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Motion Simplicity Count on Software Culture

1. Prodram monitor debug over any embedded videos and download the free software to take it for a spin communication port Or go straight to e Supports up to 256 I O locally and thousands more to buy with optional Ethernet remote I O e Supports inexpensive serial port expansion for connection to bar code readers printers etc And each Do more CPU comes with a coupon for a 30 day free trial of online video training m fi a 3 Ore ships Today i VAUTOMATIONDIRECT A M the 1 value in automation Ep SS EFL ETT
2. e Accuracy 0 005 rdg e Up to 142 Readings Per Second ES e 10 Point Linearization 595 e 4 Isolated Open Collector Output e Isolated Analog Output Optional e Four Relays Optional o Ethernet or RS 232 RS 485 Optional change color e NEMA 4 Front Bezel at any setpoint or alarm point Visit omega com dp41b 4 DIN MICROMEGA Thermocouple Terminal Large Selection of Autotune PID Temperature Blocks with Audit Capable Thermocouples Process Controllers Female Connector 5LRTC Series Starts at La 52 DRTB Series 2 Starts at 9 50 fB gm FFL fo D E n2 CN77000 Series Starts at 249 Visit omega com drtb CEOMEGA Visit omega com cn77000 Visit omega com 5lsc 5srtc O COPYRIGHT 2012 OMEGA ENGINEERING INC ALL RIGHTS RESERVED All the Tools you Need for Embedded Measurements and Control in one rugged box Graphical Software Custom Triggering The NI CompactRIO hardware platform can handle your embedded measurement and Sensor Connectivity Actuator Connectivity control applications and do it in a way that outperforms other off the shelf systems so you don t have to spend time developing a custom solution The range of high quality measurements coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software gives you all the benefits of Custom Timing Expansion Systems customization with the convenience of an off
3. hee bee ls Fipe NEE Sirexs r E 2 a m ir Stress and Strength Magnitude Fi Perit perder ea dd See ee eee ee dr cu re The strength curve indicates the chances of any particular strength value in a collection of products The area under both curves represents failure conditions When the product design produces higher strength levels failure probability decreases Area Se Continuing our anniversary retrospective of content we ve created during the past 15 years this time we offer up as it originally appeared in May 2004 an article by a renowned industrial safety expert that cautioned about the steadily growing dependency that control systems had on software and as a result why it was imperative that we recognize the need to pay a lot more attention to software reliability Eight years later the incentive to do so remains vitally important to make control software developers think it s easy to produce reliable software No one however can ignore the importance of soft ware reliability and as control systems grow in func tionality and complexity machine and production equipment builders must increasingly depend on soft ware to carry the load We ll address these issues here and include exam ples of software failures the root causes of those fail ures some rules for avoiding those causes and some guidance in evaluating software reliability in control system products More Complex
4. Autonics Sensors amp Controllers Autonics Other Products ggg j Temperature Controllers Counters Timers LP SOZOce HMI PLC MOTION CONTROL 7 TRUE COLOR LCD with the inflow of foreign direct investment prompting growth in several sectors according to the 7 Wide TFT LCD monitor with True Color 16 7 million colors Integrated HMI PLC saving space and cost External I O supported Input 16contacts Output 16contacts Motion control functionality Large memory capacity Program memory 8 000 steps Drawing memory 16MB Free software included with free upgrades Data logging functions various data collection and back up support for controllers Large image library Synchronous monitoring for multiple addresses and channels Wide range of interface support Ethernet RS232 RS422 1353 Armour Blvd Mundelein IL 60060 Tel 847 680 8160 866 862 2602 www autonics com sales autonicsusa net As CE ROHS 150 3001 PLEASE VISIT OUR BOOTH E 7414 AT PACK EXPO MU Panel Meters Pulse Meters Photoelectric Sensors Fiber Optic Sensors Stepping Motors ARC Advisory Group www arc web com After a flat 2011 the local automation market is back on the growth track and ARC predicts that market volume will exceed 1 billion by 2016 A significant amount of the investments are coming from China analysts said Manu facturing is picking up and the fo
5. i e analog control The switch from PC to PLC seemed to hap pen naturally and quickly with A B not objecting to usurping its trade name and all of us WE CELEBRATE 15 YEARS 1997 2012 users and instruc Same tors happy to be rid of the abbre viation confusion Today it is PC politically correct to call them PLCs MARVIN T ANDERL happily retired Get Some IT Help As always Jeremy Pollard hit the nail on the head with his latest column Wolf at the Cyber Door September 2012 www ControlDesign com wolf I am very concerned about many of my customers security or lack of it for their control systems A majority of my customers are small water and sewer utili ties I have put in the SCADA systems and set up security the best I know how However what I find is that all their PCs are on a simple peer to peer networks running out of date non updating antivirus and no firewalls All drives on the network are shared I can see file folders labeled Payroll Budget etc and have full ac cess to them While setting up a SCADA system at one site for three days there were two job applications lying out in full view on the desk with all personal data visible When I insist on user passwords I get 1234 for the operators no setpoint control view only and similar four digit passwords for supervisors with full access I don t believe we have to fear terrorist organizations as much as the
6. nects industrial controllers to I O devices and Simple Network Management Protocol SNMP support extends 46 Control Design October 2012 module diagnostics of network functions such as port status messages Media Redundancy Protocol MRP increases data reliability Molex 800 225 7724 www molex com KEEP OLD 1 0 G4EB2 I O processor integrates an exist ing legacy Pamux G4 digital I O system with modern Snap PAC con trollers and PAC Project software over Ethernet without changing existing I O or field wiring G4EB2 directly replaces a 32 channel digital I O processor in a legacy Pamux system Opto 22 800 321 opto www opto22 com CAT QUICK GX Series EtherCAT block I O is combined with the NJ Series machine auto mation controller with digital analog and pulse I O modules and micro second On Off times with EtherCAT s cycle times The block I O has been certified fully compatible by the EtherCAT Technology Group Omron Automation and Safety 866 88 omron www omron24 com MORE ASI 1 0 G11 AS Interface I O modules include two analog outputs each one for 0 20 mA operation for flat cable connectivity and one for 0 20 mA operation with an M12 round con nector A third module has four analog outputs of either 0 20 mA or 0 10 V for flat cable connectivi ty powered by AS Interface or an auxiliary power source The output type of each module can be selected by DIP switch Pepperl Fuchs 330
7. oped its Mach Series and F Series machines to serve in earlier food manufacturing steps and adapt to a wide range of user requirements Mach Series can run at more than 100 parts per minute and has two high speed precision checkweighers and a high speed in motion checkweigher F Series machines run at less than 100 ppm and have in motion checkweigh ers Its washdown capable systems can be deployed throughout food It s the little things that count And sort And track And trace The new Allen Bradley industrial radio frequency identification RFID systems from Rockwell Automation improve manufacturing processes and product quality Multi tag read write capabilities and premier integration with Allen Bradley control systems enhance flexibility and deliver the information you need to optimize your processes For a first hand look visit AB RockwellAutomation com Sensors Switches RFID Rockwell Allen Bradley Rockwell Software Automation Copyright 2012 Rockwell Automation All Rights Reserved AD RS2289 R1 2P production lines and its IP69K rated systems are ideal for USDA regulated plants Figure 1 In the past individual adapta tion and scaling of the controls could be tricky tasks says Kari McAllister Friesen s product de velopment director In my view some of the major controls vendors in this space are too proprietary in nature and fail to provide inter faces for third par
8. that scenario make sure you pay attention to what your industrial equipment tells you Don t be scared of alarms This is how devices communicate with us If you are scared of alarm systems going off I rec ommend you follow this advice Remain calm follow safety procedures and solve problems quickly and effectively Read my column Scared of Alarms where I point you to two different white papers that can help you better understand alarms and better prepare you to deal with them when they go off Visit www ControlDesign com alarms to learn more Are you afraid of the dark You should be and not just because spooky things happen at midnight when the lights are off For machine builders and industry professionals having your equipment down due to power outages means money down the drain If you want to learn what you can do to prevent a voltage overload how to select the right power supply what the differ ent types of power problems are and how you can reduce operational expenditures while increasing productivity and ef ficiency read my article Don t Be Left in the Dark Check in at ww wW ControlDesign com dark and start learning now Have you ever been to a haunted house Those are packed with unexpected sur prises jumping at you doors flying open things falling from the ceiling or popping up from the floor You know what is as scary as a haunted house An unprotected network system In the a
9. 3 RV 10 Flexmaster s core consists of a vertical indexing table with 10 clamping stations In each cycle the motor powered table rotates the workpieces to the next station The machine s rotary indexing principle allows it to process nine workpieces in parallel in each cycle and achieve high throughput RV 10 Flexmaster uses SERCOS III which provides profiles for smoothly integrating both drive technologies and helps accom modate frequent changeovers Previously cam controlled controldesign com machines were unbeatably fast for large scale series production says Eckhard Neth Winema s manag ing director However we ve been able to top this speed and combine it with the advantages of CNC technology for increased flexibil ity And combining the HNC with SERCOS III and IndraMotion has allowed us to improve our output by 20 compared to the previously available solutions Fast and Familiar Programming To wrangle those increasingly thin and delicate plastic water bottles and build layers from widely vary ing case sizes PAI developed its Hybrid Gantry Palletizer in 2009 and began building it last year Davis says Unlike a regular robot arm this machine and its robots and crane can be thought of as a Cartesian palletizer that moves in the usual x y and z planes he says Figure 4 Besides maintaining high speed and providing softer handling PAI found that using the eight servos via EtherNet
10. 486 0001 www pepperl fuchs us controldesign com JUMP 3 TIMES 2002 Series Topjob S terminal blocks carry three jumper slots for control cabinet flexibility DIN rail disconnect test with mechanical interlock mini automotive blade style fuse and fuse disconnect with pivoting holder accommodate one output and two input potential commoning The third jumper permits test and measurement via plugs taps without distributing machine wiring Wago 800 din rail www wago us QUICK RESPONSE Axioline real time I O system has a response time of less than 1 ps per I O module It uses push in technology for quick tool less connec tion operates in a range of 25 to 60 C and has extended protection against EMC with adjustable input filter times Phoenix Contact 800 322 3225 www phoenixcontact com REMOTE 1 0 EtherNet IP based remote I O modules include Adam 6150EI with 15 channels of isolated digital I O Adam 6151EI with 16 channel isolated digitalinput Adam 6156EI with 16 channel isolated digital output and Adam 6160EI with six channel relay output They are designed with 2 500 Vdc isolation protec tions and are resistant to field interference Advantech Industrial Automation 800 205 7940 www advantech com ea PLENTY OF ZIP Zipport heavy duty multi wire connectors in 3A 6B 10B 16B and 24B frame sizes and polyester powder coated aluminum alloy housings have a standard profile and PG threaded cable passages PG
11. 55 jeuwueunndaubisepjonuo SVOMO H S Lo Md O od Ei PRODUCT SHOWCASE EE A BRIDGE TO SAFETY SafetyBridge distrib utes safe I O modules in a network without a safety controller as the input and output modules exchange safety related signals with one another The modules process the safety function themselves so the control system and network are used only as a transport medium Safeconf software parameterizes the safety input and output channels and generates the safety logic Pre configured function blocks are available Phoenix Contact 800 322 3225 www phoenixcontact com FIVE AT A TIME For simultaneous five axis high speed machining 30i B 31i B5 CNCs have high speed smooth Tool Center Point Control TCP with fairing technology i IEI to reduce cycle times Execution of common instructions is 2 5 times faster than the previous generation with additional capability of high speed module executing every 1 ms It includes a handheld operator s unit iPendant for CNC Fanuc FA America 888 326 8287 www fanucfa com PID YOUR PLC Eurotherm Mini8 multi loop PID controller with EtherNet IP communi cations partners with a PLC in multi loop PID applications such as plastics extrusion so the PLC can concentrate on providing faster more effective logic control without the burden of run ning complex control algorithms Input accuracy is x0 176 or better Invensys Operations Management 7
12. 8258 www ashcroft com THIRD GEN VISION 4Sight GP industrial com puter for machine vision is powered by a third generation Intel Core processor for real time high definition H 264 encoding offload It accommodates full height half length frame grabbers for analog Camera Link CoaXPress DVI or SDI video capture It in tegrates Gigabit Ethernet and USB 3 0 interfac es which provide native support for capturing from GigE Vision cameras and upcoming USB3 Vision cameras Matrox Imaging 514 685 2630 www matrox com imaging ISOLATED FOR SAFETY ISM TRM ISO IN provides 24 lines of optically isolated and digitally debounced inputs from field wiring ISM TRM ISO OUT provides 24 lines of optically isolated outputs Signal isolation between an embedded computer and monitoring points creates a barrier to eliminate common mode voltage and prevent ground loops on digital signals WinSystems 817 274 7553 www winsystems com MANUAL MODES KL85xx digital and ana log I O manual operating modules provide manual machine intervention without opening the control cabinet KL8519 with 16 channel 24 Vdc digital inputs monitors ma chine status KL8528 has eight channel 24 Vdc at 0 5 A per channel digital outputs to follow disable 54 Control Design October 2012 or manually turn on outputs KL8524 with four two channel 24 Vdc at 0 5 A digital outputs has eight channels in pairs such that only one output is allowed to b
13. IP to move manipulate and rotate the cases also eliminated a lot of mechanical assemblies such as diverters case turners and conveyor rollers However the problem was that the initial programming for this new palletizer was more like using G code and a teach pendant which was hard for our customers to learn because they re more familiar with the ladder logic that palletizers usually employ Davis says So we looked for a better way and decided to use RSLogix The 750 880 series PLC with SD card is optimized for Pan today s intensive data and memory applications 5000 software because we could program it so our users could understand it better and work in amore familiar environment For example customers say they can use logic modules in the software s DMAT toolkit to bring in tags for the servos and easily set up and commission them without having to go to a second software program Also the servos communications are isolated by the Ethernet module which plugs into the Control Logix PAC and creates a private network for that EtherNet IP ring We also knew this isolation was important because in the past we had a problem with a more open network and some users and devices trying to use the same IP address and being unable to communicate fll a us a including memory expansion program backup and restore recipe exchange data logging and more On board 1 MB program an
14. Jeremy Pollard s column PLC Genesis June 2012 www ControlDesign com genesis I have to weigh in with my perhaps faulty recollections of the program mable controller name transition from PC to PLC In 1973 and 74 I worked for Texas Instruments de signing anti lock braking ABS controls This of course is an automotive prod uct and the first programmable controllers were designed for the automotive industry so TT s PC designers were in the same department In 1974 they clearly were called PC for pro grammable controller My next contact with pro grammable controllers was in 1979 at a publication printing company where a Modicon 384 was applied to control a rotogravure printing press Programmable controllers were still called PCs at that time The PC abbreviation also meant printed circuit but context usually sufficed to keep those two straight As we all realize the IBM PC brand name added confusion Even Xerox tried using PC for personal copier One trade journal changed its name from PC Design to Printed Circuit Design probably because people were disappointed to find that the magazine was not describing how to build personal computers I first saw PLC used by Allen Bradley I believe one of controldesign com its models was called PLC 01 to distinguish its product from distributed control systems DCS which were primarily concentrating on PID loops
15. Machinery 269 Printing Trades Machinery amp Equipment 519 Pumps amp Pumping Equipment 825 Rolling Mill Machinery amp Equipment 1193 Semiconductor Manufacturing Machinery 1 392 Textile Machinery 225 Woodworking Machinery 39 Other Industries amp Special Industrial Machinery amp Equipment NEC 7 226 TOTAL 40 020 T This t Cd BPA o gt WORLDWIDE S Parts by Addition HERE S A QUICK note about two of the many slick things at Sep tember s IMTS 2012 The event now includes an Industrial Automation North America IANA conference and exhibitor component produced by Deutsche Messe the folks who do the Hannover Fair In halls dominated by machin ing centers I found a very different machine that doesn t cut metal to make industrial grade parts It builds parts layer by layer This is additive manufacturing Some methods are called 3D print ing Five or six companies exhibited various types of this technology In the Emerging Technologies Center ExOne www exone com showed one of its machines which in basic terms is a giant inkjet printer with a z axis It selectively dispenses chemical binder into thin layers of powdered metal or plastics This ad ditive process creates parts or molds for parts directly from CAD data Its sweet spot is simplifying and reducing the cost of complex parts including those with quantities that make molds too costly Lot size ren dered unimportant Consider that Process co
16. Series audible in dicators come with 15 pre loaded selectable alarm and chime style sounds Users can program each unit with 15 original messages or sounds in MP3 format totaling up to 63 s with an optional SD card They provide user selectable volume control 0 87 dB at 1 m Patlite 310 328 3222 www patlite com ENHANCED BRICK Power Brick Drive has a seventh generation PMAC controller integrated with upgraded am plifier blocks It has vibration suppression of flexible mechani cal systems adaptive control of dynamic inertial fluctuations automatic cross coupling and on the fly inverse and forward kinematics com putation of a six axis actuator robot arm Delta Tau 818 998 2095 www deltatau com LOW MAINTENANCE TYPE Type ES actuator com bines caged ball LM guide Type SRS and a rolled ball screw equipped with a QZ Lubricator Type EC actuator also uses a rolled ball screw equipped with a QZ Lubricator in two models with widths ranging 40 48 mm and heights 48 5 57 5 mm THK America 847 310 1111 www thk com INDUSTRIAL TV LX Series industrial grade embedded PC based monitor has modular steel construc tion in six sizes 32 70 in industrial type mounting and AC quick disconnect and is Ethernet ready It offers a choice of industrial grade embedded AMD Fusion or Intel Core motherboards solid state drive and CPU options Dynics 734 677 6100 www dynics com October 2012 Control Design
17. and play integration with popular PC based HMI and SCADA software packages Moore Industries 818 894 7111 www miinet com DISTRIBUTED AND MODULAR Distributed modular I O with IP67 protection and in dustry standard connectors uses standard three conduc i tor cables Up to four slave devices can be connected to each master block which communicates via in dustrial Ethernet to the controller With point to point IO Link the system is fieldbus independent and vendor neutral Balluff 800 543 8390 www balluff com CONNECT AT THE SUMIT PXM UIO96 2 96 line digital I O module offers PCI Express expansion on a PC 104 sized module enabled by stackable high speed Sumit connec tor It uses a Lattice Semiconductor FPGA with a superset of the company s universal I O control ler cores Each I O line is programmable for input output or output with read back operation WinSystems 817 274 7553 www winsystems com October 2012 Control Design 49 dANANNONH LONCOdd is BRIDGE BUILDER CBC terminal blocks are designed to ad dress control and power distribution applications where cir cuit bridging of two to 50 positions is required Let U S P Ck YO U r B ra n for consecutive alternate and numerous termi nal blocks in one assembly Each terminal block In upcoming issues of Control Design E two brid j l we ll explore subjects that include can accept one or two bridges jumpers ASI 877 650 5160 www asi e
18. as one scan finishes the next one starts The advantage is that small programs run fast even on low end hardware but as the program grows so does the program runtime thus slow ing down reaction times Another disadvantage is that as different program conditions execute more or less code per scan the program execution time varies leading to inaccuracies that will have a negative impact on the repeatability from one machine or product cycle to the next On a PAC the program will run in a sched uled cyclic mode Here an underlying real time operating system will schedule program s in cyclic tasks with different priorities and cycle times independent of the program execution time This allows the application to be separated into programs running in a fast cycle time for time critical tasks e g digital I O processing and slower cycle times for less time critical tasks e g PID temperature control and HMI logic on the machine What might look more complex at first controldesign com really offers much greater flexibility to any ma chine builder in designing the application soft ware and achieving better production accuracy and repeatability due to a constant timing Another common difference between a PAC and a PLC is the ability to incorporate additional functionality like motion and robotic control remote or onboard visualization file handling web server etc on the same piece of hardware allowing consolidation of multi
19. com devicecoupler The enhance ments should give end users more confidence that registered fieldbus equipment can be employed in a control system architecture suited to industrial environments said Stephen Mitschke director of fieldbus products for the Fieldbus Foundation tll controldesign com New Eco Design N Rail Power Supply Series or Systems in Compliance Directive Energy Efficiency TPC Series 30 55 80 and 120 Watt an Fo _ i LE A j i J i gt a e EMC characteristics for industrial and residential environments e Nominal output voltages 5 12 24 and 48 VDC e High efficiency across full load range e Low standby power consumption ErP ready 0 3 W for 30 and 55 W models 0 5 W for 80 and 120 W models e Remote On Off input and DC ok signal output e Lightweight in compact robust plastic casing e Excellent price performance ratio e International safety approval package www tracopower com POWERGATE LLC 866 588 1750 www powergatellc com Power Sources Unlimited 800 966 7784 www psui com traco E 1 pL I Are you frequently wasted at work Well forget HR Go straight to PT Pilot and stop wasting your valuable time fumbling through catalogs price books and emails to specify a gear unit or gearmotor PT Pilot quickly provides a quote parts lists 3D CAD drawing and all motor and gear options The tr
20. fail ure conditions Within a product strength is the measure of resis tance to stress When the product design produces higher strength levels the product is much less likely to fail Many Potential Stressors Electronic devices have many po tential stressors Environmental C XJ EN DE RS DRIVES and physical stressors include heat humidity chemicals shock vibration electrical surge electro static discharge radio waves and others Operational stressors in clude incorrect commands from an operator incorrect maintenance procedures bad calibration im proper grounding etc Now that makes sense for hard ware but how does this concept apply to software What are the stressors on a software system Just as with hardware software failure occurs when the stress is greater than the strength The strength of a software system can be measured by the number of software faults or design errors bugs present the testability of the system the amount of soft try one of ours free Red Lion 1 717 767 6511 info redlion net www redlion net 2012 Red Lion Controls Inc All Rights Reserved ware error checking and online data validation The stress of a software system is dependent on the combination of inputs input Testing revealed that if an alarm acknowledgment key was struck within 32 ms of the alarm silence key a software routine would overwrite a critical area of memory and the
21. kid in the apart ment building next door In all honesty I feel they need an IT person to configure security I am not skilled at that and cannot keep up to date on OUT OF THIS LJ PERFORMANCE those threats and my own ar eas of responsibility too Most days I don t feel I have enough competence for my own work Keep up the great work JIM MEMMER CET JH Memmer Technical Services www jhmemmer com fil October 2012 Control Design Il AOvtucdzdz EE Pe e en i T fem S9 e e D Reliable and Flexible Panel Designs Panduit provides high quality product systems that connect manage and protect today s industrial systems throughout the physical infrastructure from on machine control panels to facility electrical panels Key product features include e Space Optimization Increase space savings and design flexibility in control panel layouts with innovative wiring duct e High Quality Connections Improve system reliability with ferrules and tooling that provide superior performance e Safe and Secure Access Maintain and monitor industrial networks using JAUNE data access ports AM AVID Comprehensive Systems To Meet Your Needs Eu n U IT A e Wiring Duct e Power and Grounding Connectors e Ferrules Disconnects and Terminals e Abrasion Protection building a smarter e Outlets e Labeling and Identification unified business foundation e Installation Tools e Safety and Facil
22. managing editor 4 digital managing editor WTB2 FB130L IEC fuse ahand putman net kbonfante putman net holder terminal blocks have a current rating 1 Jim Montague Sarah Cechowski to 30 A and accept A x executive editor associate digital editor jmontague putman net scechowski putman net a built in LED circuit 1 in fuses They have to indicate when the fuse blows and funneled wiring entry with finger safe IP20 terminals Call us at 630 467 1301 Marking system allows for fast and easy circuit identification or start the conversation in our Machine Builder Forum on excontmals 724 775 2928 wwweacontralscom M ControlDesign com What Exactly Is a PAC WE VE USED BASIC PLCS and I O for machine control for a long time Our machines have to do more than before and we need more connectiv ity options and a more COTS standards based approach to hardware and programming Some customers are on the PAC bandwagon and think it s the next step for them and us There are dif ferent opinions of what a PAC is PLC vendors say they make PACs So do PC based control suppli ers Does it matter From August 12 CONTROL DESIGN ANSWERS Mashup Control A programmable automation controller PAC can be described as a mashup between a PC and a PLC in that it typically offers the benefits of both in a single package Therefore it s becoming more common that PLC vendors position their higher end control lers a
23. saw a more cost effective way to handle motion control visu alization more advanced calculations and con nectivity to supervisory and ERP MES systems These alternative suppliers to traditional PLC vendors realized that they could provide all of these extra functions without the extra cost of ad ditional hardware and software by using a power ful industrial PC processor as the core of their con troller These powerful devices were called PACs at controldesign com first to differentiate them from enhanced PLCs Unfortunately some PLC vendors answered this development by calling their enhanced PLCs PACs as well leading to confusion with the term While PC based solutions use standard off the shelf technologies and manage more func tions in software the PLC based PACs tend to rely more on proprietary add on hardware Again you must look at the cost and function ality you need and choose the best technology for your applications In general you will get more advanced functionality higher perfor mance and a lower cost if your controller uses a PC based design as it can handle all of the tasks within one CPU and with one software package On this note the advent of multicore processor technology in PC based control technologies has given a considerable lead to the controllers that incorporate them over their traditional PLC based peers Also consider that less hardware and soft ware is normally a good engineer
24. the shelf platform Signal Analysis Embedded Storage Control Algorithms Industrial Networks gt gt To learn more about CompactRIO visit ni com compactRIO 800 891 2755 b d NATIONAL P INSTRUMENTS OCTOBER 2012 CONTROL DESIGN ISSN 1094 3366 is published 12 times a year by Putman Media 555 West Pierce Rd Suite 301 Itasca Illinois 60143 Phone 630 467 1300 Fax 630 467 1124 Periodical postage paid at Itasca IL and at additional mailing offices Address all correspondence to Editorial and Executive Offices same address Printed in the United States Putman Media 2012 All rights reserved The contents of this publication may not be reproduced in whole or part without consent of the copyright owner POSTMASTER Send address changes to Control Design Post Office Box 3430 Northbrook Illinois 60065 3430 SUBSCRIPTIONS To apply for a free subscription fill in the form at www ControlDesign com subscribe mag To non qualified subscribers in the Unites States and its possessions subscriptions are 96 00 per year Single copies are 15 International sub scriptions are accepted at 200 Airmail only Putman Media also publishes CHEMICAL PROCESSING CONTROL FOOD PROCESSING INDUSTRIAL NETWORKING PHARMACEUTICAL MANUFACTURING and PLANT SER VICES CONTROL DESIGN assumes no responsibility for validity of claims in items reported Canada Post International Publications Mail Product Sales Agreement No 40028661
25. work It s a small world after all til October 2012 Control Design 15 Joupa Buibeuew pueyuey JAIM JAI EEEEEEEEEEENI t D 2 a 9 xo c e 3 ET 5 5 D e Choices i pa Li you p hia reed Teel tre iy n Standalone Rack mounted E a a Li a a You choose where to do control With SoftPAC vou can take advantage of a PC ul rm E s S F m 7 oo 3 j Tory fle space and speed for your control application um oum qu cp erat cure MTM UE weaned CRIA OAS control strategy on industrially hardened SNAP PACs die j ioe LIP run youl 7 i m A ill Ll m a L E mm m T E a Ls fi Ld LJ m Software hbased PAC or hardware PACs The chawe is WOUrS HE BOO 3271 6786 Automation made simple It All Adds Up ExOne Machines Jet Binders onto Sand or Metal Powders to Make Parts FOR VISITORS OF last month s International Machine Technol ogy Show IMTS who weren t already familiar with additive manufacturing they were able to get a taste of itin the IMTS Emerging Technology Center at the main entrance to the North hall There for example they could see the latest 3D printer from ExOne Figure 1 which builds intricate parts and cast ings through successive pow dery layers of metal sand glass ceramics or other materials In a show crowded with enormous booths running oversiz
26. 0 cases per minute Serial Bus FSSB communication line which runs at 150 MHz to control servo and linear motors says Paul Webster engineering manager at Fanuc ww w fanuc com Machine tool builders can use Profinet or EtherNet IP to reach PLCs and control auxiliary devices such as robotic loading or conveyors or to reach the enter prise but not for CNC However though most CNC functions in machine tools remain as separate islands Webster says they still added Ethernet ports and fieldbus links over the past 10 years they download programs with Fanuc s open CNC automatic programming interfaces APIs and they use the XML based MTConnect www mtconnect org standard to communicate with PLCs monitor machine perfor mance and even download G code files that the CNC machines use to perform projects Similarly Winema Maschinen bau www winema de in Gros selfingen Germany introduced a CNC controlled rotary indexing 34 Control Design October 2012 machine in a market usually domi nated by cam controlled equip ment Designed to handle small 2 23 mm diameter workpieces RV 10 Flexmaster employs an Indra Motion CNC based system with decentralized intelligent electric and hydraulic drives from Bosch Rexroth www boschrexroth us com which control the machine s 54 CNC axes including 27 In draDrive spindle drives It basically consolidates CNC and PLC tasks into one IEC 61131 3 compliant module Figure
27. 03 724 7300 www eurotherm com ethernet ip 56 Control Design October 2012 CAN DO CAN PCI 104 Express boards for use in compact industrial computers and mobile systems have up to four CAN interfaces and optional switch able high low speed CAN and LIN interfaces In addition to a passive version for cost sensitive applications an active version with a 32 bit microcontroller is offered All interfaces are gal vanic isolated by default Ixxat 603 471 0800 www ixxat com POWER AND BEYOND Infinity power sup plies provide the tighter output volt age regulation and regulation technology Line and load regulation lower output ripple advantages of linear for many models is 2 mV and ripple less than 0 25 mVrms 0 75 mVp p with virtually no common mode noise Standard models are available with outputs to 150 V and 150 W with both slot output voltage ranges and wide adjust models Acopian 610 258 6149 www acopian com infinity CHECK YOUR VIBE Vibconnect RF wire less condition monitor ing system for machine components monitors machine vibration bear ing condition and tem perature and transmits data to the bridge for evaluation It also detects damage caused by cavita tion Vibconnect bridge acts as the central receiver and processes data from the sensor units and transmits it through the operator s network for visualization and archiving The system includes a range o
28. 772 Tel 508 485 2244 Fax 508 485 2430 Siedle Group DRIVES amp MOTION CONTROL B From A to B With Mechanical Control For Gertain Applications a Mechanical Solution Can Provide a Simpler More Cost Effective Answer to Motion Challenges by Hank Hogan FOR SOME MOTION control challenges a simple so lution might be the best When movement is between only two points and is uncomplicated then mechani cal motion control often can be the smart solution A look at several examples illustrates why for some machine builders keeping it simple isn t stupid Most colorful T shirts sold at concerts or seen on the streets passed through a screen printing textile press Years ago multi color presses used pneumatics with an indexing cylinder to rotate a carousel with the number of stops dependent on the number of colors being printed In an hour a press might crank out 650 1 000 T shirts but that wasn t good enough The market started to require more stable performance and quicker changeover of job setup says Darek Tkacz chief mechanical engineer at M amp R Printing www mrprint com of Glen Ellyn Ill The company is a global supplier of screen printing textile and graphic presses M amp R Printing s initial solution to this demand involved a direct drive mechanism with a high end servo motor and gearbox The latter had less than 3 arc min 0 05 of backlash an accuracy needed because it had to position a carousel within a s
29. Automation www br automation com Booth 4337 control design In Memory of Julie Cappelletti Lange Vice President 1984 2012 e PutmanMedia 555 W Pierce Rd Suite 301 Itasca Illinois 60143 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 AARON HAND ahand putman net MANAGING EDITOR DIGITAL MEDIA KATHERINE BONFANTE kbonfante putman net ASSOCIATE EDITOR DIGITAL MEDIA SARAH CECHOWSKI scechowski putman net SENIOR TECHNICAL EDITOR DAN HEBERT dhebert putman net EDITORIAL ASSISTANT LORI GOLDBERG lgoldberg 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 2012 Air amp Gas Compressors 790 Engineering amp Systems Integration Services 8 524 Engines amp Turbines 1 543 Food Products Machinery PASE Industrial Fans Blowers amp Air Purification Equipment 840 Industrial Heating Refrigeration amp Air Conditioning Equipment 1 494 Industrial Process Furnaces amp Ovens 1 028 Machine Tools 4 078 Materials Handling Conveyors amp Conveying Equipment 1 870 Metalworking Machinery Bes Mining Machinery amp Equipment 671 Oil amp Gas Field Machinery amp Equipment 1 211 Packaging Machinery 2959 Paper Industries
30. Canadian Mail Distributor information World Distribution Services Inc Station A PO Box 54 Windsor Ontario Canada N9A 6J5 Printed in the United States FEATURES 28 Cover Story Fast Movers Ethernet s Many Variants Are Just the Ticket for High Speed Motion Applications Get on Board With the One That Works Best for You Jim Montague executive editor 37 Drives amp Motion Control From A to B With Mechanical Control For Certain Applications a Mechanical Solution Can Provide a Simpler More Cost Effective Answer to Motion Challenges Hank Hogan 41 Machine Control Flashback 04 Reliability in Control Software Can You Count on Your Mission Critical Software Operator Safety and Product Quality Depend on It William Goble Exida 46 Product Roundup I O Solutions Cross the Board OEMs Rely on a Wide Variety of Mounting and Connectivity Routes COLUMNS 27 Embedded Intelligence Force Fits 7 ControlDesign com Machines That Go Boo 45 TechFlash Made in the Shades 9 Editor s Page Parts by Addition 13 Machine Builder Mojo Panel Meter Choices 58 OEM Insight The OEE Route 15 Live Wire Making Good Neighbors HOT BUTTONS 51 Real Answers What Exactly Is a PAC 11 Feedback 17 OEM Spotlight It All Adds Up 54 Product Showcase 20 InDiscrete Terminal PLC Combo to Rise in Popularity October 2012 Control Design 5 o ov Sr eun SLNALNOO ESS Why pay more for lower performance EtherCAT system
31. Control Powerful new tools enable us to develop software dependent control systems that are in creasingly more complex Soft eee lastre PR P ib eared ware reliability the ability of the software to perform its ex pected function when needed is essential Yet how often do we hear The network is down or My computer locked up again or How long has this opera tor station been frozen Our experience with software is far from perfect As industry s dependency on software increases so does the incentive to develop higher lev els of software reliability CONTROLDESIGN COM A OCTOBER 2012 DRILMVOE S A LINEAR MOTORS SERVOS STEPRPERS Software Failure Happens Consider why software fails The next few examples offer some in sight The console of an industrial machine operator had functioned normally for two years On one of a newly hired operator s first shifts his console stopped updating the CRT screen and would not respond to commands shortly after an alarm acknowledgment The unit was powered down and success fully restarted finding no hard ware failures With more than 400 units in the field and 8 million operating hours the manufacturer found it difficult to believe that a significant software fault existed in such a mature prod uct An extensive testing procedure CONTROLDESIGN COM A OCTOBER 2012 VALE VES CY ENDER SS DER AVIE Ss EMNIEAASR produced no furth
32. N m eo N a Lu ea o S o 2 a7 Mechanical sa Motion Simplicity Flashback 2004 Count on Software An OEE Culture Ethernet s Many Variants Are Just the Ticket for High Speed Motion Applications Get on Board With the One That Works Best for You y N LS _ PutmanMedia CALL Fact IF details on convert B from current oncle Windows CE 0 Web Wideo xi ER m m WET vm Ta i i J i d y H n y T EM CE T6 WIENWETS SULII d Od M F k E HERAVE iG IEEE ur IE UEE Lu MUIUBDUL AI mors Mold LT 3 a E D E m g W Jp P M mm m mex MU ENE aT LEN l li LE z 5 Gi d m D 4 1 5 il s j I N aM M NW m 4 v E D F x a a GE XE b m umm mx mz BH Mer let E i Fer Serial and Ethernet vrblnc ls built in AB Ethernet IP Modbus TCP IP GE SRTP Directlogix Ethernet USB amp Compact Flash for Data logging Troubleshoot your Panel Project Half way a the World without leaving your Desk Q Same Day Shipping until 7 15 PM CST Bie 1 Tech Support Lois e o 6 00 AM to 12 00 Midnight 1 Customer Service DAE Calslog 327 9 6 00 AM to 7 00 PM CST wagProduch www Automation net Process Measurement amp Control J NE bg a dad DIN Ultra High Performance Meter Controller pa ET ood e Universal Inputs DC Voltage Current T C RTD Strain
33. Novotechnik Omega Engineering ABB Low Voltage Products Allied Electronics AutomationDirect Autonics AVG Automation Panduit B amp R Industrial Automation Traco Power Balluff Red Lion Controls Beckhoff Automation Rockwell Automation c3controls Sealevel Systems SEW Eurodrive Siemens Industry Maple Systems Mersen Murrelektronik controldesign com October 2012 Control Design 57 lz fer R MACHINE esi is the only magazine exclusively dedicated to the original equipment manufacturing OEM market for instrumentation and controls the largest market for industrial controls c PutmanMedia 555 W Pierce Rd Suite 301 Itasca Illinois 60143 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 555 W Pierce Rd Suite 301 Itasca Illinois 60143 WESTERN REGIONAL MANAGER LAURA MARTINEZ martinez 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
34. SITIONS amp ALLIANCES ee The Drives amp Motion Division of Yaskawa America www yaskawa com acquired Wermac Electric www wermac com Wermac supplies software packaging solutions and on site services and has partnered with Yaskawa for 25 years to apply variable speed drives and electrical controls to the oil and gas industry Swagelok www swagelok com acquired the assets of Innovative Pressure Technologies IPT www inpressure com to broaden its offerings for fluid system technology customers IPT makes valves fittings and fluid control devices Industrial distributor Kaman Industrial Technologies KIT www kaman com completed its acquisition of Zeller www zellercorp com expanding KIT s capabilities in electrical automation and engineered systems including motion control machine vision electrical controls and power distribution The University of Alberta www ualberta ca joined the ASM Consortium www asmconsortium net which is geared toward reducing and mitigating abnormal situations in process industries Sirish Shah and Tongwen Chen both professors of engineering will represent the university in the consortium NOTEWORTHY InduSoft www indusoft com launched an educational version of its Web Studio HMI SCADA software for students and researchers at higher education institutions The goal of the program is to provide students a complete SCADA HMI package that enables them to develop real world applications
35. agoland I coach their kids in soccer we carpool to early morning choir practices and they tolerate the collapse of their lovely brick mail box when my 300 lb trampoline sets sail in a wind storm well the insurance money probably helped E With offices in Chicagoland we re surrounded by great machine and automation neighbors We should set up a play date BM So I wasn t too surprised last night when a young neighbor from across the street brought us over a big six pack of white cheddar shells that her mom had brought home from work What I was surprised about was to hear that this mother works for the company that makes the machines that shrink wrap the boxes of noodles Her com pany Arpac is located in Schiller Park Ill just east of our offices here so we share a very similar commute skirting the boundaries of the city I see more carpooling in our future and I think we ll be having a few more conversations about the world of food packaging machinery And what s one of the first things she tells me How difficult it is to hire engineers and technicians How many times have we heard that And what was the No 1 difficulty Lenze faced when setting up its new shop Finding the skilled workforce Wood marveled at the fact that about half the job candi dates didn t even show up for their first interviews Meanwhile one thing a company can do is be that good neighbor building a community where engineers and operators want to
36. ating system and though it used the correct frame format the operating system contained dif ferent data formats Because the computer did not check for a com MOTORS SERVOS STEPPERS VAEVES patible data format the data bits within the frame were incorrectly interpreted The events caused the computer to fail in a few seconds Many examples of software fail ure are documented and most of them seem to contain some combi nation of events considered unlike ly rare or even impossible Stress vs Strength Reliability engineering provides the stress vs strength concept Failures occur when a stress is greater than a corresponding strength Alhough this concept comes from mechanical and civil engineering and is most frequent ly applied to stress as a mechani cal force and strength as a struc ture s physical ability to resist that force the same concept is appli cable to software reliability A C Brombacher applies this concept to electronic hardware reliability In his book Reliabil ity by Design Brombacher notes that failures occur when some stress or combination of stressors exceeds the associated strength susceptibility of the system see figure Stress or the combination of stressors is represented by a curve of the probability of any par ticular stress value The strength curve indicates the chances of any particular strength value in a collection of products The area under both curves represents
37. barrier be tween the field side and system side wiring Dataforth 520 741 1404 www dataforth com ISOLATE AND CONVERT DIN rail mount TT230 sig nal conditioning I O mod ules are 12 5 mm wide and have a USB connection PC configuration Models isolate and convert ther mocouple RTD voltage or current input signals to a 4 20 mA output They are loop powered and support both source or sink output wiring connections Acromag 248 295 0865 www acromag com SCALABLE ST Series modular distributed I O system operates as a slave device station for CC Link or Profibus device level networks controldesign com It includes a head unit power supply and on DIN rail to form a remote system or node and has a scalable architecture that accepts mix and match I O configurations and I O concentrations from two to 16 I O points Mitsubishi Electric Automation 847 478 2100 www meau com TOUGH CONNECTOR Stainless steel junction boxes have FM approval for Class 1 Div 2 Groups A B C and D hazardous locations Rated IP67 there are six and eight port models for use with M12 s in or minifast connectors Stainless steel junction boxes are designed to house existing circuit boards and receptacle housings Turck 800 544 7769 www turck us SOME NEED IT HOT EtherCAT I O devices with Fast Hot Connect reduces the connection time for these change overs to 1 s increasing productivity as a result of changin
38. bearings on a machined rail Figure 2 With a simple air cyl inder they transported the robot between two spots Thanks to a hard stop and some built in fine adjustment Tech Con was able to achieve accurate positioning so that the robot could serially service each of the two assembly lines A shot pin held the robot in place while it performed its task with sensors detecting the position of the robot and shot pin When all was said and done this example of mechanical mo tion control paid off Heyden con cludes This simple system saved the requirement for a second robot he says i controldesign com Reliability in Control Software Can You Count on Your Mission Critical Software Operator Safety and Product Quality Depend on It A BY WILLIAM GOBLE A TH ANNIVERSARY onsidering all the components used in today s generation of control systems it s the root cause of hardware failure that gets studied most often w a The root cause of software failure on the other hand is rarely studied or well understood In the field studies that have been conducted some theories on what causes software failure have emerged but even those are not widely known or followed by soft ware engineers Similarly few practitioners know the rules of software reliability or take the time to under stand how to create reliable software Why In part be cause software development tool producers work hard Strength
39. but at a higher price point It seems the list of digital panel meter features is limited only by the imagination and the needs of machine robot and process skid builders In addition to real time control other digital meter features include signal conversion web server capability and wireless communication with sensor networks Moore Industries www miinet com makes a meter that can be used for alarming purposes as well as signal conversion and retransmis sion Our process monitor and indicator ac cepts a thermocouple or an RTD signal input notes Matt Moren director of sales support at Moore Two fully independent alarms may be specified Each may be individually config ured for high and low set points and a variety of latching sequences Additional models are available with an analog output signal propor tional to input for retransmission and with RS 485 communications Moore Industries meter like many panel controldesign com meters is programmed with front panel keys This simplifies long term maintenance because there s no programming software to keep track of and no need to lug around a PC This simplicity is a virtue of panel meters particularly for basic machines with limited analog monitoring and control requirements Though simple to program and maintain panel meters can control sophisticated operations such as weighing and scaling Our weight indicator controller panel meters have a on
40. computer would fail timing and stored data seen by the CPU The inputs and the tim ing of inputs could be a function of other computer systems op erators or both Improve Strength and Reliability Higher levels of software reliabil ity result from improving software strength Most of the efforts in this area have focused on improving the software development process and removing software faults Because human beings create software and also make mistakes the design pro cess is never perfect Companies expend many re sources to establish and monitor the software development pro cess These efforts aim to increase strength by reducing the number of faults in the software This ap proach can be very successful depending on implementation and attempts are being made to audit the effectiveness of the soft ware process For example the Flexible Field Upgradeable Meters Ranked 1 Red Lion panel meters have become the industry standard but don t take our word for it Ask the readers of Control Design magazine who voted our meters 1 for the last twelve years Available in a wide range of models and sizes our award winning digital and analog meters are a trusted field upgradeable solution that enables users to easily add or change capabilities The end result delivers real time visibility that drives productivity As the global experts in communication monitoring and control for industrial automati
41. ctLogix Rockwell Automation www rockwellautomation com A Controller by Any Other Name I think the concept of a PAC while technically defined is more of an all around automation solu tion piece of hardware rather than the simple I O controller we re used to in PLCs It used to be that the control system ended with the PLC and users interacted with an HMI to report this to the office where the numbers were punched in again Then we added SCADA and had to move information out of the PLC and into a more PC based environment October 2012 Control Design 51 jewueugndoubisepionuo GAHAMASNV IVge ES REAL ANSWERS EES It s inevitable that the next step of control systems would be to integrate a more tight knit linkage with the systems where the information needs to flow and often that information needs to flow to an IT controlled system So really I think PLCs are becoming the less expensive alternative to a PAC and becoming PACs in all but name and PC based control systems are hiding their PC background and moving toward a form factor and user interface much more akin to the traditional interfaces we re used to in the con trols industry Really I don t think it matters What does matter is that you find the proper tool for the job and more and more we re seeing connectivity options increase across the board Standards based programming gives us the ability to teach the next generation of controls engineers how to
42. d data memory e Process 1 000 instructions in 235ys Integrated Ethernet switch Mobilize your data at www wago us memorymaster Even When You Lose Power You Can Count On it The RSM2800 Magnetic Encoder counts turns measures angles down to the last degree and remembers shaft positions without power Don t try this with other encoders imagine your machine with the RSM2800 inside both lose power and are still turning without power when power is restored the RSM2800 reports the correct position including counts that occurred with no power Besides new features RSM2800 encoders provide the level of reliability accuracy and absolute position sought in demanding applications like e robotics e medical equipment e packaging machinery e cable extension transducers e mining equipment e forklifts The RSM2800 is based on Novotechnik s patented multi turn technology This new technology combines 4 advanced capabilities with AL ace CAUER mechanical simplicity to provide us 3 V Multi turn up to a lower purchase price of 16 turns under 100 and lower lifetime cost 1 Sealed up to IP 67 hh Y Resolution to 0 1 Y Diameter 29 mm Y Shaft diameter 6 mm in quantity Y Power up position Y No gears no optics no batteries For details on Novotechnik s RM2800 call us or visit wWww novotechnik com rsm2800 novotEcNNk Novotechnik U S Inc e 155 Northboro Road Southborough MA 01
43. ddressing to achieve determinism and then adjusted their communication methods and rules for increased speed by prioritizing and synchronizing how they transfer data In general tightly dedicated Ethernet net working permits greater speed but means less flexibility Meanwhile less restricted Ethernet enables more flexible communications but typically runs slower Historically there were two main schools of thought about manipu lating Ethernet to serve in higher speed motion time slicing and time stamping To prevent message collisions boost speed and achieve determinism time slicing ensures that critical devices and functions are assigned specified time slots to transmit information A managing node on the network handles time allocation so the others can trans mit without interference when it s their turn Time slicing is used mostly by EtherCAT Powerlink SERCOS III and Profinet Isochro nous Real Time IRT The second method time stamping is based on the IEEE 1588 standard s Precision Time Protocol PTP which defines a method for sub microsecond synchronization of the clocks in sensors actuators and other terminal devices on a standard Ethernet based network or other distributed application It s used primarily by EtherNet IP with CIP Sync and CIP Motion IEEE 1588 s basic function is to have the most precise clock on a network synchronize all the others and then time stamp each data packet moving on t
44. e compact instrument connects directly to an Ethernet network or can be con nected to the USB port of a computer with a USB Ethernet adapter fll October 2012 Control Design 13 ueqeuueg OFON eacd MNE ANIHOV Es dd J03Ipo e21uu229 JOIUaS o t o 0 et ao c et 3 y gt oO et The most innovative line of American made 22mm pilot devices Leading the industry with the shortest depth 22mm Pilot Devices made in the U S A c3controls new compact line saves you valuable space in your control panel and significantly reduces installation time and overhead costs Our design allows for quick assembly and disassembly of the products no tools required We have engineered a higher standard of safety requirements into our Push Twist Release which conforms to the EN418 directive With simpler installation and maximum safety features c3controls new line of Pilot Devices exceeds the demands of our customers and the industry Imagine the possibilities At c3controls it s what we do every day Go now to www c3controls com new22 and see the difference for yourself t E e WE DIDN T INVENT THE czjcontnrols LIFETIME WARRANTY GUARANTEED SAME DAY SHIPPING FACTORY DIRECT PRICING Making Good Neighbors ANYONE VISITING Disney World s Magic Kingdom in August is likely to appreciate the sweet relief of the cool slow boat ride of It s a Small World fol lowed by the frustration o
45. e interrelationships of the various processes much more thoroughly With some OEE history we will benefit from a predictive compo nent which is among the most valuable data By itself OEE isn t enough We need to create the culture where changes are embraced At the end of the day how fast the production lines ran is far less important than the throughput minus the rejects OEE will give you the numbers but the changes necessary to improve those numbers comes from you guessed it you fll JACK CHOPPER is chief electrical engineer at Filamatic www filamatic com in Baltimore controldesign com HOW DO I OPTIMIZE Se AND PROTECT m MY ASSETS Take a break from a week filled with questions by attending a week filled with answers Learn about the latest smart safe sustainable solutions to optimize production Improve machine performance Get all che answers at Automation Fair in Philadelphia Nov 7 8 Visit www AutomationFair com For the truly inquisitive attend the Safety Automation Forum or Process Solutions User Group Learn more at www SafetyAutomationForum com and http psug rockwellautomation com ies mtr oer Allen Bradley Rockwell Software Automation Copyright 2012 Rockwell Automation All Rights Reserved AD RS2290 R1P m hb ES r F F F T P 1 ji i j Tc mn ae Po PE LEAKS PANO r a LEE SE a IE PaF ii I Pay fT AE Be
46. e on at once and KL8548 has eight channel analog output 0 10 V and changeover between manual and automatic mode Beckhoff Automation 952 890 0000 www beckhoffautomation com POWER FOR FOUR MX80 vision proces sor has an Intel Core i7 quad core processor with 4 GB memory and four independent Gigabit PoE ports for up to four unique camera inspections running in paral lel It runs Version 10 4 of Impact Software Suite with features that include a simpler interface and faster image saving and image filtering tools Datalogic PPT Vision 952 996 9500 www pptvision com MICRO MILL IndraMotion MTX micro compact CNC solution for standard turning and milling machines has a cus tom HMI and multi axis drive controller with high capacity CNC and PLC It includes a comprehensive technology cy cle library for solving complex machining tasks is compatible with the standard performance and advanced versions of IndraMotion MTX has preconfigured software for turning and milling and has open PLC per IEC 61131 3 Bosch Rexroth 800 rexroth www boschrexroth us com SMOOTH PATH AHEAD Entry level Sinumerik 808D CNC provides up to three axis plus spindle control capabil ity in milling or turning applications Its 7 5 in color LCD has 640x480 resolution selectable function keyboard rotary dials for speed and spindle override LED tool controldesign com number display durable buffer battery and rear connecti
47. e the seat and flip it We designed a two stage grip per where one side had a shorter stroke than the other Gatewood says The short side would engage the seat first and push it to square it up then the longer side would do the final squaring and gripping in one motion Another issue was cycle time The entire process had to take place in less than 5 seconds Hit ting that mark meant using the lightest possible materials consis tent with the need for durability After some experimentation the Tekno engineering team settled on aircraft grade aluminum for 40 Control Design October 2012 the platform with aluminum and high density polyethylene plastic HDPE for the arms and grippers To get a fast enough turnover they used flow control to speed up the rotary actuator return stroke with a hydraulic shock absorber to bring everything to a gentle stop The final machine performed to specification and achieved its ob jectives according to Gatewood So too did the manufacturer for The offloading could not be handled by one robot This was not a capacity problem rather that the robot couldn t reach both assembly lines One very expensive solution would have been to install robots for each line whom Tekno built the machine Many of the motors and gears that Tekno uses are from Nord Gear www nord gear com Like others Mark Jones Nord vice president of engineering and marketing sees a growing tre
48. e touch no weights no wait calibration feature and can be used with a self diagnostic load cell says Rodger Jeffery director of marketing and business development at Hardy Process Solutions www hardysolutions com An embedded web server allows remote con nection to the meter from anywhere in the world via a web browser To help reduce the time and cost of integrating our meters into machine or skid control systems we provide pre tested PLC code Jeffery adds In terms of control the me ter s pre act weight can be adjusted in real time based on current feed conditions simplifying control and helping to minimize over feeds E In addition to real time control digital meter features include signal conversion web server capability and wireless communication lil Omega Engineering www omega com has a line of controllers that can be configured for PID or on off control Output options include solid state relays SPDT relays pulse and isolated programmable analog voltage current Transducer inputs to the meter can be hard wired or wireless Our point to point extended range 300 ft wireless transmitters and our high powered NEMA rated extended range 1 000 m transmitters both support a wide range of Omega transducers for extended flexibility in setting up your system solution explains Daniel Sparks Omega product manager Our 1 s DIN panel meter controller can monitor up to eight wire less sensors Th
49. e very costly Also color sensors are a lot easier to configure now The color sensor market hasn t performed especially well lately because vision systems have taken over some applications according to Steve Nylund CEO of Delta Computer Systems www deltacompsys com However both sensors and visions systems have suffered because they re of ten used in quality control projects that were put on the backburner during the recent recession Our specialty is color sensors that can handle textured materials and surface variations and so we ve been stable because this is where lower cost sensors can t perform as well Nylund explains We also have a large 0 5 in sensing area and a wide diffuse lighting pattern that smoothes out our sensing process Our sensors have been getting more sophisticated and now we can teach them up to 15 colors with our ColorSense software We gave the software the ability to more accurately show to the user what the sensor sees Michael Turner product manager for photo electric sensing at Pepperl Fuchs www pepperl fuchs us adds There s no middle of the road color sensor Either it s a basic type that s rela tively low cost with good performance but very limited in functionality or it s manufactured by a color sensor specialist and it s extremely costly I think there is room for innovation in the middle of the road category Pepperl Fuchs recently introduced a family of contrast sensors tha
50. ed milling and grinding machines the aisles featur ing additive manufacturing could have seemed a little quiet and out of place But they just might be the new face of part manufacturing able to produce quantities of one as easily as quantities of 1 000 and able to make complex and ornate metal designs without having to accommodate the con straints of traditional subtrac tive processes Figure 2 ExOne www exone com is based in Irwin Pa some 20 miles outside of Pittsburgh Founded about seven years ago as a spin off of surface finish ing provider Extrude Hone Ex One makes its own automated machines and also provides contract services At IMTS the company showcased its newest machine the M Flex 3D Print ing System which ExOne says offers more than seven times the volume output of additive manufacturing machines cur rently in use The M Flex is designed mainly for manufacturing controldesign com Figure 1 ExOne displays its latest 3D printer at the IMTS Emerging Technology Center The M Flex 3D Printing System builds metal parts one layer at a time by inkjetting binders onto thin layers of metal powder metal parts for use in such in dustries as mining automotive and energy It makes some of the same parts being made by heavy industrial machines that were on display elsewhere on the IMTS show floor but in an entirely different way Rather than turn mill and grind a part from metal ExOne s machine
51. er failures A test engineer visited the site and interviewed the new operator At this interview the engineer noted This guy is very fast on the keyboard That small observation allowed the problem to be traced and further testing revealed that if an alarm ac knowledgment key was struck with in 32 ms of the alarm silence key a software routine would overwrite a critical area of memory and the com puter would fail At another plant an operator re quested that a data file be displayed on the terminal and the computer failed This was not a new request the same data file had been dis played successfully on the system numerous times before The problem was traced to a soft ware module that did not always append a terminating null zero to the end of the file character string On most occasions the file name was stored in memory that had been cleared by zeros written into all locations Because of this the operation was always successful and the software fault remained hidden On the occasion that the dynamic memory allocation algo rithm chose memory that had not been cleared the system failed This failure occurred only when the software module did not ap pend the zero in combination with a memory allocation in an uncleared area of memory Consider a third example in which a computer stopped work ing after it received a message on its communication network The message came from an incompat ible oper
52. ets fa eo Lo SAN ILE Built in simulator Program Do more with the completely new and FREE Do more Designer E L e More program memory software DirectSOFT and ladder programs oh Moreand flexible data type memory developed with DirectSOFT are not compatible p e Faster program execution with these CPUs Download the FREE ER software e Easier to use instruction set e Integrated Ethernet on the CPU e Faster I O for counting and motion applications di Choose a Do more starter kit to get going fast You get More and easier to use communications e Prewired 3 slot base with your choice of Do more CPU e 8 point input simulator module e 8 point relay output module The new Do more H2 series CPUs leverage the existing Do more Designer software CD ROM Starter Kit line of DL205 I O modules and base units to create an USB programming cable incredibly powerful PLC at an incredible bargain User manual H2 DM1E Coupon for 30 days FREE Two CPU options are available PM NEVISE Walning H2 DM1 AutomationDirect reserves the right to substitute a larger base at its discretion H2 DM1E 1 USB port for programming 1 full duplex serial port 1 Ethernet port H2 DM1E START with H2 DM1E CPU H2 DM1 1 USB port for programming H2 DM1 START with H2 DM1 CPU 1 full duplex serial port e Over 1M bytes total memory includes program data and documentation So visit om for the details watch overview
53. f ana lytical functions to assess condition Ludeca 305 591 8935 www ludeca com vibconnect controldesign com SOFTWARE MACHINING SOFTWARE XPS GCode conversion software can read convert and ps edit G code and execute in company s XPS Univer sal motion controller It features a 3D display with a real time active tool indicator and generates smooth motion routines along optimized trajectories with con I trolled velocity It can handle an array of high precision machining processes including laser machining Newport 949 253 1247 www newport com g code TRUE CUTS Vericut 7 2 CNC machine simulation verifica tion and optimization software eliminates the process of manually proving out NC programs It simulates all types of CNC machine tools and has the ability to optimize an NC program from a saved simulation Users can adjust and re optimize without rerunning the simulation CGTech 949 753 1050 www cgtech com SOFTWARE PAC SoftPAC software based programmable automation controller for computationally intensive applications and applications that must log manipulate and exchange large amounts of data is programmed with the PAC Project soft ware suite just like company s hardware PACs Drawing on PC RAM it can provide up to 64 MB RAM and it runs under Microsoft Windows 7 32 bit or 64 bit or Windows XP 32 bit Opto 22 800 321 6786 softpac opto22 com cil SoftPAC National Instruments
54. f realizing that the sugary sticky song will never ever leave your head Yes it can be a surprisingly small world at times and as I look ahead to next year s coverage of our Global Machine topic my mind is focused on the ways that machine builders can not only survive themselves but help their customers compete globally And yet I m equally struck by the steps manu facturers take to operate on a local level as well building good relationships with local suppliers and the communities that they live and work in In September Lenze Americas celebrated the official opening of a new production facility in Glendale Heights Ill That s just a stone s throw from our office so Joe Feeley and I checked in on them to take a look at the new digs In deciding where to locate their new 100 000 ft assembly and logistics facility Lenze got some uni versity folks to run some models They figured out that the center of Lenze s universe was about 100 miles south of here so they ultimately settled on this small western suburb of Chicago where there s no shortage of industrial activity While showing us around their production facilities Lenze officials repeatedly commented on the great relationship they ve formed with KMI Systems a turnkey system manufacturer about an hour up the road in Crystal Lake Ill KMI makes the conveyor systems that carry Lenze motors and gearboxes through paint and bake processes Lenze necessarily get
55. g topologies via direct plug and play coupling or decoupling during operation WinCAT automation suite sup ports Fast Hot Connect on the master side Beckhoff Automation 952 890 0000 www beckhoffautomation com DIRECT 1 0 LioN M I O EtherNet IP modules have 16 digital I O channels with universal input output functionality for direct connec tions between sensors actuators and control systems The universal modules 16DIO uni versal provide 16 digital inputs and 16 digital outputs in any desired combination without individual parameterization Belden Lumberg Automation 717 217 2299 www lumberg automationusa com controldesign com CONNECT THERMOCOUPLES Spiro TC three channel remote thermocouple modules can be powered by USB 6 50 Vdc or Power over Ethernet PoE Support for K J N S T Eand R thermocouples is available to 0 25 C resolution with 2 0 C accuracy with no cali bration required 14 bit measurement includes built in cold junction compensation and open thermocouple detection SoftPLC 512 264 8390 www softplc com MASTER DISTRIBUTOR microNCS provides Modbus RTU RS 485 master capabilities cost effective distributed data acquisition and with expansion I O control capabilities One or both of the microNCS s Modbus RTU ports can be configured to poll other RTU slaves with all of the network polling functions of a typical Modbus master An indus try standard OPC interface delivers plug
56. gth also increas es based on several important factors referred to as software diagnostics in primarily two ways First software diagnostics can reject potentially fatal data Second software diagnostics can do online verification of proper software execution In fact in ternational standards for safety CONTROLDESIGN COM A OCTOBER 2012 critical software DIN V VDE 0801 IEC 61508 specify software diag nostic techniques such as pro gram flow control and plausibil ity assertions These diagnostics are required in safety critical software approved by recognized third parties such as FM in the U S and TUV in Germany Most of the efforts in software reliability have focused on improving the software development process and removing software faults Because human beings create software and also make mistakes the design process is never perfect One software diagnostic tech nique is program flow control In this procedure each software component that must execute in sequence writes an indicator to memory Subsequently each soft ware component verifies that nec essary predecessors have done their job When a given sequence finishes verification is done to con firm that all the necessary software components have run in the proper sequence When the operations are time critical the indicators can in clude time stamps The times are checked to verify that maximums have not been exceeded Plausibility assertio
57. hatever We have a history of prior measurements with which to compare that data Back to the road example Assuming there are alternative routes to use when traffic grinds to a standstill many drivers begin a mental exercise to choose to stay on their current route or to invest the time necessary to navigate to an alternate With GPS devices supplying real time traffic infor mation browser enabled smartphones and traffic boards that announce distance and estimated travel times the exercise now involves much more data than before Not so long ago many of us relied solely on traffic reports from local radio stations The takeaway is that the better road will change from one to the other and back as con ditions change The time of day that the changes occur is crucial if we re to react appropriately Although far more complex than a simple road example the same thought process applies to plant equipment and its performance data Many of us are engaged in supplying solutions to help enterprises become more effective with the time available we want more throughputs with fewer errors and rejects with far more precision than ever before More importantly we want to know when we re failing to meet those goals but we want to know as soon as possible so that we can mitigate To reach those goals we must make good deci sions Properly implemented OEE is one tool that will help us make those decisions since we will understand th
58. he foundation s rigorous registration process Isolated device couplers are installed where the fieldbus trunk i e home run cable is connected to the various device spurs They are designed to allow automation end users to connect more de vices per coupler while permitting live segment work in hazardous plant areas These couplers provide isolated conditioned power to multiple fieldbus devices and protect against short circuits caused by excess current in a spur MTL s 9370 FB Series fieldbus barrier provides a range of complete integrated enclosure sys tems instead of standalone barrier modules All internal components are live pluggable meaning that field maintenance can be car ried out quickly and safely The series includes six and 12 spur versions in stainless steel or GRP enclosures as well as a redundant option enabling improved system availability in criti cal fieldbus networks R Stahl s Series 9411 21 and 9411 24 isolated device couplers are suitable for use in Zone 1 Zone 2 and U S Div 2 The series also includes a unique power management feature during the startup of a feldbus segment the spurs ener gize one after the other This reduces the inrush current on a segment by up to 50 requiring less spare energy and making longer segment lengths possible The device coupler test specs were updated recently to improve reliability and availability of fieldbus control system installations www ControlDesign
59. he network Not surprisingly the different methods of altering Ethernet for higher speed motion have led to some arguments The main debate Figure 1 Friesen s washdown capable checkweighers in its material handling systems use TwinCAT software and EtherCAT I O terminals and servo drives to adapt to and serve in all areas of food production lines as well as increase the checkweigher s speed by 31 and reduce downtime by 22 30 Control Design October 2012 controldesign com seems to be between the time slicers and the time stampers The slicers say that time stamped Ethernet is basically an Internet Protocol IP that s not dedicated enough to truly handle high speed motion and that it must run slower because its master device is always on and all data must run through it However the stampers counter that time slicing might be quicker but it risks losing data because its nodes can t run and communicate when the master device is talking Speedier Checks Bickering aside to give those food processors all the precise weigh ing data they need throughout their production lines Friesen s www friesensinc com of Detroit BR CKNER Figure 2 Br ckner s linear motor driven simultaneous stretching system LISIM machine pulls and stretches plastic film at 6 6 m s between two opposing ring shaped rail lines all coordinated by Powerlink which reduced cycle time to 400 ys Lakes Minn designed and devel
60. herent in remote data acquisition UNLOCK AUTOMATION SYSTEMS FOR HIGHER BUSINESS RESPONSIVENESS Learn how integrating MES with control systems makes manufacturing more agile To download PDF papers go to ControlDesign com whitepapers EEE ES PECIAR TO THE WEB IMTS 2012 S MACHINE BUILDERS TAKE OVER CHICAGO www ControlDesign com montagueimts IS SOCIAL MEDIA A USEFUL TOOL OR WASTE OF TIME www ControlDesign com social RIDE THE PLC VS PC TIME MACHINE www ControlDesign com time LATINO INVOLVEMENT IN STEM www ControlDesign com latino FINDING A PLACE FOR TECHNICIANS www ControlDesign com technicians controldesign com Machines That Go Boo THIS MONTH MANY of you will spend time decorating your front lawns with spooky Halloween things While you place decorative cobwebs bats flying witches skeletons and tombstones all over your yard some of your machines back at the plant floor might be getting ready for Halloween too Maybe they already have a white sheet covering them Maybe they are covered by real cobwebs On this Halloween night when you least expect it they will turn on roam the plant floor and chase after you screaming BOO OK the chances of your in dustrial machines hunting you down are pretty slim but if you don t maintain them and keep them up to date they might malfunction forcing you to shut down and that is a scary Situation in itself Before you find yourself in
61. hirts per hour the crank technique offers some significant advantages For one it allows M amp R Printing to switch from a pneumatic index to a more cost effective electric system with servo motor Tkacz says explaining that the servo motor made it easier to set up different parameters for different conditions Most important for us was that we have been able to pre program the speed of the ma chine for the different sizes of the printing pallets he says Customers very often are changing pallet sizes a few times a day With the pre programmed pallet size speed of the machine changeover is a very easy and fast process Another benefit is that the crank design boosts the throughput of some presses by about 50 with little increase in price over the older technology That is possible because the crank arm method is more forgiving in what it demands from a gearbox Tkacz says Using this motion will allow us to go with a gear box that s not as accurate and not as expensive he explains We ve been able to choose a gearbox that can have 10 arc min backlash and we can still achieve our linear accuracy for the indexing October 2012 Control Design 37 SEA LEVEL Computing HMI Serial Compact Ethernet data acquisition modules support PoE Easily connect I O to your network with Sealevel s new el O family of Ethernet data acquisition modules el O provides system designers with a compact cost effective solution fo
62. ign of Fault Tolerant Computers SafeComp 96 Proceedings of the 15th International Conference on Computer Safety Reliability and Security Springer Verlag New York N Y October 1996 Brombacher A C Reliability by Design John Wiley and Sons New York N Y 1992 Humphrey W S Managing the Software N UJ Process Addison Wesley Reading Mass 1989 4 Nuefelder A M Ensuring Software Reliability Marcel Dekker New York N Y 1993 Goble W M Control Systems Safety Evaluation and Reliability ISA Research Triangle Park N C 1998 Ul Made in the Shades THINGS USED TO BE simpler A color sensor did its basic low cost red green blue RGB sensing jobs to distinguish items such as bottle cap col ors A vision system used its expensive cameras for higher level image gathering and process ing to differentiate subtle shades Now both technologies are diversifying Color sensors can distinguish shades better and vision systems are dropping in price to do simpler tasks Most color sensors didn t do true color compari sons says Jack Moermond market manager for ob ject detection and photoelectronics at Balluff www balluff com The most popular binary output sen sors took in percentages of red green and blue and output them to PLCs to indicate color presence or go no go conditions Now a lot of customers want to compare or sort different shades and textures This capability used to b
63. ing principle for improved lifecycle management The most important consideration is how it can deliver enhanced functionality while also having the best price to performance ratio GRAHAM HARRIS president Beckhoff Automation www beckhoffautomation com cil OUR PRINTING MACHINES have widely distributed I O and sensors and we could save money by connecting some of these points via a wireless network We hesitate to proceed because we re not sure where the current wireless standards are headed and we don t want to implement a supposed standard that will fall out of favor in a few years Is there currently a leading standard that would be a safer pick for the future SEND US YOUR COMMENTS SUGGESTIONS OR SOLUTIONS FOR THIS PROBLEM We ll include it in the December 12 issue and post it on ControlDesign com Send visuals if you d like a sketch is fine Email us at RealAnswers 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 October 2012 Control Design 53 OHJMSNV Ives E controldesign putman net 2 Fe Q D U CT S H OWCAS E SSS TUBE FRIENDLY Type 1009 2 5 and 3 5 in Duralife SS pressure gauges with full scale ranges to 7 500 psi are available with a 0 25 in or 6 mm OD tubing fitting for direct connection to pressure tubing systems via industry standard ferrule type mechanical grip couplings Ashcroft 800 328
64. ittle exercise are the ideal con ll OEE is one tool that will help us make decisions since we will understand the interrelationships of the various processes much more thoroughly ll ditions We don t know the incidences of backups the synchronization of the traffic lights etc Ditto that for dynamic plant conditions where few processes are truly independent Properly measuring the performance of one process requires isolating it from the others When measuring dependent processes it s important to analyze the interactions and relationships to identify and un derstand the root cause of changes in the metrics In the road case above a simple change to the duration of a particular traffic light might benefit the overall throughput of traffic Or changing such timings only during specific hours might be more beneficial Quickly we begin to envision the design of experiments to determine the best strategy for the automatic signals We need to arm ourselves with information that lets us make good decisions in a timely manner to reap the benefits Example The sooner we know that the widget machine is struggling the sooner we can take action This action helps us either to 58 Control Design October 2012 mitigate that particular issue or better use labor and materials on all of the downstream equipment We know the widget machine is struggling because we measured it whether it s output fluctuations in power consumption or w
65. ity Signage Connect Manage Automate e Cable Ties and Wiring Accessories e Copper Cabling Systems Visit www panduit com panel cd today for free control panel reference documents that can help to lower your panel costs Practical Panel Meter Choices DIGITAL PANEL METERS provide an indication of machine and process conditions but also contain a host of added functions Of course these added functions aren t free adding not only cost but also varying degrees of complex ity That s why it sometimes makes sense to use an analog panel meter Analog panel meters are a low cost solution to provide a visual cue if the machine or process is operating as expected within a given range says Greg Hendry product manager for the meter and instruments division at Yokogawa Corp of America www yokogawa usa com Analog meters don t require external power as they are powered from the input signal A typical analog panel meter has an accuracy of 2 Common input signals are ac or dc amps or volts with custom scales possible Application examples Hendry adds would be to use the input frequen cy of an ac input signal to indicate ac frequency or as a time meter Use a digital panel meter when a more precise reading is required as they have an accuracy of 0 05 or less Hendry continues Digital panel meters also can incorporate control output and communication functions giving them added features as compared to analog panel meters
66. ium Watson noted Manufacturers of larger machines typically have the space and the budget to adopt a traditional solution of separate operator terminal and PLC units This solution also provides flexibility in terms of the component supplier of each unit and enables OEMs to cherry pick the most suitable two components for specific applications Though the combined opera tor terminal type is expected to see strong revenue growth to 2016 average selling prices are projected to decrease by about 3 per year Leading suppliers such as Pro face Uni tronics and Horner APG will therefore have to work hard to maintain revenue growth as price pressure drives down selling prices over the next few years Watson added FLASHBACK Met 15 1997 British Royal Air Force pilot Andy Green broke the land speed record by driving a jet powered car faster than the speed of sound Oct 29 1998 The oldest known copy of Archimedes work sold for 2 million at a New York auction Oct 1 1999 The People s Republic of China celebrated the 50th anniversary of its founding October 2000 The United Nations estimated that there were 742 500 industrial robots in use worldwide More than half of those were being used in Japan Oct 16 2000 Chevron announced that it would buy Texaco for 35 billion The combined company became the fourth largest oil company in the world Oct 24 2003 In London the last c
67. ivided on a number of points For example about one third of respondents 32 say their I O is mostly centralized with some remote distributed while another third 30 are using remote distributed I O with some centralized A quarter of them are using mostly or entirely centralized rack mounted I O systems with just under 13 using mostly or entirely remote distributed I O Of those us ing remote I O they are predominately almost 73 mounted in cabinets with 25 machine mount varieties Machine builders responding to our survey are also using a wide range of I O connectivity options Asked which types of connectivity they mostly use more than half almost 58 respond ed with 4 20 mA and also more than half 54 indicated hardwiring is high on their list Close to 45 ranked some kind of Ethernet connec tion high as well Other usage includes process fieldbus 30 device level digital networks 30 serial 26 and wireless 12 Choosing controller technology is a less dip lomatic affair however Almost three quarters 74 of respondents say their machine controller technology is PLC That s followed by embedded control at a distant 14 and PCs at 7 Close to two thirds are specifying and purchasing their I O bundled together with the controller CERTIFIABLE MODULES Brad HarshIO Profinet I O modules are PNO certified to meet Profinet specifications for conformance class B Fast Start Up FSU technology con
68. l gear Doing so ups gear efficiency from 60 to 98 and brings other benefits You can run the helical gear faster and it s more accurate Greene says controldesign com TECH CON DRIVES amp MOTION CONTROL J 7 Figure 2 A mechanical rail system allows a robot to transfer seats from the assembly line to the drop off point Flush Away Problems Tekno www tekno com Cave City Ky produces conveyors and material handling solutions for the automotive and other industries Cost is one reason the company sometimes turns to mechanical motion control says Larry Mus tread chief operating officer Not only is a mechanical solu tion cheaper initially it also can cost less to operate because of lower support costs and quicker time to repair That s a conse quence of the simplicity of the system and the ability to spot and diagnose problems quickly I know that it s going from point to point If it Mustread says starts losing that movement from point to point it s easy to pick up that I m getting wear somewhere controldesign com 4 Let I A ur n IM d E E E LJ P E om m cmm i ry J Pin Fiore um mum d Cura m I More machines Less labor Cut construction time generate more revenue By redi Not all problems can be solved with mechanical motion con trol though Mustread notes In particular complicated motions are not good candidates An n J
69. lutions to keep manufacturing precise We re printing voxels instead of pixels but we re still dealing with resolutions like in printing explains Bob Wood ExOne s October 2012 Control Design 17 ILHO9ITlLOdS INJO E Ferraz Shawmut iS now MeRSeEN We ve shortened our name And increased your expertise in ensuring the safety and integrity of power electronics systems Power electronic protection covers a lot of ground from air and liquid cooled heat sinks to semiconductor fuses and fuse holders to switches wire management and surge protection Mersen helps you cover all of it Now we have more products solutions and support to help you increase uptime and energy efficiency while protecting equipment and the people who work with it Ready for more It s waiting for you at fsisnowmersen com us CD PE Mersen ep us mersen com Vt 978 462 6662 info nby mersen com general manager We re drop ping binder on demand so things like time of flight become important We have to have very fine tuned actuators for the x and y print planes And data transfer is a big deal for us Wood also notes the similari ties with waterjet machining They re taking away material instead of adding it but the control is very similar he says Some key differences from 2D printing come from the materi als that additive manufacturing works with You have to con sider the ballistic impact of the binder how it affects the
70. n a retrofit ted VMC The focus has been on the hardest materials such as titanium nickel based alloys and compacted graphite iron although MAG maintains that the ROI should work for less difficult materials They can t prove it yet but they say the economics of the environmental savings and eliminating flood cool ing will stand on its own The process was approved by the U S government for roughing titanium components for the F 35 fighter and MAG expects finished machining approvals by early 2013 Catch up on the story at www Con trolDesign com IMTS il p October 2012 Control Design 9 Kepeieor AO d S HOllda BET Ja1y gt ui 40 1pa 0 o Lt lt c et 3 y 23 gt oO et ABB Low Voltage Drives New Berlin WI Tel 800 752 0696 Web www abb us drives RETIUM SM amp TERRENIT ii Trim I ril T MI 4 F a Di 1 MT There are many controls out there and you want to talk to any of them for any given project ABB understand the importance of connectivity and gives you the choice of which factory control systems you want to connect to using the language it understands With communication modules embedded into the drive or added as an adapter our product gives you the power to choose which system you connect to Find more information at http drivesanswers com 31 Power and productivity for a better world More PLC Memories Regarding
71. n any web platform Scary eh Another example involves a hacker trolling for certain data packets The company that was targeted makes automotive parts The IT guy had set up the company s Internet service with AT amp T and of course the router tables reflected the local setup along with a static external IP which was required for remote monitoring and configura tion as well as remote site access into the system The hacker s learned the IP address of the router and tried to break through the user and password combinations The IT guy was alerted and after a few hours determined what was hap pening He changed the IP address of the router with AT amp T and within 10 minutes the hacker was at it again How did he get the new static IP so quickly Still a mystery but he altered the rules on the router to simply reject all traffic except for specific MAC addresses and associated IP range If the password rules had been lax much dam age could have resulted Another reader lamented that when he asks for a password for the opera tors he gets 1234 That s just asking for trouble I write in Visual Basic VB for various reasons In that community there are many developers controldesign com and I found a complete VB project for a network client server application that facilitated file trans fer from one machine client to another server How many developers use scripts and ActiveX type controls in their application
72. nd toward energy savings which is achieved by tighter integration of motors and gearboxes Though mechanical motion control can be used for packag ing or manufacturing that is not primarily where it shows up as illustrated by its use in Nord Gear We manufacture here and we use our products to move our components around Jones says So the material handling side is certainly the largest segment The Mechanical Slide Another illustration of mechani cal motion control comes from Tech Con Automation www tech con com a system integra tor in Burlington Ontario that works with automotive and other manufacturers Simpler solutions are often better solutions notes Ron Heyden vice president of sales and marketing So for simple movements that do not require multiple stops or a high degree of resolution mechanical motion control might work best Consider the case of a large North American car seat manu facturer The company had two assembly lines running in parallel and the output of each needed to be placed on a shipping system pallet at the end of the line The offloading could not be handled by one robot This was not a capacity problem rather that the robot couldn t reach both as sembly lines One very expensive solution would have been to install robots for each line After studying the situation the company s technical staff mounted the robot on a base and then put the assembly on linear
73. ndings Current for these 728 zones along the 65 m long LISIM machine is supplied by 384 single and dual axis inverter modules in conjunc tion with 14 power supply modules and drives from B amp R Industrial Automation www br automation com and they re all synchronized via Powerlink LISIM s machine concept is based on linear motors and we invented it more than 15 years ago but it s experiencing a renaissance now because of increasing demand from the packaging and flat panel display industry for film with spe cial properties says Gunter Oedl Br ckner s electrical engineer ing manager for automation and development However the drive technology that we used up to now was getting on in years and a new proprietary solution would have been difficult and costly Oedl adds This solution was possible because Powerlink al lows precise synchronization of hundreds of network nodes and simultaneously provides high data throughput On one hand we were able to reduce the cycle time significantly it s now only 400 ps On the other hand we were able to move large chunks of software from the drives to a central drive controller This also simplified ser vicing and software maintenance B amp R maintains that controlling 728 axes with a 400 us update set a world record controldesign com All 398 of the Acopos modules both power supplies and inverters in LISIM are synchronized by 12 of B amp R s indu
74. nrodut siuidgnific and cast a 1h while reduoc mg tle LFE of The One customer saved 60 on ah 3 nfm Jj dui ala P rr LG DL i ILL Less is more articulated robot arm executing when using Balluff 1 0 movement along several axes at See how it s done al vorks balluff cam BALLUFF once he says is not best solved by mechanical motion control Neither is a motion path that October 2012 Control Design 39 E DRIVES amp MOTION CONTROL requires anything beyond moving from point A to B A leading maker of bathroom fixtures and hardware came to Tekno with a problem The compa ny needed to automate a packag ing process to reduce costs so that it could compete with overseas manufacturers Tekno streamlined the entire process A requirement in the overall automated sequence was to flip over a toilet seat so that a label could be placed on it Because the motion was a simple 180 flip Tekno elected to do it using a set of pneumatic grippers and a pneumatic rotary actuator The former grabbed the seat the latter rotated it and then the grippers released dropping the seat on an indexing conveyor that delivered it to labeling and packaging equipment One of the challenges was the variation among toilet sets says Lance Gatewood engineering manager Some were long and elliptical and others were short and round They also arrived at the flipping station skewed or off centered Thus the machine had to squar
75. ns verifica tion is another software diagnos tic While program flow control verifies that software components have executed properly in se quence and timing plausibility as sertions check inputs and stored data The proper format and con tent of communication messages are checked before commands are executed Data is checked to veri fy it is within a reasonable range Pointers to memory arrays also must be within a valid range for the particular array All these techniques are con sidered online software testing When a software diagnostic finds something not within the prede termined valid range there usually is an associated software fault A software diagnostic reporting sys tem records program execution data and fault data This provides the means for software develop ers to identify and repair software faults rapidly This increases the effectiveness of testing before a product is released Assuming the data is effectively stored these methods also allow more effective resolution of field failures when they occur A William Goble is principal partner with Exida www exida com provid ing safety training and consulting ser vices for users of industrial controls and automation With more than 30 years of experience he is a recog nized expert in programmable elec tronic systems analysis safety and high availability automation systems and market analysis References 1 Avizienis A Systematic Des
76. ntrol is dedicated hardwired and proprietary in these companies Standards based control holds too much risk to their intel lectual property So as this industry matures won t they need more open systems to keep up All these systems came from very proprietary ideas in the back room and not shared one bit says Dan Maas who does business development for Ex One We won t open up the PLC to customers let alone process control We won t risk the liability of crash ing a 30 000 40 000 print head You see similarities with the way the semiconductor industry s wafer processing evolved from unique control systems designed by the ChEs who were in charge then not the EEs It worked though yields were awful and they eventually untangled the homegrown one of a kind stuff to more manageable standardized systems as production and quality demanded more On our list of 1 000 things to do controls isn t at the top Maas told me I understand But if this industry grows like it looks capable of during the next five years better controls will climb that list fast I also visited the cryogenic tool cooling process for machining titanium in the MAG booth It got a lot of buzz at IMTS 2010 with claims of faster cutting longer tool life and big environmental advantages These systems came from very proprietary ideas in the back room and not shared one bit MAG had the process on a new five axis HMC and o
77. od and beverage and automotive industries are exporting more South Africa is benefiting from developments in neighboring countries such as Botswana Namibia and Mozambique but also exports its products to manufacturing industries worldwide South Africa is still highly affected by racial inequalities however and ARC sees the social tension poverty and diminished consumer spend ing as an inhibitor to industry growth Also the lack of engi neers and skilled workers is a threat to growth but local and global companies in South Af rica have established a number of strategies to overcome this problem the report said The largest automation market in South Africa is min ing but exports of chemicals metal products machinery transportation equipment and manufactured goods have also increased in recent years ARC advises companies to evaluate investments in South Africa carefully but the group is convinced that there is great potential ARC recommends settling in the Johannesburg Pretoria region and focusing on easy to use automation with plenty of services controldesign com Fieldbus Foundation Registers Isolated Device Couplers THE FIELDBUS FOUNDATION www fieldbus org announced registration of the first isolated device couplers based on its Foundation H1 31 25 kbps device coupler test specification Devices from MTL Instruments www mtl inst com and R Stahl www rstahl com successfully complet ed t
78. ommercial supersonic Concorde flight landed Dia Oct 20 2004 The United Nations reported that Japan was using 320 robots of all sorts per 10 000 employees and Germany was using 148 industrial robots per 10 000 employees In the car industry there was one robot per 10 workers in Japan Italy and Germany Oct 9 2009 NASA launched the Lunar Crater Observation and Sensing Satellite LCROSS Oct 22 2010 The International _ Space Station set the record 3 641 days for the longest continuous human occupation of space controldesign com SIEMENS i 14 I I E ill J L 7 d y F 1 i w Es 1 d T i g a ee i 1 ow I E Read the QR code with the QR code reader in your cell phone Simple to use Smaller in size Stronger in performance A new generation of distributed periphery Increase the efficiency of processes and the productivity of a plant the distributed periphery SIMATIC ET 200SP supports plant engineers and operators in meeting these challenges The sophisticated concept of the system offers significant benefits for you a a LJ I i E i j gi i i a Fi E ri i 1 1 eiii Pr T P Se a s 1 A m The easy use of the SIMATIC ET 200SP is apparent in the clear arrangement and easy installation of the modules the clear labeling system the tool free wiring and the efficient engineering The compact de
79. on we re confident you ll find our meters superior to your current solution Visit info redlion net panelmetertrade for more information red lon ISO9000 3 standard establishes required practices The Software Engineering Insti tute www sei cmu edu created a five level software maturity mod el wherein Level 5 represents the best process In addition compa nies in regulated industries such as pharmaceuticals audit software vendors to ensure compliance to internal software reliability stan dards By reducing the number of faults in software and thereby increasing its strength these ef forts have begun to improve soft ware reliability Another factor that influences the number of faults in a software system is its testability Software testing may or may not be effec tive depending on the variabil ity of execution A test program cannot be complete for example when software executes differ ently each time it is loaded In this situation the number of test cases explodes to virtual infinity Execution variability is increased with dynamic memory allocation number of CPU interrupts num ber of tasks in a multitasking en vironment etc All of these factors need to be considered when the potential reliability of software is evaluated Increasing the amount of variability such as multitask ing or dynamic memory allocation decreases testability and indicates lower strength and reliability Software stren
80. on ports for USB RS 232C distributed and onboard I O as well as setpoint to feed axes and spindle spindle encoder and fast I O Siemens Industry 800 879 8079 www usa siemens com cnc MULTI AXIS LATHE M70V for standard production machine applications such as grinding turn ing lathes screw machines and gear hobbings includes high end CNC features high speed PLC and nano control capabilities In lathe format it controls up to four spindles with a maximum of 11 axes and two part systems Mitsubishi Electric 847 478 2100 www meau com DO MORE THAN MILL With TNC 640 milling machine control turning operations can be enabled on a milling machine allowing the operator to transition from milling to turn ing cycles in the same program The turning operations can be programmed in plain text for roughing finishing recessing and thread cut ting AsmartSelect selects cycles and syntax color highlighting improves clarity for editing machining programs Heidenhain 800 543 0192 www heidenhain us EXTREME STOPS Corrosion resistant ZS71 and ZS91 emergency pull wire switches for extreme environments in high pressure high tempera ture wash downs IP69K have an integral e stop button allowing optional e stop operation directly at the switch Each is available for ATEX IEC Ex rated Zone 1 and Zone 21 explosive environments Steute Xtreme 203 244 6304 www steutextreme com controldesign com SOUND CONTROL BSV
81. or tools in our Insight vision soft ware to identify colors more accurately says Na rayan Subramaniam principal product marketing manager for Cognex s vision systems Rick Bondy product manager for registration solutions at Sick ww w sickusa com says that be sides teaching shades and setting tolerances color sensors are aided by stronger LED light sources that allow longer sensing distances and by its own 30x10 mm rectangular illumination area instead of the usual 18 mm circular light spots Sick s sensors can identify and teach up to four colors Many users are upset by vision systems that are costly complex and hard to set up Bondy says So in the last three or four years suppli ers have been making them easier to integrate maintain and apply fll October 2012 Control Design 45 en amp uow wr HSY IHHOZI Ee 3 o 5 e EH Q 9 To c e 3 D 5 3 D e cdroundup putmannet PRODUCT ROUNDUP m I O Solutions Cross the Board OEMs Rely on a Wide Variety of Mounting and Connectivity Routes INDUSTRIAL MANUFACTURING is a world that continues to demand more flexibility and more customized solutions with less of a one size fits all approach So it shouldn t be a surprise that machine builders are all over the board with what kinds of I O solutions they need CONTROL DESIGN surveyed machine builders recently about their I O systems and termi nal blocks and found that they were often pretty evenly d
82. our pal letizers for six or eight years says Kevin Davis elec trical design manager at Production Automation PAI ww w palletizers com in Montgomery Ala Today even in our high speed areas running eight axis with servos at 80 cases per minute with a half second cycle time it s still EtherNet IP We just make sure to isolate our high speed motion from other Ethernet traffic by using an Ethernet module with a ring topology Joey Stubbs North American representative of the EtherCAT Technology Group ETG www ethercat org adds The days of dedicated networks for mo tion I O and other tasks are effectively over since all of these tasks can be serviced by one network simultaneously from one controller Traditional motion protocols don t offer anywhere near the controldesign com HISTORICALLY THERE WERE TWO MAIN SCHOOLS OF THOUGHT ABOUT MANIPULATING ETHERNET TO SERVE IN HIGHER SPEED MOTION TIME SLICING AND TIME STAMPING performance diagnostics ease of use configuration and cabling of well implemented Ethernet based protocols This isn t just due to performance It s also because machine level communications now take advantage of consumer based technologies such as Cat 5 6 cabling connectors transceivers standard NICs as masters standard diagnostic tools etc This is instead of having to use special costly hardware required by legacy protocols This piggyback ing of physical layer components drives d
83. own the cost of systems and increases product selection PAI s palletizers have to quickly but gently stack and wrap cases of super thin plastic bottles and so they use robot arms and cranes on EtherNet IP to replace traditional physical diverters So how can machine builders choose the right type of Ethernet and related networking components to sat isfy end users who need increased speed and through put better handling increased flexibility and more open networking Follow a good role model There seem to be just as many Ethernet based solutions as users have problems You just have to get on the right train and avoid the brawl in the club car Slice It or Stamp It Basic vanilla Ethernet wiring and its pure TCP IP came from IT and office realms where data was blasted to all parts of the network and speed wasn t as crucial or possibly dangerous as on the plant floor Ethernet s October 2012 Control Design 29 SmartWire DT Optimize the cost and functionality of your control panel The Eaton 5martWire DT reduces wiring time and allows efficient connection to motor control components within minutes Motor Starters amp Contactors Pushbuttons amp Pilot Devices Selector Switches Control Relays Digital amp Analog l O Modules E e Discover more possibilities at www eaton com smartwiredt FRIESEN S more recent industrial protocols adopted increasingly intelligent switches and a
84. pdickson putman net 630 467 1300 Fax 630 467 1124 EXECUTIVE STARE PRESIDENT amp CEO JOHN M CAPPELLETTI CFO JANE B VOLLAND VP CIRCULATION JERRY CLARK VP CREATIVE SERVICES STEVE HERNER REPRINTS FOSTER REPRINTS www fosterprinting com JILL KALETHA jillkGfosterprinting com 866 879 9144 ext 168 L O U LLI O E S E 9 i a 2 M ce S s a U I 8 The OEE Route MANY YEARS AGO during a Lean Manufactur ing training session I collected one of my favorite axioms If you change something before mea suring it you won t be able to determine if the change was an improvement The ideal process is to measure make a single change document measure again The key word is single But how many of us have the luxury of following that process for implementing changes In production environments I suspect very few As a controls guy I like to measure and analyze I also read everything I can get my hands on regard ing best practices and overall equipment effective ness OEE measurements and implementations Consider this question Which road will get you to the 60 mile mark faster Traveling 30 mph on a road with no traffic lights or traveling 50 mph on a road with traffic lights every 4 75 miles on average with each red light lasting an average 2 5 min To decide many focus on the minimization prob lem and the rudimentary arithmetic but what s described in this l
85. ple controllers into a single one and offering value adds in terms of diagnostics and data collection capabilities This is the area where the lines from PLC to PAC and PC begin to blur depending on what functionality the underlying hardware and operating system architecture of the controller allows Some manufacturers are using microcon troller or RISC based architectures which are in essence a PLC on steroids faster and with better timing but not too much more functional ity common in a PC based architecture Some PC manufacturers come from the other end taking an industrialized PC with a real time operating system and maybe a second OS like Win dows and calling it a PAC or soft PLC Such systems offer great performance and additional functional ity but can t necessarily be scaled down cost effi ciently for lower end applications because of the PC hardware overhead They might also lack features common in a PLC like non volatile memory to retain tag information through a power cycle ROBERT MUEHLFELLNER director of automation B amp R Industrial Automation www br automation com PAC or Enhanced PLC It doesn t really matter what you call the control ler the realissue is the functionality you need and how much are you willing to pay for it PLCs have been enhanced with extra hardware and software over the years to handle more than their original function of sequential logic PACs were introduced as some companies
86. program independent of manu facturer and often to pick and choose what lan guage is the best for the particular programming option It s an exciting time to be in this industry DAN FENTON control and software product marketing Phoenix Contact www phoenixcontact com Often Not Required The Real Answer is that is doesn t really matter PAC is simply a term used by some suppliers to de scribe what others would call PLCs and PC based controllers In general it refers to hardware that goes above the simple ladder logic found in clas sic basic PLCs and that can incorporate higher level control such as PID and sequence control Nowadays the majority of PLCs offer this higher level of functionality with standard pro gramming languages connectivity for multiple bus systems and functional expansion through add on modules PC based systems offer similar functionality with a PLC kernel and additional interfaces to allow integration of standard PC technology and peripherals PACS often offer a higher level of performance integration of higher level PC languages and vi sualization possibilities combined on one system This convergence of technologies provides benefits of consolidation of tasks into a single system but brings with it an inherent increase in complexity In the end today s PC based and PLC offerings can both handle most applications The one that is right for you depends on your specific application functional re
87. quirements and knowledge Both types of systems come off the shelf with industry 52 Control Design October 2012 standard communication and engineering and offer enough flexibility that proprietary solutions are far more costly and often not required SYDNEY MCLAURIN JR PC based automation marketing manager Siemens Industry www usa siemens com Some Things Matter Some Don t There certainly are varying definitions of what a PAC exactly is vs the traditional PLC As a machine builder the primary concern shouldn t be in the terminology Instead consider other as pects when faced with having to add the features listed in the question What level of functional ity and performance is required for controlling a particular application Is there an automation platform available that can offer right sized and cost efficient hardware for not just a single ma chine but an entire machine portfolio Can the automation platform easily be customized with off the shelf products to adapt to changing needs and can it do that while reusing any existing ap plication software Is the hardware and software built on a modern architecture that ensures both innovation and long term availability From my perspective the main difference be tween a PAC and PLC is that a PAC provides better control of the timing of the application program s that run on the controller In a PLC the program typically runs in a continuous mode meaning that as soon
88. r monitoring and control with optically isolated inputs and Reed or Forrn C relays el O Solutions Offer e Ethernet Connected I O e DC or PoE Powered Variety of VO Configurations Field Removable Terminal Blocks DIN Rail or wall Mount Design DC or PoE Powered Power over Ethernet PoE 802 5af devices receive power and data on one cable and eliminate the need for additional power supplies Ready for DIN rail mounting el O modules include a removable plastic clip that snaps onto 35mm DIN rail You Learn more about el O Data Acquisition Modules at sealevel com pcd eio or scan this QR code with your smart phone 1986 2011 Sealevel Systems Inc All rights reserved M amp R PRINTING Figure 1 M amp R Printing needs only a simple motion that bounces between fixed locations so uses a crank index sys tem instead of a direct drive to convert rotary motion into linear motion The success of the approach can be seen in the fact that M amp R Print ing has converted its product line almost completely to a crank based design and away from pneumatic indexing he adds In implementing its design the company specified gearboxes from Lenze Americas www lenzeamericas com The biggest trend Lenze has seen is a push for increased energy efficiency says Steve Greene cen tral regional sales manager That has prompted Lenze Americas to move from a worm gear design to a helica
89. rticle The Only Evil Executive Editor Jim Montague says that with the emergence and adoption of Ethernet Inter net and wireless technologies linking thousands of devices worldwide many control and automaton engineers are scared their networks and applications will be hacked and damaged Industry professionals continu ally seek software solutions or hardware modules that can help them protect their applications Read Montague s article at www ControlDesign com evil to learn about solutions that he suggests can protect and strengthen the security of your industrial network Have a safe and happy Hal loween and don t let those old machines scare you fll October 2012 Control Design 7 euejuogeuueuey NOO NOIS3QCI ION LNOO Eis eipeui e3i6ip 1031pe Huibeuew a o 3 y 3 e oO c er 3 y oO e Technology by THE INNOVATORS Advanced i J 1 i i ey D Ad UN d a 1 oe 1 p A gt Extremely low overall costs possible through the use of long lasting maintenance free products gt PC technology with long term availability that coincides with the life cycle of the system gt Individually tailored to the ergonomics design and operating characteristics of the machine gt Fulfills requirements specific to each industry gt Minimized hardware and engineering costs through a complete and scalable range of products Perfection in
90. rust with verifica tion is paramount and disable all USB and CD activity A thin client approach might be able to thwart local sabotage since many actions are initiated from inside the firewall fl JEREMY POLLARD has been writing about technology and software issues for many years Publisher of The Software User Online he has been involved in control system programming and training for more than 25 years October 2012 Control Design 27 peod Aware HONO TALNI CI3CICIHS8IAZ Ea 135 UO 2 D o e et N c o My e o 3 Ethernet s Many Variants Are Just the Ticket 1 High Speed Motion Applications Get on Boaro With the One That Works Best for You by Jim Montague executive editor 28 Control Design October 2012 controldesign com ll aboard You might want to catch this train Ethernet has rolled over the world and now it s arriving at the last few pockets of resistance or at least appearing on the horizon It s no longer a question of whether Ethernet can handle increasingly higher speed motion it s just a just question of when and in what applications But even though you can travel blazingly fast via some Ethernet based net works your data packets also have to stay on the rails and stop at the right stations to get where they re going In machines trains and on the plant floor speed is nothing without accuracy Ease of use helps a lot too We ve been using EtherNet IP for motion in
91. s start with metal powders typi cally stainless steel but also tungsten and build the part from the bottom up or top down layer by layer The process starts witha CAD rendering of the finished product which is sliced into thin layers 0 1 0 15 mm each and sent to the specialized printer The machine creates the product by putting down a layer of finely powdered metal in a build box on top of which a print head selectively deposits a liquid binder according to the design for that layer This process is repeated hundreds or thousands of times until all layers are completed The build box now contains one or more complete parts surrounded by loose powder that has to be carefully blown away before the part goes into a furnace to burn out the binder and sinter the metal The hardened part at this point about 60 dense is then infiltrated with bronze to bring it to 100 density and make it ready for use Making molds and cores for casting relies on a similar printing process that uses foundry grade sand put down in layers 0 2 0 5 mm thick In this case after the loose sand is removed from the mold or Core it is ready to be sent to a foundry for the casting process From an automation stand point there are factors in this process that make it similar to some more commonly known machine processes such as 2D printing The machine uses inkjet print heads for example and must be concerned with maintaining fine reso
92. s PACs largely because their higher end prod ucts incorporate more connectivity options and broader control capabilities than their PLC lines In your situation the key point is what you state in your question connectivity options and commercial off the shelf COTS technology PACs offer both out of the box Connectivity options like Ethernet are standards based and therefore deliver on the COTS promise For example stan dard readily available components like network ing hardware will more easily and cost effectively interface with a PAC In contrast to PC based control more often than not a PAC will have lower running and maintenance costs One advantage of a PC based controller is faster computing speed and greater data storage area but not necessarily faster I O access Will your machine accommodate a larger PC based controller Is the environment around the machine harsh in any way PACs are usually smaller and more robust Taking all this into account you must consider your customer requirements weigh in your ma chine constraints and choose the best upgrade Many options certainly exist and ideally you should choose a vendor that provides multiple con troller options both PAC and PC based for example Given the rising use of smartphones and tablets in industrial automation you should also be look controldesign com ing at a platform that will ease adoption of this technology into your machine Internet wirele
93. s controlling spindles at thousands of rpms it can help coordinate axes load and unload ar E parts manage material handling E as a ham and perform other support tasks 2012 TURCK WINEMA essentially surrounding the core machining functions Fieldbuses and Ethernet aren t fast or secure enough for CNC motion and so we use our dedicated fiberoptic Fanuc Servo SHORTER CNC SETUP Figure 3 Winema s RV 10 Flexmaster CNC controlled rotary indexing machine for small 2 23 mm parts uses SERCOS III and a CNC with decentralized intelligent electric and hydraulic drives Industr askTURCK com CUBE67 now available for CUBE67 for EtherCAT features include e EtherCAT IP67 bus node and I O modules e Support for EtherCAT s latest version Modular Devices Protocol e 32 Modules per Node Analog I O Digital I O RTD Thermocouple High Speed Counter e Up to 60m 1 0 length e Extensive Diagnostics T ELEKTRONIK stay connected 1400 Northbrook Parkway Suite 300 Suwanee GA 30024 P 770 497 9292 F 770 497 9391 murrinc com PRODUCTION AUTOMATION Figure 4 Production Automation s Gantry Hybrid Palletizer uses integrated motion via EtherNet IP to control a dual head gantry crane and two robot arms with eight axis servos to quickly but gently grab position and build layers of cases of water bottles for palletizing in a 0 5 s cycle time at an overall rate of 8
94. s from Beckhoff are high speed high performance and low cost g i rl ET RE D Ene EE LE A4 an E uu a m m CEE 4 te 5 i d T roms EtherCAT Drives t os m Highly dynamic x EH EtherCAT I O Servo Drives 1 m Real time Ethernet down m Integrated ultra fast to each I O module control technology PC based Control with m Large cost effective EtherCAT selection for all signal m Solid state IPCs and PACs types with integrated Ethernet g ports no need for network um JA scanners i Use software instead of hardware PLC and Motion Control on one PC www beckhoff com EtherCAT System Beckhoff EtherCAT components Fast flexible precise and always cost efficient Industrial PC powerful PCs for any automation task EtherCAT Terminals IP 20 l O for all signal types EtherCAT Box machine mountable IP 67 I O directly in the field TwinCAT flexible automation software for multi PLC NC CNC TwinSAFE Safety PLC integrated into I O terminals Automation BECKHOFF NEW WHITE PAPERS REDUCE ARC ENERGIES WITH CURRENT LIMITING FUSES This paper illustrates the reduction of incident heat energy and the associated flash hazard boundary EXTEND INDUSTRIAL RELIABILITY TO CONTROL ROOMS Find out why networks are more vulnerable in the control room than at field sites CELLULAR RTU TECHNOLOGY FOR REMOTE PIPELINES Understand how to face the technical challenges in
95. s some of its supplies including home ground gears from its parent company in Germany and those supplies take some five weeks to reach the Chicagoland facility But the facility is also trying to localize sourcing as much as possible according to Gene Wood director of operations for Lenze Americas to help reduce leadtimes and transportation costs for example KMI is just one example of those great neighbors you hear about in old movies and State Farm commercials There s an abundance of peo ple in the machine business here Wood notes With our publishing offices located in Northwest Chicagoland we re surrounded by some pretty great neighbors as well I got to meet several of them at the latest IMTS show DMG Mori Seiki controldesign com in Hoffman Estates Ill Fanuc FA America also in Hoffman Estates and Mitsubishi Electric Automa tion in Vernon Hills Ill just to name a few and we talked about getting together for future play dates When I covered semiconductor manufactur ing from Chicagoland I never got that sense of community that my Silicon Valley based co editor did But covering machine automation from Chicagoland now that s a different story And it actually surprises me that in this day and age of global coverage there s something to be said for the closeness you feel to your neighbors I ve got a similar feeling of camaraderie with my neighbors where I live in Northwest Indiana i e Southeast Chic
96. s that no one knows about I suspect many Not surprisingly malware has become very smart Polymorphic malware is auto morphing which means it changes on its own So normal detection might work once but not a second time because of the way these viruses are detected Should a network connection such as a remote connection into the firewall be compromised software can be loaded onto the target computer and can go many places from there if allowed Another reader sent me a link to an article about how IT needs to help secure industrial control sys tems For a municipal SCADA upgrade I m involved with I asked who in the IT department looks after their servers and client machines They told me it was their system integrator Huh I can tell you they use pcAnywhere for remote access and the SI uses the same password for all projects Yikes E They use pcAnywhere for remote access and the SI uses the same password for all projects Yikes li No IT involvement so I can tell you that they are not that secure except that the Access Con trol List is kept by a wireless company They are protected but if it was a typical LAN WAN setup not so much How can we help ourselves Some of the more simple things would be a password process in volve IT for security and access and if necessary have a control network firewall that is separate from the company network In the end ask questions of your integrator and or your own developers T
97. sign of SIMATIC ET 200SP ensures maximum economy in the switching cabinet 64 modules with 64x16 signals can be accommodated on one meter The observance of the standardized bending radii is ensured as well The strong performance of the system results from the communication via PROFINET the leading Ethernet standard of automation The back panel bus of SIMATIC ET 200SP is synchronous and ensures highest precision and fastest data transfer You profit from maximum energy efficiency thanks to the integration of PROFlenergy Discover all highlights and details of the SIMATIC ET 200SP in 3D www usa siemens com et200sp 2u AsSNpu SUdWAIS ZLOZO INDISCRETE ES Equipment Leasing Business ECONOMIC ACTIVITY for the 628 billion equipment finance sector showed that new busi ness volume for August was 6 9 billion up 21 from the same period in 2011 according to the Equipment Leasing and Finance Assn s ELFA www elfaon line org Monthly Leasing and Finance Index August volume was up 5 from July and year to date cumulative new busi ness volume increased 1676 The pace of new equipment financing continued through out the summer months as the housing sector for one showed signs of a rebound said Wil liam Sutton ELFA s president and CEO However businesses both large and small continue to build up cash reserves indicat ing lingering apprehension over increasing energy prices insta bility in the Arab
98. spheri cal powder Wood says He also notes the increased burden of keeping the inkjet nozzles in working order considering that they are essentially shooting glue through those print heads On the one hand ExOne s additive manufacturing pro cesses are highly controlled in that they rely on sophisticated mathematical models to render designs and configure the most efficient way to nest parts in the build box All software is developed in house for the metal machines Wood says and ExOne has a relationship with a university to create the software for the sand machines The machines could run for days without intervention Wood notes As mentioned precise control of print head location is necessary and also rolling out Figure 2 Additive manufacturing or 3D printing produces complex shapes with one process creating sand molds for casting top for example or finished metal parts bottom controldesign com the fine powder layers requires extreme precision to make those layers flat and uniform On the other hand there is much of the process that could still be automated Additive manufacturing is really in its infancy on automation espe cially on the material handling side Wood says There s still a lot of potential for controls For instance one build pro cess could fill a build box with literally thousands of small cores Each of those cores which at this point are so fragile as to be easily cr
99. ss and cloud based storage solutions are all growing in use Select a PAC PLC or PC that can support these technologies and protocols in a secure manner So does it matter Yes I believe so But it s your current and future customers that will ulti mately help you decide BEN ORCHARD systems engineer Opto 22 www opto22 com The One That Suits Your Needs PLC is a term generally used to describe a general purpose controller ideal for controlling standalone discrete machinery or processes A PAC refers to a controller that offers multi discipline control For example a PAC might offer the ability to execute complex motion instructions as well as possess in tegrated safety functionality while a PLC typically would offer only logic control Some PC based control suppliers might offer PACs but not all PC based controllers are PACs The terminology is often interchanged even among the most savvy machine builders Here are some questions to help guide you 1 Does your application require multi discipline control motion safety drive process etc 2 Do you have panel size constraints that should be considered 3 What is the expected lifecycle of the machine 4 Is rugged packaging required 5 What networks will you be using for your machine design Overall the terminology is less important than selecting the controller and vendor partner that best meet your specific needs DEXTER LEONG product manager Compa
100. strial computers Each is equipped with three Power link cards which control up to 13 modules Using another Powerlink card the computers communicate with each other or with a higher level industrial computer that runs Bruckner s motion control software The plant control system which is responsible for controlling LISIM s oven is connected to this industrial PC via a Profibus interface Finally Powerlink s short cycle times and minimized jitter al lowed Bruckner to position the zones along LISIM very closely The individual zones are grouped in a very homogeneous manner Oedl says So the error tolerance is significantly less than a mil lisecond which was stipulated by the application Robert Muehlfellner B amp R s automation technology director adds The three fastest Ethernet based protocols are Powerlink EtherCAT and SERCOS III and they re all fast and reliable enough for high speed motion They all can achieve fast update times between sub 500 ys and sub 1 ms and they have high syn chronization and minimal jitter There are some technical differ ences but their end results are the same and so they re all good for 95 of machine applications Closer to Machining Aside from axes one type of motion that Ethernet hasn t taken on yet is in the CNCs used in machining centers and related tools Though Ethernet isn t practical for the criti cal tasks of high speed machine tools such a
101. sts with less chance of signal deterioration Rockwell Automation 414 382 2000 www rockwellautomation com IS 1 0 Simatic ET 200iSP I O system has three modules to accommodate safety standards IEC 61508 to SIL 3 or ISO 13849 1 to PLe e Sensors and actuators connect directly to a bus system and the I O system can be mounted in a non explosion proof cabinet Siemens Industry 800 241 4463 www usa siemens com SUPPORT YOUR LOCAL MARSHAL WMF 2 5 terminal series for DCS mar shalling applications features feed through fusing and quick disconnects in a single profile The terminals have an integrated shield or ground PE connec 48 Control Design October 2012 tion and three separate jumpering channels for parallel and series jumpering Weidmiller 800 849 9343 www weidmuller com CONNECT THE CUBE Backward compatible Cube67 connects up to 32 I O modules with a reach to 60 m and has protocol support for EtherCAT Bus nodes include an integrated Ethernet switch built in T coupler for power and IP selection window Modules include analog I O digital I O RTD ther mocouple and high speed counter Murrelektronik 770 497 9292 www murrinc com DAQ AND MORE MAQ20 for industrial data acquisition and control is a family of programmable multi channel signal condi tioning I O modules and communication modules They mount on standard gull wing DIN rail Each I O module has a 1 500 Vrms isolation
102. t is a special version of a color controldesign com mark sensor contrast sensor and incorporates IO Link networking functions that can be used to establish an RGB benchmark copy custom settings to multiple devices and save changeover time With the complexities of automotive interior assemblies door panels head liners cockpits seats etc the possibility to install an incorrect component can be relatively high unless assem bly is verified says Victor Caneff automotive business manager at Banner Engineering www bannerengineering com Our color sensor can verify that an installed component matches the color scheme of the interior design Using a white LED light source the sensor analyzes reflected light from the surface of the target By compar ing the red green and blue content present in the reflected light the sensor determines if the part matches a stored value from a known good sample programmed into its memory Also inten sity thresholds can be established to detect if the part is the correct shade of the color Customers want to compare or sort different shades and textures This capability used to be very costly Even in higher tech vision systems Cognex www cognex com agrees users want high resolution and to differentiate between shades so they want 24 bit color processing software and tools to do it We came up with a color camera with 1 600x1 200 pixel resolution and Match Color and Extract Col
103. tation ary fork to lock it For a 40 in diameter carousel the location had to be accurate within less than 0 002 in The precision of the positioning directly determined the quality of the print since the colors are layered atop one another Though the direct drive approach worked and of fered higher throughput it was significantly more expensive than the pneumatic method So M amp R Print ing opted to try another route one that exploited mechanical motion control Instead of a direct drive we installed a crank type index design Tkacz says The crank is connected controldesign com The crank arm method is more forgiving in what it demands from a gearbox Using this motion will allow us to go with a gearbox that s not as accurate and not as expensive through a link to a capture fork so that rotary motion is converted into linear motion back and forth This works for the company s application he adds because the machines require only a stop and start point a simple motion that always bounces between fixed locations M amp R Printing uses a design that has the crank with a 10 starting point and a 170 stop ping point Figure 1 although these two locations can be adjusted if needed Experience during devel opment revealed that the inertia of the largest and highest output carousels was too great for this ap proach Thus those machines remained direct drive For smaller carousels which can produce 900 T s
104. thread to NPT adapters are optional AutomationDirect 770 889 2858 www automationdirect com WILL YOU CRIO cRIO 908x reconfigurable I O RIO has Xilinx Spartan 6 FPGAs and optional Windows Embedded Standard 7 WES7 OS configuration The systems have two Gigabit Ethernet ports an MXI Express port four USB ports RS 232 and RS 485 serial ports as well as a CPU eX pansion Module CXM National Instruments 800 258 7022 www ni com controldesign com October 2012 Control Design 47 HMI5070P 7 Hi Res Display LI 20 50 C 4 122 F Operating Temperature Conformal Coating Galvanic Isolation Aluminum Enclosure UL CE Listed Two Year Warranty Call 425 745 3229 maplesystems com PRODUCT ROUNDUP EEE FEED IT THROUGH DIN rail mountable AVK feed through screw connection style terminal blocks with vibration re sistant wire clamps have a plastic housing made from polyamide 6 6 thermoplastic resin with a UL 94 V2 rating for 105 C Available accessories include end plates end brackets cross connectors for bridging and marking tags Omega Engineering 203 359 1660 www omega com SAVE ON 1 0 Bulletin 931 analog j zi signal conditioners ou convert a range of device signals to a Lu standard 4 20 mA signal Systems that transmit thermocouple signals over significant distances can take advantage of the signal condi tioners to help reduce additional I O and cabling co
105. ty systems To eliminate these roadblocks Friesen s adopted Beckhoff Automation s www beckhof fautomation com embedded PC with TwinCAT software and EtherCAT I O terminals and servo drives to automate accelerate and simplify its checkweighers We sought to process product weights faster and communicate to our reject systems at higher speeds McAllister says Ether CAT can achieve update times for data from 1 000 distributed I Os in only 30 ps including terminal cycle time Up to 1 486 bytes of process data can be exchanged with one Ethernet frame which is equivalent to almost 12 000 digital inputs and outputs The transfer of this quantity of data only takes 300 ys As aresult EtherCAT and open PC based controls allowed Friesen s to decrease machine build time by 25 cut installation time in half reduce startup time by 30 and reduce downtime by 22 Also since Friesen s began using EtherCAT and embedded PCs checkweigher system speed increased by 31 which means we give our users much higher throughput and really differentiate ourselves too McAllister adds These gains are no surprise to ETG s Stubbs The highest 32 Control Design October 2012 performance Ethernet based protocols meet or exceed the capabilities of even the most de manding real time motion control tasks he states The best ones have leftover bandwidth to inte grate other functionality which previousl
106. ushed must be removed by hand and the excess material blown off by a hand tool They are transferred by hand from box to box for sin tering and infusion We could really automate the removal of the cores Wood says noting the time that could be saved in the process with automation As it is ExOne continually looks for ways to speed up the process Considering the hun dreds or thousands of layers used to build any given piece saving just a second off of each layer makes considerable dif ference There are about 250 layers in an inch Wood notes So we look at things like how to save 2 s in a layer The lat est M Flex machine achieves build speeds of 30 s per layer compared with previous build speeds of about a minute and a half per layer We ve made tremendous strides in 3D printing in the last decade and what our machines can do today is simply remark able said Dave Burns president of ExOne We are printing en gine castings for helicopters and replacing broken pumps in oil fields in days not months fll October 2012 Control Design 19 ILHO9ITLOdS INJO E INDISCRETE EES Terminal PLC Combo to Rise in Popularity IMS RESEARCH www ims research com expects global sales of operator terminals with embedded PLC hardware to rise from 99 million in 2011 to about 148 million in 2016 reflecting a compound annual growth rate CAGR of about 9 over the forecast period Such lean automation sol
107. uth is that there are more ways to save energy than using a premium efficient motor New for 2012 PT Pilot is now compatible with smartphones and tablets So you can literally obtain a quote at your fingertips anytime anywhere Visit www ptpilot com truth10 EURODRIVE ptpilot com truth10 864 439 7537 Force Fits MY LAST COLUMN on security Wolf at the Cy ber Door September 2012 www ControlDesign com wolf touched a nerve You might remember that a water plant SCADA system apparently was hacked and a pump failed These two unrelated events were forcibly related One was because of the other This was shown to be untrue but the psychological effects of such behavior linger in the depths of us control guys I had some very concerned responses to my last column and those people should be concerned Regardless of the size of the installation or the process the lack of security can be costly One reader was adamant that having control systems available on the Internet is a disaster waiting to happen While certain pieces of infor mation are needed to find a SCADA server a denial of service DoS attack can happen at any time by using common data structures such as Hash Table and or Hash Map and storing POST data Should a DoS attack happen the operators would be unable to perform actions such as responding to alarms The code to perform this DoS attack was pub lished Dec 27 2011 and can be active o
108. utions provide space and cost savings over traditional configurations There are two principle advantages for OEMs using op erator terminals with embed ded PLC hardware price and footprint said Mark Watson senior research analyst for IMS Research Every compo nent has an associated cost and space requirement By combining two systems into one both factors are reduced This enables further savings as the combined unit doesn t require extra wiring to comm unicate between subsystems and maintenance depart ments only need to support THE PLCs HAVE IT With automation and control functions split pretty evenly between motion analog sequential and discrete well over half of the respondents to our latest Market Intelligence Report said they rely on PLCs as their primary controller platform for machine automation 20 Control Design October 2012 one product type The largest vertical sectors for operator terminals with embedded PLCs in 2011 were estimated to be food bever age and tobacco machinery machine tools and packaging machinery Collectively these sectors accounted for about 35 of sales revenue The larg est unit shipment growth is also forecast to come from the food and beverage machine sector with annual shipments increasing by more than 5 000 between 2011 and 2016 The advantage of using combined solutions is most significant for small machines where price and space are at a prem
109. without limits on development time Eaton www eaton com introduced an online tool Circuit Breaker Authentication CBA www eaton com counterfeit to enable customers to identify counterfeit circuit breakers in an attempt to thwart potential danger and allow for authorities to be informed controldesign com You Have Big Ideas We Have a Big Catalog 2013 Allied Catalog Over 110 000 products Over 10 000 new products Over 300 world class suppliers New suppliers include Siemens Corporation and FLIR Commercial Systems 1 800 433 5700 alliedelec com lied Electronics Inc Fl An Electrocomponents Compan south African Automation to See Growth SOUTH AFRICA S automation market is seeing activity in more than just mining these days GP SO 70 ce HIGH VISIBILITY HMI WITH 5 7 WIDE SCREEN 7 Wide TFT LCD monitor with True Color 16 7 million colors Analog touch type monitor more diverse tag arrangement possible Data logging functions various data collection and back up support for controllers Large image library Synchronous monitoring for multiple addresses and channels Wide range of interface support Ethernet RS232 RS422 Device monitoring functions PLC port allows HMI to monitor and control the variables of additionally connected controllers Free software included with free upgrades Printer barcode reader connection Alarm history print barcode inputs available
110. world and a still fragile Eurozone economy Thomas Depping CEO of As centium Capital said the credit quality of applications at his company remains uncharacter istically strong with delinquen cies at historic lows Although we have hedged ourselves against another possible global economic slowdown we con tinue to expand our sales force as we have a generally optimis tic view of our future he said One thing I have learned over the past 30 years in the industry is that being over capitalized and having substantial excess liquidity is never a bad thing Despite concerns over whether companies will ex pand their businesses in the face of economic and political uncertainty September s con 22 Control Design October 2012 fidence index actually shows increased optimism according to a separate report from the Equipment Leasing and Finance Foundation www leasefounda tion org September s Monthly Confidence Index was 53 0 up from August s 50 2 The industry is performing well and new businesses are entering the segment to join Up 21 the positive experience our asset class enjoys said survey respondent Anthony Cracchiolo president and CEO vendor services U S Bank Equipment Finance However the growth of our industry is tightly aligned with the overall U S economy and our industry s future will be determined by the broader ac tions of the U S economy MERGERS ACQUI
111. y had to be implemented in separate systems such as non motion I O functional safety data acquisition and servicing of standard IP devices on the net work such as for web thin clients EtherCAT is capable of scanning 100 servo axes in 100 us in one network which sets it at the highest end of the performance metrics while undercutting costs eliminating the need for special cables or special infrastructure components and allowing users to integrate functions over the same network such as condition monitoring functional safety and supporting other protocols ETHERNET ISN T PRACTICAL FOR THE CRITICAL TASKS OF HIGH SPEED MACHINE TOOLS SUCH AS CONTROLLING SPINDLES AT THOUSANDS OF RPMS BUT IT CAN HELP COORDINATE AXES LOAD AND UNLOAD PARTS MANAGE MATERIAL HANDLING AND PERFORM OTHER SUPPORT TASKS Synch Lots of Axes Besides enabling traditional speed Ethernet based protocols also need to accelerate the coor dination required for multiply ing numbers of axes drives and other components For instance Bruckner Maschinenbau www brueckner com in Siegsdorf Germany uses more than 700 clips to pull stretch and heat set plastic film at 6 6 m s through its simultaneous stretching system LISIM on two opposing ring shaped rail lines Figure 2 The clips are pulled by a moving mag netic field similar to the railway cars on a magnetic levitation train which is generated by lin ear motors with 728 wi
112. z com e What the real differences are among the various Ethernet flavors of fast motion buses SLIO NOT SLOW e The threat of electronics to pneumatics and Compact SLIO I O system for hydraulics as power sources systems 100V 200V 300S and m 500S have a staircase shaped e Where relays fit in today s programmable pinche CODE wiring layer clear readability of channel states protection e How robots fit into machine design against reverse polarity back What dose Sbsps PACrealvis plane bus at 48 MBps and 20 pus response time e G M M id The decentralized I O system is a space saving e Advice for building your panels in house thin design with a simple two component setup Vipa USA 678 880 6910 www vipa usa com e Step up and talk to us about these or any other machine automation topic that s affecting the way you do your job today and those that might affect it tomorrow DECENTRALIZE THE 1 0 With IP67 protection X67 I O modules can We want to hear the thoughts and be installed on the experiences of our machine builder machine and can and system integrator readers span 100 m between modules Users can set parameters for the digital inputs and outputs and connect to all standard fieldbuses B amp R Industrial Automation 770 772 0400 www br automation com Joe Feeley Dan Hebert editor in chief senior technical editor jfeeley putman net dhebert putman net Aaron Hand a Katherine Bonfante FUSE THE CIRCUIT

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