention is also made of VSDs in AS/NZS 4871.1:2012 Appendix E. To this end, Rockwell Automation has collaborated with Australian electrical engineering and manufacturing company Ampcontrol Group to successfully test a solution that detects the impact of earth leakage on mine sites.

“The standard is of vital importance to the mining industry, particularly the coal sector. There had been a lot of discussion within the industry about detecting earth leakage with VSDs but a proven and accepted solution had not been established - until now,” said Geoff Irvine, mining industry manager at Rockwell Automation. To ensure that an earth fault can be detected at the input or output of a VSD, a wide bandwidth earth leakage relay is required. When developing its VSDguard earth leakage relay to address earth leakage issues faced by the mining industry, Ampcontrol contacted Rockwell Automation to test the product on the PowerFlex 7000 series of medium-voltage VSDs. Testing of the Ampcontrol VSDguard on a PowerFlex 7000 demo system took place at Rockwell Automation in Canada. The aim of the testing was to determine if earth leakage currents are within acceptable levels under normal operating conditions, and if earth leakage currents are detectable under earth fault conditions. In addition, the testing assessed whether VSDguard is capable of detecting earth leakage currents at all frequencies produced by the VSD and trip under all earth fault conditions. The trial successfully proved the relay does work and can detect earth leakage at different frequencies. VSDguard works in conjunction with the PowerFlex 7000 drive equipped with a direct-to-drive topology. Direct-to-drive topology eliminates common mode filters, which removes the possibility of bypassing the neutral earth resistor under earth fault conditions and maintains the integrity of the earth leakage detection circuit. “It is very promising that we have achieved these results by thoroughly testing the Ampcontrol VSDguard with the PowerFlex 7000,” said Stephen Sneddon, product manager of mining systems at Ampcontrol. “The combination will be beneficial for the mining industry in Australia and New Zealand when complying with the AS/NZS 2081:2011 industry standard and will improve the safety and productivity of a variety of mining applications including ventilation fans, conveyers and pumping applications.” Rockwell Automation Australia Contact info and more items like this at wf.net.au/W469

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NEW PRODUCTS

DATA LOGGER The HMG 3010 is a portable measuring and data-logging device with automated setting procedures and simple, self-explanatory operator guidance that enables the user to carry out a wide

range of measurement tasks in a short amount of time. The HMG 3010 is designed primarily for recording measured values of the variables of pressure, temperature and flow rate which are common in hydraulics and pneumatics. For this purpose, sensors are available with which the measured variable, measurement range and unit are

ETHERNET I/O MODULES

automatically detected by the HMG 3010.

Acromag has released two additional

The device also offers measurement

models (XT1230 and XT1240) in the

inputs for standard sensors with current

BusWorks XT Series of ethernet I/O mod-

and voltage signals. In addition to the

ules. These models provide a 16-channel

analog inputs, the HMG 3010 also has two

interface for single-ended analog current

digital inputs (eg, for frequency or rpm measurements). The

or voltage input signals. The space-saving

ability to connect the HMG 3010 to CANbus and thus to display messages from

inch-wide design features dual ethernet

the CANbus expands the range of applications. The breadth of functions and

ports, removable front-facing terminal

the simple handling make the HMG 3010 equally suitable for users who take

blocks and DIN rail power bus support.

measurements only occasionally and for professionals for whom measuring and

Suitable for use in harsh environments,

documentation is routine. The update capability of the HMG 3010 via the integral

all modules operate from -40 to 70°C with

USB port ensures that future developments of the device software can be used.

noise immunity, surge protection and CE

Up to 10 sensors can be connected simultaneously and up to 32 measure-

compliance (UL/cUL Class 1 Division 2

ment channels can be displayed at a time. Measuring rates can be up to

Zone 2 hazardous location approval is

0.1 ms and extended voltage measurement is available in the ranges -10 to

pending).

10 V and 0 to 50 V. HYDAC International Contact info and more items like this at wf.net.au/W541

The XT1230 accepts current inputs of 0-11 mA, 0-20 mA, 4-20 mA, ±20 mA, or 0-20 A AC with optional toroid sensor. The XT1240 accommodates ±5, ±10, 0-5 or 0-10 V input ranges. All units run off a 12-32 VDC power source (2.8 W) at the

LINEAR POSITION SENSORS

terminals or through an integrated power connector bussed along the DIN rail that

The LA-25-A series linear variable displacement transformer (LVDT) sensors from Bestech

can provide primary or redundant power.

Australia range from 75 to 375 mm and are designed to handle extreme industrial environ-

Each model offers a choice of EtherNet/

ments. The LA-25-A is suitable for roller gap positioning, process valve displacement,

IP, Profinet or Modbus TCP/IP protocols

head box and actuator position feedback with the durability to withstand the harsh

with peer-to-peer i2o communication

environments found in: steam and hydro power plants; paper, steel, and aluminium

support. Dual 10/100 Ethernet ports allow

mills; die and stamping presses; building and bridge monitoring; and industrial automa-

daisy-chaining units together to simplify

tion and fluid power systems. It can operate in hostile factory environments such as

cabling and minimise the network switches

lubricant and chemical mists, airborne grit and dust, and typical industrial washdowns.

required, reducing overall system costs.

The LA-25-A LVDT linear sensor features a sturdy 25.4 mm diameter heavy wall

For even more dependable com-

housing of aluminium or stainless steel and two double-contact shaft seals that keep

munication, BusWorks XT units employ

fluids and solid contaminants out of its bore, and it offers a choice of axial connectors

Innovasic Priority Channel technology,

or a cable in a metal cord grip.

which makes certain that critical data is

The LA-25-A series is robust and permits a variety of mountings, including standard

received on time regardless of traffic on

saddle-type clamps and a two-hole flange that screws onto its front bushing. The

the network. Priority Channel provides

LA-25-A’s core can never break loose as it is enclosed in a core extension rod assem-

determinism at the device for consistent

bly and offers a sturdy male thread for easy mechanical connection. When integrated

transmission of time-sensitive data with

with an SC-100 industrial LVDT DIN-rail-mountable signal conditioner, an LA-25-A LVDT

any of the supported protocols.

becomes a suitable solution for heavy-duty industrial applications for position sensing. Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/W593

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/W592

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NEW PRODUCTS

INTERLOCKING GUARD SYSTEM The Euchner MGB multifunctional gate box is an interlocking guard system designed for the protection of safety doors on machines and systems. It features an integrated

VISCOSITY METER

lockout mechanism with optional escape release handle,

The Micro Motion Fork Viscosity Meter is Emerson’s next

and optional buttons and indicators.

generation of the Micro Motion 7827 and 7829 direct inser-

The unit is easily mounted on frames, grilles or profiles,

tion viscosity and density meters and is designed to tackle

and the handle can be mounted level or rotated 90, 180,

demanding process applications such as

270° without disassembly. Once linked to machine controls,

oil-fired heater combustion control, HFO

the opening of the access door will be prevented until

blending/production and pump protection.

the machine has safely stopped.

The fork viscosity meter incorporates a

Start, enable, emergency stop and other functions

hazardous area approved head-mounted

can be added to the basic handle/lock module to turn it

transmitter that has the flexibility to con-

into a small control terminal. This enables the unit to be

nect to control systems via a wide range

used for interlocking, guard locking, escape release and

of digital and analog protocols. Because

machine functions such as start/stop, emergency stop,

it supports 4-20 mA, HART, WirelessHART,

etc. The modular design means that additional features

FOUNDATION Fieldbus and RS485 Modbus,

can be easily added at a later date. The optional escape release is intuitive to operate and

system integration and commissioning costs are significantly reduced.

enables exit from the danger area quickly and easily.

An additional benefit of the fork viscosity meter is

When working in a restricted area, the bolt tongue can be

the capability of accepting and processing external

locked open with up to three padlocks in the integrated

signals from other field instrumentation such as

lockout bar, preventing unintentional activation of the

temperature, pressure and mass/volumetric flow

interlocking/guard locking.

devices. The input of these external measurements enables the fork viscosity meter to calculate and output enhanced process measurements while minimising installation and cabling costs. The fork viscosity meter also incorporates a diagnostic capability called Known Density Verification that checks the meter for measurement alarm conditions, sensor integrity and the presence of coating, erosion

The system complies with safety Level e in accordance

or corrosion. This technology expands the availability of

with EN ISO 13849-1 or SIL3 in accordance with EN 62061,

diagnostics information in critical viscosity and density

and EN 1088 for protection against tampering. An LED

measurement applications which can result in significant

display provides continues information on system status.

maintenance costs and cycle time reductions.

Treotham Automation Pty Ltd

Emerson Process Management

Contact info and more items like this at wf.net.au/W486

Contact info and more items like this at wf.net.au/W392

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DRIVE-BASED FUNCTIONAL SAFETY

LOW-VOLTAGE AC DRIVES ARE PLAYING AN INCREASINGLY IMPORTANT ROLE IN MACHINE SAFETY Today, new drive technology is making the previously complicated job of implementing a machine safety system much easier. Recent technical advances make safer operation less complex, while at the same time offering exciting new potential for productivity and uptime gains.

n any industrial process it is critically important that when something goes wrong the machinery is quickly and safely brought to a safe state, which usually means stopped. Once stopped it must not start unexpectedly. Depending on the application and its work cycles, machines may also need to operate at reduced speed during specific times. Any malfunction in machine control can result in hazardous situations leading to serious injury, or even death, with disastrous effects for the company, its people and its image. Ultimately, machine builders and system integrators have the responsibility for ensuring that any product or machine they supply is safe. It must be designed by following safety principles and must comply with relevant directives, standards and national laws. The machine’s end user has responsibility extending through the entire life cycle of an industrial system. It is thus vitally important that safety planning is included from the very start of any machine design process. This way safety becomes a natural, functional part of the machinery and not an afterthought.

Drive-based functional safety (which we can define as “active machine safety functionality designed to work with drives”) simplifies the task because drive safety functions are certified and integrated into the drive system. Safety is important in industrial applications involving motors, drives and PLCs, and machine safety is achieved by identifying and reducing risks to an acceptable level. Risk reduction is done by an inherently safe design and by applying risk-reducing protection measures. When done correctly, these measures can be flexible, reliable and easy to use. They also bring solid economic benefits such as increased productivity and uptime, without generating additional risks.

Towards integrated drive-based functional safety The job of implementing a machine safety system is easier today thanks to three main factors: 1. Modern electronics enable safety functions to be directly integrated into a drive’s safety logic, so functional safety is a standard feature of the drive.

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Drive-based safety

level of complexity and modularity of industrial automation increases, drive-based functional safety is fast becoming an important part of overall safety design for industrial processes. When sensing a hazardous situation, a drive-based functional safety system can react in several ways. It might, for example, initiate an emergency stop based on user input. Or if it detects an out-of-control situation such as system overspeed, it can stop a process in a controlled and orderly way. In larger systems with several drives, control of the overall safety system can be done using a safety PLC, which activates drive-based safety functions when required in the whole system.

Typical drive-based functional safety functions

Safe torque off (STO) STO is the required basic foundation for drive-based functional safety, since it brings a drive safely to a no-torque state. STO is typically used for prevention of an unexpected start-up of machinery (EN 1037) or for an emergency stop, fulfilling stop category 0 (EN 60204-1).

Safe stop 1 (SS1) SS1 stops the motor safely using a controlled ramp stop and then activates the STO function. SS1 is typically used in applications like rolling mills where motion must be stopped in a controlled manner before switching to a no-torque state. In addition to a safe process stop, SS1 can also be used to implement an emergency stop, fulfilling stop category 1 (EN 60204-1).

2. Legislation has kept pace with these advancements with new standards that define the requirements and provide guidelines for implementing machinery safety. 3. Engineering companies have developed a wide range of safety devices and solutions that are easy to integrate in industrial applications for improved safety, uptime and functionality. These three factors have enabled safety solutions that can be more effective in preventing accidents, less costly to implement, easier to adapt and more reliable than previous hardwired electromechanical systems. The result is that electromechanical safety systems can now be replaced with electronic safety functions that are built directly into the drive’s safety logic, working seamlessly side by side with the drive’s normal control functions.

Drive-based functional safety solutions in industrial systems Drives, simply put, control movements such as motor speed and torque in industrial applications like conveyors and cranes. As the

Safe stop emergency (SSE) SSE is a safety function specifically designed for emergency stops. SSE can be configured to execute either STO or SS1 depending on which emergency stop is suitable for the system. For examples of this functionality see Figures 1 and 2.

Safely-limited speed (SLS) SLS prevents motors from exceeding a defined speed limit. The SLS safety function can be used in applications such as decanters, mixers, conveyors or paper machines where excess speed can be hazardous - for example, during maintenance or cleaning operations.

Safe maximum speed (SMS) SMS is a variant of the SLS safety function. It provides continuous protection against a motor exceeding a defined maximum speed limit.

Safe brake control (SBC) SBC provides a safe output signal to control a mechanical holding brake. Drills, cranes, winches, hoists, vertical conveyors and elevators that need external brake solutions require this type of safety

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Drive-based safety

|n|

Function requested

|n|

Function requested

Figure 1: Upon activation, STO immediately switches off the drive output to the motor. Motor speed then coasts to a stop.

t Figure 2: When activated, SS1 will ramp motor speed down to a standstill and then activate the STO function.

function. Typical use for SBC is when a drive is switched off with the STO function and there is an active load affecting the motor (such as a hanging load on a crane or winder).

Machinery Directive, relevant harmonised standards and national laws Under the directives, national and regional laws, end users, machine builders and system integrators are generally responsible for safety of machines and systems. In this article we will mainly refer to EU legislation, which however is based on IEC/ISO standards that are globally applicable. To fulfil the requirements of EU Machinery Directive 2006/42/EC, it is sensible for the machine builder to follow a roadmap of set safety design steps. This helps both to meet legal requirements for the CE compliance marking and also to generate the necessary technical documentation. Functional safety regulations in the EU consist of two parts: the Machinery Directive and the harmonised safety standards. The harmonised standards provide the technical means and procedures to fulfil the Machinery Directive requirements. European standardisation organisations CEN, CENELEC and ETSI have harmonised certain international IEC/ISO standards as means to fulfil the legal requirements of the Machinery Directive. Product standard EN/IEC 61800-5-2 specifically focuses on drive-based functional safety and defines the standardised safety functions such as safe torque off (STO), safe stop 1 (SS1) and safely-limited speed (SLS).

Harmonised standards: relevant for safety design including drives The harmonised safety standards are a collection of ISO, IEC and European standards listed under the EU Machinery Directive. A harmonised standard, identified by the prefix EN, is an agreed norm in the EU member states and basis for national laws. Outside the EU the same standards, in IEC/ISO versions, provide a global requirement framework that machine design should comply with.

Roadmap for achieving conformity The Machinery Directive requires machine manufacturers (or their representatives) to perform and document a risk assessment. The machine design must then take these results into account, with any risks reduced to an acceptable level. This is done either via risk-reducing machine design changes or by applying appropriate safeguarding techniques such as drive-based functional safety. After the risks have been reduced to an acceptable level, measures to control any residual risks have to be documented in user documentation (warnings, instructions etc). A common way to design a safe machine and ensure conformity is to follow suitable harmonised standards when implementing the safety system. By fulfilling requirements of harmonised standards, it is presumed that the machine conforms to EHSR of the Machinery Directive. Certified safety devices greatly simplify the design and validation process of a safety system. This is a big advantage since certified devices already have the necessary safety capability to achieve a given safety level and the necessary supporting safety data for safety integrity level (SIL)/performance level (PL) verification calculations. Usually a third-party certification is not necessary for machines. Manufacturers can ‘self-declare’ conformity to the Directive based on proper design and documentation, a conformity assessment and achievement of CE marking. Harmonised standards provide unified guidelines for hazard and risk assessment, and also outline the approach for reducing risks to acceptable level (EN ISO 12100). Designing machine safety functionality is most effectively achieved by following the harmonised standards for the specific machine types, if they exist, or the harmonised generic machinery application standards EN/IEC 62061 or EN ISO 13849-1.

Drive-based functional safety Functional safety can be easily achieved with safety devices that are, themselves, already certified to the most relevant functional safety standards. Safety functions that are integrated inside the drive eliminate the use of costly external safety add-ons like contactors, safety relays, etc. Using integrated drive-based functional

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Drive-based safety

TODAY, NEW AND IMPROVED SAFETY SOLUTIONS AND STANDARDS ENABLE SAFETY TO BECOME AN INTEGRATED PART OF DRIVE FUNCTIONALITY.

Function requested

|n| |n|

Figure 3 Upon activation, SLS will monitor that motor speed does not exceed a defined level. If it is exceeded, SLS will activate STO or SSE to stop the drive.

Figure 4: When SMS is used, it is always active and ensures that the set speed limit is not exceeded (ie, maximum allowed speed).

safety results in cleaner installation and lower costs, with fewer components needed to reach the required SIL or PL.

Example: Traditional safety solution The traditional way of building a safety system includes connecting safety limit switches, relays and external safety monitoring devices and contactors, together with the drive. Once the protective cage door to the conveyor has been opened the safety limit switch detects the open door. This sends signals to the drive to decrease speed. At the same time the signal is sent to an external safety monitoring device (safety logic), which together with an encoder speed measurement creates a safety function SLS for safe speed monitoring. People can now interact safely with the slowly moving conveyor and perform their task. After leaving the conveyor and closing the protective cage door, the safety monitor has to be reset with a button, before the conveyor is allowed to increase back to normal speed. If, for some reason, during the safe speed phase when SLS is active, there is a malfunction that causes the conveyor belt to suddenly increase speed, the safety monitor will detect the overspeed and activate the motor contactor that interrupts the drive’s output to the motor, thus stopping the conveyor. The main benefit of a traditional electromechanical safety solution is that the safety solution can be built together with drives that do not have safety functionality integrated into them.

Example: Integrated drive-based functional safety With integrated drive-based functional safety, the safety functions are implemented into the machine via the drive. As a result, the use of externally wired discrete safety devices such as safety monitors, wiring and encoder can be eliminated. Integrated drive-based functional safety not only simplifies the overall safety design process, but with fewer parts and less wiring, the complexity of configuration and installation is also significantly reduced for a lower total cost. Compared to the traditional safety solution, integrated drive-based functional safety includes the same functionality but it is simply built into the drive. The most basic functionality level is the STO circuit inside the drive, which can safely disable the drive’s power

stage, thus eliminating any need for a motor contactor. Using drive-integrated safety functions eliminates the hassle of figuring out how to hook up and wire the logic with relays, reset signals and contactors as the drive safety functions are predesigned in the module, waiting to be commissioned. Where multiple drive systems are in use, a safety PLC can be used to coordinate the safety functions of the individual drives, further eliminating the need for additional hardware, and the associated additional design and implementation costs.

Summary The industrial environment is full of moving machine parts which can cause hazardous situations and lead to severe and often permanent injuries. The role of functional safety is to protect people, property and ecosystems from often preventable accidents. It is therefore the ultimate responsibility of device suppliers, machine builders and system integrators to ensure that the products they deliver are safe. Safety for machines is achieved by complying with relevant safety directives and standards. In the EU, the EHSR which machine builders must comply with are defined in the Machinery Directive 2006/42/EC and the harmonised standards under this directive. For machine builders outside of EU, the IEC/ISO versions of the EU’s harmonised standards provide the necessary requirements and guidance. Drives have been used for decades in many industrial applications. Where safety in automation systems once required many external add-on devices, the ever-increasing levels of automation employed in industry combined with the electrotechnical capability of many modern drives and safety PLCs mean drive systems now contribute greatly to the overall safety of a system. Today, new and improved safety solutions and standards enable safety to become an integrated part of drive functionality. Drivebased functional safety means providing drive-based motion control that protects people, property and ecosystems. ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/W601

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NEW PRODUCTS

HAZARDOUS AREA BEACONS R. Stahl is introducing a visual signalling solution that withstands extreme environmental conditions, with a wide operating temperature range of -55 to +70°C and an enclosure manufactured from corrosion-resistant glass-reinforced polyester (GRP) that is designed to provide IP66/IP67 protection. All fixings are stainless steel. While the standard finish is natural black, painted units with epoxy coatings in red, yellow and blue are also available. The beacons are supplied with a robust stainless steel lens guard as standard to protect the flame-retardant polycarbonate lens. The light source is a xenon tube providing a high light output. FX15 beacons flash at a rate of 1/s. Lenses are available in seven colours (red, amber, green, clear, blue, yellow and magenta). The Fresnel lens that covers the well glass and houses the xenon tube produces a flash energy of 5 J, which ensures a luminous intensity of 49 cd for the clear version. The beacons are suitable for use in a variety of onshore and offshore applications and environments, notably including marine use, the oil and gas sector, and skid packages. Operating voltages range from 24 and 48 VDC to 115 and 230 VAC. All units feature three M20 cable entries that enable a variety of wiring and mounting options. FX15 flashing beacons are ATEX- and IECEx-certified, with other relevant approvals (GOST, PESO, Inmetro and North American listing) to follow soon. Essential installation material, such as mounting brackets, straps, glands, tag and duty labels, along with replacement parts, is also available. R. STAHL Australia Pty Ltd Contact info and more items like this at wf.net.au/W062

LIGHT CURTAINS Pilz has expanded its range of light barriers for safe access to danger zones with the launch of the PSENopt safety light curtain model. The PSENopt offers an advanced configuration

HD35 SERIES WIRELESS DATA LOGGERS

mode using an Ethernet interface adapter and PSENopt Configurator software. In this mode up to five fixed blanking zones can be set, and the number of floating blanking beams is selectable. Muting options can also be set including cross

■ Versions for wide range of parameters Including: ˚C/Rh/CO/CO2/Lux/UV.

beam, parallel beam, muting period and override.

■ Error free transmission with automatic channel selection & data security.

for cloning, and remote monitoring/logging. On-

■ Remote units with up to 74,000 reading Integral memory and display options. ■ Base units with GSM messaging, alarms,Wi-Fi and repeater options. ■ Economically priced, fast delivery & 2 year warranty and this is just the beginning...

The Ethernet interface module also provides line, the status of individual beams, the safety outputs (OSSDs), muting and blanking can all be monitored and logged. The light curtains can also be manually configured via a stylus and three recessed membrane soft keys to basic configuration mode. When using several PSENopt Advanced light beam devices at the same time, the visual coding prevents the light barriers from impairing one another. With the top and bottom beams located at the extremes of the receiver/transmitter, there are no dead zones. The Pilz light curtains can also be butted directly up to each other and cascaded where greater than 1800 mm protected profile is required without any loss of protection. The Pilz Advanced range consists of 33 types covering Type 2 hand (30 mm) and Type 4 finger (14 mm) and hand (30 mm) resolution, at protected heights ranging from 300 to 1800 mm, with an operating range of 0.5-20 m. Reaction times are as fast as 11.9 ms. Pilz Australia Industrial Automation LP Contact info and more items like this at wf.net.au/W528

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NEW PRODUCTS

CAST KNIFE GATE VALVES The DeZURIK KGC-MD maximum duty cast knife gate valves are specifically designed to provide the shearing and sealing capabilities needed in demanding services such as cyclone separators, recycle high-density cleaners, recycle detrashers or sand cleaners. Because the valve is designed to provide long service life in highly abrasive applications, it can be used in many applications in the pulp and paper, mining, chemical, petrochemical, power, steel and food processing industries. The KGC-MD knife gate valves are available in 80-600 mm sizes with metal or dual

NETWORK MANAGEMENT SUITE Moxa has released the MXstudio software suite, which combines all the tools needed for installation, operation, maintenance and diagnostics. The software suite also includes Moxa’s MXview network management software and two new tools: MXconfig and N-Snap.

metal and resilient seats. To withstand highly

MXstudio provides a more integrated version of Moxa’s network management

abrasive media, the valves are available with a

software that is designed to improve network monitoring and maintenance capabili-

replaceable hardened seat, hardened gate, full

ties, and also make mass device configuration and troubleshooting more efficient.

100% port opening, high-performance packing

MXview industrial network management software, which displays real-time network

system with wire scraper rings and heavy-duty

status information in an intuitive graphical interface, is now accompanied in MXstudio

superstructure. All these features combine to

by two new tools.

provide a longer service life, less downtime and

The MXconfig industrial network configuration tool reduces set-up time for initial

less maintenance than other valves designed

deployment of Industrial Ethernet devices, while the N-Snap industrial network

for these tough applications. Measurement Plus Pty Ltd Contact info and more items like this at wf.net.au/W490

snapshot tool serves as a standalone utility to collect and compare network data for more efficient troubleshooting. MXstudio can be downloaded from Moxa’s website. Madison Technologies Contact info and more items like this at wf.net.au/W589

Looking for an easy to install and simple to configure solution to control your system pressure? The new OsiSense™ XMLR Pressure Sensor combines intuitive simplicity with high-quality performance, allowing control and visible indication of system pressure applications. Key features include: • easy installation – swivel and reverse display • simple configuration – two push-buttons • easy to maintain – fast diagnosis function • flexibility - up to three outputs • compactness - height of 88 to 100mm. With pressure ranges from -1 to 600 bar, IP65 and 67 degree of protection, analogue (4 - 20mA, 0 - 10V) and digital (PNP or NPN) outputs; your system pressure control and visibility doesn’t get any easier than this.

Simply easy!™ Discover more

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NEW PRODUCTS

CFD MODELLING SOFTWARE COMPACT TEMPERATURE SENSORS

CD-adapco has announced the release of STAR-CCM+ v9.02, the latest major release of its flagship simulation

The Optitemp TRA-C10,

tool. The company focused on increasing users’ produc-

TRA-C20 and TRA-C30 line

tivity and reducing simulation turnaround time, as well as

of compact temperature

a range of new application areas while making simulation

sensors can be precon-

more realistic for customers.

figured with an integrated

Computational fluid dynamics simulations involve the cal-

transmitter to meet the

culation of scalar quantities such as pressure, temperature,

most common require-

species concentration, turbulence intensity etc. In order to

ments for measuring range

visualise these quantities CFD engineers have traditionally

and immersion length, as

had to use ‘surfaces’, either the domain boundaries, artificial

well as process and electri-

sections through the model or iso-surfaces. This process

cal connections.

becomes increasingly difficult as the complexity of models

Although they are for different fields of application, the TRA-C10,

increases. To address this, STAR-CCM+ v9.02 includes a

TRA-C20 and TRA-C30 share the same basic design: equipped with

new volume rendering capability that allows engineers to

Pt100 class A sensor element and build-in analog transmitter, they

‘see inside’ a flow field for

cover the temperature range from -50 to +150°C (+200°C without

the first time.

an integrated trasnmitter) for liquid and gaseous media. Accuracy

Another of the greatest

is ±0.15% of measuring range. For immediate use, the measuring

challenges of engineering

range is fixed and preconfigured to a 4-20 mA output with no pro-

analysis is being able to

gramming required.

understand how changes in

All three sensors come in standard immersion lengths 50 or 100

geometry and flow features

mm (or, on request, 25-500 mm). Classed IP67/65, the sensors are

might influence a product&#rsquo;s performance. The

dust tight and can be used in wet outdoor environments. The solid

introduction of the adjoint solver in STAR-CCM+ v8.04

mechanical design has no moving parts, making them highly resistant

allowed for direct access to sensitivity information from

to mechanical stress.

a single simulation, and in STAR-CCM+, v9.02 features

The TRA-C10 is a hygienic compact temperature sensor suitable for

have been added to broaden the applicability and improve

OEM applications in the food and beverage, pharmaceutical or sanitary

the ease of use of the adjoint solver. Chief among these

industries. It comes with process connection ISO 2852 DN25/38, and

developments is the new tumble-and-swirl cost function

the electrical connection is a standard M12 connection. The TRA-C10

implemented based on industrial users’ feedback.

can be CIP cleaned.

Also released in the version is the new Dispersed

The TRA-C20 is a compact temperature sensor for general process

Multiphase model - a lightweight, computationally effi-

applications. It comes with G1/2 process connection and standard

cient, Eulerian model which results in simulations that are

electrical connection valve EN 175301-803.

much less computationally expensive than the Lagrangian

The TRA-C30 is a compat temperature sensor with process con-

equivalent, without the need for the full physics capability

nection G½″ as standard and M12 electrical connection.

of Eulerian Multiphase (EMP).

Krohne Australia

CD-adapco Australia

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NEW PRODUCTS

HANDHELD MEASURING UNIT The HMG 500 is a mobile measuring device for simple measurement tasks in fluid technology, for example: hydraulics, pneumatics, lubrication technology, process technology or refrigeration and air-conditioning technology. Up to two sensors with HYDAC Sensor Interface (HSI), for example for measuring pressure, temperature or flow rate, can be connected. The device recognises these sensors fully automatically and undertakes all of the necessary basic device settings on its own. The measured values and the associated physical unit are depicted on an LCD in convenient size. The device determines the measurement values with a very high scanning rate and, as a result, can record and display such measurements as pressure peaks in the maximum value accumulator or rapid pressure reliefs in the minimum value accumulator. In addition, differential measurements can be carried out with two similar sensors in order, for example, to evaluate pressure drops or temperature differentials. The device offers a function for the precise and safe setting of mechanical pressure and temperature switches for the purpose of expanding the range of applications. Thanks to its compactness, simplicity and versatility, the device is suitable as a companion for employees in maintenance, commissioning and service. HYDAC International Contact info and more items like this at wf.net.au/W544

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CASE STUDY

Energy savings make conveyor investment an easy decision Industrial Conveying (Aust) Pty Ltd (ICA), one of Australia’s leading conveyor companies, has recently completed a major factory refurbishment project involving a multinational manufacturer consolidating one of its Sydney plants using a comprehensive range of technology from SEW-Eurodrive. ICA has been operating since the mid-70s across a wide range of industries, and specialises in customised projects designed and built to the client’s specific requirements. It specialises in materials handling, transporting raw materials, processed materials and finished products for a diverse range of manufacturing industries. Bruce Granger, General Manager of ICA, says that, with the increasing cost of electricity, energy efficiency is becoming increasingly important for his clients and end users. “Companies are now looking closely at what their energy consumption is, so anything they can do to reduce it is a huge advantage for them,” he said. The Sydney plant project, with all-new conveyor drive technology, has the potential to realise energy savings for the customer to the tune o f t h o u s a n d s o f d o l l a rs every year. “It was not just energy savings we were able to offer the client, there were substantial savings in installation and wiring costs as well.” “While the project is in an existing building, it had been completely stripped and refurbished inside with new equipment from us and equipment from other plants,” said Granger. The main part of the project is taking cartons from the plant’s manufacturing cells through an overhead conveyor system, then carrying the cartons down to a palletising system - with a total combined conveyor length of around 250 m. Granger said the system has several automated mergers where cartons from four different manufacturing cells travel on the overhead conveyor systems, after which they all merge onto one main trunk line which takes the cartons to the palletising system, where a sorting system sorts the cartons into various lanes. Granger explained that the manufacturer has more than 30 SKUs with two main variations of cartons; one measuring 400 x 250 x 200 mm with the larger carton measuring 650 x 300 x 280 mm and weighing up to 20 kg. “While the flow rate through the system is modest at the moment, the system has the

ability to be increased when needed as production rates increase. “We have designed the overhead conveyor system to accumulate via particular types of belts that we use, with the ability to turn the drives off and on as needed. “Like most of our projects, we are using SEW-Eurodrive electrical equipment with various types of the Movigear mechatronic drive system, which is ideal for materials handling systems. Overall, we are using 56 SEW-Eurodrive motors on this project; the Movigear SNI, linked to Movifit field controllers, and Movigear DRCs. “The Movifit system has allowed us to control up to ten of the Movigear drives from just one controller, which has significantly reduced our field wiring component and simplified the controls. “It has also considerably cut our installation times by allowing us to do the prewiring of many of the components such as the photoelectric cells - connecting them straight back to the Movigear units. “By doing a lot of the pre-installation work and dry commissioning the system in our Bendigo factory, this gives us the considerable advantage of reduced on-site work.” The efficiency and distributed control technology of the Movigear/Movifit system has been key to reducing the energy consumption. “Across the drives, we estimate the current draw will be as low as 20 A, whereas if we had designed the project the conventional way the current draw would be much higher possibly as high as 60 A, and cost the manufacturer considerably more to operate. Over the life of this equipment, there will be substantial savings in energy consumption; savings in the region of thousands of dollars every year,” he explained. While with this project energy consumption was a key element, reliability was also important to the manufacturer, as many of the conveyors are suspended overhead, so the drive system being compact and lightweight was an important factor. “With the plant presently operating two shifts, six days a week, reliability is paramount for the manufacturer who does not want any production downtime, and the reduced suspended weight was another advantage for us,” he said. SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/W494

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NEW PRODUCTS

VACUUM RECEIVER Flexicon has introduced a vacuum receiver with a pneumatically actuated dump valve for dilute phase pneumatic conveying systems.

LONG-RANGE SAFETY SENSORS

Constructed of stainless steel, the vacuum

The Reer Admiral AX-LR Long Range safety

receiver features a rugged, clamp-together design

light system has been designed for the

that facilitates rapid, tool-free disassembly for filter

protection of workers up to 60 m away

cleaning and maintenance. The modular design

as well as those workers exposed to risks

permits the addition of cylinder segments for

arising from the use of dangerous machines

increased holding volume. The flap-type dump

in a range of outdoor applications.

valve is actuated by a pneumatic cylinder via

The Admiral AX-LR has two safe PNP

manual contact closure, or programmable con-

static outputs and can work without any external control unit, having

trols based on weight gain, elapsed time or other user-defined parameters.

all the safety functions integrated inside the emitter and the receiver.

Unlike conventional filter receivers that employ multiple small filter elements,

It complies with the requirements of the European Standard EN

this unit employs a single, large diameter filter cartridge facilitating rapid filter

61496-1 and the International Standard IEC 61496-1-2, and also

changes and automatic reverse pulse jet cleaning of the filter element to

integrates the start/restart interlock function as well as providing

maintain conveying efficiency during operation.

external device monitoring (EDM).

Flexicon vacuum receivers separate solids from the air stream using filter

The features of the Reer Admiral AX-LR include: easy connection

media and gravity, and are generally specified when materials contain smaller

and installation using M12 connectors and the use of standard cables;

particles that are prone to dusting or when dust containment is a primary

integration of the main safety functions, including self-monitoring of

requirement. According to the company, the filter receiver handles a wide

the safety circuits and for the AX models, the external device moni-

range of capacities but is particularly suited to high-volume applications above

toring (EDM) and the start/restart interlock functions; master/slave

storage vessels or process equipment such as blenders and bulk bag fillers.

models for cascade connection of two light curtains and models

Flexicon Corporation (Australia) Pty Limited

with floating blanking, with a wide variety of heights and resolutions.

Contact info and more items like this at wf.net.au/W491

Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/W071

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NEW PRODUCTS

SAFETY LIGHT CURTAINS DESIGN SOFTWARE

Schmersal’s SLC440COM Series safety light curtains and SLG440COM Series safety light grids are an economi-

Intergraph has released SmartPlant P&ID 2014, the latest version of its engi-

cal, compact solution that are said to offer the highest

neering solution for creating, maintaining and improving plant configurations.

protection for the user, and incorporate highly visible

SmartPlant P&ID 2014 features updated ducting and instrumentation diagram

status signalling in a rugged housing.

functionality and the solution scope has been extended with enhancements to

The series safety light curtains are available with reso-

more efficiently support work processes for project execution and plant opera-

lutions of 14, 30 or 35 mm and protection field heights

tions and lower the cost of ownership. The version’s ducting and instrumentation

between 330 and 1770 mm, and are also available as

diagram (D&ID) capability lets users create a schematic representation for

safety light grids (SLG440COM) with two, three or four

air handling or process systems. The version configures the ducting system

beams for perimeter guarding. Both series are suited

with the connectivity, components and instruments that can next be used in

for use in safety circuits up to PLe (EN 13849) or SIL3

downstream tasks like SmartPlant Electrical and SmartPlant Instrumentation

(IEC 61508). The profile length corresponds to the pro-

and, ultimately, the physical design in Intergraph Smart 3D solution.

tective field height to allow for optimal installation with

Using the version with the D&ID extension offers clear benefits to clients

the application. Operating status can be seen from a

designing air handling and/or process ducting systems. The connectivity

distance. The end cap of the receiver unit is moulded

provides the benefits of validating the design early on as the SmartPlant P&ID

from a semitransparent plastic that is illuminated by LEDs.

Engineering Integrity rules can be created to verify ducting-related engineer-

It shows green for proper operation and red when the protected

ing and safety practices. Additional enhancements allow users to interface to

field has been interrupted or flashing red to indicate fault conditions.

SmartPlant Instrumentation for system controls; link to SmartPlant Electrical to

The SLC440COM series features a one-piece extruded, reinforced

power fans; and report on components and load balancing for the systems.

housing in a compact 28 x 33 mm rectangular profile. This housing

An API allows the users to interface to external calculation or analysis

profile has proven to be less susceptible to mechanical damage

systems for more comprehensive system checks.

and misalignment from torsion or bending.

Intergraph Corporation Pty Ltd

Control Logic Pty Ltd

Contact info and more items like this at wf.net.au/W395

Contact info and more items like this at wf.net.au/W396

LMT point level sensors with extended probe length, for hygienic applications. The new LMT point level sensors with extended probe length (up to 250mm) and G1/2 fittings have now become available. These already proven devices are perfect for detecting the levels of virtually any liquid, viscous medium or bulk material in storage tanks. Additionally, the sensors can also detect the absence of product. The sensors are resistant to build up due to a high 200Mhz Capacitive Field Technology that reliably detects the true level, even in the case of high build up on the probe. The sensors are also programmable via I/O Link software. This enables two switching outputs that can be set independently of each other so it is possible to differentiate between two different media. The sensors are housed in high-grade stainless steel with a high protection rating IP 68/IP 69K. The robust LMT sensors meet all the requirements for hygienic areas.

fluid sensors and diagnostic systems position sensors and object recognition

bus, identification and control systems

This issue is sponsored by — Schneider Electric Industry Business — http://www.tesensors.com/au/products/osisense-xm?docid=269511051

NEW PRODUCTS

HAZARDOUS AREA FLOWMETER Since its introduction in 2011, the Krohne H250 M40 flowmeter has achieved more than 30 approvals worldwide for hazardous gas and dust areas, including ATEX, IECEx, usFMc, NEPSI, INMETRO, KGS, GOST-R and PESO/CCOE, and has recently received North American FM approvals for the ignition protection types IS and NI. H250 M40 combines the main types of explosion protection in one device: it can be used in any suitable application that requires intrinsically safe or non-incendive wiring strategies or as well for dust-ignition or explosion-proof installations. Together with the worldwide approvals, the flowmeter is suitable for large international companies that have a stringent explosion protection strategy for all plants but also need the respective local approvals. OEMs can fulfil requirements of different customers with just one device. All available indicator variants can be supplied with all available approvals. Starting with pure mechanical flow indicators, the devices can easily be upgraded with one or two limit switches (NAMUR, transistor or reed), a 4-20 mA signal output with HART, a graphical LCD with totaliser and pulse output or with a digital, bus-powered communication interface according to Foundation fieldbus or Profibus PA standard - all on site, without interrupting the process. The H250 M40 also offers a stainless steel housing with explosion-proof (Ex d/XP) enclosure, dedicated for the oil and gas industry. Krohne Australia Contact info and more items like this at wf.net.au/W532

We WANT to tell you about it ... But we can’t. We want to tell you why this new technology is a game-changing evolution for civil, industrial, and commercial water industry partners. But we really can’t. This unspeakably brilliant product is being launched at Ozwater’14 as part of a coordinated worldwide event, so for now we can’t say a word – even though our R&D boffins have impressed all of us with this development. We JUST CAN’T! Please come to Ozwater’14 from 29 April, for Bürkert’s Big Reveal. If you’re not at Ozwater’14, keep watching & we’ll catch up soon! We make ideas flow. Tel 1300 888 868 www.burkert.com.au

Tel 0800 BURKERT (0800 287 537) www.burkert.co.nz

[Don’t try calling about the new product launch though – we can’t tell!]

The #BurkertBigReveal Bürkert @ OzWater Stand 1L17

OALab teaser - HP.indd 1

19/03/2014 3:54:46 PM

This issue is sponsored by — Schneider Electric Industry Business — http://www.tesensors.com/au/products/osisense-xm?docid=269511051

AS I SEE IT A.B.N. 22 152 305 336 Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA

TAKING A LOOK ON THE INSIDE

ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

ost industrial facilities, such as steel mills, oil refineries and power stations, are expensive to build and operate, so minimising downtime is of prime concern for owners and operational staff. Any unplanned stoppages could cost millions of dollars each day. Visualising the condition of the components of industrial machinery, such as engines, drive shafts, tanks and pipes, without having to take them apart can save time and money. Non-destructive testing is the term used for the examination of materials and components in a way which does not change or destroy their usefulness. There are many benefits for companies using the correct application of non-destructive testing. A major one is protection of capital investment by instituting predictive maintenance programs which allow for servicing and repairs to take place at a predetermined time in order to minimise disruption and cost. Other benefits include compliance with technical and statutory requirements and the safety of both plant and personnel. To be most effective, non-destructive testing must be reproducible, so all principal methods of non-destructive testing are covered by Australian standards. More and more companies are recognising the importance of NDT through corporate membership of the Australian Institute of Non-Destructive Testing and collaboration with other member companies and individuals in the development and refinement of NDT standards. There is a commitment to offering the best solutions to the needs of customers and industry in general through the development of new technologies, products and services that maximise the benefits of NDT. One type of NDT is remote visual inspection (RVI), which uses cameras attached to flexible probes to view the inside of an encased object or structure. Imaging can be done in two ways - firstly, by looking at the insides directly with an optical camera, or secondly, graphically, by plotting the echoes and reflections generated, for example, by phased array ultrasonics.

Janette Woodhouse

One way to directly view the inside of an encased object or structure is to use an industrial videoscope. RVI of materials, components and structures allows technicians to detect cracks, corrosion, surface burning and other flaws that might lead to failure or other problems with equipment. By using stereo measurement technology, it is possible to accurately gauge the size of observed cracks and defects. In addition, videoscopes can directly embed condition data into recorded images to easily catalogue information so that trends can be deduced and factored into preventive maintenance schedules. RVI uses purely optical methods to view interiors and you don’t need much of a hole to see through. With the latest fibrescopes, you only need an opening 0.9 mm across to pass the viewing tip into the inside. Advances in analysis software and hardware miniaturisation have led to the development of smaller and more sophisticated videoscopes, some of which combine both the light source and optical sensor into a unit at the tip of the probe. The probe, which can be up to 30 metres long, may also have small motors embedded in it which allow the operator to remotely move the LED and lens assembly. Not only can the newest videoscopes put a lot more light out of the end of the probe, but that light can be used far more effectively, through reducing flaring off surfaces and washing out, in order to generate high-quality images. Brendan Slaven is an imaging professional, specialising in industrial photography. With more than 15 years’ experience in imaging technology, Brendan is currently the Remote Visual Inspection (RVI) and High Speed Video (HSV) Product Specialist for Olympus Australia, and is always looking for new ways to apply new technologies and techniques to acquire diagnostic images from extreme environments.

Publisher Geoff Hird Art Director/Production Manager Julie Wright Art/Production Tanya Scarselletti, Odette Boulton, Colleen Sam Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins Advertising Sales National Sales Manager/NSW/QLD Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au VIC/SA/WA - Lachlan Rainey ph: 0402 157 167 lrainey@westwick-farrow.com.au NZ - Gemma Burr ph: 0800 44 2529 gburr@westwick-farrow.com.au Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application. If you have any queries regarding our privacy policy please email privacy@westwick-farrow.com.au

September 2013 total CAB audited circulation (Aust + NZ) 6,781 readers (80% personally requested)

Contact the editor

Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP100007403 ISSN No. 0819-5447 All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

This issue is sponsored by — Schneider Electric Industry Business — http://www.tesensors.com/au/products/osisense-xm?docid=269511051

Registration Now Open!

Sydney

18 – 19 June 2014

Australian Technology Park What’s On?

Keynotes — Industry leaders will share their expertise and experiences with you. Workshops — Always popular, and included in your general conference registration, the workshops will give you a more in-depth look at selected topics including: • Advanced radio over IP • Mobile broadband and LTE for critical communications • Implementing a digital radio solution — change management • In-building distributed antenna systems Industry stream — Case studies and papers focusing on key sectors and users of radio and converged communications: • Public safety and emergency management • Mining and the wider resources sector • Utilities • Transportation • Government and enterprise Technology @ work stream — A broad selection of papers on technologies used in the field, often using case study examples, will deliver critical technical content to you and your colleagues. Exhibition – and don’t forget, an exhibition with dozens of local and international manufacturers and distributors will have their experts on hand to help you find the solutions you’re looking for. In conjunction with the NSW ARCIA networking dinner, 18 June @ Dockside, Cockle Bay Wharf In association with:

Magazine partner:

Organised by:

Interested in exhibiting or sponsoring?

CALL PAUL OR NARELLE ON

+61 2 9487 2700

www.comms-connect.com.au

Make the unpredictable totally predictable.

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