What’s New in Process Technology Oct 2014

October 2014 vol.28 no.5 PP100007403

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ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY OCTOBER 2014

CONTENTS A tank overfill protection system is an SIS that

4

ptimising clean-in-place processes O in food and beverage operations Part 1

provides automated overfill control for hazardous and dangerous substances. If the level in a tank rises above set limits, the logic solver initiates the final element of the SIS to mitigate or abate

8

New products

14

Hot products online

28

Vision systems

42

As I see it

learn the steps you can follow to determine the

Jump on board the Internet of Things (IoT)

right logic solver for your needs. While many

What you need to know

any dangerous events and take the process to a safe state. This can include shutting off the input feed to the tank by isolating the pump and closing the input valve.

Read the new Logic Solver for Tank Overfill Protection white paper by Moore Industries to

people assume that a logic solver for a tank overfill protection system must be a safety PLC, in many cases a discrete logic device in the safety loop is sufficient. This avoids the complications and expense associated with a complex programmable solution.

The white paper shows the methodology and calculations for determining applicable logic solvers in SIL1 and SIL2 environments. In many cases, discrete logic devices such as Moore Industries’ STA Safety Trip Alarm are suitable for use while providing a flexible, low-cost and user-friendly solution. Get a copy of the paper, and learn more about the STA Safety Trip Alarm and other safety-related products at www.miinet.com/safetyseries.

Moore Industries Pacific Inc www.miinet.com

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

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

OPTIMISING CLEAN-IN-PLACE PROCESSES IN FOOD AND BEVERAGE OPERATIONS PART 1 Benjamin Jude and Eric Lemaire*

4 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

www.ProcessOnline.com.au

Clean-in-place (CIP) processes are often intensive and waste large amounts of energy, water, and chemicals. New innovations in CIP technology allow plant operators to cut costs in an environmentally friendly manner while still conforming to regulatory safety standards.

Many manufacturers are unsure of how their CIP systems are performing. Therefore additional steps are often introduced as a safeguard to ensure adherence to sanitation standards. This practice results in higher consumption of water, chemicals, and energy than is necessary in order to avoid the contamination issues.

A number of companies have addressed CIP improvements with small modifications such as altering the chemical concentration, or by adjusting the time taken for each stage of the CIP process. However, very few food and beverage manufacturers have put tools in place that render the CIP process efficient.

In fact, in an informal poll conducted by Schneider Electric on food and beverage clients in France, only 12% thought that their CIP systems were efficient yet only 18% of those surveyed had commenced a study around CIP optimisation. Yet industry leaders are clearly indicating that progress needs to be made in the areas of waste reduction and water and energy efficiency (see Figure 1).

Recent innovations in technology now enable plant operators to calculate the optimal mix of water, chemicals, temperature and flow required to achieve safety standards while saving at least 20% in energy cost and by reducing the downtime for cleaning by at least 20%. In addition, all the steps in the process can be easily traced and auto-

www.ProcessOnline.com.au

matically documented, which simplifies any auditing requirements that need to be performed by regulatory inspectors.

Risks of inefficient and ineffective CIP systems Food safety and litigation With many hundreds of metres of pipework, and a multitude of valves, pumps and instrumentation that make up a typical CIP system (see Figure 2), the risk of equipment failure is high and can happen at any stage of the process with a potential impact on food safety. It is quite difficult to verify that all aspects of the cleaning process have been taken into account. Consider the instance of an operator who runs a cleaning process and does not even realise that a particular component (such as a pump) did not work because no alarm was generated.

The result of improper cleaning is costly to a plant in violation of food and beverage industry safety regulations. The all-too-frequent incidences of food safety disasters around the globe are often caused by simple mistakes or faulty processes in a food or beverage factory which lead to sickness, injury, and even death for those who consume contaminated products. In addition to the human tragedy, these contamination incidents lead to the expense of product recalls, loss of confidence in a company’s brand, and ultimately loss of revenue.

Food safety authorities conduct plant audits to ensure that the critical control points identified as HACCP (hazard analysis and critical control points) are monitored and reviewed for regulatory compliance and continuous improvement.

In the event of a contamination incident, full traceability (enabled by software) and ‘proof of clean’ will reduce the legislative and legal impact. The company involved will be in a better position to identify the contamination impact and to minimise the effort required to implement a withdrawal or recall procedure.

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

© iStockphoto.com/ leezsnow

A

typical clean-in-place (CIP) process requires large amounts of water, chemicals and energy. It is estimated that, on average, a food and beverage plant will spend 20% of each day on cleaning equipment, which represents significant downtime for a plant. Energy usage varies depending on the process. For example, a milk plant is likely to use 13% of its energy on CIP, whereas a powdered milk, cheese and whey process is likely to use 9% of its energy on CIP1. In a fruit jam manufacturing facility in Manchester, England, cleaning hoses in the fruit room were identified as one of the highest end users of water in the facility (17% of total site water consumption)2.

Automation

A 20% REDUCTION IN CLEANING TIME WILL DELIVER APPROXIMATELY AN EXTRA HOUR OF PRODUCTION TIME TO EACH DAY.

Figure 1: Top sustainability priorities of food and beverage, and consumer products industries.

Production downtime Lowering operational expenditure and reducing waste to lower the cost of production without impacting product quality are universal goals of food and beverage enterprises. However, when a CIP process is in operation, production is stopped. This impacts profitability. As a result, two tendencies manifest themselves which are both negative to the business: 1. When a problem occurs, there is a natural reaction to avoid seeking the root cause of the problem. Such an intervention could involve even more time-consuming maintenance work.

2. With the risk of contamination at the forefront of most operators’ minds, the tendency of the CIP operator is to overcompensate with increased cleaning time.

Fortunately, new CIP technologies alleviate the above problems because of significant improvements in efficiency: • More advanced CIP automation enables dramatic reductions in troubleshooting time in the event of a problem, cutting what once took hours to perform into minutes of diagnostics.

• An optimised CIP process can reduce cleaning times by up to 20%. If CIP currently takes around five hours of each day, a 20% reduction in cleaning time will deliver approximately an extra hour of production time.

High consumption of energy and water Efficiency improvement does not only focus on reducing cycle time, as well as energy, water, and chemical consumption.

The primary purpose of the CIP system is to remove fouling from the equipment. When

production equipment is not completely clean, expensive raw materials have to be thrown out. Effective cleaning results in fewer instances of contamination and therefore improved production efficiency.

The cleaning function, however, is energy intensive. Almost half of a milk-processing facility’s energy is used to clean the processing lines and equipment4. Calculating the precise temperature needed to clean equipment is critical to reducing the energy consumption. For every 1°C reduction in CIP temperature there will be a 1/60th reduction in the energy needed to heat the fluid5.

The amount of water or chemicals used can also be reduced by introducing recovery tanks so that the liquid can be re-used instead of sent down the drain.

Loss of innovation and flexibility Food and beverage manufacturers must innovate in order to remain competitive.

Recipes need to be improved and new product lines developed. Therefore, CIP systems need to be flexible in order to adapt to different types of fouling on the equipment as product lines evolve. Operators need to be able to alter cleaning recipes to suit particular types of fouling, whether product (sugar, fat, protein, or minerals) or microbial (vegetative microorganisms, or spore forming microorganisms) and ensure that the CIP system is operating in an efficient manner. Chocolate, for example, will require a different cleaning recipe for butter than it will for flour.

Modern CIP systems, equipped with automation software enable a simple drill down into any aspect of the process. This traceability of the system offers a number of benefits:

6 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

1. Operators can check each CIP operation to verify whether it has worked correctly 2. Diagnostics are simple to perform and deliver detailed information on each element of the cleaning cycle 3. Faults and issues can quickly be highlighted and rectified 4. Plant managers can generate detailed operational reports 5. Food security reporting to regulators is easy to assemble and more comprehensive

Incremental process improvements Equipment manufacturers ensure that CIP systems are installed and in good working order but these systems need to be finetuned based upon the environment of the particular plant.

Some food and beverage manufacturers have tried to improve the efficiency of their CIP systems. The process usually involves a manual, trial-and-error approach which does not consider a holistic view of the system.

These efficiency improvement techniques involve the following: • Modifying chemicals: New chemicals can be experimented with or the concentration of existing chemicals can be altered to see if cleanliness is achieved more easily. The risk is that new versions may prove to be more costly.

• Altering cleaning times: Increasing or decreasing the time taken for rinse or for chemical solution cycles may result in some efficiency gains although the balance of downtime to production output and impact on safety tolerance levels will need to be reconsidered.

www.ProcessOnline.com.au

Automation

A HOLISTIC APPROACH INCORPORATING AUTOMATION SOFTWARE MAKES THE BIGGEST IMPACT ON COST SAVINGS AND SAFETY IMPROVEMENT.

Figure 2: Example of a simple single line CIP system.

• Adjusting water temperature: Increasing the temperature of water to decrease the cleaning time or conversely decreasing the temperature to lower energy costs are also possible options.

• Reconfiguring settings: A study of CIP line usage can be a useful way to improve production efficiency. For example if line 1 is at 100% capacity and line 2 is rarely used, a simple rebalancing would be to move some equipment cleaning to line 2.

• Maximising chemical effectiveness: The introduction of enzyme-based detergents to speed up chemical reactions or membranes to filter chemicals and enable them to be re-used for longer helps save resources.

• Implementing eco-friendly solutions: Bio-decontaminants eliminate the need for the use of harsh chemicals and can help reduce the amount of energy, time and water for the cleaning process.

• Using ozonated water: Disinfection with ozonated water is effective on a range of microorganisms and can save on water, chemicals, and energy.

The typical five-tank process is reduced to just three and it is extremely safe for the environment because its by-product is oxygen. However it may be more costly to implement into an existing CIP system as it requires the addition of an ozone station and other equipment on site.

• Developing a conservation mindset: The replacement of faulty valves and fittings, switching off water sprays and hoses when not in use, and disconnecting or removing redundant pipework help to improve efficiency. Installing meters on equipment will help to monitor water

www.ProcessOnline.com.au

consumption. An example of this is installing flowmeters on inlet and outlet pipes to verify the volume of liquid sent and received. This can be analysed to identify any unusual losses through the leak chamber of the valve.

Each of these above strategies is often performed in isolation and the outcomes documented. The downside of this trial-anderror approach is that it is time consuming and much waste is generated in trying to determine the proper mix of water, chemicals, and energy.

This tweaking of the CIP system can deliver some benefits, however a holistic approach incorporating automation software makes the biggest impact on cost savings and safety improvement. The complexity of finding the optimal combination for cleaning the equipment while meeting required standards is simplified thereby saving time, reducing errors, and lowering water use and energy consumption.

In Part 2 In Part 2 of this article, the benefits of using an automated CIP system will be discussed, along with examples of the efficiencies that are gained by doing so.

References 1. Eco Efficiency for the Dairy Processing Industry - the UNEP Working Group for Cleaner Production in the food industry.

Environmental Management Centre, the University of Queensland.

2. Energy Efficiency Improvement and Cost Saving Opportunities for the Dairy Processing Industry, Ernest Orlando Lawrence Berkeley National Laboratory

3. Making an Impact: Environmental Sustainability Initiatives in Canada’s Food Beverage and Consumer Products Industry, KPMG 4. Next generation clean in place report from 2009 Innovation Center for US Dairy 5. Based on the caustic soda temperature being 80°C and acid temperatures at 65°C with an ambient temperature of 20°C. Carbon Trust : Industrial Energy Accelerator - Guide to the Dairy Sector.

About the authors Benjamin Jude is a Global Solution Architect/Food & Beverage Vertical Expert at Schneider Electric. For over 20 years he has specialised in automation and process engineering, and has provided turnkey solutions for firms within the food and beverage and pharmaceutical industries. He has particular expertise in process design and electrical control engineering, batch management, (MES) and FDA compliance.

Eric Lemaire is Food & Beverage Group Marketing Director with Schneider Electric.

He holds a degree in Food and Beverage Process Engineering and has more than 20 years’ experience in the process automation industry. He has held many different engineering, R&D, marketing and sales positions, including manager of the French Food and Beverage and Pharmaceutical Industry operations.

Schneider Electric Industry Business www.schneider-electric.com

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW PRODUCTS

CONTROLLER NI has announced the CompactDAQ 4-slot controller. By integrating the processor, signal conditioning and I/O into a single CompactDAQ system, engineers and scientists can reduce overall system cost and complexity while increasing measurement accuracy.

The CompactDAQ controller features an Intel Atom dual-core

STAINLESS STEEL SENSORS

processor that can run either industry-standard Windows Embedded

Balluff Proxinox sensors made of stainless steel

7 or NI Linux Real-Time for higher system reliability. By pairing

can withstand the toughest cleaning processes

industry-standard OS options with LabVIEW system design software,

and meet all the specifications and directives

users can easily port LabVIEW code from existing measurement

for the pharmaceutical and food industries, it

systems to the new CompactDAQ controllers. Engineers and

is claimed. They are optimised for extreme

scientists can combine LabVIEW and over 60 sensor-specific I/O

conditions, with maximum seal tightness

modules for CompactDAQ to quickly customise data acquisition

(IP67, IP68 and IP69K), Ecolab certified and

systems to meet their specific application needs.

temperature resistant up to 105째C.

The CompactDAQ also offers removable SD storage, an

Balluff offers a complete range based on

integrated CAN/LIN port and four C Series module slots in a

a variety of different physical mechanisms,

rugged form factor that can be used in high shock and vibration

augmented by a precisely coordinated line of

environments as well as temperatures ranging from -40 to +70째C.

fastening and connection technology in stain-

National Instruments Australia

less steel and IP69K. Depending on the type

www.ni.com/oceania

of sensor, additional features include lasered or etched type designations, additional O-ring seals and in some cases gold-plated contacts.

The BOS optoelectronic sensors, BMF

SPIRAL CLEANING IDLER

magnet field-sensitive sensors or inductive

Kinder has introduced the K-Vee Spidler

sensors, and also the BCS capacitive and

spiral cleaning idler to its range of conveyor

BUS ultrasonic sensors fulfil all specifications

belt cleaning systems, offering a maintenance- and

for the food and pharmaceutical industries.

adjustment-free solution to conveyor belt cleaning.

The belt conveyor cleaner has been designed in response to the bulk handling need

The FDA-3A-certified Micropulse transducers with FDA-compliant casing design allows

for a cleaner to suit heavy material loads on vee return overland conveyors in the mining

them to come into contact with the product,

industry and other industries utilising wide conveyor belts.

such as fill level detection for fruit juice, milk

Similar to the conventional flat K-Spidler spiral cleaning roller, it has been designed to be

or beer in bottling plants. The stainless steel

interchangeable with existing steel/RDRT rollers. The resilient and wear-resistant polyurethane

versions are HALT tested and offer operational

spirals help to clean off sticky carry back on overland conveyors.

reliability for many years.

Kinder & Co Pty Ltd

Balluff Pty Ltd

www.kinder.com.au

www.balluff.com.au

8 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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NEW PRODUCTS

OVERMOULDED SPLITTER Turck has announced the availability of a redesigned VB2 splitter with LEDs. The updated VB2 features a translucent black, overmoulded design, which encapsulates the LEDs and protects them from physical damage while also complimenting visibility. The design enhancement also enables the LEDs to be visible from both sides of the splitter, allowing it to be mounted on either side - the previous version only allowed mounting on one side for the LEDs to be visible.

DIGITAL VALVE CONTROLLERS Emerson Process Management has introduced the Fisher Fieldvue DVC6200p series of digital valve controllers. The DVC6200p series is a suitable solution for applications in which accessibility, extreme temperatures (up to 120°C), extreme vibration or confined space make integral mounting difficult or impractical.

Industries such as pulp and paper, and metals and mining, have typically preferred to isolate valve-mounted instruments from harsh environments. With the remote mount version of DVC6200p, only the valve position feedback is mounted on the control valve, while the remainder of the digital valve controller can be mounted up to 100 m away in The VB2 splitter is used to consolidate two

a less severe or more accessible environment.

separate discrete PNP device signals into a

The remote valve mounted feedback unit utilises the Fieldvue linkage-less, non-contact

single cable and can be used in any application

feedback technology in which physical contact has been eliminated between the valve

multiple discrete PNP signals are being used. It

stem and the instrument. With no linkage to wear, loosen, corrode or vibrate, the feedback

is a suitable solution for applications trying to

unit can withstand a plant’s operating extremes.

use multiple sensors or send multiple signals

The DVC6200p supports enhanced device description (EDD) files that allow for quick

from a confined area. The LEDs provide a visual

and easy configuration. Quick set-up and calibration, including performance tuning, can

indication of when the circuit has power applied

be performed locally in a matter of minutes. For more extensive parameterisation, leading

and when discrete signals are present. The VB2

PROFIBUS configuration tools can be used. The Fieldvue DVC6200p digital valve controller

has a rating of 10-30 VDC at up to 4 A. The

is certified to Profile 3.02 for PROFIBUS PA devices by the PROFIBUS Nutzerorganisation

overmoulded design provides the splitter with

a.V (PNO) and is offered with CSA, IECEx, ATEX and FM hazardous area.

an improved ingress rating of IP68.

Emerson Process Management

Turck Australia Pty Ltd

www.emersonprocess.com.au

www.turck.com.au

10 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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OPTIMISING YOUR INDUSTRY 22-23 APRIL 2015 | SYDNEY OLYMPIC PARK, SYDNEY

Australia’s dedicated automation, control and instrumentation conference and exhibition

See the website for: Draft Conference Program | 2015 Exhibition Floor Plan | Sponsor Prospectus

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NEW PRODUCTS

COMPUTER WITH PRP/HSR The DA-820 rackmount embedded computers

POWER SUPPLIES WITH MULTIPLE OUTPUT VOLTAGES

from Moxa are said to be the world’s first native

IDEC’s PS6R Series power supplies are

PRP/HSR management servers that provide

claimed to be the first industrial DIN-rail power

bumpless redundancy, enabling efficient,

supply to provide multiple output voltages

visualised PRP/HSR network management.

from a single unit. By attaching easy-to-use

The DA-820’s main operating system runs on

expansion modules, users can configure

the lntel Quad core i7-3612QE CPU and QM77

the PS6R to their specific requirements.

chipset, which supports tow VGA ports, USB,

DC-DC converters allow up to three sepa-

two Gigabit LAN ports and two RS232/422/485

rate voltages to be used simultaneously,

3-in-1 serial ports. The DA-820 is equipped

while a branch terminal module provides

with a 4-SATA disk interface and by default

additional wiring terminals.

supports RAID 0/1/5/10 functionality.

It is specifically designed for substation

The series is a line of highly efficient, compact power supplies that are significantly

applications that require precise time syn-

smaller than other similar-wattage power supplies. They are suitable for industrial ap-

chronisation and compliance with IEC 61850-3

plications where stable power is required, but panel space is limited. The series delivers

standards. The DA-820’s flexible design makes

more power and greater functionality without sacrificing high efficiency, performance and

it suitable for local SCADA, environmental

reliability.

monitoring, video surveillance, protocol conver-

The power supplies easily expand voltage output by adding a DC-DC converter, with 5,

sion and PRP/HSR redundancy applications,

12, or 15 V options, and allow the addition of two + and - slots by adding an optional

and Moxa’s OS Smart Recovery API handles

branch terminal module.

system crashes automatically.

Each power supply also features up to 93% efficiency rating to save energy while

Madison Technologies

maintaining high output ratings, a finger-safe design to prevent electric shocks, and a

www.madisontech.com

low voltage alarm output, with both NPN contact and LED indication. They comply with all recognised global industry standards, and each model is UL and TUV approved, CE marked, and complies with both EMC and LVD directives.

IDEC Australia Pty Ltd www.idec.com/australia

www.ProcessOnline.com.au

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH PURGE PRESSURISATION SYSTEMS The Pepperl+Fuchs 5000 and 6000 Series purge pressurisation systems allow generalpurpose equipment to be used in environments that are highly corrosive or dusty.

Pepperl+Fuchs (Aust) Pty Ltd

>

http://bit.ly/YCYp7b

>

COMPACT 1 KW POWER SUPPLY

The QS40.241 is a compact 1 kW single-phase, wide input voltage range power supply that has a housing width of 125 mm and weighs 1.9 kg.

Control Logic Pty Ltd

http://bit.ly/1qYr6am

>

CAN AND DEVICENET COMPONENTS Now available with DNV approval, these converters, repeaters, segment couplers and bridges can now be used in shipbuilding and offshore applications.

Phoenix Contact Pty Ltd

http://bit.ly/1uABBP3

MINIATURE VGA INFRARED CAMERA

>

The Micro-Epsilon thermoIMAGER TIM 640 is an ultracompact infrared camera that performs radiometric image and video recording.

Bestech Australia Pty Ltd

http://bit.ly/1sVtk5Y

14 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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CASE STUDY

Australia’s largest palletising system

George Weston Foods (GWF) new production facility in Castlemaine, Victoria, is now home to Australia’s largest robotic palletising system. GWF is one of Australia and New Zealand’s largest food manufacturers, employing around 8000 people at nearly 60 sites.

Producing a wide range o f s m a l l g o o d s w h i c h a re supplied to consumers through the retail food service and small distributor networks, the factory is divided into four key plants: ham, bacon, salami and continental smallgoods. Each of these production areas is serviced by a shared palletiser and distribution service.

The system palletises over 450 different products at the rate of about 9000 cartons/h, coming from four different packing areas.

Some 27 lines and more than a kilometre of conveyors bring products into the palletising cell, which has 16 ABB robots serving 32 pallet stations and another robot at the front of the station preparing the pallets. Finally, two rail systems with four shuttles deposit the finished pallets at two stretch wrapper stations, which wrap more than 100 loaded pallets an hour and feed them to the automated guided vehicles (AGVs).

Melbourne-based Andrew Donald Design Engineering (ADDE) designed and installed the system for GWF. Barry Hendy, ADDE general manager, knew that ABB robots were a perfect fit for the food producer: “We chose ABB’s IRB 4600 robot because the orientation and positioning of the cartons needed a sixth axis, so we needed the extra dexterity of a six-axis robot to ensure the stations would be able to handle all of the palletising tasks coming in from the conveyors.”

Line configuration was chosen based on the speed of the individual lines. Each automated row is able to look after two lines and maintain the rates on those two lines, which dictates the line configuration of 16 robots, serving the 32 pallet stations.

16 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

“Before implementing the robots the problems we experienced were from manual handling, including occupational, health and safety (OHS) issues, downtime, not getting the products out fast enough and labour costs,” said GWF packaging team leader Troy T h o m a s . “ I t h i n k t h e defining factor was in knowing that we could eliminate a lot of manual handling and remove a fair bit of the labour costs associated with the manual handling.”

Kim Martin, GWF’s supply chain manager, agreed: “We had challenges with retailers in terms of making sure the consistency and quality of the pallets were what they required for their automated networks.

And like everyone else, we also had increasing labour costs and concerns about our ability to reach the productivity targets we needed in order to remain competitive.”

The market trend is towards smaller, more shelf-ready pack sizes. “Obviously that increases the repetitiveness of the tasks the team here needed to do, therefore increasing our OHS risk as well, which is probably the main risk that we have onsite,” said Martin.

He also revealed that the company upgraded its ability to manage production speed a n d vo l u m e a t i t s c e n t ra l distribution space, and that the installation also brought improvements to worker safety.

“Other improvements include significantly reduced levels of pallet rejections from customers and the ability to deal smoothly with the production volume now being processed out of this site as each of the facilities has come online,” he said. “We have also seen a huge improvement in OHS injuries associated with palletising, because we have largely eliminated that task.”

ABB Australia Pty Ltd www.abbaustralia.com.au

www.ProcessOnline.com.au

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NEW PRODUCTS

WEIGHING TERMINAL WITH PROFINET The IND780 weighing terminal from Mettler Toledo is now available with an optional Profinet I/O interface and most existing weighing installations using IND780 can be upgraded to Profinet I/O connectivity. This news is also important for businesses that would like to extend the lifetime of their weighing equipment when network technology has been modernised.

The IND780 with the Profinet I/O interface has received a conformance certificate from a PI test laboratory, ensuring conformance to the latest specification for Profinet I/O devices. A General Station Description file, as a sample for Siemens Step 7 PLC interface code for use with IND780 Profinet I/O, is available from Mettler Toledo to assist with weighing terminal implementation.

The IND780 provides interfaces for up to four independent measuring channels for scales or flowmeters. In addition, IND780 provides a wide range of communications interfaces, including 4-20 mA output, serial, Ethernet TCP/IP and USB. A simple operating system with an enhanced graphical display and SmartTrac, the IND780 improves the speed and accuracy of manual or semiautomatic operations with three display modes that relate weight status to target graphically.

Mettler Toledo www.mt.com

POWER SUPPLY DECOUPLING DIODE The Phoenix Contact Uno Power diode, which is 22.5 mm wide, decouples power supplies connected in parallel, thereby increasing operational reliability.

Due to their high power density, the power supply units in the Uno Power power supply range are suitable for loads up to 100 W, especially in compact control boxes. When used in sensitive applications that require high availability, redundant power supplies are recommended. If the power supplies, which are operated in parallel, are also decoupled by the diode, a short circuit at the output of one of the power supply units or in the supply line from the power supply unit to the diode will have no effect on the load. The diode operates with an input voltage range of 4.5 to 30 VDC and nominal input currents of 2 x 10 A or 1 x 20 A. The module is snapped onto the DIN rail without spacing either side and operates at ambient temperatures from -25 to +70째C, making it suitable for industrial use.

There are 15 corresponding Uno Power power supplies with output voltages from 5-48 VDC currently available. The power supply units reduce energy consumption through low idling losses below 0.3 W and optimised efficiency of over 90%.

Phoenix Contact Pty Ltd www.phoenixcontact.com.au

18 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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NEW PRODUCTS

MODBUS/ TCP TO HART GATEWAY

UPDATED PUSH-BUTTON RANGE

The ICP DAS HRT-

Schneider Electric has announced updated Harmony push-

711-Modbus/TCP to

buttons. The updates come after recent changes to

HART protocol gateway

the governing industry standards - a trigger-action

allows the Modbus/TCP

mechanism head is now prescribed for both Emer-

Master to access HART

gency Stop and Emergency Switch-off functions.

Slave devices. These HART

The use of standards-compliant emergency

devices may be a transmitter,

push-buttons is a mandatory requirement for

an actuator, a current output device

all machine installations to protect persons and

and so forth. By using the HRT-711, users can in-

equipment from mechanical and electrical hazards

tegrate their HART devices into a Modbus network.

in accordance with industry standards AS/NZS 3947/

Furthermore, the HRT-711 can be applied in the

IEC 60947 (Low voltage switchgear & control gear), AS/NZS/IEC 60204

various hash environments due to its high isolation

(Safety of machinery) and ISO 13850 (Emergency Stop - principles of design).

protection design. This design feature allows users

The new range of Harmony push-buttons has been designed for numerous applica-

to widely integrate this device into a number of ap-

tions across the industrial, building and infrastructure sectors. They allow for wireless

plications such as remote data acquisition, control,

operation of a relay (receiver) through a push-button transmitter enabling the control

process automation and factory automation.

of machines for distances of up to 25 m. Equipment operators have the added option

The HRT-711 supports HART Short and Long

to send a one-time radio message to one or multiple receivers, or synchronise up to

frames, as well as HART Burst Mode, and allows

32 push-buttons with just one receiver, and can provide a significant 20% saving in

for two HART Masters. It also supports Modbus

installation time and cost.

Slave/HART Master Mode, and online replacement

Other features of the Harmony push-buttons include a choice of metal or plastic bezel; push/pull, turn-to-release or key release; 30, 40 and 60 mm sizes; and a range

of HART devices.

The DIN rail- or wall-mounting HRT-711 also sup-

of enclosures, legend plates and accessories.

ports firmware updates via its serial port.

Schneider Electric Industry Business

ICP Electronics Australia Pty Ltd

www.schneider-electric.com

www.icp-australia.com.au

When There’s No Room for Error When it comes to measuring humidity in harsh manufacturing environments, you don’t want to cut corners. The Vaisala HUMICAP® Humidity and Temperature Transmitter Series HMT330 is an uncompromising transmitter you can depend on for years of trouble-free performance.

• Credibility that speaks for itself – close to 80,000 installations worldwide and counting • 10-year warranty when annually calibrated • A wide range of options and configurations • Built for extreme environments • Support and service you can count on Your customers choose the best. Why would you choose anything less?

More information: www.vaisala.com/HMT330

Tel. 03 9815 6700 Email: sales.melbourne@vaisala.com

20 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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NEW PRODUCTS

ROTARY INDUCTIVE POSITION SENSOR Turck has expanded its QR24 rotary position sensor line

CURRENT CONTROL MONITOR

with the addition of incremental and analog outputs.

Designed from the company’s rotary inductive sensor technology, the QR24 provides contactless position detection and wear-free performance in a variety

The Hiquel TIP Series

of industrial applications ranging from solar energy

TCC-H overcurrent/un-

plants and harvesters to crane vehicles and AGVs.

dercurrent control monitor

These additional output types allow for more precise

provides monitoring for

and configurable data collection via IO-Link or EasyTeach.

equipment with trip outputs

Rotary feedback is critical in nearly every installation, and

should the current flow go

most rely on their mechanical bearings to provide proper tolerance and

above or below the set point.

position of the internal system. After time, this results in mechanical wear,

The TCC-H monitors either

vibrations, potential leaks and requires spring elements. The QR24 provides

single-phase AC or DC cur-

superior performance without the need for contact or bearings, allowing it to suc-

rents and has three measurement ranges, from 5 mA to

cessfully execute the same functions. This extension provides many of the same

10 A RMS. The current control monitor has LED indicators

output types as an encoder or potentiometer while eliminating wear and extending

for power supply, contact and reaction timer and program-

sensor longevity.

mable latch/no latch alarm. It is DIN-rail mounting (45 mm)

The sensor’s multi-coil system provides high resolution, while ensuring 16-bit noiseless operation. The sensor also features a double resonator system, providing

and has an adjustable start delay timer (inrush), reaction timer and hysteresis.

increased distance capabilities and high-end signal processing with a multi-core

Supported supply voltage variation is +10% -15%, with

microprocessor for enhanced speed. It also features a fully potted and sealed IP69K/

a frequency range of 48-63 Hz. The start surge delay is

IP67-rated housing to protect against moisture and dust in demanding environ-

0-10 s, and the reaction time can be 0-5 s. Reset time is

ments. It also offers flexible parameterisation via IO-Link or Easy Teach, allowing

less than 100 ms, and the operating temperature range

the sensor to easily adapt to specific application requirements.

is from -20 to +60°C non-condensing.

Turck Australia Pty Ltd

Automated Control Pty Ltd

www.turck.com.au

www.automatedcontrol.com.au

www.ProcessOnline.com.au

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

CASE STUDY

Project Magnet extends the life of Whyalla Steelworks Arrium Mining is a leading Australian resources company, currently exporting at a rate of 12 million tonnes of hematite ore to China per annum from its Middleback Ranges and Peculiar Knob mining operations in South Australia. The company has three key businesses: mining, mining consumables, steel and steel recycling.

A significant milestone in the company’s history occurred in 2005 when Arrium decided to diversify into the resources sector through Project Magnet which would convert the Whyalla Steelworks to a magnetite iron ore feed, creating a new revenue stream for the company by making hematite iron ore available for export sales.

A project of this magnitude would require a completely integrated control system, enabling visibility for any operator station across the pit-to-port operations. To achieve this, Arrium Mining called on the expertise of LogiCamms together with Rockwell Automation to deliver a solution that would not only extend the life of the Whyalla Steelworks but also reduce the cost of steelmaking while incorporating environmental improvements.

With the mine site located approximately 60 km from the Whyalla Steelworks, a slurry pipeline was built to allow magnetite to be transported through the pipe to Whyalla.

Concurrently, hematite ore continued to be transported by rail to the port for shipping.

The three main areas of the operation that required complete control system integration were the materials handling area, which involves the handling and storage of hematite for export; the filter/flux area which receives magnetite from the slurry pipeline and prepares it for feeding to the existing pellet plant; and the mine concentrator area.

A challenging aspect of this project was the distance involved in connecting the concentration plant which was near the mine site to the filter/flux which is located at the steelworks more than 60 km away.

“This was addressed by utilising Ethernet across a large fibre-optic network. FactoryTalk View provided visibility at any operator station across the whole of the pit-to-port operation,” said Greg Schultz, executive account manager - mining, Rockwell Automation.

To provide reliable and secure control system integration based on the ControlLogix platform, multiple redundant control systems were used. Low- and medium-voltage drives were also provided for the pumping and crushing equipment, and safety components including Guardmaster safety relays were incorporated into the motor control centre design.

22 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

“This application was one of the largest FactoryTalk View applications to be completed at the time and high-level support from the Software Business Unit of Rockwell Automation was invaluable in the success of the solution,” said Andrew Thompson, senior engineer - control systems for LogiCamms.

According to Jonathon Deluao, principal control systems engineer, Arrium Mining, “The solution has provided full integration and a high level of process control which gives us the ability to control and modify the system according to the production needs.”

“We now have a fully automated plant that is flexible enough to cater to our needs both production wise and process wise,” continued Deluao.

The transition of the Whyalla Steelworks from hematite to magnetite feed has changed the iron ore pellet process from a dry to a wet process. As the magnetite ore is pumped via a slurry pipeline from the mine to the steelworks, the level of fugitive dust emissions are reduced, which greatly benefits the Whyalla community. Project Magnet has also fostered the use of covered facilities for loading iron ore and the relocation of the crushing and screening area to the mine site, which has resulted in further improvements in environmental conditions for Whyalla. A trans-shipping service has also been introduced to avoid major dredging of the Whyalla Port and a new fleet of high-sided wagons has been put into service. The benefits from Project Magnet play an important part in enhancing the sustainable competitiveness of the Whyalla Steelworks.

The successful implementation of Project Magnet has essentially provided a new lease of life for the Whyalla steelworks by extending the life span from the expected 2020 constraint imposed by hematite ore reserves, to at least 2027.

Based on the success of Project Magnet, Arrium Mining has opened another mine using a complete solution from Rockwell Automation. “We have migrated to a completely integrated Ethernet network with advanced segregation and security components,” said Deluao.

Through combining leading technology with high-level domain expertise, Project Magnet has resulted in a completely integrated pit-to-port solution that continues to provide many benefits to the Whyalla and South Australian communities.

Rockwell Automation Australia www.rockwellautomation.com.au

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NEW PRODUCTS

IP67 ETHERNET SWITCHES The ICP DAS NS-205/8PSE-IP67 and the NS-205/8-IP67 series IP67 unmanaged Ethernet switches are designed for industrial applications in harsh environments.

The rugged RJ45 connector ensures tight, robust connections, and guarantees reliable operation, even for applications that are subject to high vibration and shock. The NS-205/8PSE-IP67 switch provides five or eight Fast Ethernet ports with four or eight IEEE 802.3af-compliant PoE ports. The switch is classified as power source equipment (PSE) and provides up to 15.4 W of power per port.

FLOW COMPUTER POWER MODULE Emerson Process Management has released an updated power module for the ROC800 and ROC800L RTU flow computers. The PM-30 offers increased power delivery and the flexibility to install the ROC800 in either 12 V solar installations or 24 V rackmounted installations without needing to change the power module.

The PM-30 power module auto regulates any voltage between 11 and 30 VDC. It offers an increased power delivery to the ROC800 I/O of 70 W - exceeding the PM-12’s 60 W and the PM-24’s 30 W. The additional power enables users to expand the I/O in the ROC800 without concern regarding power consumption. The PM-30 module The Ethernet switch supports IEEE 802.3/802.3u/802/3x with 10/100 Mbps, full/half-duplex, MDI/MDI-X auto-

also offers improved monitoring with LEDs indicating the status of the 12 VDC and 3.3 VDC on the backplane.

sensing, and provides an economical solution for

The ROC800 series flow computers are suitable for a variety of

industrial Ethernet networks. Delivery includes all RJ45

applications for a wide range of liquid hydrocarbons including crude,

plugs and caps.

refined products, special application products, lubricating oils and

ICP Electronics Australia Pty Ltd

light hydrocarbons.

www.icp-australia.com.au

Emerson Process Management www.emersonprocess.com.au

www.ProcessOnline.com.au

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

LEVEL SWITCH WITH SAFETY APPROVALS The Rosemount 2120 range of vibrating fork point liquid level switches is now certified for SIL 2 functional safety with SIL 3 capability, enabling the device to meet safety application requirements.

IP65-RATED RACKMOUNT KVM SWITCH

The 2120 range is now approved for marine applica-

Backplane Systems Technology has released its

tions by the American Bureau of Shipping (ABS) and

short-depth IP65 1U rackmount 17″ TFT LCD KVM

Emerson has also added an expanded choice of process connections for greater installation flexibility.

switch, which is available with 1, 8 or 16 ports.

The KVM’s LCD screen features IP65 protection

For safety critical applications, SIL 2 certification is now available

against liquid and dust ingress, while the silicone

for the 2120 with NAMUR and 8/16 mA electronic outputs. There

keyboard with touchpad is fully water and dust proof,

are five plug-in electronic outputs available providing a choice of

and rated to IP68. The KVM is suited for installation

switching functions. The SIL 2 certification extends the time between

into devices which require a 1U rackmount height

proof tests and allows users to avoid extra shutdowns for safety testing.

and a short mounting depth of 460 mm.

The 2120 also offers an expanded choice of process connections. In addition to

The 17″ LCD screen features LED backlit

the new 2″ NPT process connection, the switch is now available with Mobrey A and

technology with a resolution of 1280×1024 with

G flanges enabling compatibility with mechanical float switch process connections.

250 cd/m2 luminance and 1000:1 contrast ratio.

For marine applications such as oil and ballast control and HFO blending, the

Users have the flexibility of connecting either PS/2

2120 is now approved by the American Bureau of Shipping (ABS) - expanding on

or USB keyboard and mouse, making is suitable

the existing Germanischer (GL) approval.

for integration with legacy systems.

The simplicity, ease of use and reliability of the Rosemount 2120 vibrating fork

The KVM switch is hot pluggable, allowing users

switch makes it a popular choice for high and low level alarm and pump control

to add or remove connected PCs without powering

duties in wide range of process and marine applications.

down the KVM switch or PC.

Emerson Process Management

Backplane Systems Technology Pty Ltd

www.emersonprocess.com.au

www.backplane.com.au

THREE FOR ANY EVENTUALITY VEGABAR series 80

Fast track to the right pressure transmitter The new VEGABAR series 80 is a testament to VEGA’s innovative strength. Three sensor variants cover measuring ranges from 25 mbar to 1,000 bar and process temperatures from -90 to +400 °C. VEGA has completely re-engineered their VEGABAR pressure transmitter family as well simplifying them down to just three innovative model ranges.

overload resistant ceramic-capacitive CERTEC® measuring cell, and it boasts some new and extraordinary innovations.

Its sensitivity to condensation has been virtually eliminated, also its sensitivity to sudden temperature change.

The three transmitter variants can solve practically any process pressure application.

VEGABAR 82 is the all-rounder, with its ceramic measuring cell, covering 60 to 70% of all applications. If high temperature and chemical resistance is required, the VEGABAR 81 with a chemical seal assembly is the first choice. For very high pressures the VEGABAR 83 (with its metallic measuring cell) is recommended.

The CERTEC® cell from VEGA is the only ceramic measuring cell that is almost impervious to temperature shocks; a patent has already been applied for on this world first.

The versatile VEGABAR 82 features the proprietary, oil-free, high abrasion and

The VEGABAR 80 series can be quickly and easily combined into an electronic differential pressure system. Compared to conventional, electronic differential pressure measurement is often cheaper and much easier to handle.

VEGA is the only supplier that offers this solution with ceramic pressure transmitters.

VEGA Australia Pty Ltd Freecall: 1800 817 135 Email: info.au@vega.com www.vega.com/au/

26 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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MULTILINGUAL SAFETY-DESIGN SOFTWARE

NEW PRODUCTS

PANEL PCS The PPC-3150 and PPC-3170 are slim-form-factor 15″ and 17″ panel PCs designed to operate in harsh environments whilst also providing the ability to expand their functionality to meet the user’s requirements. With highperformance Quad Core Intel Atom E3845 processors, the units have been designed to be fast panel PCs for machine building and process applications.

The PCs have been designed to work in ambient temperatures between -20°C and 60°C, thereby allowing them to continue to operate in a wide range

Engineers designing machinery

of environments. For added performance in unstable environments, the units

safety systems can now more

accept power inputs of 9-32 V, thereby ensuring that when power fluctuates,

easily collaborate across multiple

the devices keep working. Both models include a wide array of I/O ports: two RS-232 ports, one isolated

languages using the Safety Auto-

RS-422/485 port with terminal, one USB 3.0 port, three USB 2.0 ports and one dual GbE port. They also

mation Builder software tool from

come with either a PCI or a PCIex1 integrated expansion slot and there is an optional expansion module

Rockwell Automation.

with four port choices (internal USB, CFast, CF, one digital I/O plus one RS232) available.

The software tool automates the safety-selection process. Users

Advantech Australia Pty Ltd www.advantech.net.au

import an image of the machinery they need to safeguard and answer questions using a drop-down menu and help screens to identify and select the necessary safeguards.

The software then compiles all product selections, generates a bill of materials, and compiles necessary data to populate IFA’s SISTEMA (Safety Integrity Software Tool for Evaluation of Machine Applications). SISTEMA helps evaluate the system in accordance with ISO 13849-1:2008.

The software, which is available as a free download from the Rockwell Automation website, requires that users download and run SISTEMA. SISTEMA is available in a limited number of languages, so the tool’s expanded language functionality allows engineers to more easily generate SISTEMA reports outside of their local language. For example, an engineer who doesn’t speak any of the languages offered by SISTEMA can create a bill of materials in their local language using the tool. They can then import the data into SISTEMA, and generate a final report without needing to translate the information.

The new languages include Chinese, Czech, Danish, Dutch, Finnish, French, German, Hungarian,

Emerson Industrial Automation Sydney phone: (02) 9838 7222 Melbourne phone: (03) 9738 1777

Italian, Japanese, Korean, Polish, Portuguese, Romanian, Spanish and Swedish.

Rockwell Automation Australia www.rockwellautomation.com.au

www.ProcessOnline.com.au

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

VISION SYSTEMS WHAT YOU NEED TO KNOW

Christopher Chalifoux, International Applications Engineer, Teledyne DALSA

Vision systems are a primary consideration for any manufacturer who is looking to improve quality or automate production, but choosing systems that match your application and ownership requirements can be confusing.

V

ision systems can be thought of as computers with eyes that can identify, inspect and communicate critical information to eliminate costly errors, improve productivity and enhance customer satisfaction through the consistent delivery of quality products. Primarily used for online inspection, vision systems can perform complex or mundane repetitive tasks at high speed with high accuracy and high consistency. Errors or deviations in the manufacturing process are immediately detected and relayed, allowing control modifications to be made on the fly to reduce scrap and minimise expensive downtime. Vision systems are also deployed for non-inspection tasks, such as guiding robots to pick parts, place components, dispense liquids or weld seams.

Vision systems come in all shapes and sizes to suit any application need, but they all have the same core elements. Every vision system has one or more image sensors that capture pictures for analysis and all include application software and processors that execute user-defined inspection programs or recipes. Additionally, all vision systems will provide some way of communicating results to complementary equipment for control

28 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

or operator monitoring. That said, it is important to know that there are significant and important differences between vision systems that make one more suitable than another for any given application. It is equally important to know and appreciate the importance of choosing the optimal sensor, lighting and optics for the job. Failure to do so may result in unexpected false rejects or, even worse, false positives.

There are many variants of vision systems on the market, but for the purpose of this article we will classify them all into two categories - those with a single embedded sensor (also known as smart cameras) and those with one or more sensors attached (multicamera vision systems). The decision to use one or the other is dependent not only on the number of sensors needed, but also on a number of other factors including performance, ownership cost and the environment where the system needs to operate.

Smart cameras, for example, are generally designed to tolerate harsh operating environments better than multicamera systems.

Similarly, multicamera systems tend to cost less and deliver higher performance for more complex applications. Another way to differentiate the two classes of systems is to think in terms of

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Vision systems

capabilities (such as pattern matching, feature finding, barcode/2D recognition, OCR) and can interface with complementary devices using standard factory protocols. If your needs are more complex and you are comfortable with programming, you might look for a more advanced software package that offers additional flexibility and control. In either case, make sure that the software you choose is available across vision system platforms in case you need to migrate due to changing inspection requirements.

Implementation factors to consider

© iStockphoto.com/ filipjelic

Image sensor resolution

processing requirements. For many applications, such as in car manufacturing, it is desirable to have multiple independent points of inspection along the assembly line. Smart cameras are a good choice as they are self-contained and can be easily programmed to perform a specific task and modified if needed without affecting other inspections on the line. In this way processing is distributed across a number of cameras. Similarly, other parts of the production line may be better suited to a centralised processing approach. For example, it is not uncommon for final inspection of some assemblies to require 16 or 32 sensors. In this case, a multicamera system may be better suited as it is less costly and easier for the operator to interact with.

Perhaps the most important consideration when selecting any vision system is software. The capabilities of the software must match the application, programming and runtime needs. If they don’t, you will find yourself investing more time and expense than you anticipated in trying to make the system conform to your expectations. If you are new to machine vision or if your application requirements are straightforward, you should select software that is easy to use (doesn’t require programming), includes core

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Image sensors convert light collected from the part into electrical signals. These signals are digitised into an array of values called ‘pixels’, which are processed by the vision system during the inspection. Image sensors can be integrated into the system, such as in the case of a smart camera, or into a camera that attaches to the system. The resolution (precision) of the inspection depends in part on the number of physical pixels in the sensor. A standard VGA sensor has 640 x 480 physical pixels (width x height) and each physical pixel is about 7.4 microns square. From these numbers, resolution can be estimated for your real-world units.

Image sensors used by vision systems are highly specialised, and hence more expensive than, say, a webcam. First, it is desirable to have square physical pixels. This makes measurement calculations easier and more precise. Second, the cameras can be triggered by the vision system to take a picture based on a part-in-place signal. Third, the cameras have sophisticated exposure and fast electronic shutters that can ‘freeze’ the motion of most parts as they move down the line. Image sensors are available in many different resolutions and interfaces to suit any application need.

In many cases, multiple image sensors are deployed to inspect large parts or different surfaces of the same part.

Sensor lens selection Each sensor needs a lens that gathers light reflected (or transmitted) from the part being inspected to form an image on the sensor. The proper lens allows you to see the field of view (FOV) you want and to place the camera at a convenient working distance from the part. The working distance is approximately the distance from the front of the sensor to the part being inspected.

A more exact definition takes into account the structure of the lens and the camera body.

Consider this example: If a part to be inspected is 100 mm wide by 50 mm long, you would need an FOV that is slightly larger than 100 mm, assuming you can position the part within this FOV. In specifying the FOV you need to also consider the camera’s aspect ratio - the ratio of the width to length view. The sensors used with vision systems typically have a 4:3 aspect ratio, so the example 100 mm x 50 mm part would match the sensor dimension, but a 100 mm x 90 mm part would require a larger FOV to be seen in its entirety.

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

Vision systems

THE CAPABILITIES OF THE SOFTWARE MUST MATCH THE APPLICATION, PROGRAMMING AND RUNTIME NEEDS. IF THEY DON’T, YOU WILL FIND YOURSELF INVESTING MORE TIME AND EXPENSE THAN YOU ANTICIPATED IN TRYING TO MAKE THE SYSTEM CONFORM TO YOUR EXPECTATIONS. SELECTING THE PROPER LIGHTING REQUIRES SOME KNOWLEDGE AND EXPERIENCE THAT MOST SUPPLIERS CAN PROVIDE DURING APPLICATION EVALUATION.

Figure 1: Resolution affects quality. Left: Image taken with 640x480 image sensor. Right: Same image taken with 1600x1200 sensor.

From the FOV, working distance and the camera specifications, the focal length of the lens can be estimated. The focal length is a common way to specify lenses and is, in theory, the distance behind the lens where light rays ‘from infinity’ (parallel light rays) are brought to focus. Common focal lengths for lenses in machine vision are 9, 12, 16, 25, 35 and 55 mm. When the calculations are done, the estimated focal length will probably not exactly match any of these common values. The way around this is to pick a focal length that is close and then adjust the working distance to get the desired FOV. Most vision suppliers have tools that will help you calculate the closest lens to match your FOV and working distance. There are other important specifications for lenses, such as the amount and type of optical distortion the lens introduces and how closely the lens can focus.

Lighting source The human eye can see well over a wide range of lighting conditions, but a machine vision system is not as capable. You must therefore carefully light the part being inspected so that the vision system can clearly ‘see’ the features you wish to inspect.

Ideally, the light should be regulated and constant so that the light changes seen by the vision system are due to changes in the parts being inspected and not changes in the light source.

While some vision algorithms can tolerate some variation in light, a well-designed implementation will remove any uncertainty. When selecting a light source, the goal is to amplify the elements of the part that you want to inspect and attenuate elements that you don’t care about. Proper lighting makes inspection faster and more accurate, whereas poor lighting is a major cause of inspection failure. Generally it is recommended to avoid using ambient light, such as overhead light, as this can vary over time. Factory lights can beat, burn out, dim or get blocked. Similarly, if there are windows near the inspection station, outside light changes can have a negative effect on system robustness. Selecting the proper lighting requires some knowledge and experience that most suppliers can provide during application evaluation.

Predictable part presentation It is important to consider how parts will be presented to the vision system for inspection. If the part is not presented in a consistent way, you will not achieve the desired result. Therefore,

30 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

you will need to ensure that the surface of the part you want to inspect is facing the sensor at runtime.

Next you will need to decide whether the part is to be inspected while in motion or stationary. If the part is moving, the motion will likely need to be ‘frozen’ by turning the light on briefly (strobing) or by using the high-speed electronic shutter feature of the sensor (standard on most industrial vision sensors). In this case you will need to provide a trigger to the sensor to let it know when to take a picture. The trigger is typically generated by a photoelectric sensor that detects the front edge of the part as it moves into the inspection area. If the part is stationary, for example indexed or positioned in front of the sensor by a robot, the sensor can be triggered to take a picture from a PLC or the robot itself.

Finally, if you are inspecting parts at very high speed, you will likely need to optimise part positioning to reduce processing time. Keep in mind when designing your system that everything consumes processing bandwidth. So, when considering a vision system for high-speed inspection, you should try to determine which of your requirements are critical or just ‘nice to have’.

Armed with knowledge, support and a reputable supplier, the cost of implementing vision solutions on the factory floor will be returned many times over through increased quality, production efficiency and scrap reduction.

Want to learn more?

If you want to learn more, particularly about machine vision interfaces, there is a new Global Machine Vision Interface Standards brochure jointly published by the Automated Imaging Association (AIA), European Machine Vision Association (EMVA) and the Japan Industrial Imaging Association (JIIA). The brochure contains detailed descriptions and comparison charts of the hardware and software specifications that power the machine vision industry around the world, including Camera Link, Camera Link HS, GigE Vision, USB3 Vision (AIA) and CoaXPress (JIIA). In addition, the software standards covered in the brochure include GenICam (EMVA) and IIDC2 (JIIA). It marks the first time all these industry groups have come together to issue a comprehensive global resource.

Adept Total Turnkey Solutions www.turnkey-solutions.com.au

www.ProcessOnline.com.au

NEW

NETWORK MANAGEMENT SUITE

PRODUCTS

Moxa has released an updated version of its network management software suite, MXstudio. The version supports a variety of devices, including Ethernet switches, wireless AP/ bridge/clients, Ethernet gateways, serial device servers, and IP cameras, aiming to deliver a easy management experi-

ULTRASONIC FLOW METER

ence to automation network administrators.

The Series UFB ultrasonic flow meter

The MXstudio software suite includes the company’s

set utilises the transit-time difference

MXview network management software and two added

for measuring flow rates in pipes

tools - MXconfig mass configuration tool for initial mass

non-invasively. This is the permanent

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troubleshooting. This one suite allows users to handle almost

converter on a surface or pipe.

every task at each stage of the network management life

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cal devices using ideally homogeneous

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liquids that contain no air pockets.

to easily run a high-availability network, reducing the total cost of ownership.

The Series UFB comes with a sturdy IP65 rating, protecting it from dust and direct water contact, and has 4-20 mA and pulse output capabilities.

MXstudio industrial network management suite includes:

Two sensors are placed on the exterior of the pipe, and each transmits an

the MXconfig industrial network configuration tool that re-

ultrasonic pulse through the pipe and fluid to the other. The velocity of the

duces set-up time for initial mass deployments; the MXview

liquid flowing through the pipes causes the pulse to accelerate or decelerate.

industrial network management software to display real-time

The difference in the transit times of the two pulses is used to calculate the

network status information in an intuitive graphical interface;

flow rate. The use of transit time allows the flow meter to be unaffected by

and the N-Snap industrial network snapshot tool that serves

pressure or temperature changes.

as a stand-alone utility for collecting and comparing network

Applications include treated, demineralised and potable water; river or sea

data for quick troubleshooting.

water; glycol/water mixes, hydraulic systems; and diesel oil.

Madison Technologies

Dwyer Instruments (Aust) Pty Ltd

www.madisontech.com

www.dwyer-inst.com.au

www.ProcessOnline.com.au AUS.indd 1

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 31 14-8-19 下午6:30

NEW PRODUCTS

UPDATED PLANT MODELLING SOFTWARE The latest release from AspenTech, aspenONE v8.7, incorporates new capabilities in Aspen DMC3 Adaptive Process Control software that enables process controllers to stay online and sustain optimum performance for a much broader range of changing operating conditions. Also included is the enhanced Aspen Petroleum Scheduler software that extends its scheduling capability with new Pipeline Scheduling which, when combined with the Dock Scheduling, addresses for the first time the complete petroleum scheduling challenge, as well as Aspen PIMS-AO software that has new optimisation capabilities that enable the feedstock planner to achieve the most profitable solution faster than before.

The DMC3 adaptive control software enables control engineers to ensure that their advanced process control (APC) controller models always reflect the current operational and business drivers. The Aspen DMC3 Robust LP Tuning feature provides the control engineer with the ability to make the controller more tolerant of model inaccuracy thus improving controller performance under rapidly changing process conditions.

Automated Pipeline Scheduling extends the scheduling capability of the Aspen Petroleum Scheduler down to ancillary terminals to accurately track inbound and outbound pipeline movements. Refineries can now manage multiple and bidirectional pipeline segments and injection points with increased visibility and accuracy.

Aspen PIMS-AO software includes parallel processing, enhanced global optimisation, feedstock basket reduction and nonlinear modelling to improve planning for refineries and olefins plants. New optimisation capabilities enable the feedstock planner to achieve

CONTROL VALVE RANGE Established brands including Midland-ACS, Alcon and Landon Kingsway have been added to Rotork Instruments’ product offering with the formation of Rotork Midland.

The ISO9001-certified company, which has been designing and manufacturing stainless steel control equipment for the oil and gas industries for over 60 years, is now part of the Rotork Instruments division. It brings with it a range of solutions for a wide range of applications, including control systems for pneumatic and hydraulic control valves, electro-pneumatic and electro-hydraulic actuators, local control panels, manifolds and components such as solenoid valves, level controls, gas detection and firefighting equipment.

Within the Rotork Instruments division, the Rotork Midland product range complements the pneumatic control devices and motion control equipment manufactured by Rotork Fairchild, the Soldo range of control accessories for valve automation and the Young Tech Company’s range of valve positioners and accessories.

Rotork Australia www.rotork.com

the most profitable plan up to eight times faster than before.

Aspen Technology Australia Pty Ltd www.aspentech.com

32 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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NEW PRODUCTS

RISC COMPUTERS

NON-CONTACT TEMPERATURE SENSORS

Moxa is rolling out a small form factor wireless

The TW type non-contact temperature sensors are designed

Linux computer - the UC-8100 - specifically

for temperature measurement of hot objects up to 2500°C, and

designed for large-scale, big data WAN comput-

show the temperature value on a display or transmit it as an

ing solutions. The UC-8100 is built around an

analog or switching signal to a controller. To achieve maximum

ARMv7 Cortex-A8 processor and comes with

accuracy, users can select from sensors with different spectral

up to two RS422/485 serial ports alongside dual

ranges for different temperature ranges. For a precise meas-

10/100 Mbps Ethernet LAN ports. It also features a

urement, the emissivity of the target object can be set using

Mini PCIe socket that supports a cellular interface

push-buttons and the display.

and other modules. These versatile communication capabilities let users efficiently adapt the UC-8100 to a wide variety of complex communication and processing solutions, useful both as a communications platform in large-scale distributed applications and as a reliable and secure gateway for data acquisition and in-the-field processing.

For distributed processing applications, management and maintenance are big challenges. UC-8100 computers combine high-performance RISC architectures with ample storage capacity, allowing users wide flexibility when developing new automation systems. Programmable LEDs allow integrators or end users to define

Scratch-resistant precision lenses minimise the impact of

unique event signalling, to aid when building troubleshooting tools into a system.

divergent light. In combination with different lengths of optical

UC-8100 computers also come with strong protection from network attacks.

fibre to separate measuring heads, the sensors can be used

Moxa has taken the powerful Trusted Platform Module (TPM) one step further

at extremely high ambient temperatures up to 250°C. Besides

and integrated a patented secure boot algorithm that is claimed to deliver strong

variants with switching and analog outputs (4-20 mA), sensors

protection against current methods of kernel corruption.

with two freely programmable switching outputs are also available.

Madison Technologies

ifm efector pty ltd

www.madisontech.com

www.ifmefector.com

Need to simplify traceability and allocation control?

OsiSense™ XG RFID 13.56MHz is a fully open RFID system, which performs object traceability, tracking and access control functions with ease and simplicity, while providing freedom of choice: • 100% compatibility • 30% savings on install and set-up time • 100% RoHS and UL, CE, FCC certification.

It also allows automatic integration with your system architecture, as well as adaptation to network protocols such as: • Modbus® TCP/IP • Modbus® RTU • Uni-Telway™ • PROFIBUS-DP • Ethernet I/P.

Simply easy!™ Discover more Visit our website and sign up for our FREE newsletter. www.tesensors.com/au | Call 1300 369 233 © 2014 Schneider Electric. All Rights Reserved. SEAU114452

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OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NEW PRODUCTS

DIGITAL OUTPUT MODULE The Axioline F digital output module allows coupling relays to be easily connected to I/O stations via pre-assembled system cabling. The relays of the PLC series can be connected to the module using the Varioface-V8 adapter and without any tools. This simplifies mounting and saves time. The output module offers 16 channels, each with an output current of 0.5 A with an overall width of 35 mm. The outputs also offer a fast scan time of less than 100 µs. Axioline F also has a particularly short update time of just 1 µs per I/O module in the Axioline F local bus. The very low electromagnetic emissions of Class B mean that

LIGHTWEIGHT ROBOTS

the I/O system can be used in office and residential buildings. With

Universal Robots, a Danish manu-

the extended temperature range of -25 to +60°C as standard, the I/O

facturer of flexible industrial robot

stations are also suitable for applications which have special ambient

arms, has released the third genera-

temperature requirements. The I/O terminals can be integrated into all

tion of the lightweight robots UR5

standard networks via compatible bus couplers.

and UR10. Special features of the

Phoenix Contact Pty Ltd

revised robot arms are true absolute

www.phoenixcontact.com.au

encoders, eight adjustable safetyrated functions, twice the number of built-in I/Os and improved connectivity options.

The true absolute encoder enables a faster start-up of the robot arms. The absolute position is recognised right after power-on, eliminating the need for jogging during initialisation of the robot arm.

The safety settings of the latest generation of the company’s lightweight robots allow the robot arm to run in two operating modes; a normal and a reduced speed.

A switch between safety settings during the robot’s operation is also possible. To achieve this, eight safety functions are monitored by the safety system: joint positions and speeds; TCP positions; orientation; speed and force; as well as the momentum and power of the robot. The settings can only be changed in a password-protected area.

The UR Safety 3.0 safety system is certified by TÜV Nord and tested in accordance with EN ISO 13849:2008 PL d and EN ISO 10218-1:2011, Clause 5.4.3. Sixteen additional digital I/Os are available, which are easy to configure either as digital signals or as safety signals.

The six-jointed, cost-efficient robot arms UR5 and UR10 are especially suited for small and medium-sized businesses, due to their light weight and their easy programming and user-friendly handling via touchpad.

Sensorplex Pty Ltd www.sensorplex.com

34 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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NEW PRODUCTS

WIRELESS REMOTE CONTROL FOR HOISTING The Harmony eXLhoist range of wireless

EMERGENCY STOP SWITCHES

remote control systems is designed for

APEM has released the ES series of

operator control of cranes and other

emergency stop switches. These emergency stops feature a diallyl

materials handling equipment.

The system is a combination of a handheld remote (transmitter) and a base station (receiver) that communicates wirelessly over a dedicated and reserved 2.4 GHz frequency protocol. It allows the crane operator to move freely (within 100 m) for better vision of the load, obstacles and the target destination.

This also eliminates all installation, operation and maintenance difficulties associated with cabled crane control devices such

phthalate (DAP) case with a red aluminium anodised actuator, and yellow aluminium anodised bushing and epoxy sealed terminals.

The ES series can be sealed to IP65, IP67 or IP67K and the switch fully complies with EN60947-5-1. Further environmental specifications include vibration from 10-500 Hz at 10 g, shock resistance

as pendant control stations.

The ergonomic design of the eXLhoist controller allows comfortable,

of 50 g and axial robustness rated at IK10.

single-handed operation, with intuitive button positioning and tactile response.

The maximum current and voltage rating into a resistive

It allows 2-speed motion control in all three axes (long travel, cross travel

load is 1 A at 24 VDC with a choice of electrical function

and hoist) and can be used for 30 h on a 15 min charge, with a battery

of double-pole N/C, double-pole N/O and N/C or 3-pole,

life of five years. The Harmony eXLhoist also has a robust design with IP65

N/O and two N/C. The total travel to lock of the actuator is

protection on the remote and base station, and compliance to drop-testing

2.2 mm. Electrical terminals can be straight PCB or solder

and IK08 impact resistance standards directed by the crane code.

lug, and markings on the actuator are optional.

Schneider Electric Industry Business

Control Devices Australia

www.schneider-electric.com

www.controldevices.net

Projekt1 10.09.14 08:43 Seite 1

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OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

CASE STUDY

Airport baggage receives an upgrade

It’s a scene that is repeated thousands of times daily, in airports all around the world. Collect the boarding pass. Drop the bag at the check-in counter. Proceed to the departure lounge, sometimes with time to spare and sometimes in a last- minute dash.

Not so familiar to most travellers, though, is the technology that delivers baggage to the aircraft once the items disappear from view at the check-in point. Behind the scenes is a sophisticated system of conveyor lines, sortation, storage facilities and controls, all designed to ensure that each bag proceeds efficiently to the right aircraft at the right time. By improving these systems, terminal operators are able to increase capacity, cut costs and improve service to their customers.

Keeping the conveyor lines rolling is clearly fundamental to the smooth running of the terminal. Consequently, choosing the most appropriate motors and drives to power the conveyors is a major requirement for any new system.

As Qantas geared up for the end-of-year rush in 2013, Rainer Dinkelmann, Projects Manager at ICM Airport Technics Australia, oversaw the design and installation of such a baggage handling upgrade in one of the airport’s busiest departure terminals. ICM chose the latest version Movigear DAC drive system from SEW-Eurodrive for the upgrade, based on its power-saving features and reduced requirements for spares holding.

Following the upgrade, the resulting increase in capacity has dramatically increased throughput at the terminal. This has contributed to facilitating the Qantas Group moving the operations of QantasLink from Terminal 2 to Terminal 3, within the existing building’s constraints.

Key to the increased capacity was the installation of an automated bag store. Dinkelmann says that because of the new storage facilities, which can accommodate 200 bags at a time, capacity has been extended to over 10,000 bags per day. Bags that have been checked in well before flight time are held in the new automated bag store on ‘early arrival’ conveyor lanes.

There are a number of ways of configuring automated bag stores at airports. “We use standard conveyors, with bags packed tightly together on storage lanes using smart technology,” says Dinkelmann.

Prior to the upgrade, early arrival bags were manually removed from the conveyors, stored on a trolley, and then manually returned to the conveyors in time for departure.

“It was a lot more handling,” says Dinkelmann. “In fact, each item would be handled three times instead of once.”

36 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

At the departure point the baggage is placed in unit load devices (ULDs), which are the aluminium containers familiar to passengers who watch their baggage brought out on trolleys and loaded in to the aircraft hold. The new storage facilities include an integrated batch building ball deck, consisting of a large array of steel balls that can rotate in any direction. The ball deck allows the ULDs to be positioned easily, both for storage and in readiness for assembly for the appropriate flight. This also allows preloading of batches of bags into ULDs well before flight departure.

In addition to the automated bag store, the upgrade included a set of general improvements, with ICM’s team replacing the high-level control and SCADA systems. The supervisors can see how many bags are in the store for each flight and, while the store will automatically eject the bags according to their flight times, the supervisors can override the auto setting and call bags down in batches to specific destinations. This gives them far greater control and also means that the double handling of early bags is greatly reduced. In essence, this gives the supervisors the ability to tightly manage the baggage system and making the whole process far more efficient.

With more than 10,000 bags being handled each day, reliability of the conveyor system is all important.

To ke e p t h e co n ve y o rs rolling, ICM required around 100 of the Movigear DAC drive units.

The design calculations confirmed a short payback period for the drives, which combine the motor, gears and drive electronics within a single unit and provide control communications via a standard AS-interface. This high level of integration resulted in fewer components being necessary for the conveyor system. In turn, this led to the reduction in spare parts requirements and a corresponding increase in the calculated availability figures.

Designed for maximum energy efficiency, the selected drives provide up to 50% improvement over traditional systems. “Power consumption is very important for these projects. Power costs money. Both the calculations and results for the drives have been fantastic to date,” says Dinkelmann. “Delivery time was an important factor in the project too. SEW bettered their delivery time estimate, which helps immensely on tight project time lines.”

A slightly longer and more detailed version of this article can be read online at: http://www.processonline.com.au/case_studies/69958 SEW-Eurodrive Pty Ltd www.sew-eurodrive.com.au

www.ProcessOnline.com.au

NEW PRODUCTS

SMALL ROBOT FAMILY ABB has introduced the IRB 1200 robot family to address the needs of the material handling and machine tending industries for flexibility, ease of use, compactness and short cycle times while still maintaining large working envelopes.

The IRB 1200’s smooth surfaces make it easy to keep clean. Both electrical and air connections can be made to the robot via side ports or from beneath the base. In addition, an Ethernet port makes it easy to integrate with other equipment like the ABB Integrated Vision. These connections are routed internally on the robot from very close to the wrist flange, all the way to the foot, thus enhancing the compactness of the package. The IRB 1200 comes in two variants which can handle a wide range of applications and are cost effective due to commonality of parts. The 700 mm reach variant can carry a payload of up to 7 kg, while the longer reach 900 mm variant can carry up to 5 kg of payload. Both variants can be mounted at any angle.

By design, the IRB 1200 has no offset in axis two. This innovation results in a longer stroke than other robots, meaning the IRB 1200 can be placed very close to the work piece and still be functional. One particular benefit of this long stroke is that it allows for a much more compact installation when the robot is mounted on the ceiling inside a small cell, such as in electronics machining or polishing applications.

ABB Australia Pty Ltd www.abbaustralia.com.au

www.ProcessOnline.com.au

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

NEW PRODUCTS

PORTABLE VIBRATION CALIBRATOR The 9110D digital portable vibration calibrator from The Modal Shop is a compact, battery-powered and completely self-contained vibration reference source which can be used to calibrate individual sensors, vibration switches and data collectors, as well as to validate the entire measurement channel of a condition monitoring or recording system.

Designed for use in situ, including on the manufacturing plant floor, the unit calculates and displays the sensitivity of the sensor under test on the display in real time. It also has a built-in ICP input for common piezoelectric accelerometers and can save up to 500 calibration records directly to the unit’s internal memory. Users can copy records to the included USB flash drive with Report Generation Workbook via the unit’s USB port.

Saved calibration data is then transferred to a computer where the user can generate and print an ISO 17025-compliant customisable calibration certificate.

The 9110D provides enhanced stability and good vibration calibration over an extended 7 Hz to 10 kHz frequency range, at amplitudes up to 20 g (196 m/s2).

The 9110D features an integral precision quartz reference accelerometer and closed-loop level control, packaged in a rugged Pelican Storm case with two press and pull latches. The 9110D is always ready for travel to industrial test sites or bringing laboratory accuracy to the field.

John Morris Industrial industrial.johnmorris.com.au

38 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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NEW PRODUCTS

CROSSBELT SORTER

PRESSURE SENSORS

The Dematic FlexSort SC3 Crossbelt Sorter is

The key to measuring highly dynamic pressure variance

a high-rate, high-accuracy sorting solution for

is to achieve, as far as possible, a direct connection

distribution and warehousing operations. Suitable

between sensor element and medium. The Keller

for sorting satchels, pieces, stuffed envelopes,

M5 offers a micromechanical solution without media

cartons and totes, the sorter uses discrete belt

isolation diaphragm (with its damping effect), capillary

conveyors mounted on carriers in a recirculating

tubing, sealants or adhesives. In the M5 series, the

loop configuration.

rear of the silicon sensor is soldered to a supporting element designed for good fluid dynamics, which in turn is secured flush at the front of the pressure connection. This design enables dynamic measurements with a bandwidth of 0-50 kHz. The pressure sensors in the M5 series are intended for operating temperatures between -40 and +180°C with a narrow total error band (ie, including temperature errors) of ±1%.

Without the remote signal converter, they come with a typical output signal range of 80 mV (based on a 1 mA supply) and an individual calibration certificate. The 3, 10 and 30 bar measurement ranges are available for absolute pressure measurements. Separating the pressure sensor and the signal converter enables measurements at close proximity, even in units installed in cramped conditions and exposed to high temperatures.

To avoid any reduction in dynamic range, Keller has opted not to digitise the measure-

The sorter allows high throughput and precise

ment signal to be produced. Instead, the purely analog signal is adjusted in real time via

controlled handling and operational flexibility, along

the compensation electronics, which are fully controlled by a microprocessor. This ensures

with sustained order accuracy. The sorter cells

the output signal, amplified to 0-10 V, retains the full dynamic range of the sensor signal.

can be activated anywhere along the sorter loop,

KELLER AG für Druckmesstechnik

making it possible to add and/or move chutes

www.keller-druck.com

and induction stations, or change the sorter speed without additional hardware installation and commissioning.

DATA ACQUISITION SYSTEMS

The machine’s design is based on a common modular platform that is built around standard

Dataforth Corporation’s MAQ20 data acquisition and

commercially available off-the-shelf components.

control system is now available with IPEmotion software

This modular platform provides the foundation

which provides synchronised data acquisition

around which standardised mechanical, electri-

and is easily adaptable to specific customer

cal and controls components can be configured.

requirements, including device configuration,

The engineering allows for multiple configura-

data acquisition measurement, visualisation

tions, enabling users to select the motion drive and

and analysis.

power/data options appropriate for the application.

To meet these requirements, IPEmotion provides

The sorter drive system can be configured with

automatic recognition of connected devices, automatic

linear induction drive motors (LIMs) or with linear

configuration of all channels, automatic start of measuring and instant visualisation

synchronous motors (LSMs). The LSMs operate

of all measurement values. Designed for long-term measurements, IPEmotion Soft-

using 50% less energy than the LIMs. Additionally,

ware allows measurement analysis and verification during data acquisition. Storage

cooling fans are not required.

can be on a local hard drive or a remote drive, including a mapped internet or

For power and data transmission, the sorter can

network drive.

be configured with either a bus bar with brush

IPEmotion Software communicates with the MAQ20 via a PlugIn driver. The

contact technology or with non-contact technol-

software also enables many functions to be integrated by linking external DLL and

ogy. The contact technology uses a power rail

Visual Basic Script (.VBS) files to the application. This is a powerful tool, as VB-

and collector brush on every master carrier. The

Script enables users to automate the measurement process and to change menus

non-contact solution includes IWLAN RCoax cable

and settings, analyse procedures and change other aspects of the software. The

communication for data and a high-frequency,

MAQ20 industrial data acquisition and control system is a high-performance, highly

energised cable for power transmission. It op-

flexible system that was developed for a wide range of applications including test

erates with non-wearing parts, resulting in less

and measurement, factory and process automation, machine automation, military

maintenance.

and aerospace, power and energy, oil and gas, and environmental monitoring.

Dematic Pty Ltd

Scientific Devices Australia

www.dematic.com.au

www.scientific-devices.com.au

www.ProcessOnline.com.au

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 39

NEW PRODUCTS

EDDY CURRENT SENSOR The Micro-Epsilon eddyNCDT SGS 4701 eddy current sensor is suitable for measuring the thermal extension of high-frequency spindles in order to minimise positioning errors in machine tools.

The spindle is at the heart of a machine tool and so plays a decisive role in the dimensional accuracy and surface quality of the respective workpiece. High speeds and the heat generated result in axial extension of the workpiece spindle and therefore to positioning error during finishing of the workpiece. The miniature sensor measures the thermal and centrifugal force extension of high-frequency spindles by measuring on the labyrinth ring.

The measured values are fed into the CNC machine tool as correction values and compensate for any positioning errors.

The miniature eddy current sensors have dimensions of 4.5 x 10 x 12 mm3 or 4 x 4 x 10 mm3 and can be integrated with the controller into the machine tool spindle.

For ease of handling and in order to achieve maximum accuracy, the device is factory calibrated for ferromagnetic and non-ferromagnetic materials used by the customer. The temperature of the sensor is measured via the resistance of the eddy current coil for temperature compensation. This signal is also available to the user, which can eliminate the need for any additional temperaturesensing technology.

Bestech Australia Pty Ltd www.bestech.com.au

40 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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NEW PRODUCTS

VIBRATION MONITORING SYSTEM

BATTERY ANALYSERS

The VSE series vibration monitoring

The Fluke 500 Series battery analysers are designed

systems make it possible to connect ac-

to simplify the workflow of testing stationary batter-

celerometers with IEPE interface as well

ies and battery banks. The analyser’s user interface

as a range of MEMS-based VSA vibration

provides quick, guided test set-ups, ensuring tech-

sensors over four dynamic channels. It is

nicians are capturing the correct data while visual

also possible to connect common acceler-

and audio feedback cues reduce the risk of errors.

ometers, microphones or force sensors that

The series perform all key measurements includ-

are based on the IEPE standard. The improved

ing battery resistance, DC and AC voltage, DC

history function enables the user to record over 600,000

and AC current (BT521 model only), ripple volt-

time-stamped values, making it possible to accurately record

age, frequency, and battery temperature (BT521

over a considerably longer period of time.

only). The battery analysers have been specifically

A wide range of filters for real-time indicators are available

designed for measurements on stationary batteries

for process monitoring. It is possible to select preset, such as

including GEL, AGM (absorbed glass MAT) and

high or low frequency bands, and a combination of filters is

lithium-ion, as well as wet-cell, lead-acid batter-

also possible. Up to 32 counters supply characteristic values,

ies. The series intelligent test probes streamline the testing process by

performance and run-time information, and the short reaction

displaying measurement results on their integrated LCD, eliminating the

time of <1 ms as well as variable alarm limits can be used to

need for technicians to stop and look at the mainframe. Technicians can

optimise production and machine protection. The gateway via OPC

capture voltage readings and temperature logging automatically or via the

enables integration into higher systems and further transparency.

integrated save button, simplifying and speeding up the test process. The

ifm efector pty ltd

probes feature infrared temperature measurement (BT521 only), tricolour

www.ifmefector.com

LED for pass/fail/warning indications, and audio feedback.

Fluke Australia Pty Ltd www.fluke.com.au

www.ProcessOnline.com.au

OCTOBER 2014 - WHAT'S NEW IN PROCESS TECHNOLOGY 41

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

JUMP ON BOARD THE INTERNET OF THINGS (IOT)

Wahroonga NSW 2076 AUSTRALIA 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 Janette Woodhouse

O

bjects around you are increasingly being embedded with a myriad of sensors and actuators - from your roadway, to your body, to industrial processes. Kevin Ashton (from Proctor & Gamble) used the term â&#x20AC;&#x2DC;internet of thingsâ&#x20AC;&#x2122; to refer to everyday objects autonomously communicating with each other.

There are incredible opportunities opening up in engineering and industry to apply these technologies and data to your work. When formerly inanimate objects can sense the environment and communicate, they become tools for discerning what is happening in remote environments and making decisions on the data.

You are already probably aware of the tiny microcameras that you can swallow to view your gut to pick up sources of illness.

Or cars that brake automatically when detecting an object ahead.

The IoT will undoubtedly impact your life in the next decade - no matter whether you are a plumber, plant operator, R&D scientist or CEO of a blue-chip company. And today, the Internet of Things has finally come into its own. Technology costs have been steadily falling and the field is now enjoying wide support from the business community.

Recent research has identified a number of key features of the growth of the IoT. Firstly, most organisations are well aware of the IoT, but investment is still slow, and new skills are required to unlock the full potential. In addition, cooperation between companies (including competing companies) is required to make it work, but consumers will soon be swamped with IoT products and services (even though many will not know it).

The result will be that everyone from businesses to consumers will be overwhelmed with data from the IoT. According to McKinsey there are six types of applications that suit the IoT: behaviour tracking; situational awareness; mass data gathering for decision making; process optimisation; smart metering and the smart grid; and complex autonomous systems.

Sensors can track usage of equipment ranging from cars to the level of thrust of a jet engine to products moving through supply chains (using RFID). This behaviourtracking data is then relayed back to make decisions on such things as fees to charge for usage of a jet engine, or instructions to adjust shipments of goods. Data from sensors can indicate soil moisture, ocean currents, weather, rain, traffic intensity or intruders in a particular zone.

Masses of sensors can also gather data - for example for oil and gas, or mining exploration (to locate high-grade deposits) - and feed this back for mapping, analysis, and decision making.

As for process optimisation, we have been monitoring data from instrumentation for years, but the lowering cost and smaller size makes for even better process control and optimisation of flow, level, temperature and pressure - and more effective ways of processing previously inaccessible or slowchanging data. Smart meters are also increasingly being used to provide details of energy usage and real-time costs to consumers and power companies.

Application of sensors and actuators to the car industry means that we are now seeing complex automation systems in which automatic braking is now available - and eventually self-driving cars, perhaps allowing us to cut down on the million deaths per year due to car accidents.

These technologies are not pie in the sky - they are being rolled out today. See if you can apply them in your next project. *Steve Mackay, PhD CPEng, has worked mainly in the industrial automation and data communications fields across the world for the past 30 years and is currently technical director with worldwide engineering education business IDC Technologies (www.idc-online.com). He has also published over 30 engineering books, as both editor and co-author.

42 WHAT'S NEW IN PROCESS TECHNOLOGY - OCTOBER 2014

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