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May 2014 - Control Design

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1. oO W 2 74 gt je f oO W I PIOZ AVN pS Made in America Ez 12 a Next Gen AKT era series TFT color at cost oftheir monochrome e 65K colors 400 Nits White LED with 75K Hrs 55 C 4 Yr Warranty e Ethernet 2 Serial Ports 2 USB Micro SD Data Acquisition and Storage Remotely Accessible 6 TFT EZ3 EZTouch 499 T EZ3 T6E E Remote Monitor and Control Any Android or Apple iOS Phone or Tablet Includes Ethernet 2 Serial Ports USB Type A for Data MH i Storage USB Type B for a I Programming Micro SD Slot mo ne Automatic Email on Machine Productivity and Diagnostics Built in Anti glare Screen Rae 090 Thick Touchscreen F en rn Modem Support Ja Distortion free Scaling of Objects Recipe Management Animation Objects Universal Connectivity to PLCs Plus DH RIO Optional Remote Monitoring and Control Real time Video Feed Anywhere in the World as if you are in front of the Touchpanel Call EZAutomation net at 1 877 774 EASY 3279 Af Broadest line x ots First 1000 Callers get Free Revolutionary K ar EZ Viz Proximity Sensor with EZ3 Order Same Day Shipping US Based Tech Support i tH 7 PM CST from 6 AM to 12 Midnight CST Automation has never looked better 4 a LJ 11 iz 1 m a4OEHHEEAo g a TIPHIENIK CONTACT Powerful technology attracti
2. C amp E Sales www cesales com And from LinkedIn s Automation com group All About Frequency I have dealt with solar powered seismic sensors Increas ing the time between samples greatly decreased the power requirements thus allowing the use of smaller and less expensive solar panels The question is what is the minimum number of samples required per time period to meet the desired functionality DAN MAZORRA project engineer EMA emainc com bill controldesign com WON T TOUCH THAT RFC4800 touchless rotary angle sensors provide abso lute rotary position Analog digital redundant and switch are standard output options It uses a magnetic pickup to provide a touchless mea surement range of 0 to 360 Key specifications include ingress protection from liquids and dust to IP 69K repeatability of 0 1 and independent linearity of 0 5 Novotechnik 508 485 2244 www novotechnik com TOUGH SWITCH EBGS403RSO0 H enclosed disconnect switch has 16 gauge 304 stainless steel a continuous hinged cover with secure latch wide welded mounting flanges DIN rail welded directly to the back of its enclosure foam in place polyurethane gasket and ground studs welded to door and enclosure It s commonly used for 30 A applications but rated to 40 A Mersen 978 462 6662 www ep us mersen com GREAT THREADS WMX general motion controller with up to 64 axes of high end motion control functions on EtherCAT has a
3. y Current Pressure Level 100 240 S 15VA 50 60Hz Connect to lots of process devices with analog I O modules for the CLICK PLC The CLICK PLC now has more ways to help you with simple control applications Monitor pressure level current even thermocouples and RTDs directly Perform simple variable control with analog outputs connected to devices such as drives These high resolution modules offer fast setup no DIP switches with software scaling to make your life and program easier Choose from e 4 channel current or voltage in 13 bit 89 each e 4 channel thermocouple or RTD in 16 bit 149 each e 4 channel current or voltage out 12 bit 119 each Combo 4 channel in 2 channel out current or voltage 149 each no PID gt See our Web site for details and restrictions Copyright 2014 AutomationDirect Cumming GA USA All rights reserved i a 4 oe A be fa I Z Ki pa Temperature Variable Speed Control Flow Control e RR C0 00DD1 D 020m a S0 04THM ra ae SSCS EEET ERR 29 00 69 00 89 00 149 00 119 00 CO 00AC CO 00DD 1 D CO 04AD 1 CO 04THM CO 04DA 1 Mighty as a stand alone unit or expand to 142 total I O With CLICK PLCs you get a lot of application control in a small package You can replace even just a few relays cost effectively but do a whole lot more with the easy to understand ins
4. MULTI TASK CONTROL MultiCell Type 8619 multi channel controller can be used for regulation of pH dosing of chemicals and ratio control The controller is fac tory set to customer speci fications Standard version includes user interface mainboard and ac adapter two analog and digital outputs and two digital inputs Burkert Fluid Control Systems 949 223 3100 www burkert usa com MOTION DOES HMI CP26xx Panel PC series with ARM Cortex A8 processor has a hard ware based floating e point unit which makes floating point operations significantly faster for motion control applications in addition to running the HMI software An on board 10 100BaseT Ethernet adapter an EtherCAT adapter with RJ 45 connector and an RS 232 interface with two USB 2 0 ports are also available The multi touch panels with projective capacitive touchscreen PCT technology have a high touch point density and response is assured even while wearing thin work gloves Beckhoff Automation 877 twincat www beckhoffautomation com PID CONTROLLER PXU PID controllers come in 1 16 1 8 and 1 4 DIN size models and include optional 48 Control Design May 2014 RS485 communications They re also programmable via front panel pushbuttons and or Crimson configura tion software have on demand auto tuning and have universal inputs supporting thermocouple RTD 0 to 10 Vdc and 4 20 mA They re UL listed to 61010 1 Red Lion Controls 717 76
5. municating with other control switch a field device between CANopen Profibus or controldesign com Serial RS 232 RS 485 within one unit with no third party converters The devices have a 600 MHz ARM Cortex A8 processor and compatibility with DHCP DNS SNTP FTP TELENET and HTTP protocols enables the units to interface with standard PLC applications and additional control systems Wago 800 din rail www wago us ON MACHINE CONTROL Armor GuardLogix programmable automation controller PAC can be installed directly on machine with pre configured quick connect systems to simplify wiring layouts The PAC is IP67 SIL 3 PL e CAT 4 rated with 4 MB of application code storage space with two full featured EtherNet IP device level ring DLR capable connections It pro vides access to the controller mode switch USB port secure digital SD card and power supply switch along with 24 Vdc power pass through to supply power to other on machine products The controller is programmed in the Studio5000 design and engi neering environment Rockwell Automation 414 328 2000 www ab rockwellautomation com TEMPERATURE CONTROL Nanoline controllers include a temperature expansion module and an operator display for connec tion of two RTDs or thermocouples and is compatible with PT 100 and PT 1000 in two or three wire configurations or thermocouple Types B E J K N R S and T It has four PNP outputs rated at 50
6. IIC is to accelerate the development of connected industrial applications Industial VPN Routers www ewon us User Imarnet Talk IM Ea m m Easy setup using customer s LAN Firewall friendly FREE Talk2M VPN Service AAA The eWON COSY 141 eliminates the need to travel onsite to troubleshoot your equipment using a secure VPN connection Pittsburgh PA 412 586 5901 2014 Siemens Industry lnc TANA TIJA Da n r iPAL rrF I r SEE EA en an a a a Me eh ei r ap iE od am T one sauer FaacTicad wann Salety Naturally Integrated One system one engineering tool one network SIMATIC S7 1500 the new generation of controllers along with the new fail safe I O offers you the ultimate plus in automation with power efficiency and safety integrated Your Plus in Efficiency Innovative design and easy handling for simple usage and commissioning as well as Safe operation Integrated system diagnostics for full transparency of the plant status automatically generated and consistent appearance Your Plus in Power Outstanding system performance for shortest response times and one guayo Comto TIA Portal for highest engineering efficiency to reduce project costs and naturally with Safety integrated Technology integrated for seamless integration of drives and other devices Siemens is the global l
7. automated safety PLCs better coor dinated networks and other supporting devices Integrated into machines at their earliest design and assembly stages these safety components and software can establish safe zones guarantee safe speeds and non injurious motion and allow opera tors to stay safe even as they interact more closely with their machines Likewise domestic and inter national machine safety standards are harmoniz ing to better help builders and users apply com mon uniform safety components Figure 1 The Occupational Safety and Health Administra tion s www osha gov regulations have been around for more than 40 years so most companies have some safeguards in place on their machinery but most of these safeguards are expensive physi cal barriers that most likely limit productivity says Jeff Winter safety business manager for North America at Grantek Systems Integration www grantek com in Oak Brook Ill How ever recent changes in international safety standards have plowed the road for the rest of the world to integrate safety technology into standard automation functionality Compared to conventional guarding we now can reduce hardware costs simplify control architecture reduce design and engineering time increase diagnostics and ultimately make a safer work envi ronment So even if a machine is conven tionally safe overhauling its safety sys tem could improve its safety and overall equipment
8. info adalet com TEL 216 267 9000 FAX 216 267 1681 Q IntelliMotor Stepper motor encoder AC Stepper Motors and Drives Robust AC DC Stepper Motors and Drives Intelligent drive controller I O and communication in Stepper motor and drive solutions to match drives and new motors feature robust 10 shielded an integrated package even the most challenging motion applications cables and industrial grade cable glands IQ Software Suite Complete suite of _ intuitive software solutions L N gt 0 F gt L E GT R C AA IQ Stepper Configure stepper a 1a 7 motor and drive hardware SO LUTI 0 N S u ER IQ Programmer Configure a AQ motion profiles according to the application requirements r IQ Update Used to update stepper drive firmware IR Original Line Electric Thruster Designed to handle side and moment loads with the precision and control of the Bimba OLE MEET THE ORIGINAL LINE ELECTRIC FAMILY The most comprehensive suite of electric solutions just got smarter With the addition of new stepper motors drives and software packages P Bimba s Original Line Electric continues to the lead the way in providing E unparalleled control superior performance and innovative solutions for all your motion control needs Meet the newest members of the OLE family at bimba com electric Original Line Electric Actuator Built and tested to provi
9. product development and U S manufacturing in order to offer the widest variety of permanent magnet and wound field industrial DC motors in the world DC motors continue to provide the right solutions to many application requirements We now can supply IEC or NEMA frame motors stock motors from 1 50 to 500 Hp or custom designed motors to 3000 Hp to meet your specific application If you need a DC motor anywhere in the world call Baldor baldor com 479 646 4711 BALDOR A MEMBER OF THE ABB GROUP 2012 Baldor Electric Company e The Most DC Choices e Unmatched Quality e Superior Reliability e Quickest Delivery Available e American Made Since 1920 Scan to watch a video and learn more or go to http qr2 it Go 1418777 lt Ontroldesign com MA CHI R I P PLC Great to see your March 2014 piece on the PLC Live Wire p 17 www contr oldesign com articles 2014 plcs days numbered Quite a statement This is something I have been saying for some time although coming from a slightly different context I got dragged into a silicon start up specializing in embedded motor control and got exposed to the power and cost of these devices Five years ago it was possible to make a PLC work on a 6 processor with Ethernet already built into it The PLC might be on the verge of extinction as a hardware proposi tion The fact that CoDeSys has pretty well co opted the entire in dustry is nothing
10. 24 inch 16 9 viewing window and a generously sized work surface Should a Titan ever fail due to manufacturer defect ITSENCLOSURES will replace it immediately so your business does not skip a beat To learn more about IceStation TITAN call 1 800 423 9911 or visit ITSENCLOSURES com by ITS DRIVES amp MOTION CONTROL The Not So Odd Couple Like an Old Married Couple a Motor and Its Generator Are Bound Together One Does Not Exist Without the Other by Ernst Dummermuth FLASH We celebrated our 15th anniversary two years ago by republishing some of our more timeless content It was really well received so we decided to do it again from time to time Here s a tutorial article as we we first published it in March 2008 This is one of several that Ernst Dummermuth wrote for us that generated a large number of views on ControlDesign com for years after we first posted it and it still draws attention today SOME IMPORTANT PROPERTIES and characteristics of electric motors and electric generators can be dem onstrated easily using an actual motor and generator Grade or middle school students could conduct these experiments Through my own experience I ve ob served that these experiments executed on a labora tory table can be very useful as a teaching tool Basically Speaking Motors come in all shapes and sizes and are used mostly to convert electrical energy to mechanical energy via the rotation of a shaft The pri
11. Most Important Part of Your System OF ALL THE COMPONENTS in your system which is the most important Is it the logic processor Is it the high accuracy laser sensor that detects product posi tion Maybe it s the precision positioning stage that moves the product based on laser sensor input and logic processor commands Could it even be the operator All of these components with apologies to all ma chine operators are important but there is one that is more so Oftentimes this component is not even remotely near the system It s the documentation I simply don t understand the culture in the U S about documentation When did reading the docu mentation that comes with a system a machine an appliance etc become not worth the effort or have a negative connotation Not even all engineers do this absolutely important task Ideally I suppose a machine could be so intuitive that no manuals are needed to learn its functions Steve Jobs came close but even in iTunes some features are not immediately clear and require resorting to the documentation to figure out E Why is reading the manual for a machine that costs in the six figures considered such a waste of time I If a company pays hundreds of thousands of dollars for a new machine wouldn t it be smart to read through the manuals that come with it in order to maximize the return on investment This seems obvious yet time and again I ve encountered the opposite behavior M
12. NOSIG is the only magazine exclusively dedicated to the original equipment manufacturing OEM market for instrumentation and controls the largest market for industrial controls gt PutmanMedia 1501 E Woodfield Rd Suite 400N Schaumburg Illinois 60173 630 467 1300 Fax 630 467 1124 PUBLISHING TEAM GROUP PUBLISHER amp VP CONTENT KEITH LARSON klarson putman net DIRECTOR OF CIRCULATION JACK JONES jjones putman net SALES TEAM NORTHEASTERN AND MID ATLANTIC REGIONAL MANAGER DAVE FISHER dfisher putman net 508 543 5172 Fax 508 543 3061 24 Cannon Forge Dr Foxboro Massachusetts 02035 MIDWESTERN AND SOUTHERN REGIONAL MANAGER GREG ZAMIN gzamin putman net 630 551 2500 Fax 630 467 1124 1501 E Woodfield Rd Suite 400N Schaumburg Illinois 60173 WESTERN REGIONAL MANAGER LAURA MARTINEZ Imartinez putman net 310 607 0125 Fax 310 607 0168 218 Virginia Suite 4 El Segundo California 90245 DIGITAL SALES SPECIALIST JEANNE FREEDLAND jfreedland putman net 805 773 4299 Fax 805 773 0451 INSIDE SALES SPECIALIST POLLY DICKSON pdickson putman net 630 467 1300 Fax 630 467 1124 EXECUTIVE STAFF PRESIDENT amp CEO JOHN M CAPPELLETTI CFO RICK KASPER VP CIRCULATION JERRY CLARK VP CREATIVE SERVICES STEVE HERNER REPRINTS FOSTER REPRINTS www fosterprinting com JILL KALETHA jillk fosterprinting com 866 879 9144 ext 168 O EM N S G HT TJ McDermott tjm systems interface com The
13. Sensors Product Detectors Fiber Optic Options Accurate Reliable Easy to Use Setup and Maintain Material Handling Shaft Wheeled and Absolute Encoders Small Compact Affordable Sensors Fiber Optic Sensors for Tight Spaces Environmentally Robust Designs Custom Solutions Available Accurate Repeatable Easy to Use Setup and Maintain Fast Delivery Packaging Registration Mark Sensors High Speed Product Detectors UV Sensors for Invisible Marks Splice Detectors Clear Object Sensors Reliable Repeatable Robust Easy to Use Setup and Maintain Printing Print Triggers Inspection Sensors Encoders for Line Speed Accuracy Environmentally Robust Accurate Fast Repeatable Easy to Use Setup and Maintain MEMBER PMMI a Electrotechnical Commission www iec ch standards it s important to be aware of their contents too In Europe this burden is on machine designers and builders Because U S and Canadian machine builders and system integrators are at the mercy of clients requests they ll follow national or internal standards most of the time Winter continues However it s not uncommon for them to also embrace unique company specific homemade requirements Europe has a much more restrictive approach and to meet the presumption of conformity of the EHS requirements in the Machinery Directive 2006 42 EC you must foll
14. USA COM 315 701 0315 INFO EUCHNER USA COM REAL ANSWERS controldesign putman net What Are Our Wireless Options WE LL SAVE OURSELVES and our customers some significant money by using wireless sensors in places to connect a battery of machines across varying dis tances many nearly 1000 ft distant First issue The sampling rates will vary from 10 sec to 1 sec with some others transmitting on status change only So it looks like we have options for powering the sensors At these rates can we economically use energy harvest ing methods What s the general state of battery life for these conditions There even are a few spots where photovoltaics PV is an option Second issue We heard that the level of encryption say 128 bit has a big effect on battery life which no one seems to want to talk about Any practical advice for these issues from March 14 CONTROL DESIGN ANSWERS 0 _ Check Your Data Rate Needs Technology can deliver low power wireless sensing but there are challenges such as range rate power and encryption to consider An excellent way to extend range is with wire less meshing technology Mesh solutions based on 802 15 4e are far more robust and resilient than 802 15 4 and they ll provide the most flexibility and reliability A 1 000 ft range is workable although en vironmental factors such as RF interference frequen cy choice and the presence of physical objects in the line of sight wi
15. VGA DisplayPort 1 1 and LVDS connections WinSystems 817 274 7553 www winsystems com OPEN TO LOGIC MLC motion logic controller version 13 supports integrated safety robotics and new applica tion development Integrated CIP Safety on Sercos protocol ensures safe communication from the controller to the drive without additional wiring Open Core Engineering functionality enables creation of machine applica tions using any platform and programming language FlexProfile on the MLC creates motion profiles without costly programming Bosch Rexroth 630 654 0170 www boschrexroth us com PLC HMI FT1A SmartAxis Touch with 3 8 in touchscreen interface and logic controller in one has a built in RJ45 Ethernet port and an embedded RS232C RS422 RS485 interface terminal Available in 65K TFT color or STN monochrome display with brightness to 700 cd m the unit has 12 I O eight inputs four out puts 10 A relay outputs built in two point analog inputs and 5 MB of programming memory Automa tion Organizer software suite includes WindO I NV3 software and the controllers support ladder function block and script programming IDEC 800 262 4332 www idec com touch PROTOCOL FLUENCY PFC200 line of four controllers combines dual Ethernet ports fe N a8 Ur Br as fieldbus gateways while com Ben systems Users change between integrated ports to with multiple fieldbus interfaces enabling the controllers to serve
16. Windows Class Library that supports up to 256 threads and includes over 200 API functions including EtherCAT network management Motion func tions include jog PTP various types of interpolations listed motion event interrupt control and buffered API execution just to name a few Override functions are able to change target position velocity and even profile parameters dynamically during motion Motion profiles include jerk free and jerk limited profiles Soft Servo Systems 781 891 9555 www softservo com DATA PROTECTION Storm 5100 toughened water resistant data displays with integral USB 2 0 in terface are encased in a sealed impact resistant bezel The bezel features a hard coated UV and scratch resistant polycarbonate window Available in either 20 character x 4 line 20 character x 8 line or 128 x 64 pixel graphic versions in a range of eight different configurations specifications Storm Interface 480 584 3518 www storm interface com controldesign com controldesign putman net P R O D U CT S H OWCAS DC MOTOR CONTROL Model 0794 enclosed speed control for PMDC gearmotors has forward brake reverse switch and dynamic braking housed in a NEMA 1 IP 20 enclosure Filtered dc output to the motor lew cooler operation longer brush life lower audible noise and wider speed range It accepts 115 Vac 50 60 Hz single phase input Power ratings are 7 16 hp at 90 Vds or 5 8 hp at 130 Vdc Bodine Electr
17. back EMF is now reduced because of increased load The generator capability can be demonstrated with the battery removed from the circuit Using the hair dryer blow air into the fan making it spin backward Once the fan turns fast enough the lightbulb will glow since the fan is generating power Generally blowing from either side will work but this particular fan motor is polarity protected so only one direction works after first commutation The rotor Position of Rotor Time RR field is reoriented in discrete steps according to the number of rotor windings while the rotor turns Details about pole shaping and ar rangement of air gaps aren t shown The rotor could have many more individual windings and for that reason two or three adjacent wind 0 60 120 180 240 300 360 60 Phase Angle in Degrees ings could make contact through commutation at any one time In another form called a brush less dc motor or an inside out dc Tu Figure 3 In general the outside field for a synchronous motor is a three phase motor Figure 2 the permanent sinusoidal excitation obtained from the three phase 60 Hz line magnetis on the rotor This magnet again can be a rare earth magnetora on and off Atstandstill and low speeds the active fixed electromagnet connected via slip rings External stator phase isn t a pure dc signal but is a pulsed dc solid state switches turn on the proper stator winding signal
18. by 6 5 In 2013 machinery production growth in the Americas slowed to 2 0 but still fared better than some of the other regions In the Asia Pacific region however growth slowed to only 3 5 A ma jority of this slowdown came from China where production remained nearly flat because of overcapacity Meanwhile Europe struggled as revenue declined by 5 6 in 2012 a result of the economic prob dragging down the entire global lems persisting throughout the market Europe increased output region and machinery production last year but only by 1 1 tl NEWS AND NOTEWORTHY Continued from p 18 Chemineer www chemineer com has been chosen by Cynar PLC www cynarplc com as its engineering partner for agitation at the U K s first waste plastic to diesel plant at Avonmouth near Bristol The end of life plastics to diesel ELPD facility is the first of a multi plant project that will be established across sites in the U K Chemineer will supply agitators for other planned sites in the U K and Europe ABB s robotic division made a gift of 50 000 to the Oakland University OU School of Engineering www oakland edu secs in support of the school s development of a four year industrial robotics and automation program Real Time Innovations RTI www rti com a real time Internet of Things communications platform company became an initial member of the Industrial Internet Consortium IIC www iiconsortium org The goal of the
19. easily use ultrasonic technology www sensing net pulse Scan Learn More FJPEPPERL FUCHS SENSING YOUR NEEDS Encoders For Safety A safety encoder detects when the machine stops and lets the operator in right away Unlike traditional setups encoder based safety controls can also detect overspeeds and ifthe machine is turning in the wrong direction Factories usually put safety fences around sorters fillers and other rotating machines that pose a danger to workers Gates in fences let operators and maintenance personnel into a machine s workspace only when it s safe Typically the worker hits a button that sends a request to enter signal to a timer The timer counts down a preset wait period to give the machine time to come toa halt even if it was not running at its fastest when the worker requested access For added security the machine s drive power is disengaged Then the gate opens A safety encoder detects when the machine stops and lets the operator in right away Unlike traditional setups encoder based safety controls can also detect overspeeds and if the machine is turning in the wrong direction While effective timer based safety is inefficient because it results in unnecessarily long wait periods and safety margins to 50 For example if a machine coasts to a stop in 30 sec assuming that a faulty system lacks the means to actively brake the added safety margin results in a 45 sec wa
20. effectiveness OEE For instance Sandvik Materials Technology www smt sandvik com is a worldwide developer and producer of advanced stainless steels alloys titanium and high performance mate rials and its cold rolling mill in Sand viken Sweden has been a key part of its precision strip steel production line since it was built in the 1930s The mill is 20 meters long and processes high carbon steel and stainless grades and produces strips up to 400 mm wide and 1 to 6 mm thick Figure 2 Understandably the mill s mechanical electronic and control systems were renovated over the years and Sandvik recently added servomotors standard controldesign com PLCs and touchscreen HMIs from ABB www abb com However the company s latest effort to migrate its hard wired safety systems to zoned safety guarding required it to switch out even more equipment We needed to expand the plant and production line s safety so we decided to installa new control system with a safety central process ing unit CPU on the cold rolling mill but this also meant replacing its safety related electronics and controls and adding some automatic functions too says Torbjorn Pettersson Sandvik s engineering development specialist Put Risks into Zones To find the most appropriate safety and control solution for their cold rolling mill Sandvik s en gineering and production staffs conducted a risk assessment RA in accorda
21. guards in loading and infeed areas and safety related robot and drive functions are programmed in the safety controller Programmable custom output curve and switches Digital or analog output speed 3 000 RPM Resolution 0 09 5 Repeatability 0 05 Accuracy 0 35 Operating temperature 40 C to 85 C Also once the PLC s programs are val idated they re password protected to prevent unauthorized changes while access to the PLC s safety components also can be password protected for added safety during start ups Similarly Kia Motors KMC www kia com builds three SUV models which make up more than half of the almost 230 000 vehicles it produces each year at its Kia Motor Slovakia KMS division in Teplicka nad Vahom The body shop at KMS and its body complete BC line assemble all moving parts with manual handling performed by 20 workers and equip ment managed by controllers and software from Rockwell Automation www rockwellautomation com Long dte trom Non Contacting Rotary Technology in Rugged Stainless Steel Housing Novotechnik s Vert X 3700 series of non contacting sensors incorporate a microprocessor to provide up to 360 absolute angle measurements with 12 bit resolution Designed to operate under adverse conditions the Vert X 3700 series has a stainless steel housing sealed to IP 67 to protect against shock vibration humidity dampness oil and dust Plus it s protecte
22. motor started from a standstill An auxiliary phase is required A capaci tor is connected to the primary phase to create the auxiliary phase 90 ahead of the primary This creates a rotating field Once the rotor reaches its rated speed the auxiliary phase can be disconnected Observing the gray rotor coil the current in C changes rapidly going through zero The rotor magnet is established in the gray coil through induction At that time A is positive and Not A is negative and the rotor will move counterclockwise After 90 C is negative and Not C is positive At the same time the current in A changes rapidly and reestablishes the rotor magnet A circuit diagram Figure 6 shows the connections for a single phase induction motor Generators The dc motors in Figures 1 and 2 already have been presented as dc generators Indeed some current ripple exists as commutation takes place This is true for both motor and generator www controldesign com The synchronous motor in Figure 3 needs no modi fication to run as a generator In motor mode current flows from the source into the stator windings and the rotor lags behind If the rotor is driven by an external force such as a turbine to overtake the outside rotat ing field then current flows from the windings back to the source and the rotor now leads the rotating field This is the primary mode of electric power generation Because it has no magnetic field of its own
23. short of amazing So now that the logic is software based there s not much market basis that will sustain hardware The only thing that will endure is the need for I O and the ability to host the application for the point of use How that is implemented can be anything if the application is software based The other thing to factor in is the ladder diagramming language We ve predicted the demise of ladder logic for decades And it s still here with us Too much installed base and no obvious replacement Manufacturers using the cloud I don t think this is likely on indi vidual machines Plant network Yeah Corporate IT Hell yeah Why pay for owning all that over head if someone will host it for you for cheap Thanks for taking the risk to say it I am impressed with your candor The industry needs more honesty Let s give it to them STEVE MEYER senior consultant Solid Tech www solidtechinc com ES ST es ERs Are Hybrids the Answer Re What Killed the Electric Car October 2013 www controldesign com bie I articles 2013 what eee tA killed the electric car You overlooked a potential au tomotive power source fuel cells but there is the issue of storing hydrogen and no fueling infra structure A parallel hybrid like the Prius still requires batteries though they need not be as large A series hybrid like the Volt is really an electric vehicle that carries an on board
24. to avoid saturation For higher power systems as a function of the rotor orientation The commuta an almost perfect three phase excitation is created tion takes place in the stator windings through solid state switches When the red stator coil in Figure 2 is turned on the rotor moves clockwise trying to align the op Synchronous Motors posite poles At that time commutation moves to A synchronous motor is basically the ac equivalent of the blue coil and then to the green coil and so on the brushless dc motor just discussed In these motors At nominal speeds the excitation moves from one the rotor turns at the same speed as the outside field phase to the other turning the different stator coils In general the outside field for a synchronous motor Powerful Industrial HMIs Boiler Controi System for Eve ry Need Stream Flue 13 14 29 O 0gal s O 0ps 25 C 250 4 3 to 15 starting as low as 320 e Optional Aluminum Enclosure VNC Access e SD amp USB Expandable Storage Email Alerts e Serial Ethernet amp USB e Qty Discounts Available at a fraction of the cost of competing brands Call today for a Free Demo 425 745 3229 Needs the Human Touch www maplesystems com is athree phase sinusoidal excitation obtained from the three phase 60 Hz line When no mechanical load is connected to the motor the rotor is lined up almost exactly with the stator field Figure 3 As the m
25. 0 mA each and two temperature inputs Color switchable dot matrix display offers up to four lines with 20 characters per line It s programmed with free nanoNavigator software with relay ladder logic RLL or flow chart language Phoenix Contact 800 322 3225 www phoenixcontact com UNIFY THE LAYERS PACSystems RX3i modules provide communication protocols as in rack solu tions standardized on Profinet and include IEC61850 DNP3 and IEC60870 5 104 Ethernet based commu nication protocols The modules enable two way controldesign com communication between the SCADA and intelligent electrical device IED levels By uniting the control and software layers under a common architecture information stored in the controller becomes more accessible and actionable GE Intelligent Platforms 800 433 2682 www ge ip com FAST PICKUP AND DELIVERY Sysmac NJ machine automation ie controller provides direct control of up to eight Delta robots in multiple conveyor pick and place applica tions with a single controller The controller CPUs have the same functionality as standard NJ5 CPUs with addition of dedicated robotic function blocks FB in Sysmac Studio software Update time is 1ms with up to four robots and 2 ms with five to eight robots and can be synchronized with multiple conveyors Omron Automation and Safety 866 88 omron www omron247 com ROLL YOUR OWN PLC OEMs can custom build an in house PLC for their own
26. 7 6961 www redlion net PXU WELL HEELED SECURITY M580 ePAC has Achilles i earl cybersecurity Firmware a Level 2 Certification for integrity is checked at every start up and is compiled and stored in memory preventing its decompilation by a third party Upgrading to the PAC is possible without additional investment in wiring software development or training It s compatible with the xBus communications of the Modicon M340 and Premium PLC Users can switch between the controller sizes in the Modicon range without chang ing I O racks and cabling Schneider Electric 877 342 5173 www schneider electric com us PLUS A KEYPAD iPC Plus industrial computer includes a 15 in front panel keypad model Intel Dual Core i5 and Quad Core 17 processing UL cUL hazard ous location testing approval and a 55 C rating It offers three backplanes with various combinations of PCI and or PCI Express PCIe All models come with a powder coated aluminum front bezel and analog resis tive touchscreen 4 GB of DRAM an 80 GB solid state drive a SATA DVD R W drive Windows 7 Pro 32 bit operating system and 100 240 Vac power supply Nematron 800 636 2876 www nematron com GAP FILLER Programmable and modular PCU Safety Control Unit bridges the gap in technology between traditional safety relays and PLC systems for safety device integration for machin ery builders rebuilders and users PCU 1 main control unitis mod
27. B11 Series 2007 2010 X To be followed for application Institute www ansi org specific standards without shutting down and hav ing to resynchronize the entire National Fire Protection NFPA 79 2012 machine safety X Compliance required wireless i Association www nfpa org NFPA 85 2011 burner management X and drives safety allowed 5 machine says Gary Thrall NFPA 86 2011 burner management X senior product support engineer nr UNI UL NRGF covers ANSI UL 508 1998 X New UL functional safety mark a and T V certified functional www ul com NFPA79 and IEC 61508 and recognition same as TUV New UL FS mark is similar to TUV certificate u safety engineer at Bosch 3 Robotics Industries Association ANSI RIA R15 06 2012 X Required for all robotic 5 Rexroth www boschrexroth us yww robotics org ANSI RIA ISO 10218 1 2007 X X machine safety applications g com Similarly safe direction l 2 Canadian Standards Association CSA Z434 safety requirements for robots and Required for OEMs shipping A functions can be set up in safety www csagroup org robotic systems machines to Canada zones so all power won t have SAFETY STANDARDS SNAPSHOT Figure 1 Many local domestic and international machine safety standards have been harmonizing in recent years but it s still crucial to investigate which apply als This can save 10 on many to machine builders and their users based on location and part
28. L THE HEAT UTAdvanced hybrid temperature controller combines PID control with embedded ladder sequence control It supports 84 ladder commands 24 DIO points four analog inputs and three analog outputs Up to 500 ladder steps can be programmed and run with the PID control It has full text scrolling configu ration prompts three configuration levels user defined function keys user settable default values and multiple language support along with a NEMA 4 IP56 front panel USB powered configuration tool with software and fuzzy logic Yokogawa 281 340 3800 www utadvanced com YOU LOAD 16 AXES Compact rack style Model 5300 PAC with up to 512 YO and 16 axes of advanced motion control and data logging can be used stand alone or networked via its serialand LAN connections Built in web server pro vides Internet or intranet access fast Programmingis handled in QuickBuilder state language or advanced applications can use C C Control Technology 888 818 2600 www ctc control com EMBEDDED CONTROL Multi core Intel Atom E3800 embedded computers oper ate from 40 to 85 C They 46 Control Design May 2014 include on board USB gigabit Ethernet serial ports and additional I O expansion through MiniPCle and IO60 connectors They maintain a low thermal design power TDP range of 5 to 10 W Intel Generation 7 based graphics engine supports up to two simultaneously active displays with interfaces available for analog
29. O isolated OXPCle 952 Isolated Automation Size Automation FieldBus ProfiBus 16 Die DO 1x RS 232 2x DB9 isolated Computer w 1x Computer w 4x 1x DB9 DB37 RS 422 485 n UR PCM 26D2CA PCM 24D4R2 PCM 24D4R4 SJA1000 CANBus OXPCle 954 UART Non CANOpen 2x DB9 Isolated RS 232 1x DB37 Non isolated RS 422 485 www advantech com INDISCRETE Industrial Machinery Market Growth to Double in 2014 HIGH DEMAND FOR machines in manufacturing sec tors ranging from automaking to packaging will push the industrial machinery market to new heights during the next five years highlighted by a doubling of growth this year according to a new report from researchers at IHS Technology https technology ihs com As economic conditions continue to improve worldwide the demand for machines in sectors such as agriculture packaging materials handling and ma chine tools will push revenues to 1 6 trillion this year up from 1 5 trillion in 2013 This represents annual growth of 6 3 more than twice the 2 9 increase seen in 2013 Strong growth is forecast to continue for the next four years with revenue rising to 2 0 trillion by 2018 see page 22 During this period the machinery mar ket s annual growth rate will remain quite impressive averaging between 5 and 6 The improving economic outlook is a key factor in the strong growth of machinery in the coming years a a a 5 said Andrew Robertson senior an
30. Point I O components and only two or three meters of wiring Each safety I O is connected to the safety PLC via Eth erNet IP So when the BC line is in terrupted only the relevant zone is stopped which indicates its location and enables quick recovery while other zones remain operational With the ability to identify failures and solve problems quickly we ve increased productivity by reducing safety breakdown time up to 70 explains Ondrey Vasek body shop maintenance manager at KMS The body complete line is easier to maintain and makes our lives easier INDUSTRY LEADING COST AND PERFORMANCE Mean Well DIN Rail Power Supplies a wo ere El BEN J ral INC www trecelectronics com Providing exceptional customer service since 1982 P TRC Electronics Inc 101B Domorah Drive Montgomeryville PA 18936 T 215 367 5124 F 215 367 5431 West Coast Sales Office Northern California Toll Free 888 612 9514 TRUE STORY Food processing and pharmaceutical plants are harsh environments for electronics Your critical systems must withstand water and chemicals used during wash down including the electronics inside every computer enclosure The NEMA 4X Titan from ITSENCLOSURES is made specifically for these extreme conditions The Titan is constructed of 14 gauge Type 304 stainless steel to handle corrosive cleaners and chemicals that would break down a lesser enclosure The Titan features a
31. VER STORY Safety Is Elemental Once an External Add On After Construction Safety Is Now a Fundamental Unifying Building Block in Modern Machine Design Jim Montague executive editor DRIVES amp MOTION CONTROL Flashback 2008 The Not So Odd Couple Like an Old Married Couple a Motor and Its Generator Are Bound Together One Does Not Exist Without the Other Ernst Dummermuth PRODUCT ROUNDUP Programmable Controllers More Sophisticated Easier to Use Standards Based Languages and Integrated Functions Provide Controllers With 21st Century Capability Voted 1 by Automation Professionals Trust Allied to bring you name brand suppliers for all your automation projects OMRON ABB Ei Je Honeywell TYS AO HellermannTyton BELDEN 0 oleh N ebmpapst SOLA HD DBbeeretrchs erydom Altech Corp Crouzet SIEMENS red lpn HIRSCHMANN He MANCING i TURCK Arc PHCENIX CONTACT OPTO 22 RITTAL For Standard Control products Source Automation World Magazine 2011 2012 2013 ORDER TODAY Get the products you need from the brands you trust thinkallied com thinkallied com Al 1 800 433 5700 f Allied Electronics Inc 2014 Allied Electronics and the Allied Electronics logo are trademarks of Allied Electronics Inc EI An Electrocomponents Company ecia N N Volume 18 No 5 COLUMNS 9 Ecditor s Page lof You Ain t Seen Nothing Yet Joe Feeley editor in chie
32. With cast aluminum construction Red Lion s new Graphite series combines flexible plug in modules with protocol conversion data logging and web N ene xT lieve OT based monitoring to meet all of your industrial SW ioe f KA automation needs From factories to extreme remote H IS MOW Mere locations Graphite enables customers worldwide to connect monitor and control processes across Sleek Rugged Flexible a broad range of industries ries n I JE NUET Wied a il II HMI Solutions Brochure or visit www redlion net Hvi Available in eight different models with touchscreens ranging from 7 to 15 inches Red Lion the trusted name in automation now offers Ethernet and Cellular 1 717 767 6511 info redlion net better redlion net networking solutions Connect monitor and control virtually anything anywhere ASis iii ERP 3 PHOENIX CONTACT AND AUDI which means added PLC cycles are needed However Audi s engineers report that this solution helped reduce PLC cycle times to an average of 12 milliseconds which means the cycle time of the larger cells could be reduced by up to one second The controls are programmed with two interconnected tools An engi neering tool configures the Profinet system hardware and creates the standard IEC 61131 application and the safety PLC s software handles the safety PLC Safety functions of each cell including emergency stops protective door contacts
33. Xpress and Factory Display is available for iPhone 4 4S iPhone 5 iPad2 iPad mini iOS version 4 3 and higher and Android OS version 4 2 2 Interact Xpress is a web published HMI designed for distributed applications and remote support Factory Display is a compact HMI solution that leverages the availability of the Internet and IP networks Parker Electromechanical Automation 800 358 9068 www parkermotion com fil en WWW CONTROLDESIGN CO Adalete ar a ee an Te Advantech Automation INCVOUCE IN ct cesta cto enter E E een Allied EleCtromiCS o 4 8 4 2 2 AutomalionBireetz ser gan AVG Automation e setae dere whan ree ee B amp R Industrial Automation Baldor Electric a tenet au eens on Ball tenance re a Banner Engineering 4 2204 2222 ESC CHO Wilts nem ten Oa teen ee aah et controldesign com INDUSTRIAL MICROSCOPES Standard amp Custom light microscopes for today s life and materials science Santa Barbara Imaging 805 729 0422 NES Enclosures ah oy ee 36 Maplesylems een 39 Ne War ee ee ee 8 Novotechnik armen mer 34 Pepperl Fuchs een 12 13 Proceni Conlaclereen ss sewer ens 3 Rediliion Conlrolserers ee 33 Rockwell Automation 28 SEW Eurodrnive aise a ee 42 siemensilndusuryeem een we 24 TRC Electronic er 35 RATOM Ser ESR een ey 31 Unitronic S eee a a 32 NYE CIN UC coarae a ot 44 Wielandi Electric a er 22 Yaskawa American 39 May 2014 Control Design FOR MACHINE
34. al safety atthe design stage there are a variety of domestic regional and in ternational machine safety standards that builders can use Most signifi cantly the ISO 13849 standard pushes machine builders and users to move from complying with traditional safety categories to instead calculat ing and achieving performance levels Grantek s Winter adds that Risk assessments are like resumes Everyone has one but they all look a little different The important part is they all achieve the same basic purpose and contain the same basic information For that reason it s important to use an RA and risk reduction process that works for your organization The first and most important step is to base your process on nationally recognized Bring Your Machine To Life Your design Is unique Shouldn t your control system be too Aerotech s control systems are tailored for your machine to your specifications Let our Control Systems Group experts bring global experience to your machine We customize Aerotech automation for you e Hardware Software HMI e Firmware Packaging 1 0 e Motors Electronics Global sales service and support The Americas Europe Asia Pacific at 412 967 6839 or sales aerotech com to or see go aerotech com csg9 ee Contact our Control Systems Group ff discuss your application today consensus standards such as ISO 12100 ANSI B11 0 or other industry s
35. alyst for industrial automation at IHS The growing populations and the expanding middle classes in developing countries are generating more disposable income This translates into increased demand across a vast number of sectors Sales growth for industrial machines in 2014 is being driven by a number of factors First higher demand for cars worldwide is spurring the requirement for more spending on tools and robot ics in the automotive business as well as the rubber and plastics segments Meanwhile an increase in the standard of living and growing spending on nutrition will benefit the food and packaging machinery sectors Furthermore rising spending on technology prod ucts will boost the demand for robotics semiconduc tor equipment mining and oil and gas machinery At the same time increased demand for housing in frastructure and commercial buildings is benefiting the construction equipment sectors Moreover social aware ness of green technologies is resulting in higher demand CAST STAINLESS STEEL XCESX ENCLOSURES gt Ideal for offshore applications in oil amp gas industry gt 5 standard sizes available up to 24 W x 36 H x 10 D Rated for Division 1 and Zone 1 Hazardous Areas gt Corrosion resistant cast stainless steel 316L gt UL cUL ATEX and IECEx Certifications gt Flat plate cover design TARA 4 4 4 4 4 Call for a Free Application Evaluation adalet com
36. and because it slips with varying loads the induction motor in Figure 4 isn t typically used as a generator It still has the same properties however and certainly develops a back electromotive force Running in idle this back EMF is nearly as large as the driving volt age Under load turning more slowly the back EMF is reduced and the motor consumes more current In a stalled condition like the dc motor it draws very large current In 2008 Dr Ernst Dummermuth was a consultant in process control motion control automation and intellectual property He has been involved in advanced technology endeavors including architecture proposals fast prototyping concept verification standardization and product development His work has yielded 46 patents and dozens of publications You can reach him at ehdummermuth juno com Dr Dummermuth has contributed several well received technical articles to Controt Design during the past few years Autonomous Cooperating Agents In a rod mill multiple cooling functions coordinate efforts to achieve an overall performance characteristic Go to ControlDesign com agents Warm and Fuzzy Fuzzy logic can extend traditional binary logic A heater control application demonstrates the method Go to ControlDesign com fuzzy Algebraic Solution Beats Fuzzy Logic Non linear tunable PI controller provides improved performance in closed loop control application Go to ControlDesign com algebrai
37. applications Delta Computer Systems 360 254 8688 www deltamotion com A LOT IN ONE AKD PDMM combines a multi axis motion controller com plete IEC61131 3 soft PLC Ether CAT master and AKD servo drive in one compact package to reduce panel space and sim plify wiring and integration while increasing flexibility scalability and performance In addition the device is fully programmable through KAS Integrated Development Environment and its solution is scalable from one axis to 128 axes with one controller Kollmorgen 540 633 3545 www kollmorgen com HIDEAWAY PLC FX3S battery less PLC for Space and cost conscious applications requiring up to 30 I O includes integrated ac power supply maintenance free EEPROM memory and built in USB port for the programming communication function This enables high speed communica tion at 12 Mbps built in positioning control and integrated real time clock Programming is via GX Works2 or GX Works2 FX Mitsubishi Electric 847 478 2100 www meau com Fl controldesign com You Are Here by Hank Hogan contributing editor IFYOU WANT to know where you re going it helps to know where you are For machines engaged in motion control satisfying that truism starts with resolvers and encoders These devices measure position and velocity information that s fed into the controller to output com mands needed to control machine movement Select ing the right solu
38. ashdown by water jets according to Dynapar s Mahn In general the higher the IP rating the greater the attention paid to seals and coatings That s the only way to bolster ingress protection and therefore the IP value For instance instead of a simple gasket the system might use multiple levels of interlocking flanges These are often partnered with complex seals The combina tion can drive up cost and increase size In some situations there s little choice because the motion control being tracked is taking place ina particularly demanding location Dynapar for instance offers products that it classifies as light industrial and mil duty in terms of their ability to withstand harsh conditions The last category can be used outdoors il lustrating how robust these systems can be Speaking of this Mahn says I know of an application where an SL series is installed on a drawbridge We re tracking the motor speed and possibly the angular posi tion of the drawbridge fil www euchner com MGB ER Multifunctional a Gate Box Safety system for safety guards gt Simple mounting and integration into your safety concept engineering i N gt Modular construction for custom applications gt Diverse connection options gt Highest safety level PL e category 4 gt Robust design Series connection of up to 10 devices EUCHNER More than safety EUCHNER USA WWW EUCHNER
39. c Closed Loop PID Algorithms in Motion Motor Control Differential feed forward can be used for numerical controls or integral feed backward can be used for trajectory control of motion Go to ControlDesign com algorithms May 2014 Control Design 41 MORE MORE MORE war ring PT Piel Sup Loe Boel patt SE Hank Hogan contributing editor hank hankhogan com TECH Get n Touch With HMIs and Machines MACHINE TO MACHINE communication might ben efit from the right touch specifically the right multi touch input displays Along with the ability of modern HMIs to remotely collect data the technology could give control engineers new tools and capabilities An example of how this might unfold comes from Lenze www lenze com The automation supplier an nounced a panel controller a year ago that features an ARM processor Ethernet connectivity a USB port and a resistive touch display Importantly its operating system is Windows and that brings a host of features explains Lenze s tech nology evangelist Tom Jensen These include the abil ity to easily pass information around and the power to graphically display it leading to some interesting usage scenarios If Ihave one HMI and two machines when one machine burps the HMI will notice and automatically ask Hey do you want videos to help troubleshoot this other machine Yes or no Jensen explains The two machines operating under such unified cont
40. ch as power monitors or smart overload relays As time goes by the computers behind the panels will produce a wider array of data and will interface with more systems on and off the plant floor Some of this data will be accessed remotely For instance the manager of a beverage plant might need to access a screen showing a key performance indicator of a bottle filling machine That can be done by connecting to the filling room HMI and extracting the data This sort of machine to machine communication and a modern touch enabled device mean there s no need for person nel to stand at an HMI to diagnose and solve a problem As Dirks says The support person be they mainte nance operations or an engineer can connect into the terminal see exactly what s going on and be able to walk an operator through some troubleshooting steps without having to come out on the floor tll May 2014 Control Design 43 Se u Le Q dl B Weidm ller _ u remote Let s connect More Sophisticated Easier to Use cdroundup putman net PRO D U CT RO U N D U P Standards Based Languages and Integrated Functions Provide Programmable Controllers With 21st Century Capability THE TRENDS MOST influencing programmable controllers are the use of IEC 61131 3 and PLCopen programming standards a unified controller solution for robots motion and other functions and safety and network safety says Jacky Wong Yaskawa s product mar
41. d against over voltage and short circuits For complete information visit www novotechnik com vx37 novotechnik Dil nm E a FE Siedle Group Novotechnik U S Inc 155 Northboro Road Southborough MA 01772 Telephone 508 485 2244 Fax 508 485 2430 Unfortunately the BC line also suf fered frequent breakdowns that de creased productivity and sometimes caused the entire line to stop KMS reports its BC line had been using Sick s www sick com safety relays and safety scanners which itsays had complicated wiring and long conductor routing from safety devices to relays in the main cabinet and lacked a bypass function from the scanners Though traditional relays long have prevented hazard ous interactions between operators and machines KMS adds its safety relays also caused many small line stops and often made it hard to identify why and where they were happening Consequently KMS decided to add Allen Bradley safety PLCs to its ControlLogix control system The BC line added remote safety I O mod ules and connected to the plant s EtherNet IP network which allowed visualization of safety conditions alarms emergency events and pro gramming developed for its HMIs Previously if a person entered a cell or if a device failed during produc tion the entire line stopped and each area had to be checked to find the source of the fault Now the BC line is divided into five zones each with a cabinet with Safety
42. de longest life highest speeds and greatest thrust per dollar BIMBA BRANDS I ACRO I MEAD I MFD I PNEUMADYNE I TRD Copyright 2014 Bimba Manufacturing Company All Rights Reserved INDISCRETE FE 2011 2012 2013 2014 2015 2016 2017 2018 CAGR 2011 18 Revenue T 1 46 1 48 1 52 1 62 1 72 1 82 1 92 2 02 4 7 Annual Percentage Growth 0 9 2 9 6 3 6 3 5 9 5 6 5 1 2 1 7 0 1 6 5 3 2 Bu 2 11 3 5 a gt S wn oO E 0 5 18 amp 0 0 2012 2013 2014 2015 2016 2017 2018 GLOBAL MACHINERY PRODUCTION REVENUE FORECAST AND ANNUAL ROW IH RA rx N N IR ONS Q DO AR High demand across several verticals will boost the industrial machinery market to 2 0 trillion by 2018 Leid SNO4083 Universal Safety Relay Accepts all sensors Input contact debouncing Vibration and heat tolerant Download the data sheet at vs WI el an d www wieland safety com SNO4083 1 800 wieland 1 800 943 5263 technical support wieland electric com for industrial machines in photovol taics PV and in wind turbines These findings are contained in the Machinery Production Market Tracker from the Machinery group at IHS The growth of the machinery market represents a welcome change from just two years ago when not every region performed well The Americas prospered in 2012 boosted by a significant government investment that caused machinery production revenue to grow
43. e appli cations They should go for nine or 10 years Naturally as the update rate increases the battery life will decrease At one second updates battery life will be from about seven months to 1 5 years depending on the transmitter type a I I ENE STR OBE i WE HAVE CUSTOMERS with varying preferences for the method of terminating field connections outside the panel We even have our own internal disagreements We d like to move toward some simplification and wonder if anybody whether vendors or independent test centers etc has compiled meaningful data about termination failures meaning some MTBF comparisons that include M8 M12 as well as screw spring and IDC It would help to argue a preference based on data rather than mostly subjective or anecdotal viewpoints SEND US YOUR COMMENTS SUGGESTIONS OR SOLUTIONS FOR THIS PROBLEM We ll include it in the July 14 issue and post it on ControlDesign com Send visuals if you d like a sketch is fine E mail us at ControlDesign putman net Please include your company location and title in the response HAVE A PROBLEM YOU D LIKE TO POSE to the readers Send it along too 54 Control Design May 2014 There are energy harvesting products available today that can be interfaced with WirelessHART transmitters Two primary energy sources are thermal and vibration The normal method of interface is to use a purpose built power module with provision for an external energy source If
44. eader in Safety and recognized by Frost amp Sullivan for the 2013 Company of the Year Award for Smart Machine Safety Networks and the 2011 Global Machine Safety Customer Value Enhancement Award Security integrated consistently incorporated for highest investment protection Your Plus in Safety Seamless integration with one system one engineering tool Standard and fail safe communication via the same network to lower initial and operating costs Consistent implementation of proven safety technology to protect lives and increase productivity Machine safety lifecycle Savings up to 30 in Total Cost of Ownership Answers for industry Jeremy Pollard CET jpollard tsuonline com EM B ED D ED NTELLIG EN C E Still Feeling Insecure THE HEARTBLEED SECURITY bug is a programming error in an open source encryption protocol layer of OpenSSL The gist of the bug is that it allows entry into cached memory that would normally be malloc ed allocated memory by an application and protected by that application So if a hacker can get access to that memory space which now appears to be unencrypted then the data that s in that space is easily read Believe it or not the Canada Revenue Agency uses this open source layer to connect to official users such as accountants and the general public for e filing I subscribe to an investment service whose site was hacked for reasons unknown The resulting repo
45. echanical load increases the rotor lags the stator field by several degrees but is still in step with the field If the load is increased beyond the rated value the rotor will fall out of synch and stop With a moderate load applied the rotor follows behind the sta tor field by several degrees If the load increases the lag increases and vice versa A synchronous motor can t be started from standstill by simply turning on the three phase ac It needs to be brought up to speed by auxiliary means before it can be connected to the line Then it turns synchronously with the three phases no matter what the torque Induction Motor At first glance an induction motor Figure 4 looks like a combination of the dc motor Figure 1 and the synchronous motor Figure 3 It has many rotor windings similar to the dc motor but they aren t connected to any external source or commutation These are indi vidual short circuit windings in different orientations If a fluctuating stator field is ap plied the changing magnetic flux induces a current in at least one of the rotor windings and thus creates a rotor magnet of opposite polarity in that plane At the same time the current in the other stator windings 60 and 120 offset to the rotor magnet produces strong stator magnets As with the dc mo tor the rotor now rotates to align After a 60 turn of the rotor the sta tor excitations also have changed 40 Control D
46. ected volume density temperature and viscosity Promass I Seamless integration into process control and asset management systems via HART PROFIBUS DP EtherNet IP or Modbus RS485 Modern webserver technology provides fast onsite device configuration without additional software Industry optimized sensors for each application Heartbeat Technology monitor your process via continuous diagnostics multi parameter monitoring and onboard verification for maximum process reliability 888 ENDRESS Endress Hauser 4 Service 800 642 8737 317 535 8498 People for Process Automation Flexible Conveyors Look Up OCS IntelliTrak s Modular Overhead Conveyors Help Automotive and Subassembly Builders Keep Up With Rapid Design Changes MASS PRODUCTION USED to mean everyone got the same product Well those days are long gone To accomplish today s goals of producing numerous custom ized products faster automotive and subassembly manufacturers need extreme levels of flexibil ity in their production lines and IntelliTrak s overhead conveyor systems give it to them Located in Fairfield Ohio OCS IntelliTrak www intellitrak com builds modular overhead con veyor systems that are used for manufacturing and assembling numerous parts including front end modules door lines engine lines instrument panels seats headliners and center consoles Using technology licensed from OCS in Boras Sweden Intel liTrak wa
47. eguards in response to encoder pulse counts that represent overspeeds and stops Some setups verify the direction of rotation useful in applications that can only turn safely one way Here if the encoder detects the machine is spinning the wrong way as the result of a drive failure or PLC programming error the controller will shut the machine down oe WEN ant poate Nee Now you have a choice There or Where Distance based photo sensors address more challenging applications by not just determining if an object is THERE but also WHERE it is located Three methods have emerged as front runners to show you Where E Background Suppression Multi Pixel Array E Pulse Ranging Technology Download our e book that explains how these technologies will work for you www sensing net where Scan Learn More Distance based photo sensors will have your standard photo sensor nervously looking over its shoulder FJPEPPERL FUCHS SENSING YOUR NEEDS Pepperl Fuchs Inc 330 486 0001 www pepperl fuchs us Proline simply clever NEW Heartbeat Technology Endress Hauser Inc 2350 Endress Place Greenwood IN 46143 info us endress com www us endress com Compact without compromise As a direct digital Coriolis flowmeter the Promass 100 opens entirely new perspectives Compact design without limitation of functionality Simultaneous measurement of mass or volume flow corr
48. er s site with minimal in terruption to the manufacturing process Since Ether CAT obviates the need for much point to point wiring and is supported by many devices in our industry it was a natural choice to move in that direction NEED MORE DO MORE Do more T1H Series PLC with Ter minator field I O hardware as a platform supports stackable base units and discrete and analog I O modules Fast processor speeds support Ethernet connectivity and custom communication protocols as built in functions The controllers are programmed controldesign com using free downloadable Do more Designer software version 1 2 1 or later The PLC provides an advanced instruction set to reduce programming time superior memory mapping to improve data management and data structures to simplify initial programming and long term software maintenance AutomationDirect 800 633 0405 www automationdirect com do more pl PANEL PC POWER With Intel Core 17 technology Panel PC 900 has multi touch displays ranging 15 6 in to 24 in with full HD resolution Many of the panel PC s variants can operate without fans Used with SSD drives and or CFast cards these systems completely eliminate rotating components B amp R Industrial Automation 770 772 0400 www br automation com PAC S A SNAP Standalone Snap PAC S series and rack mounted PAC R series indus trial controllers are fully integrated with PAC Project software Snap PAC brain
49. esign May 2014 Current 0 60 120 180 240 300 360 60 Phase Angle in Degrees and Rotor Orientation Figure 4 While an induction motor also has many rotor windings they are individual short circuit windings in different orientations by 60 The new stator field now excites the rotor winding again and the strong stator magnets now appear 60 turned Note that the ro tor magnet is reestablished through induction when the current in the stator changes most rapidly at zero crossings of the stator current The condition described here is under no load Under load induc tion motors turn more slowly than the driving stator field This speed loss is called the slip When slip occurs the rotor basically falls one rotor winding back and continues to fall further back over time Slip increases with load If the load is excessive the rotor will drop out and come to a halt Because of that slip however induction motors can start from standstill by just connecting the stator excitation BR In the gray rotor coilin the il lustration the currentin C changes rapidly going through zero The rotor magnet is established in the gray coil through induction At that time A is positive Not A is negative B is negative and Not B is positive We can see that the rotor will move clockwise and follow the rotor movement and the corresponding stator fields along the time line Many applications use three phase 60 Hz line directl
50. f 43 TechFlash Get in Touch With HMiIs and Machines Hank Hogan contributing editor 11 Live Wire Help Safety Break Free of the Past Jim Montague executive editor 58 OEM Insight The Most Important Part of Your System TJ McDermott Systems Interface 25 Embedded Intelligence Still Feeling Insecure Jeremy Pollard CET HOT BUTTONS 15 OEM Spotlight Flexible Conveyors 51 SpecMate You Are Here 53 Real Answers Wireless Options 17 Feedback R I P PLC 18 InDiscrete 55 Product Showcase Industrie 4 0 at Hannover Industrial Machinery Market Growth Doubles controldesign com May 2014 Control Design 7 BALLUFF sensors worldwide PROBLEMS WITH GLASS SCALES You have options When contamination and physical damage are issues magnetic linear encoders offer enhanced survivability at a lower cost Absolute and incremental versions available Immune to contamination Resistant to shock and vibration Non contact operation 1 um resolution Drive system accuracy up and initial costs down El Read the whitepaper at ol bit ly balluff BML gt HERE Systems and Service Industrial Networking and Connectivity Industrial Identification Object Detection Linear Position Sensing and Measurement Fluid Sensors Accessories Phone 800 543 8390 www balluff us get what need to keep my line running when I need it It s great to be an engineer Your one stop sou
51. f OPC UA means that the devices can exchange data with other machines Beckhoff s products can be either the client or the server without hardware add ons Thus they can do machine to machine communication with other sys tems on the plant floor Beyond that they can also talk to management systems and move data from shop floor to top floor and vice versa according to Eisel Looking forward he sees two trends One is unifica tion of HMI and controllers into a single unit that talks both upstream and downstream interacting with ma chines and management systems The other is a change in the input and display systems For example Beckhoff Automation has studied the use of Google Glass which integrates a heads up display with a camera in an industrial environment The technology could indicate things to come the birth of a wearable HMI E Machine to machine communication and a modern touch enabled device means there s no need to stand around an HMI to diagnose and solve a problem E HMIs today are the main point of decision making for operators and this will continue in the future notes John Dirks global product manager for Rockwell Automation s www rockwellautomation com Panel View Plus The product family has panel sizes as small as four inches with a 19 in display planned In Spring 2013 the company announced a new ver sion of HMI software It allows its panels to connect to and display data from noncontrollers su
52. g 888 7saelig www saelig com TWO OR MORE IN ONE OmniClient runs real time control and visualization simultaneously on one computer It uses an Intel Core 13 15 i7 processor and includes Wi Fi Bluetooth and RFID It s shock and vibration resistant thermally stable has an IP65 front panel and is EMC compliant Kontron America 858 677 0877 us kontron com RIO MULTIPLIER RIO 47142 Pocket PLC in cludes an internal switch with two Ethernet ports for daisy chaining multiple RIO units Each RIO unit is self contained and provides 32 optically isolated digital inputs and outputs and 16 analog inputs and outputs The controller can be programmed using company s standard two letter language Software is available for converting relay adder logic into code for input into the RIO controller Galil Motion Control 800 377 6329 www galilmc com 50 Control Design May 2014 REDUNDANT OPTIONS RMCTools soft ware supporting the company s RMC motion controllers includes built in support for con necting to redundant sensors support for gather ing feedback information from multiple sensors of different types and the ability to mathematically generate feedback inputs to control loops User has flexibility in defining the logic by which the feedback is selected permitting various types of redundancy methods The controllers can switch between feedback sensors on the flyin position speed and pressure control
53. generator and uses a large expensive battery Neither suffers from the range limitations of a pure electric vehicle EV Unlike a paral lel hybrid the Volt can function for a limited range as an EV whereas a parallel hybrid uses the electric Make a lasting connection with HARTING USA Board to Board Connectivity Industrial Connectivity FEEDBACK motor to aid in starting from a stop meaning the hydrocarbon powered engine need not be as large As for non intermittent renew able energy sources I would love to see more use of tidal or wave or water current based not dam based hydro sources Interesting reading at www eia gov forecasts aeo er electricity_generation cfm Based on that document new generating capacity will all be natural gas as thatis the most cost efficient Offshore wind is the second most expensive largely due to capital costs whereas hydro I guess defined as gravity driven water is right in the mix but loca tion limited I have seen designs for water current based genera tors It would be interesting to see where they fit in the equation RANDY ZEITVOGEL vision specialist C amp N Mfg www cnmfginc com ci HARTING Pushing Performance Communication Connectivity INDISCRETE Hannover Fair Introduces Industrie 4 0 IN APRIL more than 180 000 visitors from 100 coun tries descended on Hannover Germany to experience the latest of what s po
54. he major safety organizations will be even more crucial as the standards themselves evolve and are updated For example ISO 13849 just recently took over for EN 954 and builders need to know how to calculate safety performance levels and not just how to fit into former safety categories In fact efforts are already underway to combine ISO 13849 with IEC 62061 and builders need more input on how this will affect them Heck many suppliers and governments might be willing to fund greater dissemination of safety stan dards to builders because it would mean greater use of safety PLCs and other products and prevent some tragic injuries at the same time Just like with rust proofing safety will eventually get where it needs to go but why not give it some help along the way fll May 2014 Control Design 11 MIMMI THE PULSE OF AUTOMATION World s Largest Selection of Ultrasonic Sensors Pepperl Fuchs Inc 330 486 0001 www pepperl fuchs us A product of world class acoustic engineering expertise Pepperl Fuchs ultrasonic sensors are completely unaffected by dust color variations gloss or transparency With sub millimeter precision software configurability and detection ranges from 1 inch to over 30 feet ultrasonics are ideal for both switch point and analog control of objects as diverse as bottles refuse containers wooden pallets steel coils and foods Download four application reports that show you how to
55. he only advantage about wireless instruments is if they can be locally powered by PV solutions or by ensuring continuous power from any power source JAVIER ERNESTO OTALORA SANCHEZ control design engineer Genser Power www genserpower com May 2014 Control Design 53 REAL ANSWERS These are responses received when we posted the question to LinkedIn s Industrial Automation amp Process Controls group Don t Worry About the Encryption Overhead With the technology on the market today you have a choice between proprietary wireless products or those conformingto a standard Both ISA100 Wireless and WirelessHART conform to standards different ones Both use AES 128 encryption Battery life for both depends on the frequency of transmission ISA100 is capable of transmitting 10 sec but not WirelessHART Typically battery life can be expected to be between one and five years Either one can be powered by energy harvesting devices especially those using the ISA100 18 specification for energy harvesting power connection Reducing the length of the encryption key willhave no effect on the power consumption but you can t do it with current products anyway DICK CARO industrial networking consultant owner CMC Associates www linkedin com in dickcaro Need Backup WirelessHART transmitters have demonstrated six year battery life in the Arctic on actual installations Update rates are generally one minute or longer on thos
56. ial systems Probably even more so in the future No one knows what the future holds but one thing is for sure the evil doers always will be there and they ll be knocking on our door We must be as in formed and knowledgeable as we can Being our own advocate is paramount In God we trust yes But in firmware software and protocols we can t or at least we shouldn t Off topic final note ISA s Automation week in North America which I pronounced dead two years ago is Officially gone No longer will the paths of professionals of varying technical disciplines cross in the technical session hall of learning I m sad dened but also looking forward to what s next I just don t know what it looks like yet Condolences to the ISA and congratulations to the organization for providing so much opportunity for so many over the years Thank you fll JEREMY POLLARD CET has been writing about technology and software issues for many years Pollard has been involved in control system programming and training for more than 25 years May 2014 Control Design 25 Once an external add on after construction CA safety is now a fundamental unifying building block in modern machine design by Jim Montague executive editor M achine safety is moving from the outside to the inside Traditional guarding and other protec tions are being replaced or at least supplemented by intelligent
57. ic 773 478 3515 www bodine electric com MAKE SAFE CONTACT MS T Series contactors and motor control products range 10 to 32 A Design is finger safe and back of the hand safe to prevent contact with a live terminal Optional streamline terminals improve wir ing efficiency workability and it s compliant with or approved by IEC JIS CE TUV CCC UL and cUL Mitsubishi Electric Automation 847 478 2100 www meau com DYNAMIC MOTION LMS iron core linear motor with anti cogging design for thermal 4 drift sensitive precision can be used in machines where a high power ae is required with a high dynamic for mid range moving masses It has continuous force to 664 N peak force to 2 760 N with speeds to 15 m s has low force ripple and is 600 Vdc compliant Etel 877 565 951 www heidenhain com SWITCH ON SWITCH OFF HP HE and LE Series pressure switches provide up to 2 mil lion lifecycle ratings They have an operating range of 40 to 120 C and accuracy to 2 The electromechanical gauge pressure on off switches are available with single pole single throw normally open or normally closed circuitry or single pole double throw circuitry Honeywell Sensing and Control 800 537 6945 sensing honeywell com May 2014 Control Design 55 ROLL EFFICIENTLY Roller pinion system RPS for precision linear mo tion control applications offers linear positioning with zero backlash more than 99 efficie
58. icular industrial production cycle times function and application to be removed when operators are loading or unloading materi LISTEN THINK as By a he E SOME Safety Simple You need safety but you also need it to be flexible and easy to apply while enhancing productivity The Guardmaster 440C CR30 software configurable relay does just that Free Connected Components Workbench software provides simple seamless configuration of standard and safety control in the same environment Plus drag and drop logic with certified safety function blocks reduces programming time StztseceGtGucaa t1t63tjsklttl gt l ee Learn more about how the Guardmaster 440C CR30 PR rss en can help keep things safe and simple www rockwellautomation com go cr30 Allen Bradley Rockwell Software Guardmaster is a registered trademark of Rockwell Automation Inc Copyright 2014 Rockwell Automation Inc All Rights Reserved AD2014 45 US hazardous area indicators i K50L EZ LIGHT gt a f AG ae 9 KUNA KL v i Bright lo sting LED IT Afro ce f Fully encapsulated for harsh environments IP67 and IP69K Red Blue Yellow Green or White colors with up to three color indication in a sir BANNERU EZ LIGHT 2014 Banner Engineering Corp Mpls MN USA Simpler Standards Proactive Mindsets To conduct thorough uniform RAs and achieve the greatest practic
59. ig data analytics and algorithms to accelerate efficiency dramatically increase productivity and lower the marginal cost of pro ducing and sharing a wide range of products and services to near zero E Social capital becomes as important as financial capital access trumps ownership E This spawns a hybrid economy part capitalist market and part collaborative commons with far reaching implications for society Rifkin says Prosumers plug into the IoT to make and share their own information green energy and 3D printed products at near zero mar ginal cost They share cars homes and other items via social media rentals redistribution clubs and cooperatives at low marginal cost Now social capital is as important as financial capital access trumps ownership sustainability super sedes consumerism cooperation ousts competition and exchange value in the marketplace is increas ingly replaced by sharable value on the collaborative commons fll pr May 2014 Control Design 9 Open I Hi ETHERNETB I I MEE SAFETY POWERLINK More power for decentralized motion control Room for new L 4 Oo g ja Yea gt Motor mounted ACOPOSmotor servo drives Machine modularity in motion gt Significant space savings in the control cabinet gt Power classes from 500W to 4kW Fully integrated safety technology for SIL3 based on openSAFETY STO SOS SS1 SS2 SLS SMS SLI and SDI gt Maximum system pr
60. ile bringing the uptime and reliability of the plant operations to a higher level as well Michael Fey worldwide chief tech nology officer at McAfee explained We must build new solutions that secure operations but also enable the user he said NEW AND NOTEWORTHY ISA www isa org offers an online instructor assisted course that reviews the knowledge and skill areas tested on the Control Systems Engineer CSE Professional Engineer PE examination The Control Systems Engineer CSE PE Exam Review Course ENOOE Online provides the same comprehensive in depth review of ISA s classroom led CSE PE course but enables students to study at their own pace with 24 7 access to the course materials 18 Control Design May 2014 Continued on p 23 controldesign com Expand Your Automation Computing with Advantech s iDoor Technology AD ANTECH Enabling an Intelligent Planet Compact Design with Infinite Options e Fanless rugged design for reliability in industrial applications e Various expansion modules and I O doors offer flexible customization e Modular design for easy installation and upgrades e Connectivity support includes serial digital I O fieldbus and wireless networks lt gt De UNO 2362G UNO 2483G FieldBus iDoor DI DO iDoor Communication iDoor AMD Dual Core Intel Core i7 i3 PCM 26D1PB PCM 27D24DI PCM 24D2R2 PCM 24D2R4 T40E Small Size Celeron Regular Hilscher netX100 Digital I
61. in their machines he adds Both approaches can do these jobs Similarly as a longtime practitioner of PC based con trol Beckhoff Automation www beckhoffautomation com includes its TUV approved Functional Safety over EtherCAT FSOE capabilities in its existing control sys tems which achieve ISO 13849 Level E and SIL 3 ratings ISO 13849 went into effect in January 2012 so machine safety s been at the forefront of everyone s thoughts since then and their awareness is growing quickly says Tony Rigoni regional sales manager for northern California and safety expert at Beckhoff Automation www beckhoffautomation com Up Into Auto Plants Of course once builders and users get a taste of designing and integrating intelligent safety into machines many want to deploy it in larger production lines and facilities 32 Control Design May 2014 controldesign com For example Audi www audi com recently redesigned its A3 model and built a two level production building at its plant in Ingolstadt Germany for its new body assembly line which operates up to 800 robots in 130 work cells Fig ure 3 The A3 s lightweight third generation body needed a higher performance production line that was flexible reconfigurable and able to deliver more sophisticated diag nostics in the cells and on conveyors so Audi s engineers 1 m selected Profisafe and Profinet networking and safety PLCs from Phoenix Contact ww
62. it period even if the machine was running slowly and can still brake This increases machine downtime and tempts frustrated operators to bypass the safety devices An alternative for rotating machines is to base safety controls on safety rated encoders Here the encoder tracks system speed When a worker needs to get close and triggers the request to enter signal the controls slow the machine As soon as the encoder detects that potentially hazardous motion has stopped the gate opens In some cases encoder based safety eliminates the need to remove power from the drive The safety encoders continuously track machine motion and trigger safety shutdowns if a faulty drive tries to start the machine while a person is near Safety encoders even prevent machine runaways caused by drive failures that can occur when the drive is programmed with bad limits the range of movement is incorrectly set or there are bad references in the motion program Runaways are dangerous to operators They also necessitate costly repairs when they cause crashes Safety encoders can detect overspeeds before a machine goes out of control then the controls initiate a machine shutdown One caveat Machine safety systems must incorporate redundancies Conventional safety devices such as e stops for example have redundant contacts In contrast encoder based safety uses redundancies programmed into a speed monitoring module Here programmed in logic activates saf
63. keting manager Programmable controls increasingly are moving on machine adds Geoff Sieron GuardLogix safety con troller product manager Rockwell Automation The on machine approach simplifies design and cabling and reduces maintenance costs With M12 quick dis connect cables it s much easier to install or replace I O connections without additional wiring One of the problems that programmable controls address is the lack of skilled labor in proportion to the worldwide demand for consumer goods production argues David Bachman product manager c3controls Economies are bouncing back and an expanding middle class is creating a demand for more products But there aren t enough workers for that demand To meet consum er demand goods manufacturers can either work faster or automate Our controllers self check and determine not only when they need attention but also when some thing in the application itself needs attention Tom Schermerhorn CEO of CTC says We made the strategic decision to support EtherCAT based on feedback from customers who are under greater and greater pressure to develop machines and systems with two specific characteristics First the builder or integrator has the design flexibility to choose the best components for the project and be confident the component devices will play well together Second the builder can develop prototype set up test and move the machine system to the us
64. lders started adding some of their own auto body preserva tives before or during assembly Similar to the rustproofing saga machine safety used to be mostly a difficult and often ineffective afterthought Gates guards E stops light cur tains and other protective devices were added after machines were built but were so cumbersome that operators frequently bypassed them In recent years some standards such as the National Fire Protection Assn s NFPA 79 rules have enabled safety and control communications on the same network This enabled the advent of dual processor safety PLCs and other components that can be designed into machines and production lines before they re built and help set up safe zones safe speeds and safe directions in ma chines These capabilities allow operators to interact much more closely with machines with little or no risk of injury or having to completely power down The main trick is to plan ahead include safety func tions in initial designs and get protections integrated before equipment is assembled and tested Many machine builders have adopted these principles and the devices and standards that support them How ever others have been slower to get on board because they ve always built and guarded their machines a certain way or they don t know which standards apply controldesign com to them or they re unaware how easy it is to apply new safety PLCs and other components Changing mindse
65. line of equipment products Design one s own carrier I O board and snap on the SmartTile integrated gt amp logic engine Programmed in iTriLogi Ladder Basic language it includes an integrated Ethernet port and carries all the processing capabilities of company s F series PLCs including floating point math Triangle Research Int l 877 874 7527 www triplc com SIMPLER SAFETY SC26 2 programmable safety controller uses safety function blocks Boolean logic functions and a user friendly programming environment to create safety control logic It has 26 input terminals and two redundant solid state safety outputs to monitor E stop buttons rope pulls interlock switches safety light curtains and other input devices Free configuration software has pre configured safety function blocks a ladder logic diagram and text based summary of the input device and controller output settings Banner Engineering 888 373 6767 www bannerengineering com May 2014 Control Design 47 PRODUCT ROUNDUP STUDIO SUPPORT Apax 5620 with Intel XScale PXA270 CPU supports Microsoft Visual Studio Net for PC based users to develop applications Two CAN bus interfaces support CANopen stack and two RS 485 ports connect to remote I O devices and support up to 32 I O modules It s compatible with IEC 61131 3 based Multi prog KW languages and supports WinCE Advantech Industrial Automation 800 205 7940 www advantech com ea
66. ll affect the range To get the maxi mum range you ll need an external antenna rather than an on board chip antenna Gain and antenna type directional or omni will be determined by the local environment Ten samples per second is a high rate for a battery powered sensor node Do you require that much raw data for the application You can preserve a lot of bat tery power if you push some event processing out to the sensor nodes and let them make decisions about how much data really needs to be transmitted If high data rates are truly required some wireless technolo gies will prove to be impractical Consider the total amount of data that will pass through the system The total number of nodes combined with their sampling rates will determine the bandwidth that the system design must be able to handle Sampling rates heavily influence power budgets As the sampling rate rises you re looking at either larger controldesign com batteries or shorter battery replacement intervals Note that the industrial process world has gotten good results with WirelessHART Many products boast multi year battery life in applications that call for sev eral samples per minute using just one or two D cell lithium batteries Energy harvesting is becoming more viable all the time but it does call for careful system choices Photovoltaic power PV is still the most practi cal option and it works well outdoors Indoor PV provides much less powe
67. lute and incremental An absolute feedback device gives independent position information while an incremental one provides current information relative to a previous position Selecting between these alternatives comes down to what information is required for motion control HA downside of resolvers is that translating their output into useful position information is left up to the machine maker or end user That can be challenging E Do you need to know the actual position of the en coder when you power on and power back off again Or are you just looking for speed information asks Man dee Liberty encoder product specialist at Sick www sickusa com The company offers many encoder and motor feedback products The type of location information needed varies with different applications It might be important to know how fast a conveyor belt is moving but not the position of a particular point On the other hand a robot using an absolute encoder can pay dividends in shortening start up times and reducing power consumption By knowing where it is in a motion cycle a robot can stop in mid movement and avoid having to rehome at start up and shutdown It s also the case that knowing absolute position over time allows calculation of speed The most basic absolute position encoders only provide position information In contrast the latest generation of these devices particularly those using some sort of fieldbus are incorporati
68. mary electric source in a home is single phase 110 Vac For simplicity and reduced control circuits many of these motors turn only in one direction In your car the motors run on 12 Vdc the starter being the strongest electric motor in a conventional automobile Industrial applications often require much higher me chanical outputs and use much larger motors designed for higher dc voltages or multi phase ac voltages These motors also have much higher current ratings Generators usually aren t found in a household Some houses have emergency generators in case power is lost Every automobile has a generator to provide electricity for ignition various fans accessories and lights and to recharge the battery On the whole most generators are big and supply power grids with electricity It takes a lot of mechani cal power to crank these shafts Mechanical power is obtained by making steam in power plants from coal gas and nuclear sources with diesel engines or hydro turbines or more recently with wind turbines on hill tops often in groups as windmill farms Motor Designs 101 Motors are based on the principle that opposite polarity magnets attract each other while magnets of the same www controldesign com Figure 1 The stator has the fixed permanent magnet while the rotor is composed of a number of windings To sustain rotation and since the permanent magnet can t be reoriented the electromagnets mu
69. more connected industrial supply chain is the need for cybersecurity Siemens www siemens com was among the companies announcing new efforts in this arena at Hannover Siemens significantly deepened its relationship with McAfee www mcafee com a division of Intel Security Digitized integrated industry is putting down roots before growing into a mighty tree said Dietmar Harting right chairman of the Hannover Messe Exhibitor Committee and president of Harting on the role of Hannover Messe as a showcase for progress toward making Industrie 4 0 a reality www intel com to build industry specific security solutions leveraging next generation firewalls security information and event management SIEM endpoint security and global threat intelligence These offerings are intended to provide greater visibility and control at the factory level while reducing the risk of intellectual property theft Industrial security is one of the building blocks for strong demand of connected manufacturing environ ments and for the continued resurgence of manufactur ing globally said Siegfried Russwurm CEO of Siemens Industry This partnership will be an important founda tion for the future of manufacturing and Industrie 4 0 By combining forces Siemens Intel and McAfee intend to drive the adoption of connected managed and secured solutions at the plant level to help indus trial customers manage their security wh
70. n is needed which brings me to the removal of support of Windows XP a new chapter in the life of automation If we believe in Murphy s Law things will hit the fan I m guessing about the total here but the number of SCADA nodes HMI boxes and programming lap tops still running XP must be monstrous Everyone controldesign com wants remote access to everything and if you use XP as an endpoint there is now a built in security risk since no more patches will be forthcoming The lon ger you use XP the more vulnerable you are It would almost be best to go back to Windows 2000 It has been estimated that hardware cycles vary from three to six years Windows 7 has been with us for five years XP for 13 Because of the chaos with Vista not many moved to Windows 7 thus the plethora of computers out there with XP The U S Navy canceled an order for 1 400 iPads be cause a portion of the BIOS was written in Russia by Russians No disrespect to the Russian programming community meant but there wasn t any love given to them by the Navy Cloud based technologies are safe and cost effec tive we are told Really Great idea but maybe not the best implementation E You have to wonder when a flashlight application for your Blackberry wants to have access to your personal info and turns on your location services But it is free I While not all issues are security issues now more than ever we must be vigilant with our industr
71. nce with Swedish direc tive 2006 4 anvandning av arbetsutrustning use of work equipment and determined the mill needed six different safety zones based on its inlet parts rolling and removal parts sections It s important to have a risk assessment to start with Pettersson explains After that you must work through function descriptions and operat ing instructions For us it took a lot of time to find solutions for our new safety functions so they would be safe and productive Once the instructions are finished it s much easier to write the safety program This is important because it can take lot of time to do a new RA and change safety functions and programs during commissioning if the initial solutions don t work out It s also important to separate safety and the non safety programs in the controls This will make it easier to commission and test the safety functions and these systems will be much easier to maintain because a clear readable program will minimize the risk of any misunderstandings Sandvik also adopted ABB s safety PLC with Pro fisafe network architecture via Profinet communica tions protocol to independently control the six safety zones The new dual processor safety CPU module and the safety I O channels are integrated alongside the mill s existing PLC which controls six dc and ac drives and motors The dc motors drive the main steel belt and rollers while the ac motors adjust roller p
72. ncy and operational life to 60 mil lion pinion revolutions It features a roller pinion toothed rack combination The pinion is comprised of bearing supported rollers that engage a unique tooth profile Each tooth profile is measured to eliminate cumulative error Nexen Group 651 484 5900 www nexengroup com STEP RIGHT IN N TMCM 1043 embedded driver stage custom designed for direct mounting on NEMA17 stepper motors is pre programmed and pre configured with all operating parameters to sup off the shelf use without additional programming With optional programming kit it becomes a custom izable smart driver stage for a broad range of embed ded motion control and mechatronics requirements Trinamic Motion Control 49 40 514 8060 www trinamic com SOFTWARE _ HARNESS YOUR CONNECTIONS f Harness proD is a 3D 2D software system for the efficient design and docu mentation of wire harnesses Automated steps range from importing mechanical models as 3D environments for wire harness layout and combining them with wiring lists from the Eplan platform to routing the cables and generating the engineering documenta tion and manufacturing 2D nailboard drawings It can incorporate mechanically relevant information from various MCAD systems as well as the ECAD port standard 1 1 A motors for rapid design in and pontrol design Bu u os LDERS Get Up to Speed Quick With the Control Design Essentials Series co
73. ng velocity calculations adds Liberty With regard to price absolute encoders are generally more expensive than the incremental variety That s May 2014 Control Design 51 SPECMATE because the absolute encoders are a bit more complex than the equivalent incremental device The final set of considerations involves mechanical and networking options With regard to networking the output can be a standard incremental signal over HTL TTL or it can be transmitted over Ethernet a newer ap proach that is gaining favor The choice of interface also sets the refresh rate of the position data E It might be important to know how fast a conveyor belt is moving but not the position of a particular point On the other hand a robot using an absolute encoder can pay dividends in shortening start up times and reducing power consumption I As for mechanical options there are a number of choices for shaft and flange size Other elements of the mechanical package determine how well the encoder operates in settings that are vibration prone dirty or wet There are varying degrees of robustness within different families Liberty says Some are considered heavy duty and some are considered light duty Safety technology for mechanical At Dynapar this distinction shows up in how well encoders are sealed against the elements A heavy duty encoder has NEMA or IP67 certified protection against such environmental assaults as w
74. nnection information providing the potential to Written by the editors of Control Design our new Control Design Essentials series is designed to provide industry professionals with an up to date top level understanding of a range of key machine automation topics Our intent is to present essential engineering concepts in a practical non commercial fashion together with a review of the latest technology and marketplace drivers all in a form factor well suited for onscreen consumption Get in and get out quickly with just the information you need 40 60 Made Possible By i Made Possible By AMK Made possible by AD ANTECH Enabling an Intelligent Planet Now available at ControlDesign com Essentials To download your complementary copy visit ControlDesign com Essentials be seamlessly integrated into PDM environments Eplan 248 945 9204 www eplanusa com TAG IT Cscape v 9 5 control software has tag based advanced ladder logic to program using tagged variables rather than a fixed registerin the target device It has graphics control and func tionality with background and button gradations on 15 bit or higher color units smoother gradient transitions on all in one controllers that support 24 bit color and bitmap transpar ency It supports PID tuning for IEC environments Horner Automation Group 317 916 4274 www hornerautomation com APPLY THE APP Remote Manager mobile app for Interact
75. oductivity One solution covers CNC robotics and motion control Perfection in Automation www br automation com bel Jim Montague executive editor jmontague putman net LIVEWI RE Help Safety Break Free of the Past TRADITIONAL MACHINE SAFETY is a lot like Ziebart or Rusty Jones Remember those long ago rustproof ing services You d buy a new or at least late model car take it to one of their local shops and they d drill a bunch of holes in the body and spray in a rust inhibit ing coating It seemed like a good idea at the time Well I took a new 1987 Toyota Tercel to a local Zie bart and it got the usual treatment which I found out included sticking little plastic buttons into and over the new holes inside the door panel rear hatch and other locations Even then this seemed a little goofy to me I mean punching holes in a new car didn t seem like a logical way to prevent rust Why not apply the anti rust stuff during assembly and avoid all the holes My concern only grew as the years went by and I routinely saw rainwater dripping out of the drill holes and little spidery trails of rust start branching out from under the plastic buttons Terrific I d bet the whole rust proofing industry got started because the automakers weren t doing it given all the rusted hulks we used to see in moister parts of North America So I d also guess that Ziebart and other shops and their aftermarket dried up once the car bui
76. oltage can be measured with a voltmeter AN FAN VOLTAGE VOLTAGE SPEED CURRENT SPEED SLOW DOWN WITH HAND STILL CURRENT STANDSTILL A high stall current or start up current is typical for motors At start up the bulb shines brightly and then dims while the current decreases until full speed is reached and just a weak glow remains The voltage across the fan increases with speed This voltage is the back electromotive force Because the fan is turning it becomes its own little generator generating a voltage that opposes the 9 V battery and in the experiment at full speed it was measured at about 7 0 V with the battery itself holding at 7 7 V Indeed every motor generates this back EMF while rotating The back EMF opposes the current flow into the FAN VOLTAGE BACK AT FULL SPEED RELEASE motor It s actually a smaller current back out of the motor in the opposite direction So every motor is a built in generator If this fan is forcefully made to rotate even faster then the opposing back EMF voltage may eventually exceed the battery level and the battery will begin to recharge A strong hair dryer can help to verify this behavior If air is blown into our experiment fan to help it rotate faster the light bulb completely darkens and the back EMF is increased If air is blown from the other side to slow down the fan the lightbulb gets brighter since the
77. osition to achieve desired pressure during strip steel processing This new arrangement with the safety PLC allows parts of the mill to remain operational while an operator gains safe access to some other zone where May 2014 Control Design 27 wa ees power About 50 safety PLC International Organization for ISO 13849 1 functional safety FS application X Can use Safety Integrity I O channels also link to gate Standardization www iso org specific AS uses performance levels PLs Software Tool for the Evaluation a ISO 13849 2 FS validation x of Machine Applications switches light curtains and ISO 12100 FS risk assessment X SISTEMA E stop buttons The I O points International Electrotechnical IEC 61508 generic safety standard X X Can use SISTEMA at www dguv also monitor pressure switches Commission www iec ch IEC 62061 FS AS uses SIL categories X X de ifa en pra softwa sistema to sense that hydraulic power is IEC 61511 process safety standard X X index jsp disabled for maintenance U S Occupational Safety OSHA 29 CFR 1910 Subpart O machinery and X Safety products and solutions i lt 2 and Health Administration machine guarding safety are tested and certified by Establishing safe zones www osha gov OSHA 29 CFR 1910 147 control of hazardous X national recognized testing inside machines allows power energy lockout tagout labs NRTLs to be brought to a safe level American National Standards ANSI
78. otor At start up referring back to Figure 1 the green winding is activated With the polarity shown the rotor will turn clockwise trying to align the green magnet with the stator magnet As the rotor turns the blue coil becomes activated while the green coil is deactivated and so on as shown AE MOTOR EXPERIMEN For this demo I used a Comair Rotron Model MD12B1 brushless dc 1 f THE BRUSHLESS DC MOTOR Figure 2 The permanent magnet is on the rotor External solid state switches turn on the proper stator winding as a function of the rotor orientation ennag Te Niere oe 2 motor Get a 9 V alkaline battery with a snap on connector an alligator clip a PR3 flashlight bulb and some copper wire You ll also need a small soldering iron and solder to make connections Mount the fan battery and flashlight bulb on a piece of plywood Drill a hole to stick the lightbulb into the plywood and drill smaller holes as needed to run wires from top to bottom for conductors or for fastening equipment Motor behavior can be observed under all conditions stalled start up some load no load by controlling the movement of the fan with your hand These same characteristics are present in high powered motors Notice the relationship between the current through the motor indicated by the brightness of the bulb the voltage on the motor and its speed for various operating conditions V
79. ow one or more of the hundreds of harmonized standards listed in the European Union s official journal In lieu of customer specifications it s highly advisable to have an internal specification of minimum safety requirements and to list the standards chosen to demonstrate compliance To help machine builders learn and perform ISO 13849 1 s calculations the free Safety Integrity Software Tool for the Evaluation of Machine Applications SISTEMA is offered by the German Social Accident Insurance orga nization s Institute for Occupational Safety and Health www dguv de ifa en pra softwa sistema index jsp The tool provides comprehensive support in evaluating safety in the context of ISO 13849 1 NIST Modular All In One PLC HMI Cut system costs Cut programming time by 50 e Enjoy a great user experience TM VV uniTRONICS www unitronics com Unitronics Inc 1 Batterymarch Park Quincy MA 02169 USA Tel 617 657 6596 Toll Free 866 666 6033 usa sales unitronics com Safe Motion New Tools Besides setting up safe operating zones the most im portant benefit of integrating safety PLCs into machine designs is establishing safe direction speed and other motion that won t allow operators to be injured Back at Sandvik s cold rolling mill the safety PLC provides safe speed control which ensures that hands or fingers can t be trapped between the mill s belt and rollers The safety PLC also allow
80. pecific standards The second and most challenging step is to develop a procedure and rules to support the process to ensure you have consis tent results from one RA to another Winter reports that deciding which safety standards to follow begins with the location ofthe end user s manufacturing facility and then OEMs integrators contractors and everyone else follows suit In the U S you start with federal and state OSHA regulations and then use standards it has incorporated through reference which are pri marily American National Stan dards Institute www ansi org and National Fire Protection Assn www nfpa org Winter says that because recently revised ANSI standards are starting to harmonize with Interna tional Organization for Standardiza tion www iso org and International Ethernet Connectivity Automation Controller Custom Software bo on MAA ABB AND SANDVIK COLD ROLL WITH CARE gt Figure 2 Sandvik Material Technology recently added a safety PLC with dual processor CPU Profisafe networking and safety I O channels to its cold rolling mill in Sandviken Sweden This enabled six safety zones and safe speeds in the mill s inlet rolling and output sections and improved strip steel processing efficiency Custom Motor Design AEROTECH Dedicated to the Science of Motion Labeling Paper Label Sensors Clear Label Sensors High Speed Label
81. r It can work but only in applications with lower sampling rates and lower range requirements To your second issue encryption adds overhead How much overhead will depend on data payload packet size Always factor encryption overhead into the power and bandwidth budget specified by the vendor And don t take chances with the security by obscurity rationale where security depends on the secrecy of the system s implementation or its components That s like thinking you can leave your back door unlocked because a burglar can t see it from the street MIKE FAHRION director of product management B amp B Electronics www bb elec com The following response came as a result of posting the ques tion to our own CONTROL DESIGN LinkedIn Group Saving Money Isn t the Big Factor From my personal experience with wireless instruments and sensors the majority of these types of instruments have non rechargeable batteries Unless you have a huge amount in backup for them you can t guarantee a continuous measurement of your process On the other hand it s the responsibility of a capable technical service group to ensure the minimum power consumption via device configuration Finally saving money must not be a factor when you decide to use wireless instruments The money that you save in installation and engineering might be spent in medium term by replacing batteries and pay ing for technical service I ve seen that t
82. r event notifica tions via email text message Ethernet serial USB and local I O are options An embedded web server allows the device to provide an operator interface that can be viewed via wireless Bluetooth cell to any web browser including those on tablets and smart phones An embedded firewall is included SoftPLC 512 264 8390 www softplc com DUAL RESETS TCN Series temperature controllers have dual preset indicators newly developed PID control algorithm and 100 ms high speed sampling They have eight types of input sensors built in relay output or SSRP output selectable and 2EA alarm outputs SSRP output makes phase control and cycle control possible ac power Autonics 847 680 8160 www autonics com May 2014 Control Design 49 PRODUCT ROUNDUP MORE MORE MORE _ Find more automation and controls product and software roundups at www ControlDesign com roundupsarchive TOUCHPANEL PC GK 7000 touch panel PC runs on Windows CE 6 0 and has an optional built in rechargeable battery It has a 7 in 800 x 480 TFT color display with a four wire resistive touch panel Its Samsung ARM based S3C2416 32 bit 500 MHz processor is powered from regulated 9 to 12 V supply and uses 8 W of power Built in interfaces include USB 1 0 x 3 USB 2 0 x 1 RS232 RS485 SD slot and opitonal extras include 802 11 b g Wi Fi GSM GPRS Bluetooth VESA 75mm rail mount and 2000 mAH battery Lilliput Electronics Saeli
83. ra to check airbag switches on the Dodge Dakota instrument panel line at Chrysler s plant in Warren Michigan and we were able to get it up and running in just four hours on a Saturday The modularity of IntelliTrak s conveyors is further aided by its controls which include drives and I O distributed throughout each separately driven zone These controls include program mable automation controllers PACs distributed motor con trollers and I O modules from Rockwell Automation www rockwellautomation com which are networked via EtherNet IP Distributed motor controls en able each carrier and zone to run independently and at varying speeds which allows production line speeds to be matched to dif ferent assembly tasks prevents parts from being tied up on the line increases efficiency and saves time One of our primary benefits is that we can independently control all zones in a user s process and stop slow reverse and move carriers back and forth and even create movement recipes that best suit the geometry needed for each part explains Robertson This means we can clean paint or assemble many parts much more efficiently Our distributed drives and remote I O also mean we don t have to send hundreds of wires back to a main enclosure fll May 2014 Control Design 15 DC On Demand While other manufacturers have chosen to leave the DC motor market ABB and Baldor continue to invest in
84. rce for INDUS TRIAL ELECTRONICS For Industrial Automation and Control we have the products AUTOMATION S SAFETY amp solutions you need from the most trusted brands u Featured product Digital Temperature Controller newark com 800 463 9275 05W3874 NEN elementu 00060 FOR M A EHIN E NOS In Memory of Julie Cappelletti Lange Vice President 1984 2012 gt PutmanMedia 1501 E Woodfield Rd Suite 400N Schaumburg Illinois 60173 630 467 1300 Fax 630 467 1124 EDITORIAL TEAM EDITOR IN CHIEF JOSEPH FEELEY jfeeley putman net EXECUTIVE EDITOR JIM MONTAGUE jmontague putman net MANAGING EDITOR NANCY BARTELS nbartels putman net MANAGING EDITOR DIGITAL MEDIA KATHERINE BONFANTE kbonfante putman net ASSOCIATE EDITOR DIGITAL MEDIA ERIN MASSEY emassey putman net SENIOR TECHNICAL EDITOR DAN HEBERT dhebert putman net CONTRIBUTING EDITOR HANK HOGAN hank hankhogan com EDITORIAL ASSISTANT LORI GOLDBERG Igoldberg putman net COLUMNIST JEREMY POLLARD jpollard tsuonline com DESIGN PRODUCTION SENIOR PRODUCTION MANAGER ANETTA GAUTHIER ASSOC ART DIRECTOR ANGELA LABATE SUBSCRIPTIONS CUSTOMER SERVICE 888 644 1803 CIRCULATION AUDITED May 2013 Air amp Gas Compressors Sl Engineering amp Systems Integration Services 7 746 Engines amp Turbines 1 649 Food Products Machinery DAS Industrial Fans Blowers amp Air Purification Equipment 794 Industrial Heating Refrigeration amp Air Condi
85. rginal costs he reminds us are the costs of producing an ad ditional unit of a product after fixed costs are covered Rifkin talks of a paradox embed ded in capitalism that is responsible for its great success but is now lead ing to its demise He says businesses always welcomed the reduction of marginal costs but they never an ticipated a technological revolution so extreme in its productivity that it might reduce marginal costs to near zero across the value chain making goods and services essentially price less abundant and not subject to a market exchange economy He says the first inkling of this paradox was Napster in 1999 which introduced file sharing and bypassed the recording indus try s royalties system It has since invaded the entire information goods industry Consumers became prosumers producing and shar ing their own information goods with videos on YouTube news controldesign com Joe Feeley editor in chief jfeeley putman net EDITOR S PAGE blogs and ebooks and decimated the publishing industry Economists thought there s a firewall here so these concepts won t cross into the world of brick and mortar goods and services Rifkin said That s not the case Rifkin says the IoT Communica tion Internet is converging with an emergent Energy Internet and Logistics Internet to create a new technology platform that connects everything and everyone Prosum ers will use b
86. rol could be an application such as a filler capper combination which are used in pharmaceutical or beverage processing These devices might process 250 units per minute for pharmaceutical operations and as many as 1 200 per minute in the case of bever ages according to Jensen In part this new approach that could involve trouble shooting videos is now possible because the devices have the computing horsepower to oversee several multi axis motion operations simultaneously They also can handle the data load associated with a high volume of manufacturing throughput Software running on the devices also can react to defined conditions such as an alarm a changeover request or a need for maintenance In those cases a video could pop up and guide person nel through the appropriate actions to take Some of Beckhoff Automation s www beckhoff com industrial display families have multi point projective capacitive input This means that swiping flicking zooming and other operations found on consumer devices are possible That familiarity brings benefits It s much easier for training in an international market to get operators to understand a machine and navigate the different HMI screens more efficiently says Nathan Eisel Beckhoff s North America support manager He adds that the input technology can be used with thin gloves on unlike some other multi touch technologies controldesign com Behind the scenes the use o
87. rs have om _ a motion engine integrated with IEC61131 3 and PLCopen programming standards and provide scalability from single to 62 axis applications within company s MotionWorks IEC development platform Sigma 5 servos are easily accessible through a built in web server and they have reusable program code libraries for PackML camming and a variety of other functions to reduce development time Yaskawa 800 927 5292 www yaskawa com controldesign com MULTIPLE BATCH CONTROL N410 panel mount batch con trollers have a full numerical ar nme keypad and amodern LCD display and they provide multiple batch control data simultaneously including a graphical indication of the batch process and relay status Fluidwell 31 0 41303430786 www fluidwell com CAN T BE SHOCKED LPC 630F fanless small form com puter has an Intel 3rd generation Core i7 mobile processor 2 gigabit LAN two USB 3 0 four USB 2 0 Serial RS232 e SATA Intel HD4000 graphics two Dis playPort DVI I and audio in out ports It supports up to 16 GB of DDR3 memory has optional built in 802 11 b g n wireless networking and a 120 GB solid state drive to protect against vibration and shock Stealth 905 264 9000 www stealth com VERSATILE CONTROLLER Model BB is a low cost platform that can act as a programmable automation controller as a data gateway to existing controllers or as a data logger Other functions include alarm o
88. rt from the owner of the site was that the version of WordPress was an older version that had known vul nerabilities and it hadn t been updated By whom Well it seems that the creator of the web site was using a web hosting service in California that provided the secure platform and the WordPress appli cation and database as part of its service So the trust was placed with the service along with the developer Misplaced trust can be deadly The result of the hack was simply to replace hyperlinks and direct users to other websites in Europe and other locales but the results could have been much more significant We do trust in the capabilities of those services that we use banking downloads free apps etc Free apps You have to wonder when a flashlight application for your Blackberry wants to have access to your personal info and turns on your location services But it is free The NSA has brought to light the backdoor theory of almost all systems be they hardware or software We have relied on the powers that be read IT depart ment to keep us safe at work We rely on our ISPs to keep us safe at home Maybe we should rely on ourselves a bit more to protect ourselves The Apple 10S 7 had a bug that sent out unencrypt ed data over the network Anyone that does banking with a portable device is nuts How can you trust that a flashlight application isn t monitoring and sending info to the mother ship Trust with verificatio
89. s Sandvik s engineers to use floating point numbers that simplify safety programming required for tasks on the mill such as cal culating speed Programming was further simplified by ABB s integrated PLC development tool which supports safety PLC programming in its CoDeSys based integrat ed development environment and supports the PLCopen Safety Library ABB also provided its own safety code analyzer tool which verifies safety programming rules Establishing the zones and using the safety PLC improve the cold rolling mill s safety but they also aided our efficiency because we designed new functions for threading the strip to separate operator and machine and this enabled the millto run more effectively and more safely Pettersson says To help more users gain these safety capabilities some developers take them beyond the usual safety PLC For instance B amp R Industrial Automation www br automa tion com just introduced its safety PLC that comes in the form of an I O module while its soft counterpart is a virtual purely software based version that can run on other hardware devices if needed The PLC provides programmable and network safety to machines that don t need a large complex safety system according to Corey Morton B amp R s technology solutions director Safe motion and safe limited speeds and positioning can produce big productivity gains because users can maintain existing power positions and axes
90. s and Snap digital and analog I O modules to form a complete control system The controllers can log data to a remote PC or controller as well as toa microSD card in the controller itself Free PAC Control programming software is included Opto 22 951 695 3000 www opto22 com RELAY THE COMMANDS Series 900 smart program mable relays have eight digital inputs and four relay outputs and in the 12 24 Vdc model 4 two analog inputs that can be used as digital inputs Three modules can be added expanding digital inputs to 32 and relay outputs to 16 The relays enable cre ation of complex programs that increase application options with features such as analog comparators and up to 250 lines of ladder logic programming c3controls 724 775 7926 www c3controls com May 2014 Control Design 45 PRODUCT ROUNDUP FAIL SAFE CONTROL Simatic S7 1518 failsafe CPU with 10 MB of memory handles up to 128 drive axes operates isochronously in 250 us and has 1 ns bit performance It has a Profinet interface with a two port switch for communication with the field level two Profinet interfaces and one Profibus interface Programs are created with standardized Step 7 Safety Advanced V13 engineering tool and the device is certified to EN 61508 2010 for functional safety and is suitable in safety relevant applications up to SIL 3 per IEC 62061 and PL e per ISO 13849 Siemens Industry 800 333 7421 www usa siemens com plc CONTRO
91. s founded in 1995 and still produces the only rotating tube friction drive conveyors in North America Driven by skewed wheels trolleys ride on Intel liTrak s load rail while the drive beam s spinning tube is attached via bearing assemblies Opera tors can change trolley direction easily by reversing the drive tube s rotation This rotating tube also requires no lubrication for cleaner quieter operation The flexibility of the company s overhead conveyors such as its IntelliTrak 500 Series come from their bolt together design This en ables easy system changes for new car designs allows manufactur ing zones to be added or removed from the line with minimal im pact eliminates the need for many replacement systems and reduces downtime and costs Because our customers needs controldesign com OEM SPOTLIGHT This automotive assembly line uses the Intellitrak 500 overhead conveyor system to build instrument panels while its modular components can be reconfigured quickly for new designs change so quickly now 50 to 70 of our systems will be modified within the first five years of implementation says Tom Robertson IntelliTrak s president Fortunately we can unbolt the end of our overhead conveyors and add two four or eight more stations in just a few hours This job usually takes two weeks with traditional conveyors In fact we recently added a 10 foot inspection station with came
92. sition information is left up to the machine maker or end user That can be challenging which is why encoders are often used An encoder provides position information by captur ing the passage of an optical or magnetic mark past a point The mark could be on a shaft that turns in re sponse to movement so it can be used to track motion Optical encoders tend to offer higher resolution with more pulses generated for instance per revolution Higher resolution is beneficial in speed control especially at lower speeds Mahn says If there s a lot of rotation between edges of pulses you can get velocity controldesign com Hank Hogan e contributing editor e hank hankhogan com SPECMATE ripple between edges and it s difficult for a drive or mo tion controller to keep that speed steady For an encoder the first basic choice is between opti cal and magnetic methods with the selection often dictated by the environment If strong magnetic fields are present or if it s necessary to minimize any electro magnetic interference then an optical method might be the best choice On the other hand in dusty settings an optical system could quickly fail while a magnetic encoder continues to function Beyond environment the next consideration is the type of motion to be monitored and what the manner of feedback should be The motion is classified as either lin ear or rotary The second has two basic categories abso
93. ssible in industrial technology Under the theme of Integrated Industry Next Steps many of Europe s major factory automation suppliers fielded booth demonstrations designed to illustrate their visions of next generation advanced manufactur ing capabilities Industrie 4 0 is an initiative of the German govern ment intended to foster the country s manufacturing competitiveness by leveraging the potential of cyber physical systems and ubiquitous network connectivity to create more efficient and productive factories work processes and supply chains Industrie 4 0 will be with us sooner than many people would have thought possible just one short year ago said Jochen Kockler member of the managing board for Deutsche Messe Hannover Fair s organizer Exhibitors have demonstrated a clear commitment to negotiating the next steps on the road to the fourth industrial revolution rapidly and purposefully Throughout the automation halls the integration of design and manufacturing platforms was apparent as RFID badged products moved through modular produc tion lines carrying instructions for their own manufac ture along for the ride Tablet computers and smart phones interfaced directly with automation controllers or reached up through secure cloud connections to ease engineering and integration tasks and enable new information transparency Secure Communications a Given Underpinning any effort toward building a
94. st be activated or deactivated This shows rotor position at start up and after one commutation polarity repel each other One magnet is located on the stator and one magnet is on the rotor If those magnets aren t lined up the rotor will turn until they do Once the magnets are lined up rotation stops These magnets could be permanent rare earth mag nets or quasi permanent magnets electromagnets with coil windings driven by a dc current The other magnet is an electromagnet the orientation of which is modified continuously As a result the rotor keeps try ing to line itself up If this magnet modification is done in an intelligent way such as in a rotation to the right then the rotor will rotate to the right DC Motors To sustain rotation and since the permanent magnet How helpful do you find refreshers and primers on engineering topics Do back to basics articles provide you with the kind of information that helps you to perform better as a controls engineer Which topics would you find helpful Sound off at ControlDesign com refresher May 2014 Control Design 37 EH DRIVES amp MOTION CONTROL can t be reoriented the electromagnets must be acti vated or deactivated In a typical dc motor Figure 1 the stator has the fixed permanent magnet and the rotor is composed of a number of windings Basically one or two windings are activated at a time via commutation depending on the number of coils on the r
95. t Since it was in dry dock the ship was not powered at the time of the valve replacement so the technician could not check his work After the ship was powered up I began tests and discovered two separate problems I asked to see their equipment documentation The search for the binder took nearly a half hour Why is the documentation on a 200 000 system so difficult to find Even when the documentation might be avail able there s still the problem of why it isn t used In factories across the country I repeatedly encounter operators who have never seen the user manuals and maintenance technicians who have never seen the maintenance manual or the parts book Part of the problem might stem from equipment that is imported Much of the machinery used in the United States today is not manufactured here Every reader probably has encountered a poorly written poorly translated manual that was not worth the time to read let alone print I suppose I could accept that answer for some cases But that does not give due credit to compa nies that take pride in the documentation they supply My former company had a technical illustrator and technical writer who created a custom parts book manual and a custom user manual for every piece of machinery that left the factory These were superbly executed yet frequently were lost during shipping The writer and illustrator began shipping the manuals in that specially labeled carton dedicated
96. the external energy source is providing enough power it feeds the transmitter If it drops out for any reason then the power module picks up the slack and prevents loss of the transmitter from the network With this supplemental methodology the power module life on a one second update application can be extended to four years or more KEITH WEEDIN business development manager PCE Pacific www pcepacific com These are from LinkedIn s Automation Engineers group Just Do Monitoring Have used wireless sensors for temperature transmis sion The sampling rate was every 60 sec The battery we used on them lasted from five to seven years I did not see any significance of the encryption having an effect on the battery life The more you transmit waking the device up the more power you would use I am not confi dent with the equipment yet to use it for control at this time For monitoring it is great BILL FRIDEGER HDL Process PC amp IS engineer technician Procter amp Gamble www pg com Test Energy Consumption First We have deployed hundreds of wireless sensor products There is a tradeoff on speed or sampling rate power needed for the device and radio and battery life One of our suppliers will do testing on a previously unused device to determine minimum values for current voltage and power uptime for stability They then provide battery life values which drives your PM program CHRIS BRAMLAGE sales and marketing manager
97. tion for a particular problem involves answering questions about the environment type of position information needed and mounting and con nectivity options The environment is the first consideration as can be seen by the basic technology used in a medical setting Such locations often require any system be immune to and produce as little electromagnetic interference as possible That in turn can dictate what type of encoder to use The absolute optical encoders are typically used in medical applications such as bariatric beds and scis sors lifts as well as in the vicinity of the CAT scan that rotates around you says Cory Mahn senior product engineer with encoder and resolver supplier Dynapar www dynapar com Dynapar explains that a resolver is a special type of rotary transformer that consists of a stationary stator and a rotor that moves with the load Voltage from the input winding couples to the output winding with a magnitude that varies as a function of angular position This construction makes a resolver a simple inher ently absolute highly reliable position feedback device There are no onboard electronics making resolvers the position information device of choice for harsh condi tions such as temperatures up to 200 C elevated radia tion levels or a high degree of contamination as well as settings with high shock and vibration A downside of resolvers is that translating their output into useful po
98. tioning Equipment 1 465 Industrial Process Furnaces amp Ovens 806 Machine Tools 3 874 Materials Handling Conveyors amp Conveying Equipment 1 882 Metalworking Machinery 3 537 Mining Machinery amp Equipment 627 Oil amp Gas Field Machinery amp Equipment 1 213 Packaging Machinery Gall Paper Industries Machinery S552 Printing Trades Machinery amp Equipment 510 Pumps amp Pumping Equipment 785 Rolling Mill Machinery amp Equipment 157 Semiconductor Manufacturing Machinery LAOS Textile Machinery 232 Woodworking Machinery 215 Other Industries amp Special Industrial Machinery amp Equipment NEC 8 696 TOTAL 40 020 gant This py BPA lt gt lol Ain t Seen Nothing Yet N AUTHOR JEREMY RIFKIN has written about economic and social trends and issues for years He says we ve entered the third industrial revolution and we d better get ready for the changes it will bring His new book The Zero Marginal Cost Society foresees how the Internet of Things IoT will lead to nearly free goods and services diminishing the influence of capi talism and ushering in a global collaborative commons We re just beginning to glimpse the outlines of the first new eco nomic system since the emergence of capitalism and its antagonist so cialism in the 19th century It has long term implications for us and our children and grandchildren Rifkin said at a recent speaking en gagement at Google s headquarters Ma
99. to the docu mentation and customers still didn t bother to open it I wonder why factory managers do not have a documentation set near each machine and another one in the maintenance shop One might reasonably expect a factory manager to give a copy to operators with the expectation that their job requires them to read and understand it tl TJ MCDERMOTT is project manager at Systems Interface a system integrator in Bothell Wash Learn more about the company at www systems interface com controldesign com SPELL RELIABLE ETS BR We don t like to brag but we are proud of our ability to offer the highest quality drives and servos in the industry We also work very hard at providing quick response to customer orders and questions And we boast some of the best meantime between failure rates in the industry Is that because of our quality products and innovative manufacturing processes Sure But it s also because of the Yaskawa associates that come to work every day looking to maintain a standard of excellence in serving you that we d match against anybody s Our people and our products are held to this standard every day That s why we spell reliable Y A S K A W A Y YASKAWA ve PE RSON NAL IT S ASKANA FR o E For more info Follow us n Tube http Ez com yai612 Shown at 95 actual size r The best little PLC just got better J N I a en u 2
100. truction set An 8 input 6 output base unit with built in serial ports can stand alone starting at just 69 or add any combination of up to 8 discrete and analog I O modules Simple 4 b ori And with FREE programming software we ve made it even easier to give CLICK a try Download the free software so you can see just how simple control can be Configure price and buy at www automationdirect com click plc 1 800 633 0405 the 1 value in automation a FN com
101. ts is a lot harder than revising designs and that s why useful foresight is always in short supply One thing that could help reluctant builders get over the new safety learning curve a lot faster would be to make today s standards much more available and accessible than they ve been in the past When ever I cover machine safety I m always encouraged by everyone saying how important it is to get build ers system integrators and end users more educated about safety but then I m stunned at how few specific details there are about what the primary ISO IEC ANSM NFPA UL RIA and other standards require where they must be applied and how to comply with them Most sources say builders must either shell out hundreds or thousand of dollars for their own copies of the safety standards or pay system integrators or certified consultants who are familiar with the stan dards to advise them E Standards organizations must be paid for developing safety rules but they could provide more basic guidance to builders adding safety earlier to their designs I I know standards organizations must be compensat ed for the resources they spend on developing safety standards However given the paltry details usually available I also know they could do a lot more to pro vide basic guidelines and encouragement to builders seeking to add safety earlier in their machine design and prototyping processes Of course this improved outreach by many of t
102. ular with 14 expansion modules has up to controldesign com 128 inputs 16 dual channel safety outputs and 16 status outputs An available integrated PCU 1 main unit has PCUEU 1 for adding multiple safety devices integration for switches mats edges bumpers etc It s certified up to CAT 4 SIL CL 3 SIL 3 Ple safety level Tapeswitch 800 234 8273 www tapeswitch com HARSH HANDLING HEC P5000 harsh environment controller is ROHS compliant has an operating range from 40 to 80 C sealed water tight enclosure analog and digital I O high speed counting TCP IP communications ports CAN network communications and Structured Text programming Program using EZ Ladder Toolkit PC based software that parallels the IEC 61131 standard Divelbiss 800 245 2327 www divelbiss com CAN BE TAKEN TO EXTREMES AC500 XC PLC is protected against extreme conditions eliminating the need for sophisticated protective enclo sures The operating range is 30 C to 70 C with reliable system start ups as low as 40 C Circuit boards are conformally coated to protect against high humidity levels and it has extended immunity against atmospheres with corrosive gases Vibration and shock can be tolerated with accelera tions up to 4 g from random vibrations up to 500 Hz or 2 g from sinusoidal vibration It also offers extended EMC protection ABB 262 780 3000 www abb com plc STANDARDS BASED PROGRAMMING MPiec machine controlle
103. ve design The industrial PCs in the Designline series are narrow feature IP65 protection multi touch capability machine Create an easy maintenance custom operating concept of your own with Designline el To learn more call 1 800 322 3225 ore or visit www phoenixcontact com designline and can be easily installed directly on the DOGO 000 OD Kein OCDE 2013 PHOENIX CONTACT INSPIRING INNOVATIONS TS11 03USA TwinSAFE Machine safety Sim plitied u OLLE uuene Tier us RER ER ai SKE BB 0 48 00 48 40 44 4048 HERE net Kae ie ahs r k Be 9122 ee ueeeucue Fur i www beckhoff com TwinSAFE TwinSAFE from Beckhoff from 1 0 to drives it s the universal and flexible safety system TwinSAFE 1 0 for the EtherCAT Terminal system makes optimum use of the exceptional performance offered by EtherCAT Compact Safety PLC in a 12 mm terminal block Powerful up to 128 safety devices per Safety PLC Versatile integrated function blocks for emergency stop protective door two hand control Modular standard and safety I Os integrated in a single system Flexible tieldbus neutral communication eliminates dedicated safety networks Certified solution up to SIL 3 according to IEC 61508 EN 954 Cat 4 and DIN EN ISO 13849 PLe approved for use throughout North America IRE 1O Motion Standard PLC Automation BECKHOFF gt Volume 18 No 5 FEATURES CO
104. w phoenixcontact com The safety PLC is unusual because it consists of two in dependent controllers One is a standard programmable IEC 61131 compliant PLC and the second is a SIL 3 rated safety control system While one platform is responsible for standard applications and Profinet communications the other prepares Profisafe telegrams and performs its safety application This means the PLC executes its stan dard system and safety programs in parallel but separate from each other which ensures independent control and timing for each function and keeps cycle times short for CAUTION IN CAR ASSEMBLY CELLS the control and safety programs Short software cycle Figure 3 Audi s new A3 body assembly line includes 800 robots in 130 cells which are managed by cell operator control units that have an industrial PC for programming diagnostics and visualization and use safety PLCs network switches and safety control of individual command devices such as robots or I O modules installed in a lower unit for easy access times are crucial to maintain optimal production cycle times by the various work steps in Audi s cells Also the frequency converters requires a handshake technique E Sleek touchscreen displays Rugged operator panels Flexible plug in modules red N on Available in 8 different models Remote monitoring and control Converts over 250 protocols Er Introducing the industry s first rugged HMI solution ra ite
105. y but advances in solid state power switches made it possible to cre ate three phase quasi sinusoidal phases at virtually any frequency The incoming ac is rectified and a dc voltage is created The dc is switched in a sophisticated sequence in the three phase wind ings Control circuits are called ER 0 60 120 180 240 300 360 60 Current Phase Angle in Degrees Figure 5 With a single phase source low power induction motors temporarily require an auxiliary phase via capacitor connected to the primary phase www controldesign com 110V 60HZ Figure 6 Circuit for single phase induction motor with required auxiliary phase to initiate motor start up variable frequency inverters or solid state drives be cause the primary applications are servo drives Since the rotor slips very accurate position and velocity feedback are needed to properly control the artificial phase generation Control is difficult at low speeds at standstill it becomes tricky Actually two rotating excitations with equal strength are overlap ping each other one rotates left and one rotates right When a command is given to move right the strength of the left excitation is diminished and the strength of the right one increased Eventually the left one disap pears completely once the motor is on its way Low power induction motors can be driven from a single phase source Figure 5 However the single phase isn t sufficient to get the
106. y old company sold machines to a nationally known bakery The machines performed the same function but were of several different generations I was asked to help improve the performance of one of the bakery s newest generation models The plant supervisor was unhappy with the machine because it didn t function as well as the older models I took a quick look at the various adjustment points some mechanical guide settings some pneumatic regulator settings Right away I could see some of the pneu matic pressures weren t right but I didn t have the exact factory settings committed to memory I asked to see the machine manuals which included all of the parameters as they were set upon leaving my factory After five minutes of searching high and low through the maintenance shop they were found The manuals were in the original still sealed specially labeled shipping carton Why didn t they look at these before calling for help 58 Control Design May 2014 One might guess that since they had similar machines they already knew from years of experience how to operate the newer model The fact they ran into trouble making the machine run properly proves that false More recently I visited a ship that has equipment from my current company The ship was just out of dry dock overhaul and the owner wanted the equip ment to get a factory checkout A technician had been there two days prior to installing all new air valves for the equipmen

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