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VOL 07 | AUG-SEP 2014 | ` 100

www.AandD24.in

Enabling flexible design experience

A U TO M AT I O N & D R I V E S

ENgINEERINg DESIgN

FOCUS Semiconductors & electronics P. 36, 42

ROUND-TABLE Ushering in the robo era P. 30A&D - InterviewPatrick Schwarzkopf Managing Director, VDMA Robotics + Automation Association (p.24)

Coverpage_Aug-Sep_cover.indd 1 8/18/2014 6:46:12 PM

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ed i tor i al

Robotics is said to be the next big disruptive technology in the manufacturing sector with increasing demand for both industrial and service robotics. Although automotive industry has emerged as the biggest customer for industrial robotics, there has been a growing demand for robots from sectors like electronics, machine tools, plastics, pharmaceuticals, food & beverage, etc.

According to a recent market report, the global demand for industrial robots reached an all-time-high of about 1,68,000 units in 2013 and the global industrial robotics market revenues are expected to cross US$ 37 billion by 2018. According to industry experts, the basic reason for the continuous growth in the use of robotics is its continuous technological development in relation with market and industrial requirements, accounting for product quality and competitiveness as well as safe processes. Also, the software to work with and run robots and automation cells has developed rapidly over the last few years and the ease of use has transcended into more applications under a very demanding and dynamic manufacturing landscape. This has enabled manufacturers to provide products to the market quicker and with flexibility of variations to meet consumer demand and at the same time ensure the quality required and the performance demanded.

Check out the Round-table feature in this issue that highlights the market dynamics, technology trends, innovations and new application areas in the global industrial robotics sector.

Please do write to us with your feedback.

Shekhar JitkarPublisher & Chief [email protected]

The next big disruptive technology

3a& d i n d i a | A u g -Sep 2014

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d Vijay SrinivasanPartner, Effectus Consulting LLP

Anup WadhwaDirector – AIA (Automation Industry Association)

P V SivaramMD – B&R AutomationMember – AIA

Anant MaheshwariPresident Honeywell India

Ganapathiraman GVice President & GM (South and South-East Asia)ARC Advisory Group

Ravi AgarwalDirector, Pepperl+Fuchs (Factory Automation)

Raj Singh RatheeManaging DirectorKuka Robotics India

Jasbir SinghVice President – Electrical & InstrumentEssar Project Management Consultants

Dr KLS SharmaAdvisor Automation Education & Training

Mandar PhadkeCEO, Abhisam SoftwareFormer Head – Process ControlLanxess India Pvt Ltd

Arcot RajabahadurAutomation Consultant

Thampy MathewChairman, Fieldbus Foundation IndiaRegional Sales Director, Pepperl+Fuchs (Process Automation)

overseas Partner:

China, taiwan, Hong Kong & South-east asia

editorial_Aug-Sep14.indd 3 8/18/2014 8:01:08 PM

CO N T E N T S

Market Management

24 “We are looking at professional

service robotics”

Interview with Patrick Schwarzkopf, Managing Director, VDMA Robotics + Automation Association

roUnD-table

30 Ushering in the robo eraIndustry experts in discussion on technology and market drivers in industrial robotics sector

control & regUlation

48 Open core engineering The article on open core engineering that increases application flexibility and engineering efficiency across value chain

Semiconductors & Electronics

36 MeMs vibration Monitoring

A read into the inertial MEMS technology which is ushering in a new era of vibration monitoring

42 seMiconDUctor test systeM

An application story on how IDT lowered test cost by using NI semiconductor test system

Focus

Technology

10 neWs

18 “creating traineD resoUrces across

inDia”

Interview with Subash Nambiar, Country Manager, PTC

trenDs

26 Strategic approach to global sourcing activitiesAn article on how TÜV SÜD Chemie Service ensures the implementation of quality-assurance measures for global sourcing

event report

88 Creating information driven digital enterprisesA post-event report on ARC Advisory Group’s 12th India Forum

Cover Story

20 enabling flexible Design experience

The article focuses on the latest functionalities added in Synchronous Technology, ST7 – the latest version of Solid Edge

54 Evolution of switching interfacesThe article details on ultra-slim relay interface modules that provide a low-cost, space-saving solution for a host of industrial applications

content page_Aug-Sep14.indd 6 8/18/2014 8:52:26 PM

CONTENTS

Technology

New Products

93 OPC Unified Architecture for industry 4.0; Signal conditioners; Screw clamp fuse terminal blocks; Heady duty encoder

94 Intelligent earth leakage relay; Data portal; Relay interface modules; Pressure transmitters & sensors made of titanium

95 IT powered automation; Linear modules; Handheld barcode readers; Eddy-current measuring system

Columns

07 Editorial08 Contents96 Highlights - Next issue96 Company index

Advt

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WIRELESS AUTOMATION

58 Applying wireless to Ethernet/IP

An article on the use of wireless technologies in Ethernet/IP based networks for industrial automation systems

66 Wireless technology for utility monitoring

A feature on how wireless technology from Emerson helped Hindustan Zinc improve visibility in real-time

MOTORS & DRIVES

68 Out-of-the-box ideasThe article highlights on how Universal Robots aims to establish the flexibility of articulated-arm robots in industrial production

70 Intuitive engineering A read into how thermoforming machines can be equipped with efficient synchronous motors

72 ROBOTICS & HANDLING

Designing cable management systems for 6-axis robotsAn article on designing cable management systems for 6-axis robots

76 F IELDBUS & NETWORKS

Remote eavesdroppingAn application story on how an American manufacturer of equipment for concrete pipe production added remote maintenance capability

80 M2M COMMUNICATION

Transforming industrial & energy systems with IoTA feature highlighting the challenge in translating intelligence in connected embedded devices to new products

MACHINE VISION

83 Keys to successful multicore optimisationA read into how to optimise machine vision application for multicore PCs through field-testing

86 Revolutionary simple & ingeniously fast

Article on the new 3D vision automation for greater flexibility & higher productivity

92 TECH TALK

Cable trolley solution An insight into cable trolley system used to support, protect and manage flat & round cables for the transfer of electrical energy & data

content page_Aug-Sep14.indd 7 8/19/2014 3:36:05 PM

marke t | news

10 a&D I nd i a | A ug -sep 2014

Manufacturing PMI rises to 17-month high in July

According to HSBC Purchasing Managers' Index (PMI), manufacturing

activities in India in

July 2014 was the

maximum compared to

the past 17 months on

increased orders. PMI

was up by 53 points in

July 2014 from 51.5 in

June 2014. As per

Markit Economics,

which co mpiles PMI

data, output grew at

the quickest rate in line

with the headline

indicator, in the past 17

months (since Feb 2013), marking a 9-month period of increased production.

Among the monitored sub-sectors, makers of intermediate goods raised

production at the sharpest pace. The eight core sector industries, which

have a combined weight of 38% in the IIP, increased by a 9-month high of

7.7% in June 2014, signalling that IIP and manufacturing could see better

recovery in the month.

Providing modern automation solutions for the Indian market

SPS Automation India will take place on February 5–7, 2015, in Ahmedabad,

Gujarat. The show will be

organised by Messe Frankfurt

Trade Fairs India. Focused on

modern automation solutions

for the Indian market, SPS

Automation India will cover a

wide range of topics from

automation products to

services and solutions, in

order to meet India’s demands

as one of the fast growing

automation markets in the

world. The trade fair, will

represent a leading platform

for advancements in automation and their cost optimising and latest

technologies in factory and process automation. Commenting on India’s

high-growth path over the next decade, Raj Manek, MD, Messe Frankfurt

Trade Fairs India, says “India, has established itself as an economic

powerhouse and has the potential to become the world’s 5th largest

consumer market by 2025.”

The trade fair, will represent a leading

platform for advancements in automation

and their cost optimising and latest

technologies in factory and process

automation

> MORE@CLICK ADI03515 | www.AandD24.in> MORE@CLICK ADI03514 | www.AandD24.in

Siemens PLM software used at Toyota

Toyota Motor Corporation has expanded its vehicle safety information

management system based on Siemens’ Teamcenter® software. The

system has been in use since January 2013 as part of a comprehensive

initiative to produce safe vehicles for its

customers. Teamcenter was selected

based on its widespread usage

throughout the global manufacturing

industry. Market requirements regarding

safety compliance for vehicles are

constantly increasing. In 2011, the

International Safety Organisation (ISO)

published the ISO 26262 Functional

Safety standard which defines functional

safety for automotive equipment

applicable throughout the lifecycle of all

automotive electronic and electrical systems. In order to ensure compliance

with ISO 26262, Toyota decided to implement a new safety information

management system based on PLM that would standardise processes

across multiple divisions. After evaluating several PLM software systems,

Toyota selected Teamcenter. Toyota cited the widespread adoption of

Teamcenter by the global manufacturing industry and Siemens’ open policy

for PLM technology as important factors in its decision.

The company’s successful deployment

of Teamcenter has allowed it to

enhance collaboration between

multiple divisions and significantly

improve traceability management

> MORE@CLICK ADI03516 | www.AandD24.in

Turck officials announcing the

launch of its India manufacturing

operations

Turck opens assembly line in Pune

turck India automation recently inaugurated a new warehouse-cum-

assembly line at Hinjewadi industrial area and shifted to a new office at

Baner – Balewadi Link Road, Pune.

Announcing the new facility,

Pradeep Arora, MD, Turck India,

said, “The assembly line is a small

start for Turck’s manufacturing

footprint in India. This has been

possible with the able support of

our customers, vendors and the

channel partners”. He also

thanked Ulrich Turck for showing

confidence in Turck India

operations. On the occasion, Ulrich Turck, MD, Hans Turck GmbH, shared

the company’s technological vision for the growing needs of factory &

process industrial automation. Turck said, “In the expansion mode, apart

from sales, we have added expertise in terms of integrated solutions for

customers; system integration together with hardware combination,

including 3rd party products; and value added solutions on-site. We have

also added sourcing of components from the Indian market. As India has a

vast engineering talent pool, we are also planning to use India as an

engineering pool for our activities.”


Market_news_Aug-Sep14.indd 10 8/19/2014 3:39:10 PM

marke t | news


Fieldbus Foundation & HART Communication Foundation join hands

Fieldbus Foundation and the HART Communication Foundation join hands

to create a new industry organisation dedicated to the needs of intelligent

devices and their integration in the world of process automation. The

combined power of both these organisations will serve to protect the

investments that end users in process

automation have made in HART® and

Foundation fieldbus communication

technologies. The mission of the

combined organisation is to develop,

manage, and promote global standards

for integrating devices into automation-

system architectures, providing

functional solutions for process

automation suppliers and end users. Suppliers will also profit from the

increased efficiencies in resource utilisation, procedure consistency and

member service and support improvements. These two organisations will

continue to exist individually, and evolve into the future. Each protocol will

retain its own brand name, trademarks, patents, and copyrights. The new

organisation will continue development, support, and promotion of the two

existing protocols, and will direct the development, incorporation, and

implementation of new and overlapping technologies.

M Arokiaswamy, MD, IED

Communications suggests that

India should grab the potential

opportunities for investments

abound


Republic of Rwanda – the partner country for AUTOMATION-2014


IeD Communications Ltd in its continual endeavour of promoting Indian

automation industry on the global platform, has now

reached African countries. Republic of Rwanda, one of

the rapidly growing countries on economical and

infrastructural levels is the partner country for

AUTOMATION-2014 exhibition. The 9th edition of

AUTOMATION-2014 will be held on 15-18 October 2014

at the Bombay Exhibition Centre, Mumbai. Other African

developing countries are also expected to come on the

board as bilateral partner countries for the event. The

Govt of Rwanda and other African countries will have a

strong presence at the event with participation from the

Govt representatives and business delegations. “We are

proud to serve Indian industry for its economical growth

through business development on the platform of

AUTOMATION-2014”, said M Arokiaswamy, MD, IED

Communications.

Republic of Rwanda is an attractive destination for

foreign investments. There is a great opportunity for Indian industry to

develop business in Rwanda, the most competitive place to do business in

East Africa, ranked 3rd in African countries as per the Global Competitive

Index Report 2013-2014. In Rwanda, new special

economic zone has been developed and operational.

More zones are planned on the districts level. Rwanda’s

workforce has demonstrated increasing capacity for

knowledge-based industry. “The Govt of Rwanda is very

investor-friendly and committed to market the economy,

which is very inspiring for Indian industry and especially

for the automation industry. Indian industry should grab

the potential opportunities for investment abound,

particularly in the sectors such infrastructure, energy,

information and communication technology, mining,

manufacturing, real estate and construction & financial

services & agriculture,” added Arokiaswamy.

AUTOMATION-2014 will also be organising knowledge-

based technical conferences, in-depth discussion with

experts on various subjects like innovations in

technology, Foundation Fieldbus technology, safety and

security, tank automation & metering.

Bhadresh Dani Joins Bharat Bijlee

Bhadresh Dani has recently joined Bharat Bijlee as Vice President & Head

– Drives & Automation Division. A

Power Electronics Engineering

graduate, he completed his

management education from

Henley Management School, UK

and IIM - Ahmedabad as well as a

leadership development program

from the Scandinavian Management

Institute, Denmark. Prior to joining

Bharat Bijlee he was with Danfoss

Industries, and he brings with him

domain expertise and rich

experience to realise Bharat

Bijlee’s ambitious growth strategies in the Drives and Automation segment.

Bharat Bijlee is one of the leading professionally managed companies

engaged in the manufacture & marketing of transformers, motors, pump

sets, industrial electronics products, drives & automation and execution of

turnkey electrical projects. The company's manufacturing facilities are

located on a 1,93,000 sq m campus, with a working area of approximately

50,000 sq m, in Airoli (Navi Mumbai).


Bhadresh Dani, Vice President & Head

– Drives & Automation Division


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marke t | news


MathWorks conducts MATLAB EXPO 2014

mathworks recently conducted MATLAB EXPO — the 5th edition of its

annual user conference in Bengaluru and Pune to cater to a growing

customer base in the country. The two-city event welcomed more than

1000 participants from the commercial,

government and academia sectors.

Design engineers, professors and

industry experts were in attendance from

across the aerospace & defense,

automotive, computers, electronics and

semiconductors, industrial automation

and machinery and technology services

industries. Jason Ghidella, Product

Manager — Simulink platform & controls,

MathWorks, delivered the keynote

address titled ‘Behind today’s trends: The

technologies driving change.’ The

highlights of the two-city event included Simulink and LEGO MINDSTORMS

NXT workshops that demonstrated the potential for project-based learning

techniques while teaching undergraduate technical courses. Participants

worked through lab modules with examples of sound tone control, line-

following robots.

The two-city event welcomed

more than 1000 participants from

the commercial, government and

academia sectors


Representational image from the last edition of enhancing

manufacturing competitiveness event hosted by F&S

Frost & Sullivan to host a forum on enhancing manufacturing competitiveness


Frost & Sullivan’s Industrial Automation & Process Control (IPC) Practice

will host Industrial Technologies summit 2014

titled, “Enhancing manufacturing

competitiveness: Reality of adopting global

trends and technologies in the Indian context”,

on October 8, 2014, in Mumbai. The summit

will highlight the mega trends in the Indian

manufacturing industry and the evolving

imperatives that enable companies capitalise

on short term growth opportunities. The

summit will focus on sharing best practices

and ideas on how to leverage innovative

technologies and best-in-class solutions as a

resource to address the evolving challenges

for a better tomorrow. It will examine the

reality of adopting global technologies and

following international trends in the unique context of India. Success stories

will be showcased and key challenges will be examined with respect to

implementing state-of-the-art technologies and solutions. It will bring

together solution providers and solution adopters in a true meeting of

minds, to collectively deliberate on the key steps to be taken to catapult the

process, discrete, and batch industries into a new growth era. “Having

tracked the manufacturing sector in India for more than a decade, Frost &

Sullivan is confident that the current slowdown

in the Indian manufacturing sector is a

temporary phenomenon. India has the

potential to be a manufacturing powerhouse

of the world”, says Niju V, Director, Automation

& Electronics, Frost & Sullivan. He further

adds “Advanced automation and control

solutions are expected to play an important

part in this transition.”Apart from knowledge

gathering on future prospects for the market

and evolving dynamics, the event is poised to

facilitate business interactions that can evolve

into long term rewarding relationships.

Participants would benefit from insightful and

strategic discussions involving industry

experts and the opportunity to meet and network with peers and potential

customers. The event will also have an awards evening and witness the

coronation of the industry's best-in-class companies at the Excellence in

Industrial Technologies Awards, India banquet.

Shaping the future of embedded design

National Instruments recently announced NI SOM, the first global product

launch from India, with the company introducing a major transformation in

embedded technology for the world at Chennai. It combines the Xilinx Zynq

All Programmable system on a chip (SoC) with supporting components such

as memory on a small PCB and features a complete middleware solution

and ready-to-go Linux-based real-time operating system (RTOS) already

integrated. With this

launch, it is paving

the way for its

e m b e d d e d

technology to be a

game changer for

the future. “The NI

System on Module

(SOM), combined

with powerful LabVIEW libraries, enables engineers to transform their ideas

into embedded products faster than any other tool available on the market.

Healthcare devices, smart machines and other applications that require

embedded technology will benefit as the NI SOM not only speeds up, but

also bridges design, prototyping and deployment with a single platform,”

says Joel Shapiro, Leader for Marketing, Emerging Markets Region.

With this launch, it is paving the way for its embedded

technology to be a game changer for the future



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a&D I nd i a | A ug -Sep 201418

“Creating trained resources across India”Subhash Nambiar, Country Manager, PTC, discusses Indian manufacturing industry and how companies are looking at creating and delivering smart, connected products to their customers,

during an interview with Srimoyee Lahiri. Excerpts…

How crucial is the Indian market for PTC?India is a very important market for PTC. We offer products in CAD, Application Life Cycle Management (ALM), Service Lifecycle Management (SLM), and Product Lifecycle Management (PLM) and now, we also have a platform for Internet of Things (IoT) to meet customer expectations. We have customers in India who have invested in our flagship 3D product and Pro E for the past 20 years. Like any other industry, manufacturing industry, particularly automobile, faces a lot of competition from both domestic and international companies. Most of the companies look at reducing their manufacturing cost and India is no different. In the last three decades, we have grown from a CAD company to a software product and service solution provider for manufacturing companies. Many Indian companies are using our products for meeting their industry transformation.

What are your views on cloud computing in CAD space?There are mixed responses from the customers on cloud computing due to security, bandwidth, uptime, dependency, etc. At present, based on the customer requirements, we have been offering Creo software in CAD space on our perpetual license model. If customers are looking at a managed service, we are in a position to offer them a private instance model, offering a better performance and uptime at a lower cost compared to the customer hosting the solution in their infrastructure.

How is PTC pursuing its service strategies in India? We have been encouraging our partners to imbibe enterprise consulting using our service advantage program to drive value based selling to enterprises. The customer gets a complete solution either directly from PTC or through partners from consulting, product positioning, implementing and getting the solution advantage - meeting/exceeding customer expectations.

Apart from consulting and implementation, we also provide high-end training to adopt our e-learning tools supported by trainers in precision learning programs. Our

University Academy program supports this initiative and many customers are enjoying the benefit of the product through this knowledge.

As the new leader at PTC India, what are your strategies to enhance performance during this fiscal year? I am excited to join PTC which owns a long history of technology innovations and is the leader in technology solutions that transform the way companies create and service products. India is one of the fastest growing markets in the world with a significant customer base for us. As a strategy, we always looked at changing environment and industry needs

and offered products and services to help our customers achieve competitive advantage. The company has pursued an aggressive strategy of acquisitions and rapid organic development to expand its offerings into fast-growing markets. We currently have huge focus on creating well-trained resources across India.

What are the latest technology & demand trends in your domain?Indian manufacturing industry contributes more than 50% of export revenue and is 15% of India’s GDP. All the manufacturing companies are looking at how they can

create smart, connected products. In the IoT era, customers are bringing to market increasingly smart and connected products which can generate value in new ways as streams of real-time operational data are captured, analysed, and shared to deepen a company’s understanding of its products’ performance, use, and reliability.

Acquiring ThingWorx will allow us to accelerate and help our customers capitalise on the market opportunity that the IoT presents. The opportunity, however, goes well beyond this immediate pragmatic application. Industries of all types are poised to see disruption from the Internet of Things and the expanding networks of connected sensors and devices, and a growing ecosystem of ThingWorx partners is forming to capitalise on this growth. ☐


PTC_Market Interview.indd 18 8/14/2014 8:59:40 PM

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Enabling flexible design experience

For manufacturers to realise more profitable innovation, they need to consider opportunities to optimise & accelerate designs, improve validation earlier in the development process, enable faster product to market, reuse 2D & 3D at maximum, and improve visibility to program execution and risk management. Siemens PLM Software’s Solid Edge has been able to address these needs, and ST7 - the latest version of Solid Edge with Synchronous Technology brings in breakthrough innovations in this area.

Sumedha Mahorey Deputy Editor [email protected]

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that were possibly unnecessary or redundant. This was the principle applied when Dynamic Dimensions were added. This allows users to key in dimensions as they sketch without stopping to click an icon. In the case of a rectangle, users can apply multiple dimensions, just by using Tab to move between fields. If they don’t want to use the Dynamic Dimensions, one can ignore them without the need for extra steps (or turn them off altogether).

Part of focusing on the user is certainly making the interface more intuitive with more “heads-up” functions. Heads-up interface elements have enabled the user to keep focus on the work area while helpful cursor symbols or other visual feedback help to indicate items such as selections or automatic sketch relations.

One of the new enhancements where this is most evident is in the Quick View Cube, displayed in the lower right corner. One can select from dozens of view orientations directly from the cube. Select a corner for an isometric, or a face for a primary named view. Rotate with the arrows.

New document templates have been organised by drafting standard as well as units, and document type (part, assembly, draft, sheet metal). Using units in this way is new, and enables users to have templates set up in various units for different purposes rather than needing to do this at the time of creation. During installation of the Solid Edge software, templates are created and saved based on the language specified in a user’s Operating System, and all templates for all standards are saved for later access. This allows multinational companies to easily work with multiple standards.

Along with the new startup screen comes a new File Open. Solid Edge has implemented the Microsoft File Open standard interface. This allows the user to reuse knowledge from other Office applications such as Word, Excel, or PowerPoint, also enabling tasks such as copy/paste, delete, rename, sorting, and previews. Providing a consistent experience across the entire technical computing environment leverages shared skills and saves time.

Manufacturers have to rely on a combination of design innovation, more electronics and embedded software content to meet the demands of the marketplace, today. They are also required to demonstrate and provide increased responsibility for the design, development, prototyping and final production of parts. Siemens PLM Software was able to respond to these challenges with Solid Edge, a hybrid 2D/3D CAD system that uses Synchronous Technology (ST) for accelerated design, faster revisions and better re-use of imported geometry to help companies design better. Packed with over 1,300 user-requested enhancements, the latest version of Solid Edge – ST7 has grabbed the attention of its existing as well as new adopters worldwide. With its remarkable attention to detail, newly-added functionalities and ease of use, ST7 was introduced in May, this year during the Solid Edge University 2014.

Based on four major pillars of development – accelerated 3D modeling, streamlining design management, powering up with new apps and amazing user experience – ST7 features some standout enhancements such as patent pending duplicate components command, blank from a 3D model, powerful photorealistic rendering using KeyShot®, and enhanced Microsoft Surface Pro functions, among many others.

Dan Staples, Vice President, Solid Edge Product Development, Siemens PLM Software, while focusing on the product development strategy behind the new upgrade, asserted, “The key thing in development is to ensure that with every function added, complexity is kept to the minimum. There is saying, if I had more time, I would have written less. Similar is the trend in user-based design. It is very easy to cover everybody’s needs, but to do that elegantly where it is simple to use, and caters to everybody’s requirements is quite hard. But we have successfully achieved this in ST7.”

Enhancing users’ experience

A great deal of attention in ST7 has been applied to streamlining the interface and trimming areas of the workflow

Blank body functionality



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Tool tips have been enhanced to include short video clips for simple actions. This is not only good for users migrating from other CAD packages, but has been singled out by CAD managers of larger organisations as being helpful in training and in reducing support inquiries.

Accelerated 3D modeling

First things first. In most cases, designers start off by applying/choosing a relevant material for a part. ST7 has brought big changes to material tables. Users can now group materials, Table Primitives select them from a visual interface. Material data can be imported from sources such as Matlab.com using an Excel file. Materials include mechanical and visual properties that are reused downstream by mass calculations, stress analysis and even rendering applications.

Quick Shapes / Primitives

Quick Shapes are a set of primitives for box, cylinder and sphere. For example, to create a sphere in ST6, one would have to sketch a semi-circle on a plane and revolve it. In ST7, users can click a keypoint or any point on a plane and drag a radius. According to Dan Staples, this results in four times fewer clicks.

Intelligent relationship filters

Another ease of use enhancement aimed at easing migration from other CAD systems comes in the sketch environment. In ST6 and prior, to assign sketch relations to multiple sketch elements, a user would have to click on each element individually, and use the Action-Object workflow. There was nothing wrong with working that approach, so Solid Edge

allows users to continue to work that way. But in ST7, users can now fence-select objects, and then select the sketch relation which they want to apply. This is essentially Object-Action. What’s new here is the ability to do it either way. If a user has different types of geometry selected, for example, lines and circles, Solid Edge automatically filters the entities for valid types (for example, circles cannot be made parallel).

3D sketch is a new function, and is available for all types of entities. This used to be only available for pipe/wiring functions. Making this available for general modeling (consistent in Part, Sheet Metal & Assembly environments), most specifically wireformed products, will be a big time saver. 3D measure tool: A new and comprehensive 3D Measure tool is also part of ST7. The results of 3D Measure are visual, and the window stays available until the user dismisses it. The text from the results can be copied to be used in other dialog boxes or dimension entry boxes, which will save a great amount of time.Sheet metal: In ST7, sheet metal has got a fair bit of attention. The “part to sheet metal” enhancement, which enables to wrap a sheet metal part around (outside or inside) a solid body, is a remarkable feature. In fact, in one example, creating a particular sheet metal part has been found to be 5X faster than doing so in previous versions. Blank body: Also noteworthy is the Blank Body functionality, which flattens a punched, drawn or formed sheet metal shape. This tool can also be used on lofted shapes, for example, on a fabric seat cover. This tool replaces separate third-party software that would cost thousands on its own.Standards-based holes: One of the most exciting of the revamped Solid Edge ST7 tools is the Holes tool. In the past, a user would need to have their Machinery’s Handbook available to reference hole sizes for particular bolts correctly, ST7, however, incorporates all of this information in an editable

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Users can publish their designs to GrabCAD Workbench for collaboration with team members, suppliers and customers

Drawing views of parts and subassemblies coexist with views of the top level product

ST7’s user experience features an intuitive user interface which informs users’ work


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database, and enables one to select hole sizes based on screw size. Users can also specify edge breaks and bolt head clearance. This is a big step forward in automating machine design parts.Comprehensive material definition: A more intuitive, visual interface for storing, categorising and applying material specifications is also available with ST7. The interface has enhanced material appearance preview capabilities and users can add their own properties. Material information can be imported from external sources and stored in multiple libraries to support the needs of different departments.Duplicate component tool: This functionality is “Patent Pending”. Turning to assemblies, a duplicate component tool has been added to ST7. This is like a pattern, but it works where there are no identifiable regular patterns. For example, if there is a set of parts that fit into every bracket in the assembly, Duplicate Component will take the original set of parts and duplicate them in every situation where it finds that bracket, orienting the parts to match the original occurrence. Early trials found this to be 10X faster than doing the work manually, and results in fewer assembly relations.

ST7’s new ability to rename a family of assembly (FOA) member is another enhancement that’s sure to be a huge time saver. In draft enhancements, the automatic placement and arrangement of coordinate dimensions on parts is a new tool. For this, the amount of time saved is a function of how many dimensions of this type are used. This new function actually makes coordinate dimensions feasible.Enhanced Microsoft Surface Pro support & Keyshot: The Microsoft Surface Pro offers full support for Solid Edge design tasks and expanded support for finger gestures is now included. For example, a single finger drag enables a pan operation in 2D and a rotate operation in 3D, and a two finger pinch enables a zoom-in operation. ST7 also features a significant inclusion of Luxion’s Keyshot software available with Solid Edge Keyshot

Classic and Premium versions. A single click will take a Solid Edge model with its visual properties into the Keyshot environment. The Live Link function enables updates to the Keyshot geometry directly in Solid Edge, so users never have to start over again after re-importing. Improved productivity for working with massive assemblies: Users now have more control over the extent to which an assembly is recomputed during open and save operations using the Limited Update option. This option speeds response times when working with large assemblies. Users can also check for out-of-date components within an assembly and update & save them using the Component Tracker command.

Users can also insert reference assemblies from a higher level of the assembly into the current level, enabling this data to be used as part of the design process while maintaining correct bill of materials (BOM) generation. They can also designate assemblies as simplified assemblies that are treated as leaf parts and are not automatically expanded. This improves performance when working with large assemblies, while users can still expand these assemblies as needed.

ST in the future?

With patent pending innovations & breakthrough tools already included in the ST7, what should users expect in ST8 next year? Answering this, Staples affirmed, “Some years ago, we saw traction in direct modeling in ST, but then it was just not adequate. We thought that direct modeling needed to be addressed in a completely new way and we have been successful in achieving it. We think there is a lot more potential in ST in the future and we will continue to explore it in unique ways for all industry models.” ☐


3D Sketch provides the users a fast creation method for components bent in more than one plane

Streamlined, graphical and intuitive design management bought to you by Solid Edge SP

Material selection is made easy with an intuitive interface presenting multiple libraries utilised by different departments


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“We are looking at professional service robotics”Patrick Schwarzkopf is the new Managing Director of VDMA Robotics + Automation Association, which has nearly 250 member companies. In this exclusive interview with Megha Roy, he stresses on the growth prospects in the industry, foreign markets focus and development opportunities for newer applications

What are the recent developments in VDMA Robotics + Automation in terms of new managing board, new initiatives, international activities, global strategies, standardisation plans, etc? This year, we focused on the AUTOMATICA Fair in Munich, which presented the latest trends in robotics and automation. The latest development is the direct cooperation between the industrial robot and the human worker. VDMA Robotics + Automation has published a position paper that helps users ensure that such solutions are absolutely safe. Another topic that is high on our agenda is sustainability. We provide many solutions for increased safety, the more economical use of material and saving energy. We are also looking at new application areas, such as professional service robotics. The robotics and automation sector is also expanding exports every year. Currently, some 55% of business is made through

exports. Naturally, we are supporting our member companies in becoming more global through our VDMA representative offices in India.

How do you look at the performance of the robotics & automation sector, in Europe as well as globally? How are the growth prospects in 2014?The robotics and automation sector has been receiving a lot of attention recently. The European Commission has just launched SPARC, the world’s largest civilian research programme for robotics. AUTOMATICA 2014, the leading trade show of the sector, concluded with record results. There is great demand for robotics and automation technology from high-wage as well as low-wage regions across the world. Therefore, we expect the global turnover of the German robotics and automation sector to grow by 7% in 2014.

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way through production and will book certain “services”, e.g. robot. The devices will communicate with each other, everything will be a network, all players uniquely addressed (e.g. with an own IP address) and the production will become much more flexible and efficient. This integration will pave the way for new business models, in which the customer’s order will trigger the manufacturing of an individualised product that need not be more expensive than today’s mass produced off-the-shelf item. Robots will come out of their protection cages and will collaborate directly with human workers. Each side will focus on their specific strengths and the outcome will be increased productivity. To reach this goal, the robots must be made safe to work with in a shared work space. Our members are developing the necessary solutions.

According to you, where will be the focus of technical developments for the next few years?The application of robotics and automation will be made a lot easier and more intuitive. The result of it will look simple, but the technology behind it is complex. This requires new ways of communication and collaboration between humans and machines through gestures or speech recognition.

How important is the networking of different areas of industry as well as different countries so as to make a globalised technology approach?To employ robotics and automation to the benefit of the companies, the workers and the customers, a thorough knowledge is needed on the technology, specific market requirements, skills of the workers and many more factors. Those who are good communicators and networkers and those who share knowledge will be taking the lead and producing the best solutions. ☐

Besides automotive industry, what are the other major industries being targeted globally? Do you plan to come up with any new application in the near future?For robotics and assembly technology, automotive industry accounts for some two third of sales. For machine vision, the situation is much more diversified, with approximately one quarter of turnover going to automotive. Electronics is a major application field. We believe there is a big growth potential in the food and pharmaceutical industries. In machine vision applications “outside the factory” are the big growth drivers, such as intelligent traffic systems, surveillance or precision farming.

How do you look at the business potential in India for the robotics & automation sector? Any new initiatives/activities planned from VDMA India office?The technology is indispensable for many products that are miniaturised, safety-critical and of particularly high quality. If an economy wishes to play a major role in the high-tech segment, it needs to apply robotics and automation in production. Currently, the so-called robot density (the number of industrial robots applied per 10,000 employees in the manufacturing sector) is still very low in India. Thus, there is still a very big potential which will gradually be tapped over the coming years with time. In the meantime, we will monitor the Indian market, provide information services and organise a management meeting later this year.

What are the technological breakthroughs expected in the robotics & automation sector in the coming years, for example, Industry 4.0, Big Data, Cloud Computing, Digital factory, human-robot collaboration, etc?Industry 4.0 will be the next leap development that will bring a paradigm change: If production systems are currently centrally controlled; in the new scenario, the workpieces will find their

“Industry 4.0 will be the next leap development that will bring a paradigm change”Patrick Schwarzkopf

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Strategic approach to global sourcing activitiesFor global sourcing in the chemical and process industries, quality assurance schemes embracing the whole supply chain are imperative. This article highlights how TÜV SÜD Chemie Service points out such weaknesses and ensures the implementation of quality-assurance measures.

For companies in the chemical and process industries, reducing the cost of materials is one of the essential strategies to stay competitive. Known as ‘global sourcing’, medium-sized enterprises are increasingly joining large multinationals in engaging in procurement management at international level, to identify lower-cost sources. The construction of world-scale plants, for example, is moving over to emerging markets, a trend accompanied by increasingly networked international supply chains. Manufacturers purchase plant components – including process-engineering equipment and pressure vessels for the European market – at attractive prices in, say, India. Conversely, complex high-tech equipment such as process-engineering devices made of special materials or process-control systems are imported to the Asian market from countries such as Germany.

While the share of third-party costs in revenue has been rising for years and numerous studies have raised awareness of sustainable purchasing, practice shows that there is a common trend towards “Best cost sourcing”, which can involve

considerable risk factors.Globally sourced products do not always reliably fulfil the

relevant legal, regulatory and standard requirements in the country of destination. Ultimately, quality or delivery issues may use up the forecast savings. When quality-assurance aspects are not examined individually and in detail but only across the board, opportunities and risks may become distorted. A one-sided focus on purchasing prices may consequently become expensive; all the more if extensive rework becomes necessary in a country with high labour costs before a plant or piece of equipment can be placed into service.

Approaches

Against this backdrop, a more strategic approach to global sourcing activities by purchasing departments makes good sense. Such an approach must include all relevant types of costs, e.g. investment costs, life cycle costs and total cost of ownership, in the purchase decision. To do so successfully,

Kurt SchumacherGlobal sourcing expert & Member of Managing Board TÜV SÜD Chemie Service GmbH [email protected]

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SucceSS factorS in global Sourcing

• Systematicandcompleteoverallstrategy• Individualopportunitiesandrisksanalysis,cost-effectiveness,empiricalvalues

• Comprehensiveprojectspecifications(design,materials,manufacturing,testing,qualityassurance,documentation)

• Manufacturerselectionandevaluation• On-sitequalityassurance(in-lineandpre-shipmentinspec-

tions)• Familiaritywiththelocalsituation(language,culture)• Flexibilityinsuppliermanagement(highdynamisminsomesuppliercountries)

quality assurance along the supply chain must cover the entire manufacturing process up to shipping from the country of manufacture. The devil is frequently in the detail when problems arise later on. In these cases, statutory and singular tests will not be enough to identify and eliminate critical issues before they turn into problems. Furthermore, many purchasing experts underestimate supply chain dynamism, which renders adequate process design next to impossible without in-depth familiarity with the local market situation in the country of origin.

Given this, a systematic and complete purchasing strategy that extends along the entire supply chain is of critical importance. This strategy must consider economic and technical aspects, but also supplier relationship management, including monitoring of production conditions. First and foremost, this means thorough selection and evaluation of manufacturers, watertight specification of product characteristics and differentiated control of implementation.

End-to-end quality management

The central element of an optimised procurement strategy is quality assurance that primarily aims at ensuring that the design of the purchased systems or components is in conformity with the rules. Project specifications, too, must be comprehensively clarified to ensure end-to-end quality management. This includes, for example, the traceability of materials and the completeness of the required documents such as drawings, plans and documentation.

At what point does TÜV SÜD Chemie Service support global sourcing? Originating from the former user inspectorates > More@clicK aDi03527 | www.aandD24.in

of Bayer, Dow Olefinverbund and Hoechst, the specialists are on-site at all major chemical and industrial centres in Germany and accompany their clients to international markets, expanding their worldwide presence. This ultimately created the Team of Global Networking, a group of specialists dedicated to intensive exchange of know-how and experience.

To ensure that the materials used will also meet the ambitious requirements, the experts combine conventional and innovative non-destructive testing procedures. Based on decades of experience in the chemical and process industries, the experts have adopted the indispensable high level of quality as a core value, supporting purchase decisions in global sourcing to ensure far-sighted planning and keep the risk of service interruption to a minimum. ☐

A systematic and complete

purchasing strategy that extends

along the entire supply chain is of

critical importance

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USHeRIng In tHe ROBO eRa With the number of robots in the world crossing well-over 1,000,000 mark, this feature aims at analysing the various technology & market trends emerging in industrial robotics while assessing the key challenges the industry is facing globally

As per a recent report by International Federation of Robotics (IFR), in 2013, about 1,79,000 industrial robots were sold worldwide, an all-time high and 12% more than in 2012. Robot sales have reached record levels in Asia/Australia, Americas and Africa. Almost 1,00,000 new robots were installed in 2013 in Asia/Australia, 18% more than in 2012. The European market also increased by 5% to more than 43,000 units almost reaching the all-time-high of 2011.

With this in the backdrop, A&D India analyses the views of industrial robotics experts – Arturo Baroncelli, President, IFR; Rajesh Nath, Managing Director, VDMA India; Sunil Raibagi, Managing Director, GÜDEL India; and Raj Singh Rathee, Managing Director, KUKA Robotics India – to gauge the

emerging technologies, market drivers and understand the issues faced by manufacturers in this industry.

Market drivers

The use of industrial robots has increased steadily in the recent years. In the past, industrial robots were used almost exclusively in the automotive sector and in series production. Rathee notes, “The continuous on-going development of robot and control technology has enabled robotics to establish itself across a broad spectrum of different markets in sectors outside the automotive industry. In the general industry, the primary objective of development work is to tap into new markets,

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CAGR of 4.38%. One of the major drivers in this market is the increased automation across industries. The growing need to reduce human effort and errors in the production process has led to the adoption of SCARA robots across industries. In many industries, workers performing repetitive tasks cause errors in the production process. However, the adoption of SCARA robots that can perform repetitive tasks with unmatched efficiency can lead to a drastic reduction in production errors. Another major growth driver is the low maintenance cost of SCARA robots.” As per a recent study, the global SCARA robot market is witnessing an increase in the adoption of articulated robots as a substitute for SCARA robots. Nath stresses, “The market is witnessing the replacement of SCARA robots with articulated robots in the automotive industry. Further, the integration of artificial intelligence with articulated robots has led to the high demand for such robots globally.”

With the demands growing for all kind of robots, Raibagi highlights, “As we manufacture more gantry robots, we are seeing that articulated robots are mounted on gantry systems to increase work envelope and reach. These combi robots are giving lot of application functionality and reduce overall costs.”

Increasing demand for robots with higher speed and advanced vision system for pick & place applications has also been seen in the food and pharmaceutical industries. Identifying major demand trends in such sectors, Baroncelli states, “Increasing demand for robots used in hygienic areas such as in the food and pharmaceutical industries; in the assembly of cars; increase of multi-axis-robots, i.e. robot arms with 7, 8 axis instead of 6 for better maneuverability; increase of riveting technology in the automotive industry; increase of welding for high tension and zinc coated material, because the automotive customers try to use lightweight and rust proof material, among others, have emerged.”

Emerging technology trends

The new industries are built around areas of robotic automation cells. Due to this, there are new requirements for the development of robots and industrial production benefits

particularly in the fields of foodstuffs, plastics, metalworking, foundry, electronics, medical technology and the entertainment industry.” As per Nath, “Automotive and metal industries are the main drivers of growth in industrial robotics. The automotive industry increased robot investments continuously and considerably between 2010 and 2013, by 22% on average per year. The main countries involved were China, Germany and the United States. In 2013, robot sales to the automotive industry increased by 5%. Also, the metal and machinery industry had an average annual growth rate of 22% in the same period. In 2013, robot sales to this industry were up by 17%. The food industry as well as the pharmaceutical industry increased robot investments substantially in 2013. The electrical/electronics industry - which had reached a peak level in 2013 - increased robot orders by 9% in 2014.” Quoting statistics, Nath adds, “The trend towards automation fuels further growth in robotics. The main drivers of automation are energy-efficiency and new materials, e.g. carbon-composites, requiring new productions; global competiveness requiring increased productivity and higher quality; growing consumer markets requiring expansion of production capacities; decreasing life-cycles of products and increasing variety of products requiring flexible automation; and robots improving the quality of work by taking over dangerous, tedious and dirty jobs that are not possible or safe for humans to perform.”

Sharing a similar thought, Baroncelli points out, “The incentives to automate are forcing manufacturing industries worldwide to improve their production processes continuously to be competitive in a global market. This is true for traditional, emerging markets and low-wage countries. The demand for consumer goods is increasing especially in the emerging markets; and the life-cycles of many of these products are decreasing.”

Demand trends

With huge demand for industrial robotics, let’s analyse the latest demand trends in articulated robots, SCARA(Selective Complaince Assemby Robot Arm) robots and gantry robots. Nath elaborates, “The global SCARA robot market is expected to witness moderate growth during the period 2013-2018 at a


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from these recent technological trends in robotics. Raibagi explains, “Robots, and even the control units, become smaller and more compact. That minimises the required floor space and offers opportunities to integrate more robots and increase the productivity.”

Multi-functional robots and combi robots can take over additional tasks which are needed for a complete robot-based automation solution, such as process control, motion control of additional axis, NC-motion, logic control, safety control. Integrated solutions reduce investment costs, reduce the communication effort between the different components, lead to an improved process quality (since motion and process control are optimally synchronised), and facilitate configuration and diagnosis since the operator has only one user-interface. Identifying key innovation drivers like fast performance growth, alterations in classical fields and enhanced product diversity combined with reduced product life cycles manifest themselves in specific innovation trends, Nath elaborates,

“Some major trends in industrial robotics are increased adaptability of robot cells and robot periphery; vanishing boarders between simulation and reality; smart robot controllers; advanced Human Machine Interfaces (HMI); redundant kinematics and cooperative robots; advanced sensor performance and sensor fusion; energy efficiency; service robotics becoming innovation motor for industrial robotics and human robot collaboration.”

Commenting on the future technology developments, Rathee says, “Technological trends, such as robot-robot cooperation, human-machine cooperation, production assistants or modular, interactive robot generations, will all serve to secure the market of the future. Cooperating robot systems, for example, are modifying and optimising manufacturing processes.”

Adding on the safety front of industrial robotics, Baroncelli stresses, “The most important challenge is connected with safe

use of robots. Therefore, emerging technologies are in general oriented towards this issue: capability of robots to react to unexpected collisions, definition of interference regions where robots can choose automatically max kinematical parameters, sensors to detect the presence of operators and so on.”

With multiple evolving technologies, which influencers are affecting the innovation roadmap of industrial robotic technologies? Answering this, Baroncelli elaborates, “Software and man-machine interface, besides being a key part of a robot, are obviously influenced by key trends in information technology. Main issues in this perspective are: more intuitive programming, easier operator interface, interaction with smart devices, image recognition. Anyway, when applications of such general trends are to be when applied to industrial robotics, very specific issues are to be considered: safety and reliability.”

Challenges

The global trend towards adoption of robotic automation is increasing in India, but is still in early stages. Nath explains,

“Automation still being in its infancy in several sectors is a reflection of being in the ‘low value-addition’ zone. India is required to leap-frog to ‘higher value-addition’ manufacturing processes. The real drive for automation started only in 1997 and India is lagging behind in comparison to the world growth in automation sector. The factors affecting automation sector in India is the political scenario, the economy conditions prevailing and the social & technological challenges.” As per Baroncelli, “The biggest challenge today is the possibility that human operators and robots cooperate. Traditionally industrial robots have always worked in operating areas protected by fences and safety devices which separated them from human beings. Now, all the robot producers are trying to solve this in different ways but all with the same objective: man and robots working together in a safe way.” While for Raibagi the main

“Automotive & metal industries are the main drivers of growth in industrial robotics” Rajesh Nath, Managing Director, VDMA

“The biggest challenge today is the possibility that human operators and robots cooperate” Arturo Baroncelli, President, IFR


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challenges lie in achieving energy-efficiency and lightweight construction to reduce energy costs. He avers, “The potential of the use of industrial robots in the general industry will substantially grow when robots will collaborate with workers and when the integration of the robot will become easier. Especially, the end-customer-friendly-integration of robots in machine tools provides an enormous potential for new robot installations.”

Future outlook

With robotic intelligence, artificial intelligence, the need for increased factory productivity, efficiency, safety and quality resulting in many technology breakthroughs in the robotics sector, how does the technology outlook for the industrial robotics sector in the next decade? Replying to this, Baroncelli affirms, “Robotics has, among others, the fantastic feature of being a synthesis of many technologies: mechanics, material science, electronics, mathematics, software, control…all these disciplines, at various paces, are naturally evolving bringing sound innovation to the market: the combined effects of such improvement would result in an overall better and better performance of a robot.” Moreover, robot has the feature of being able to interface with other equipment, in turn subject to technological evolutions: sensors, vision systems, inspection systems. The integration of these technologies with the robot can create new performing systems to be applied in more and more segments, therefore, populating areas where robotics is not applied yet. Adding further, he says, “Finally, there can be a cross fertilisation of technologies between industrial robotics and the younger discipline of service robotics. Service robotics is a relatively younger branch having as a target to use robots (of different kinds) in environments different from factories, such as, for example, at home with people with no specific training. I am sure that technologies and approaches deriving

from the ones having found solution for service robots can be usefully employed in factories. Frankly speaking, it is difficult to forecast today the limits of robotics, but the direction is clear towards technical developments and new fields of application.”

Building a technology roadmap, Raibagi asserts, “Even with primitive intelligence, robots have demonstrated ability to generate good gains in factory productivity, efficiency and quality. Beyond that, some of the “smartest” robots are not in manufacturing; they are used as space explorers, remotely operated surgeons and even humans – like Asimo. In some ways, some of these other applications show what might be possible on production floors if manufacturers realise that industrial robots don’t have to be bolted to the floor, or constrained by the limitations of yesterday’s machinery concepts.”

Indeed with rapidly increasing power of the microprocessor and artificial intelligence techniques, robots have dramatically increased their potential as flexible automation tools. Raibagi notes, “The new surge of robotics is in applications demanding advanced intelligence. Robotic technology is converging with a wide variety of complementary technologies – machine vision, force sensing (touch), speech recognition and advanced mechanics. This results in exciting new levels of functionality for jobs that were never before considered practical for robots. Additionally, the introduction of robots with integrated vision and touch dramatically changes the speed and efficiency of new production and delivery systems. Robots have become so accurate that they can be applied where manual operations are no longer a viable option. Semiconductor manufacturing is one example, where a consistent high level of throughput and quality cannot be achieved with humans and simple mechanisation.” ☐


“The continuous on-going development of robot & control technology has enabled robotics to establish itself across a broad spectrum” Raj Singh Rathee, Managing Director, KUKA Robotics India

“The end-customer-friendly-integration of robots in machine tools provides an enormous potential for new robot installations” Sunil Raibagi, Managing Director, GÜDEL India


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Se mico n d uctorS & elec tron ic S | Focus

A&d i nd i a | A ug -sep 201436

Mark LooneySenior Applications EngineerAnalog Devices - Greensboro, North [email protected]

MEMS vibration monitoringThe inertial MEMS technology is ushering in a new era of vibration monitoring and enabling a wider user base for this type of instrumentation. Through functional integration and ease of adoption, MEMS devices are gaining increasing attention in new vibration monitoring applications as well. New adopters of vibration sensing are also finding that quick deployment and the reasonable cost of ownership are good reasons to evaluate fully integrated MEMS devices.


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Focus | Sem i conductor S & el ectron icS

A& d i n d i a | A u g -sep 2014

Mark LooneySenior Applications EngineerAnalog Devices - Greensboro, North [email protected]

Inertial MEMS(micro-electro-mechanical system) sensors play a significant role in the massive expansion of today’s personal electronic devices. Their small size, low power, ease of integration, high level of functionality and superb performance encourages and enables innovation in gadgets such as smartphones, gaming controllers, activity trackers and digital picture frames. In addition, inertial MEMS sensors have substantially improved reliability and reduced cost in automotive safety systems, allowing them to be deployed in most automobiles.

The continuous advancement in functional integration and performance has also helped MEMS accelerometers and gyroscopes find their way into many different industrial systems. Some of these applications offer lower-cost alternatives to present products and services, while others are integrating inertial sensing for the very first time. Vibration monitoring is emerging as an application that has both types of users. Traditional instruments that monitor machine health for maintenance and safety often use piezoelectric technology. High-speed automation equipment monitors vibration to trigger feedback control of lubrication, speed, or belt tension—or to shut down equipment for quick attention from maintenance staff.

Although piezoelectric devices have a mature user base, MEMS accelerometers offer easy integration and reduced cost to an emerging group of new users. In addition, their advanced functional integration allows devices such as the ADIS16229 digital MEMS vibration sensor with embedded RF transceiver to provide a complete solution including signal processing and communications. This type of programmable device can wake itself up periodically, capture time-domain vibration data, perform a fast Fourier transform (FFT) on the data record, apply user-configurable spectral analysis on the FFT result, offer simple pass/fail results over an efficient wireless transmission, provide access to data and results and then go back to sleep. New adopters of vibration sensing are finding that quick deployment and the reasonable cost of ownership are good reasons to evaluate fully integrated MEMS devices.

Vibration monitoring applications

When using vibration to observe machine health, the objective is to correlate observable vibration with typical wear-out mechanisms, such as bearings, gears, chains, belts, brushes, shafts, coils, and valves. In a typical machine, at least one of these mechanisms require regular maintenance. Figure 1 shows three examples of the vibration v/s time relationship

for a normal wear-out mechanism. Although it takes time and experience to develop this type of relationship, a well-correlated vibration signature can be a cost-saving alternative to regular maintenance that follows short cycle times. Using actual observations, such as vibration, provides an opportunity to take quick action when warning conditions are detected (red curve), while avoiding premature maintenance on machines that have more life remaining (blue and green curves).

Sometimes, these three zones of operation (normal, warning, critical) can correlate to the three stages of a machine’s maintenance cycle: early life, midlife, and end-of-life, in which case they may influence the vibration monitoring strategy. For example, during early life, an instrument might only require daily, weekly or monthly observation of key vibration attributes. As it moves into midlife, this might change to hourly observation, and as it approaches end-of-life, vibration monitoring might occur even more often, especially in cases where people or the asset are at risk. At this stage, machines that monitor vibration using portable equipment will accumulate recurring costs that might become prohibitive when compared to the cost of maintenance. While major assets can justify special attention, many other instruments cannot bear the recurring cost. To complement manual measurements, embedded MEMS-based sensors provide a more cost-effective approach for equipment that requires real-time vibration data. Nature of vibration:Vibration is a repetitive mechanical motion. A number of attributes are important for developing a vibration-sensing instrument. First, an oscillating motion often has both linear and rotational components. Most vibration-sensing relationships tend to focus on the magnitude of the oscillation, not on absolute position tracking, so linear sensors such as MEMS accelerometers are sufficient for capturing motion information. When the motion is mostly linear, understanding the direction can be important, especially when using single-axis sensors. Conversely, a 3-axis sensor can offer more mounting flexibility, as the orthogonal orientation enables pickup on one or more axes regardless of the vibration direction. Since vibration is periodic, spectral analysis offers a convenient way to characterise the vibration profile (the relationship between vibration magnitude and frequency). The profile shown in Figure 2 has both broadband and narrow-band components, with primary vibration at

~1350 Hz, four harmonics, and some low-level wideband content. Every piece of moving equipment will have its own vibration profile, with the narrow-band response often


38



representing the natural frequencies of the equipment.Signal processing: The sensor selection and signal-processing architecture depends on the application’s objectives. The manufacturer’s insight into the mechanical design aids with the band-pass filter design, specifically with the start frequency, stop frequency and pass-band roll-off rates. Rotation speed, natural frequencies of the mechanical structure, and fault-specific vibration behaviours can all influence the band-pass filter. While this type of approach is simple, vibration monitoring requirements can change as historical data from a particular machine becomes available. Changes in monitoring requirements can lead to changes in the filter structure, which can present a recurring engineering cost. Developers can trade complexity for flexibility by digitising the sensor response, implementing key signal processing functions such as filter, rms computation, and level detectors, and leveraging auxiliary I/O outputs to control indicator lights or provide a numerical output.Core sensor: The core sensor for either approach can be a MEMS accelerometer. The most important attributes for selecting a core sensor will be the number of axes, package/assembly requirements, electrical interface (analog/digital), frequency response (bandwidth), measurement range, noise and linearity. While many triaxial MEMS accelerometers support direct connection with most embedded processors, capturing the best available level of performance might require single or dual-axis solutions that have analog outputs. For example, the ADXL001 high-performance wideband iMEMS® accelerometer leverages its 22-kHz resonance to provide one of the widest available bandwidths, but it is only available as a single-axis, analog-output device. Analog outputs can enable a quick interface in systems that have an available analog-to-digital channel, but the present trend of development seems to favour those sensors that have digital interfaces.

The core sensor’s frequency response and measurement range determine the maximum vibration frequency and amplitude that it can support before saturating the output. Saturation degrades the spectral response, creating spurious content that can cause false alarms, even when the saturation

frequency does not interfere with a frequency of interest. The measurement range and frequency response are related by Ap-p=Dp-p × ω

2 where D is the physical displacement, ω is the vibration frequency, and A is the acceleration.

While the frequency response and measurement range place upper boundaries on the sensor’s response, its noise and linearity place limits on the resolution. The noise will establish the lower limit of the vibration that will cause a response in the output, while the linearity will determine how much false harmonic content is generated by a vibration signal. Analog filter: The analog filter limits the signal content to one Nyquist zone, which represents one half of the sample rate in the example system. Even when the filter cut-off frequency is within the Nyquist zone, it is impossible to have infinite rejection of higher-frequency components, which can still fold back into the pass band. For a system monitoring only the first Nyquist zone, this fold-back behaviour can create false failures and distort the view of the vibration content at a particular frequency. Windowing: Time-coherent sampling is often not practical in vibration-sensing applications, as nonzero sample values at the start and end of the time record result in large spectral leakage, which can degrade the FFT resolution. Applying a window function before calculating the FFT can help manage the spectral leakage. The best window function is dependent on the actual signal, but in general, the trade-offs include process loss, spectral leakage, lobe location and lobe levels. Fast fourier transform (FFT): The FFT is an efficient algorithm for analysing discrete time data. The process transforms a time record into a discrete spectral record, where each sample represents a discrete frequency segment of the Nyquist zone. The total number of output samples is equal to the number of samples in the original time record, which in most cases represents a number in the binomial series (1, 2, 4, 8 … ). Spectral data has both magnitude and phase information, which can be represented in either rectangular or polar form. When in rectangular form, one half of the FFT bins contain magnitude information, while the other half contains phase information. When in polar form, one half of the FFT bins

Figure 1: Example of vibration v/s time


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Figure 2: Vibration profile, natural frequency ~1350 Hz

contain the real result, while the other half contains the imaginary result.

In some cases, both magnitude and phase information are helpful, but the magnitude/frequency relationship often contains enough information for detecting key changes. For devices that offer only magnitude results, the number of FFT bins is equal to one half of the samples in the original time-domain record. The FFT bin width equals the sample rate divided by the total number of records. In a way, each FFT bin is like an individual band-pass filter in the time domain. provides an example of an actual MEMS vibration sensor, which samples at 20480 samples per second (SPS) and starts with 512-point records. In this case, the sensor only provides the magnitude information, so the total number of bins is 256 and the bin width is equal to 40 Hz (20480/512).

The bin width is important because it establishes the frequency resolution as the frequency shift from one bin to an adjacent bin, and because it determines the total noise the bin will contain. The total noise (rms) is equal to the product of the noise density (~240 μg/√Hz) and the square root of the bin width (√40 Hz), or ~1.5 mg rms. For low-frequency applications, where noise tends to have the most influence on resolving vibration, a decimation filter prior to the FFT process can help improve the frequency and magnitude resolution without requiring a change in the ADC’s sample frequency. Spectral alarms: One of the key advantages of using an FFT is that it enables simple application of spectral alarms. The warning and critical levels correspond to the levels in the machine-health vibration vs time profile. The start and stop frequencies complete the process variable definition represented by this relationship. When using an embedded processor, the spectral alarm definition variables (start/stop frequencies, warning/critical alarm levels) can be in configurable register locations that use digital codes for configuration. Using the same scale factors and bin numbering scheme can greatly simplify this process.Record management: One of the key functions associated with process variable relationships is record management. Storing FFT records from different stages of each machine’s

lifetime enables analysis of a variety of behaviours that may lead to a wear-out curve, which contributes to maintenance and safety planning. In addition to compiling historical vibration data, some will find value in capturing condition data associated with parameters such as power supply, temperature, date, time, sample rate, alarm settings and filtering. Interface: The interface depends on the existing infrastructure in a particular plant. In some cases, industrial cable-ready communication standards such as Ethernet or RS-485 are readily available, so the interface between a smart sensor and the communication system might be an embedded processor. In other cases, that same embedded processor might be used to interface the smart sensor with an existing wireless protocol, such as Wi-Fi, ZigBee, or a system-specific standard. Some smart sensors, such as the ADIS16000 wireless gateway node for remote sensors and the ADIS16229, come with a ready-to-deploy wireless interface that is available through common embedded interfaces such as SPI or I2C.

Conclusion

Inertial MEMS technology is ushering in a new era of vibration monitoring and is enabling a wider user base for this type of instrumentation. Performance, packaging, and familiarity may contribute to continued use of piezoelectric technology, but vibration monitoring is clearly growing and evolving. Through functional integration and ease of adoption, MEMS devices are gaining increasing attention in new vibration monitoring applications. Convenience, through advanced signal processing at the point of sensing, reduces the monitoring burden to a simple state (normal, warning, critical) for most situations. In addition, remote data access through convenient communication channels is creating new applications for vibration monitoring instruments. Future advances in key performance metrics (noise, bandwidth, and dynamic range) and the high level of functional integration will help this trend to continue in the near future. ☐


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Glen E PeerDirector of Test EngineeringIntegrated Device Technology Inc

Semiconductor teSt SyStemSAn application story on how IDT lowered cost of test by adopting the NI semiconductor test system. The solution creates a wide range of mixed-signal semiconductor solutions from low-power to high-performance devices.

IDT faced a major challenge in keeping pace with continuously increasing test performance requirements in a fast moving environment where device performance is constantly pushing the limits of ATE system capabilities and thereby, accelerating tester obsolescence and driving test costs higher.

Solution

IDT used the open PXI architecture of the NI Semiconductor


Test System (STS) to achieve flexibility and the ability to reconfigure and grow its test platforms in parallel with their rising performance needs. They also built on their original investment rather than throw it away like with traditional ATE systems, which generally require major costly reboots of the test floor as generations of test systems advance.

Project details

IDT creates a wide range of mixed-signal semiconductor

Focus- Semiconductors & electronics NI.indd 42 8/14/2014 7:17:04 PM

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This methodology worked well, but IDT eventually faced hardware obsolescence that required replacing its chosen ATE and, therefore, a system redesign. Secondly, though the company’s hybrid approach was successful from an engineering and performance perspective, it was not always production friendly. In general, as novel engineering enhancements get

“bolted” onto ATE systems, the systems become more difficult to support in high-volume manufacturing. Adding cables, hardware, and sometimes device under test boards with extravagant electronics to ATE systems increases the potential for possible failure points in high-volume manufacturing environments.

The most ideal solution is to create or find a test platform with an open architecture that allows users to build on their investments from within the tester rather than through bolt-on enhancements or reinvestments in high-dollar big iron ATE. The company needed an architecture that was resistant to hardware obsolescence and could be reinvented as technology improved. The NI STS provided this architecture.

STS’s PXI platform is perfectly suited to solve these problems. The system offers multiple PXI chassis inside a tester mainframe to offer expansion capabilities so the user can add enhanced test features within the tester itself. The PXI open standard gives users the flexibility to select instruments from a variety of vendors based on their needs instead of from the limited choices of a single ATE hardware vendor.

STS works well for IDT as the natural extension of the company’s tester evolution. With it, IDT can continue to build high-performance, low-cost test platforms using only the modules and components we need to meet our performance targets. The open architecture of the NI STS makes this even easier.

During the past year of STS deployment at IDT, the company already enhanced the systems from their original configuration to meet its evolving test needs. Through careful planning during the startup phase, the company ensured that despite these enhancements, these systems maintained 100 %

solutions from low-power to high-performance devices. A worldwide leader in timing devices (clock ICs), IDT offers a broad portfolio for networking and communications, consumer, and computing applications.

As the performance of IDT’s devices increases, it becomes more difficult to maintain the pace in the production test environment. Traditional ATE systems capable of meeting IDT’s high-performance measurement requirements are expensive and often include extra capabilities that are not used but add to the cost. Additionally, within the traditional ATE environment, upgrading a tester to improve its performance often requires upgrading to the next-generation test platform and phasing out the current platform. This is both expensive and wasteful because a large portion of the engineering investment made during previous generations can be lost.

To combat this, IDT typically engineers its own solutions on top of the installed base of test systems. Having used various models from nearly every ATE vendor, the company have become proficient at extending the useful life span of these ATE platforms while controlling costs and enhancing its measurement capabilities.

Evolution of test

The evolution of test within the timing business unit at IDT is the perfect example of this approach. The company began with an off-the-shelf, high-dollar ATE system. Soon they realised that this approach was too expensive, so the company built its own internal test system(s). These homegrown systems met the high-performance requirements but sacrificed some of the benefits of using a commercial platform such as high parallelism and external support. The company therefore migrated to a hybrid of these two approaches and combined a low-cost commercial ATE system with its own performance enhancement system as shown in Figure 1.

Figure 1: Combination of a low-cost commercial ATE system with IDT’s enhancement system


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backward compatibility with the initial target solution(s). All of the company’s initial investment was preserved as it expanded the testers to enable a broader usage base throughout IDT.

Benefits of using an NI solution

IDT took advantage of many benefits to using NI solutions. First, unlike its previous hybrid approach, IDT could consolidate the test head, which reduced the number of potential failure points within manufacturing, downtime for maintenance and repair, and floor space requirements. The company also increased its ability to test a wide range of devices with the same configuration because the system has interchangeable interface boards, and IDT can use the same tester configuration for different device types. The multisite system allows for higher test throughput because it is a true parallel test system with high-accuracy performance parameters for hardware optimisation. Lastly, this solution was lower in cost compared to alternative integrated solutions because the company needed to build only one set of instrumentation and had fewer individual systems to maintain.

Growing for the future

STSs installed on IDT’s production test floor run 24/7. The company has experienced test time reductions in the 10% to 25% range, enhanced measurement capability and accuracy, and cleaned up footprint on the test floor, which made its testers much more production friendly. Using the NI STS, the company not only increased its test performance but also reduced its overall cost of test by retiring older, difficult to support and maintain test systems. Some of these older systems had expensive power and cooling requirements, but the NI STSs simply plug into any 110 V outlet with no extra facilities required. Hourly test costs per unit on these older systems were as much as twice that of the NI STS. Additionally,

NI STSs provide high-performance measurement features across multiple test sites with true parallel test capabilities to further reduce the cost of test.

The NI STS is a scalable tester family with models available using one (STS T1), two (STS T2) and four (STS T4) internal PXI chassis. IDT designed its NI STS beginning with the T2 model with upgrades and enhancements in mind. The ability to grow the test platforms in response to the company’s own needs is one of the strongest selling points of these systems. Previously, it was difficult or impossible to share test systems across internal business units, but the company now have other teams evaluating its NI STS. These groups’ test needs are different from those that the company’s systems are currently configured to handle, but with the open architecture of the PXI platform, these users can add capabilities to the original IDT system definition, which have been already proven in production.

Though no single ATE platform is ideal for all situations, for the first time the company saw the possibility of maintaining an ATE platform that can be reconfigured and reused across multiple business units through the simple swapping of interface boards or internal instrumentation modules. With the NI STS, IDT believes that it can define one or two system configurations and use these systems on its production test floor to satisfy the different needs of all the businesses within IDT. The company designed its NI STSs so that they can simply swap interface boards to enable various hardware configurations as required. This ability will greatly simplify overall test operations and help further drive down the total cost of test.

Finally, the company can break away from the big iron ATE vendors and their hardware obsolescence cycles and determine the best test strategy based on their own overall needs. The current and future investments in test hardware and software are preserved and reusable for the foreseeable future. ☐

STSs running production test within IDT’s manufacturing facility


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CO N T RO L & RE G ULAT ION | T echnology

A&D I nd i a | A ug -Sep 2014

Open core engineeringA read into open core engineering that combines a high degree of engineering efficiency and future-readiness, which increases the application’s flexibility and engineering efficiency along the entire value stream

Machinery manufacturers and users require more engineering efficiency for a faster time to market and future-proof automation solutions in order to protect their investments. At the same time, they are looking for possibilities to customise their machines economically with new automation ideas for machine processes and functionalities to meet the needs of individual customers. This is how they can set themselves apart from the competition. As a result, the wish for more flexibility to implement these customised concepts rounds out the list of new requirements.

Rexroth meets these requirements with open core engineering, which represents the company’s comprehensive package of solutions that increases engineering efficiency along the entire value stream for all drive and control technologies. Users benefit from accelerated engineering at

lower cost and increased future-readiness based on open industry standards. At the same time, it also provides new degrees of freedom for customisation and flexibility for various programming languages and device classes. This engineering uses the Open Core Interface to connect previous engineering that is based on the newest IEC standards.

Engineering efficiency

Open core engineering accelerates engineering efficiency decisively with software tools, function packages and multi-technology solutions. It makes contributions at every step, from project planning to programming and parameterisation, commissioning to service. The engineering framework IndraWorks provides all required tools for the engineering of

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all technologies. In complex projects and tasks, innovative function packages accelerate the work processes. For example, the “Generic Application Template” (GAT) creates the optimal requirements for the development of modular machine software. Based on templates, GAT uses wizard support to automatically generate an executable machine program to match the specifications of the project planner, thereby significantly increasing engineering speed. Interfaces such as the Automation Interface further increases engineering efficiency. With this interface, engineering tasks can be carried out in an automated manner according to a script, and interfaces to eCAD systems.

Open core engineering replaces time-consuming programming of complex machine processes through simple parameterisation of customised technological functions. For example, the FlexProfile: with this function, machinery manufacturers can easily fulfil their customers’ requests for more flexibility and retrofits at the push of a button. Based on two analytical motion profiles, it automatically adapts all drive movements to changed parameters in the production process.

Future-proof solutions

Choosing an automation system means big investment for machinery manufacturers. Open core engineering protects this investment through the consistent use of open standards and uses the IEC 61131-3 and PLCopen standards for open PLC programming. The automation bus Sercos can be homogeneously integrated into all solutions to this end. With its high performance, application flexibility and the number of available field devices on the market, a highly functional and more future-ready Ethernet field bus is available as the backbone for state-of-the-art machine concepts. Open core engineering continues to integrate the newest standards such as FDT/DTM for tool integration or OPC UA for M2M communication. Through multi-Ethernet interfaces, Rexroth drives can also be integrated into heterogeneous automation

topologies, which allow machinery manufacturers to create customised versions with regionally preferred communication systems without additional effort.

Thanks to the library concept in engineering and the scalability of the automation portfolio, machinery manufacturers can reuse entire programs or individual program modules on larger or smaller versions of their machines with a control unit that complies with the requirements. They can place the corresponding content into the new project via drag and drop, hence saving time. Today, open core engineering safeguards major investments in modern, software-based solutions and in the future too.

Individualisation

In the past, applications requiring access to all functions of the control core, could only be accomplished by the drive manufacturer. With the Open Core Interface, Rexroth opens the door into a new world of automation and offers machinery manufacturers entirely new degrees of freedom, with room for individual solutions.

In order to increase productivity, increasing amounts of information from various sources at the production and control system level must be exchanged quickly. By adapting Ethernet-based communication for fast production processes and integrating it into automation systems, as happened with Sercos, the data network stemming from the IT environment has become the current backbone of modern machines.

The Open Core Interface also expands the software tools and function packages of open core engineering and creates additional degrees of freedom in the engineering of machines and systems. Rexroth opens its drives down to the core and provides methods for economically creating individual functions oneself. With the Open Core Interface, applications based on high-level programming languages on external devices receive flexible access to all control and drive functions down to the core. Applications become executable based on

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Near Chaturshrungi Temple, Pune – 411016 (M.S.), INDIA.Email: [email protected], Mobile No:+ 91 83800 66578

URL: www.hms.se

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Save time, save energy, save resources™

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With the Open Core Interface, Rexroth opens the

door into a new world of automation and offers

machinery manufacturers entirely new degrees of

freedom, with room for individual solutions


calculated in which the lubricants are to be renewed or topped and warnings are displayed. All these functions can also be simulated, so this app can also be used to show the functionality without a connected control. Apps for smart devices also increase the efficiency of maintenance work in the production arena. Unlike in the past, the user needs no special consoles with a physical connection to the control unit. For example, a technician can simply use his/her smart device to scan a QR code on the machine. The app immediately provides the user with wireless access to this control unit and allows him or her to call up all diagnostic data. With the appropriate infrastructure and authorisation, diagnosis can be performed from any desired site. In the event of a malfunction, for example, the control unit can send error messages directly to the smart device per SMS or email and allow the technician to access the control unit directly for remote troubleshooting.

For commissioning, diagnosis and operation, in the long term, smart devices will therefore replace the HMI devices that were necessary in the past. For example, users will be able to use a tablet PC to operate several machines, which in turn no longer need their own dedicated HMI devices.

Conclusion

Open core engineering combines a high degree of engineering efficiency and future-readiness with same degrees of freedom available with modern high-level languages and IT-based technologies in new production machines. This combination enables the customisation of machine concepts and increases the application’s flexibility. For commissioning, diagnosis and operation, in the long term, smart devices will therefore replace the HMI devices that were necessary in the past. For example, users will be able to use a tablet PC to operate several machines, which in turn no longer need their own dedicated HMI devices. ☐

C/C++ directly in the real-time environment of the drives. Machinery manufacturers can use the Open Core Interface to implement firmware expansions of the Rexroth motion logic drives by themselves.

Flexibility

The penetration of smart devices into the consumer world has also opened up new communication channels between humans and machines. In the future, intelligent control systems will adapt even more easily to human communication, thereby making interaction at the user level faster, more intuitive, more intercultural and more flexible.

The Open Core Interface is already turning such innovative machine concepts into reality. The wide support for open programming and data interfaces in the IT world enables a high degree of flexibility in the selection of programming languages and device platforms. Hence, the user is free to choose between C/C++, C# (.NET), Visual Basic, VBA (Office), LabVIEW G, Objective-C, Java as well as all programming environments that support the integration of Microsoft COM libraries.

The Open Core Interface supports Apple® iOS and Google® AndroidTM, currently the two most important operating systems for smart devices such as smartphones and tablets. Machinery manufacturers can, therefore, implement native apps for Apple iPhones®, iPads® or Google Android smartphones and tablets. Users can simultaneously connect to several control units or access a control unit from various user applications at the same time.

With the Operation App for Handling, one can operate a machine using tablet PCs. Setting up and commissioning the system is possible via functions for teaching, jogging and referencing. There exist manual functions to execute user specific switching functions of the system. Machine specific programs can be selected, started, stopped and debugged. With maintenance functions for linear systems, the cycles are


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Evolution of switching interfacesThis article briefs on a number of interface relay modules that are made available to provide the bridge between the industrial controller and the increasing number of real-world control scenarios

As processes, machine control and automation become ever more complex, industrial controllers have become more of a commodity item, offering an amount of ‘control power’ sufficient to handle most applications. However, controllers invariably provide fixed and inflexible electrical interfaces. This inflexibility is almost inevitable since no single interface can satisfy the disparate needs of switching both thermocouples and high power contactor coils. And since the provision of optimised plug-in interfaces is seen as too costly a feature for the standard industrial controller, no ‘easy fix’ exists within the controller. This point, combined with the need for quick and easy replacement of worn or damaged interfaces, has

meant the use of external interface relay modules that has become the de facto solution.

Concern

The common concerns of the system integrators and end users these days are of different nature when it comes to relay interfaces. An end user has a need for easy diagnostics, faster uptime, redundancy/standby features for easy replacements and above all longer electrical life under the harsh industrial environment. Whereas an integrator apart from the above also looks forward to solutions which are able to save costs directly

Dr Ashish ManchandaManaging Director Finder India

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or indirectly by saving space, less wiring, faster installation & commissioning, etc.

The relay boards as a concept thus got initiated almost two decades ago and later got spread in the nooks and corners of the industry due to its easy availability at local assembly units near to the cabinet builders. At one time the most common style simply incorporated multiple PCB relays on a single board, which was in turn mounted on a 35 mm rail. This was helpful where an enhanced current rating was needed across a block of outputs, but it tended to hinder the tailoring of outputs from channel to channel and be inflexible & bulky.

However, lately, some more of the concerns with these relay boards have come to light. Some of these issues are non-availability of a common industry standard on the quality of the PC board design & soldering, PCB insulation strength, electrical creepage, temperature withstand capabilities, MTBF values, behaviour under failures, consistency of components used, international test standards for finished product and last but not the least the compatibility of the soldered sockets with respect to the requirement of the relays.

Evolution

To overcome these elements of doubts, a number of interface relay modules were made available to provide the bridge between the industrial controller and the increasing number of real-world control scenarios.

Today, the preferred solutions are of an ultra-slim single pole module type, particularly those equipped with a replaceable relay element. Different versions can be selected channel-by-channel to match the particular requirements of the load, without any kind of over or under-specification.

The replaceable relay type also offers quick and easy maintenance for those applications where exceptional longevity is paramount. Development of this approach has led to further benefits in cost and time-saving through innovations such as multi-way jumper links for simple common circuit interconnection between adjacent interface relay modules, and the inclusion of identification labels to aid commissioning and maintenance.

The new approach

By identifying a relatively limited number of relay/socket/ module combinations, the technology has now advanced to a level where the designer of the control panel has even better flexibility for selecting and using a combination of single part numbers. The new technology Ultra Slim Relays in Solid State (SSR) as well as Electro Mechanical (EMR) has now provided the design engineer access to a range of ideally matched components that are assembled and ready to accept wiring – offering the additional benefits of reduced inventory, purchasing time, wiring time, space inside the cabinet and cost.

However, there are small but significant differences in the ideal feature set of an interface relay, depending on whether the device is on the input or the output side of the controller. Until now this aspect of design had not been fully addressed, but of-late new solutions have even made the life easier by reducing control cabinet foot print, wherein the regular set of terminal blocks can be avoided which saves a lot of space and wiring cost too! ☐

Relay interface in control panels


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While EtherNet/IP has many advantages, cable installation is often expensive, and communications to remote sites or moving platforms may not be reliable or cost-effective. Wireless Ethernet technologies have emerged that can reduce network costs while improving plant production.

However, applying these technologies is not a simple matter as industrial Ethernet systems vary greatly in terms of bandwidth requirements, response times and data transmission characteristics.

Features

Ethernet Industrial Protocol (EtherNet/IP) is a network protocol defined by Open DeviceNet Vendor Association (ODVA). As an open standard, vendors may implement EtherNet/IP communications in their devices without licensing fees. Many vendors have adopted EtherNet/IP including Rockwell Automation, who selected the protocol as one of three preferred networks on their popular Logix controllers (DeviceNet and ControlNet are the other two).

An important part of the EtherNet/IP standard is definition of Common Industrial Protocol (CIP) messaging. CIP defines the information packet with recognition that the message attributes will vary as applications do. Thus CIP message definition takes into account a wide range of applications including programming/diagnostics, data collection, PLC data exchange and I/O communications.

Wireless as an alternative to cable installation

The cost of installing cable in industrial plants is a function of the material costs plus the labour charges. Cable installation costs have been estimated as ranging from $20 to $2,000 per foot depending on installation challenges (distances, obstacles), environment and local labour costs. Factors that impact total cable installation costs include distance and number of locations; conduit design and installation; trenching; fibre optic cable & infrastructure and hazardous location regulations. Once the total cost of cable installation is calculated, a comparison can be made to wireless. Similar to cable installation

Applying wireless to EtherNet/IP An article on the use of Ethernet which is growing rapidly in factory automation, process control and SCADA systems. The ODVA EtherNet/IP network standard is gaining popularity as a preferred industrial protocol. Plant engineers are recognising the significant advantages that Ethernet-enabled devices provide such as ease of connectivity, high performance and cost savings

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though, the total cost of wireless should be examined. This not only includes the wireless hardware (including wireless nodes, antennas and cables), but also antenna installation (if applicable) and personnel training. However, even when factoring in these additional costs, the savings realized by wireless is often dramatic and significant.

Additionally wireless (when implemented properly), offers better reliability than cabled systems because there are fewer mechanical connections to fail. If the cable is broken by moving equipment, severed during construction or damaged by vibration, production may be down for hours until the problem is located and corrected. Wireless also offers electrical isolation as fiber optics do, eliminating potential surge damage from ground plane transients.

Finally, a significant benefit of wireless is reducing project time. Wireless systems are typically much quicker to install than wired systems. This is especially beneficial in systems that move over time such as mining operations or the reconfiguration of production equipment on the factory floor.

Wireless in motion

Where wireless can significantly benefit production is in processes using motion such as material handling systems where controllers and I/O are on moving platforms. Examples include overhead cranes, transfer cars, stacker/reclaimer cranes, automatic guided vehicles (AGVs), conveyor systems and rotating packaging machines.

Mechanical methods of Ethernet communications (Figure 2) such as festoon cable systems, flex cable, slip rings and rails are prone to frequent maintenance and sudden failures. These systems are often relatively expensive, especially when supporting Ethernet.

Wireless may be less expensive and, if implemented correctly, significantly more reliable. Today, many of these mechanical systems are being retrofitted with wireless as production

shutdowns become more frequent. Designing wireless into the system upfront could have reduced installation costs and increased plant production.

Industrial Wireless Considerations

TCP/IP or UDP/IP: Before selecting the wireless technology, it is important to consider the EtherNet/IP application and determine if it will be based on TCP/IP, UDP/IP or a combination of the two. This is important because TCP and UDP protocols behave differently over wireless networks.

UDP/IP is typically used in implicit messaging systems where controllers communicate to I/O blocks over Ethernet media. TCP/IP is much more common as it is the basis for explicit messaging between controllers, HMIs, remote programming and data collection. Ultimately the automation architecture will determine the EtherNet/IP protocol type and appropriate wireless technologies.

Proprietary FHSS v/s 802.11 DSSS/OFDM: The most common approach to wireless Ethernet is RF transmission in the spread spectrum bands. Globally, the 2.4 GHz and 5.8 GHz bands are available for license-free use in most countries.

Direct sequence and Orthogonal OFDM offer the fastest spread spectrum data rates as the wide channel permits transmission of complex modulation schemes. OFDM uses a complex modulation technique and is capable of high data rates and low latency (the transmission time a packet takes from one end to the other). OFDM is also significantly more immune to multipath fading, a problem due to RF reflections that high data rate systems frequently have.

Direct sequence and OFDM are the methods used by all popular open Wi-Fi standards including IEEE 802.11b, 802.11g (both transmitting in the 2.4 GHz band) and 802.11a (transmitting in the 5 GHz band. The wide band modulation offers high speed, it unfortunately is more prone to noise

Festoon and slip ring

communication systems


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Wireless TCP/IP system for HMI connectivity

A common error though is assuming that faster technologies are better. If the application can handle slower speeds, then using relatively slower frequency hopping technology may be the best approach. Frequency hopping is the most robust especially regarding communications in high RF noise areas, and easier to implement. As applications demand higher speeds, then more considerations and engineering challenges are typically encountered.

Wireless for explicit messaging between PLCs

One of the most popular uses of wireless is in sharing I/O information between PLCs. Because these messages are unscheduled at the protocol layer, slower wireless Ethernet technologies may be used. MSG blocks in PLC ladder code may be programmed to accept long delays in transmission. If the application (process) is not time-critical, then a slower (but robust) frequency hopping technology may be the best choice.

There are many factors influencing how fast an explicit MSG may be executed. Generally, applications requiring 200 ms response time or slower are a good candidate for FHSS. Faster response times may require faster technologies such as OFDM available in IEEE 802.11a and 802.11g standards.

Wireless for HMI networks

Another popular application for wireless is connecting Human Machine Interfaces (HMIs) to plant networks or machines. HMIs use TCP/IP communications and are not time critical other than to meet the needs of the process and, most importantly, the operator.

While HMI screens may look very complex and data intensive, usually the actual data being transmitted (updated) is minimal. If programmed efficiently, slower wireless technologies (such as Frequency Hopping) may be used. The key consideration is update times and the amount of information actually being transmitted.

FHSS may be the best choice if appropriate. However, if portable computers or PDAs are used, then the industrial

problems when multiple systems are operating in close proximity. For example, IEEE 802.11b/g has thirteen available channels (eleven channels in North America), but only three channels don’t overlap.

Due to overlapping channels and the popularity of Wi-Fi systems in plants, band crowding and RF saturation can lead to poor wireless performance. Frequency hopping is a very popular technique for industrial systems because it has outstanding noise immunity techniques. Unlike direct sequence and OFDM, Frequency Hopping uses many smaller channels in the spectrum and rapidly changes channels or hops around from channel to channel.

The disadvantage of Frequency hopping is that it is slower than Direct Sequence/OFDM and has longer data latency. Most Frequency Hopping systems are limited to 1 Mbps or less RF data rate. But if the data rate is fast enough for the application, the reliability of frequency hopping is tough to beat especially in high noise environments.

Frequency Band Selection: There are many considerations when selecting the frequency band for EtherNet/IP communications including required data rate, distance, line-of-sight obstructions, modulation technique, band availability (government regulation) and band saturation (crowding). There are also spectrum management issues to consider if wireless is already in place or planned for the future.

The major consideration is band usage and management. Many industrial plants use the 2.4 GHz extensively for IT and inventory systems. Therefore, the 900 MHz band (for slower speed systems) or 5 GHz band (for higher speed) may be the best choice for industrial wireless systems.

Wireless EtherNet/IP Reliability & Performance

Industrial wireless applications can be divided into two broad categories: Those requiring high speed, low latency performance, and those permitting slower speed with longer packet latency. Wireless technologies are available to accommodate both.


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wireless network must support the standard built into these portable devices. 802.11b and 802.11g (Wi-Fi) are the most common. This technology supports mobile operators while providing high speed, low latency communications.

Wireless for Ethernet I/O (implicit messaging)

An emerging application for wireless is communications to distributed I/O blocks using EtherNet/IP. Wireless offers many advantages in these applications including elimination of mechanical coupling methods used in moving systems (e.g. rails, slip rings) and general cost savings due to reduction of Ethernet infrastructure.

Communication to EtherNet/IP I/O blocks can also reduce automation costs compared to using remote PLCs. Programming is simpler using I/O instead of remote PLCs because MSG blocks are not required in the main controller’s ladder program. But remember that Implicit Messaging is UDP/IP based, not TCP/IP. Wireless networks must be carefully designed, and the plant RF environment more closely managed to ensure reliable communications.

Several factors should be carefully considered before choosing this architecture including:• Lack of remote PLC control (intelligence) in case of

communication failure• Amount of I/O and required scan times (network traffic)• Packet handling ability of wireless technology• Efficiency of the RF technology with multicast UDP

packets• 802.11 clear channel availability

However if circumstances are right, wireless EtherNet/IP I/O can be a significant cost saver and actually improve system reliability when correctly implemented, especially in moving systems.

Prosoft Technology has performed extensive tests of its Industrial Hotspot technology with EtherNet/IP and has many

successful customer installations. The following information is provided only as a guideline towards predicting wireless performance and should not be relied upon for any other purpose. Prosoft Technology always recommends field testing to confirm wireless performance and reliability.

Predicting Wireless I/O Performance

Because EtherNet/IP I/O messages are scheduled, it is possible to predict scan time performance over industrial wireless systems if the following conditions are met:• Packets per second performance of wireless technology• Wireless behavior in multipoint systems (handling of UDP

Multicasts)• Number of CIP connections

The first step in designing a wireless EtherNet/IP system is calculating packets per second which determines minimum wireless bandwidth requirements. Start by counting the number of CIP connections.

To calculate how many connections are in an I/O system, sum up all direct connections and rack optimized connections. To determine how many packets per second the system will be using, multiply each connection by two. It is multiplied by two because each CIP connection is bi-directional meaning that during every Requested Packet Interval (RPI), a produced packet is sent by each end of the connection.

For example, if there are five direct connections and two rack optimized connections (with six digital modules in each) equals 7 total CIP Connections, the total number of packets is then calculated:

7 CIP Connections x 2 = 14 Packets Note that the six modules in each rack that are rack

optimized only count as one connection. Rack optimization (if available in the I/O hardware) can significantly reduce wireless traffic.

Then multiply the packets by scan time (derived from RPI

EtherNet/IP protocol stack


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setting) to calculate packets per second (pp/s). Let’s assume that in the above example, the required RPI time is 20 milliseconds (actual RPI time is application dependant), we know that there are 50 packets per second at an RPI time of 20 ms (1 / 0.02). We then multiply the 14 connections by the 50 packets per second to get the over all packets per second rate:

14 Packets x 50 per second = 700 packets per second (pp/s).The overall packets per second rate for 802.11 a/g radios

can be in the thousands. However it is best practice to not operate the radio network at maximum capacity. Rockwell Automation suggests reserving 10% of each adaptors bandwidth so it is possible to use its RSLogix 5000 software for remote programming.

The next step is to determine a reliable packet per second (pp/s) rate that the wireless technology will reliably support while keeping in mind that at least 40% should be reserved for other applications and RF overhead.

Emerging Wireless Technologies

IEEE 802.11n: Not a ratified standard yet at time of this

paper, 802.11n promises several features that are attractive for EtherNet/IP communications including dual band (2.4 GHz, 5 GHz) support, significantly faster packet transfer rates with a reported throughput up to 300 Mbps and RF propagation that actually takes advantage of reflected signals (quite common in industrial plants with lots of metal) using multi-input, multi-output (MIMO) antenna systems.

IEEE 802.16 (WiMax): While popularly known as an emerging cellular technology, WiMax technology will soon be available in the spread spectrum (license-free) bands including 2.4 GHz. WiMax offers high speed (up to 70 Mbps) at potentially long range. WiMax technologies may dramatically improve data rates to remote industrial sites and SCADA systems.

ISA100.11a: The ISA is working on the ISA100.11a standard for wireless enabled devices, such as sensors. Operating in the 2.4 GHz band, the technology will “sense” existing 802.11b/g systems and work around them. While designed primarily for embedded devices, EtherNet/IP adapters and gateways will likely be supported. ☐

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Improving process performance is all about understanding what is happening and being able to respond quickly. There is always a paradigm shift in the manufacturing industry which is periodic in nature. Today, the shifts seem to be towards smart factories where information generated in the virtual world flows into real manufacturing processes to make the production environment more intelligent, flexible and attuned to the necessary specifications and standardisation. This will enable devices and systems to communicate with one another more smartly and exchange information precisely.

By introducing cost-effective measurements based on wireless technology has helped Hindustan Zinc to improve visibility with real time, online, accurate process monitoring and at the same time enhancing flexibility for future needs.

To remain competitive amid a fluctuating market condition and wobbly economic scenario, utility monitoring is identified an area in the plant with more than 50% of energy consumption. Hence the decision to implement wireless technology in the facility for utility monitoring is a strategic choice as it will help

to improve visibility, optimise the production cost, reduce energy consumption, congregate real time process variables from the fields, ensure safety and compliance. Moreover, it was first time ever in Hindustan Zinc that it was conceptualised to use wireless mass flowmeters for mass reconciliation at Chanderia Smelting Complex(CSC).

Challenges & issues

There was a huge shortfall of High Speed Diesel (HSD) consumption v/s receipt ratio, which was identified in the month of May 2012. Soon after one task force team was formed to find out the various causes for this variance. Also, an external auditor was appointed to assist in finding out the probable causes.

As per the outcome of the auditor report as well as the task force, it was recommended to install mass flow meters to measure the HSD consumption at major locations which was one of the implementation part of the report submitted by the

Wireless technology for utility monitoringThe article discusses how cost-effective measurements based on wireless technology have helped Hindustan Zinc to improve visibility with real time, online, accurate process monitoring and at the same time enhancing flexibility for future needs.

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auditor. In existing HSD circuit, mechanical type meters were being used to measure the HSD consumption that has lower accuracy levels (upto +/- 2%). There were total 15 such meters in existing scheme. Also wiring the meters would prove to be highly cost prohibitive and time consuming.

Inspired by technology

Many industries are deploying wireless networks for targeted applications. Hindustan Zinc thus chose Emerson Process Management’s wireless technology to monitor flow and level of High Speed Diesel (HSD) for mass consumption/reconciliation at CSC complex. Both the requirements of online accurate and real time monitoring and measurement of main HSD tank is now possible and highly accurate HSD consumption & reconciliation of data for different areas of the plant.

The new wireless solution with mass flow meters can deliver accuracy level of +/- 0.1%. A proposal to deploy 10 numbers of highly accurate mass flow meters to bring the consumption and receipt difference within (+/-1.3%) as an overall system accuracy of HSD volume handled has been made. The system needs no site survey or line of sight requirement for deploying wireless & is reliable, safe and secure.

The mass reconciliation wireless system at the CSC complex is based on 10 mass flow meters, 1 set of inventory radar gauging system, 1 set of smart wireless gateway and wireless components. It is seamlessly integrated to the system and complete device communication status is available as shown in the above figure. The performance of wireless network after the

installation and commissioning is excellent in terms of HSD reconciliation at CSC complex from May 2013 onwards.

Technology advantages

Wireless technology offers several advantages such as review of historic trend of consumptions; cost savings with no cable laying and associated hardware; faster startup; web/network based secure and safe data monitoring at centralised location; accurate data with accessibility from remote location; fully automated system with no manual intervention; ability to add devices ‘at will’ for future expansions/debottlenecking and predictive maintenance due to availability of advanced diagnostics.

Start anywhere

With current wireless network now in place, additional devices can be added anywhere in the plant at much lower cost than if they had to be wired in and without having to worry about the existing cable infrastructure. Potential applications where the benefits of wireless technology can be extended in future could be pump health monitoring, steam trap/relief valves monitoring, temperature profiling, moving/rotating equipments, water intake monitoring, waste water treatment, fire, gas, smoke, spills & leaks, heat exchangers & filters, corrosion and many more. ☐

Courtesy: Emerson

A complete device communication status


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Universal Robots has developed the UR5 and UR10 models for small and medium-sized enterprises in particular. The handling units lift a payload of five and ten kilograms, but only weigh 18 and 25 kg themselves, respectively. This low weight makes it possible to move the units easily without complex subcomponents. The multi-functional robots are just as flexible in operation given their user-friendly software. It supports the Danish company with a user-friendly piece of software. Using this, the six-axis lightweight robots are ready for new tasks in no time. No special knowledge of robotics is necessary for the programming.

Modular design

The exceptional ratio of dead weight to loading capacity is the result of a sophisticated lightweight construction that does not contain anything that is not required. With the drive technology, this minimalist strategy means integrating the company’s frameless kit motors directly into the articulation axes. In doing so, the robot takes on the function of the motor housing, while the gear unit simultaneously serves as the primary bearing of the rotor. Viewed as a whole, the components used by UR frequently take on multiple functions

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Ian YoungKey Account ManagerKollmorgen, Ratingen

out-of-the box ideAsThe article highlights how Universal Robots aim to establish the flexibility of articulated-arm robots in industrial production by developing UR 5 and UR 10 models for SMEs in particular

moto rs & d r iv es | AppL i CAT i ON

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and this ultimately reduces the number of mechanical components such as ball bearings, couplings, or shafts considerably, thus decreasing the overall system weight and form factor. In addition, with their high power density, it also increases the lifting capacity of UR5 and UR10 platforms.

The KBM motor series offers advanced electromagnetic designs for optimised torque and minimal cogging & harmonic distortion. These benefits are offered over a large operating speed range. The electromagnetic technology with a high packing density in the stator increases torque and keeps thermal losses low. High strength rare earth magnets are used in the rotor, which allow a continuous torque of 1.45 to 3,445 Nm along with a peak torque of 4.91 to 12,812 Nm. “The high quality of these motors was a reason why we opted for Kollmorgen”, explains Esben H Östergaard, Technical Business Manager, Universal Robots.

Operation without noise but high energy efficiency

One of the advantages of the robots is its low-noise and energy-saving operation. From a total-cost-of-ownership perspective, the economical use of resources directly increases the efficiency of the overall robots. Thus, the competitiveness of this technology also increases. An additional benefit of high energy efficiency is closely linked to reduced losses in the motors. Since efficiency is high, less heat is produced. This means the motors stay cooler, operate below their maximum ratings and consequently achieve a longer service life.

The KBM motors offer a great deal of

freedom to configure the servo axes

in space-optimised way due to their

variable, modular design

The improved temperature behaviour also prevents the entire construction from heating up. “The motors we used in the past became pretty hot when in continuous operation. For the lower losses, the KBM motors simply stay colder. We can therefore run our robots in continuous operation without derating”, says Östergaard. He also refers to test procedures with long operation periods and comparatively high loads.

The KBM series is an innovative direct drive frameless motor technology provided by Kollmorgen. The frameless kit motors offer mechanical and plant engineering a wide range of solutions for creating applications with a maximum degree of flexibility, power density, dynamics, and durability. In addition to the technical advantages provided by this product, it includes 14 frame designs and many pre-engineered standard options with competitive lead times. “We can basically order as many motors as we want, when and how we want,” emphasises Östergaard. This aspect is of particular importance because Universal Robots is growing strongly.

“We therefore need a partner in drive technology who is a good fit for us.” In this regard, Kollmorgen was able to impress the Danish robot specialists with delivery reliability and has since established a UR-specific production line at the Czech location in Brno. “We can expand our business channels,” says Östergaard. This development is accompanied by the fact that due to sophisticated safety technology both models are even able to be employed without additional shielding. This opens the path to a safe and comfortable cooperation between staff and technology. ☐


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Intuitive engineeringThe article illustrates how thermoforming machines can be equipped with efficient synchronous motors. These machines are used in food packaging, industrial products and medical pharmaceuticals.

The global population is growing and by 2050, the need for food will double. This means not only the production of food, but also transport and storage are the important areas that will have to be taken into consideration. Even today, an enormous portion of food does not reach the consumer because it spoils en route or in storage. Approximately 1.2 billion tonnes of food is wasted worldwide per year. The packaging industry, therefore, needs to offer solutions that provide better storage and safer transport of food worldwide.

Thermoforming machines in particular is very important. Cheese, meat, fresh fruit and vegetables are the food categories packaged by thermoforming machines. Not only food, but

MOTO RS & D R IV ES | T E CH N OL OG Y

also industrial products or medical pharmaceutical products are packaged and sealed by thermoforming machines. Although the energy consumption of thermoforming machines is not particularly high, it is still worthwhile to take a look at this aspect. Due to the tight calculated costs and low profit margins for packaging materials, significant benefits for the machine operators can be achieved by small optimisations.

Higher degree of effectiveness with synchronous motors

Considering these factors, Baumüller, a Nuremberg

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consumers in thermoforming machines. With the most precise regulation possible, this consumption, which is unavoidable in thermoforming machines, can be reduced as much as possible. Using software modules, for precisely recording print marks, can also quickly regulate positions. This saves material since the plastic shells are cut very precisely. Via controls using cam disc technology with a virtual guide axis, sporadic movements in the machine are avoided which in turn protects the mechanisms, reduces wear and tear and, due to the optimised motion control, increases the energy efficiency of the machine. By using EtherCAT, the high-performance real-time ethernet bus system, Baumüller achieves coordinated motion control in real time.

Benefits

All software modules are integrated into the ProMaster Engineering Framework. The machine builders can depict the entire machine in this intuitive and comprehensive automation suite. This saves an enormous amount of time as a system diagnosis can be performed during commissioning. In addition, during programming, different machine models can be designed which simplifies the variant handling for the machine builder as the correct version is automatically created for the respective machine type. This is an enormous advantage for the machine builder for designing different machine concepts. In addition, the company has integrated a service and production technology which reduces the system down time to a minimum.

Conclusion

When it comes to efficiency in thermoforming machines, there are a number of options for reducing energy consumption and increasing the overall efficiency of the system. The improvements include selection of the right motor, movement optimisation via software and precise control of the heating elements. Such improvements increases energy efficiency and also reduces material wear & tear along with increasing the product quality and productivity. ☐

Courtesy: Baumüller

specialist for automation systems & drive technology, equipped thermoforming machines with efficient synchronous motors. In comparison to asynchronous motors currently preferred for such machines, synchronous motor has a higher degree of effectiveness, and thus more efficiency, due to the use of permanently excited magnets. The DS synchronous motors from the company also offer high torque precision and provides machine builders more flexibility in machine design and decrease the necessary space thanks to their compact structural shape. In conjunction with the energy efficient inverters b maXX 5000, which are also available as feeder and regenerative units and the scalable b maXX controller PLC, the company supplies an efficient and reliable automation system for thermoforming machines. One of them has been installed, for instance, at the Indian manufacturer — Rajoo. The stackable inverter b maXX 5000 offers the benefit of flexibly expanding and modifying entire drive lines without disconnecting the line thanks to the integrated drive-connect system. In addition, pluggable safety modules are available for these inverters, so they can be flexibly adapted to the requirements of the applicable national regulations and the respective application. The safety controls for controlling the respective application and the safety-related programming in accordance with the machine directive are included in the portfolio of the Nuremberg manufacturer.

Faster and more efficient software modules

Comprehensive software module kits offer special benefits to machine builders. The technology modules significantly shorten the time-to-market since these provide pre-programmed and validated software modules to the automation technician. The existing library is so comprehensive that the movement processes in thermoforming machines can be executed using pre-programmed modules. These standard modules include modules for automatic roller changes, energy-optimised adaptations of the movement profiles in the machine or for regulating heating elements. The heating elements integrated in the machine, which warm the laminate for processing are controlled centrally or locally via software modules. Here, in particular, significant savings are possible because heating elements are by far the largest energy > MORE@CLICK ADI03536 | www.AandD24.in

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In recent years, cable management has come into the limelight because machine reliability has increased dramatically, even though robots have grown more complex. Unfortunately, the methods used to attach and guide cables have not quite followed suit. While managing cables and hoses is often an afterthought in most designs, it is truly a vital part of any well-functioning robot. Since the 1960s, cable management methods for robots have not changed dramatically. Most experts agree that one of the top blunders made is underestimating cable management issues. For instance, during a conference hosted by the Robotic Industries Association (RIA), a group of leading system integrators cited cable issues as the number one reason for downtime in robotics cells. Headaches range from tangled and corkscrewed cables, to complete breaks that cause downtime, lost revenue and damaged reputations. This is why the ways in which robot cables are attached and guided is important. The less is more approach to cable management is a

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Designing cable management systems for 6-axis robotsThis article deals with designing cable management systems for six-axis robots including cables, hoses, tubing, carriers, and connectors in three separate sections

best practice that robotics engineers and integrators can apply. It centers on designing cable management systems for six-axis robots – including cables, hoses, tubing, carriers, and connectors

– in three separate sections.

Overview of industrial robots

The term robot is defined as a machine capable of carrying out a complex series of motions automatically. It was first introduced in a Czech science fiction play and then in 1942, the term “robotics” was coined by Isaac Asimov, a well-known American author and professor of biochemistry at Boston University.

By 1970s, robotics had made its way into most manufacturing facilities, predominately in the automotive industry, and by 1980, more than 4,000 robots were being used in the US. Fast forward 30 years, and more than 1.3 million industrial robots

Jörg OttersbachHead of Industry Management, Automotive & Roboticsigus GmbH

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This breakdown is the key to longer-lasting cables. Each cable section needs a minimal dress pack, strain relief with service loops, and a junction box that contains and protects the electrical connectors joining the cables.

Use of a strain relief mechanism can eliminate stresses and extend the service life of a moving cable. This strain relief may consist of standard elements such as tie wrap plates or clamps. Engineers should ensure the cables are in the neutral axis, not touching the inner or outer radius of the cable management system. From the sixth to third axis • Strain relief cables on the moving end (sixth axis) with a

one- to two-foot service loop. • Protect cables and hoses with a modular, multi-axis cable

carrier. • Separate cables at the third axis and install a junction box

for diagnostics and cable replacement. From the third to second axis• Strain relief cables on the third axis with a one- to two-foot

service loop. • Use a modular, multi-axis cable carrier. • Separate cables and install a junction box at the second

axis. From the second to first axis • Strain relief cables on the second axis with a one- to two-

foot service loop. • Multi-axis, reverse bend radius (RBR) cable carrier,

protecting and guiding rotating cables. • Separate cables and install a junction box at the first axis.

Separating the dress pack into three shorter sections

have made their way into manufacturing plants throughout the world. During this robotic evolution, many different types of robots emerged. Some of the most common include cartesian (gantry / linear) that are rectangular arms described as using X, Y or Z axes spherical (polar) 1 linear axis and 2 rotational axes around the vertical shoulder joints. Jointed-arm (6-axis / articulated) that are rotating shoulder and elbow in horizontal axes. SCARA (selective compliance assembly robot arm) the special jointed-arm version and cylindrical (post-type) 3 degrees of freedom, Y and Z linear movements, rotating base.

What do all these robots have in common? The cable management system is typically left to the last minute, but without it, unprotected cables are likely to fail. Cable damage can shut down the most important robot on the line, which leads to costly downtime.

The less is more approach for six-axis robots Current systems try to keep the cables on a six-axis robot

static while everything operating around them is dynamic. Using one, long restrictive cable package prevents movement in sync with the robot. Restrictions stress cables, which accelerates failure. Often technicians severely bind cables with excessive dress packs (protective coverings on cables), cable ties, and even duct tape. The goal is to minimise tangling and interference with the machine, but these types of solutions cause corkscrewing and failure.

Instead, consider a six-axis robot as three separate sections: the sixth to third axis; the third to second axis; and the second to first axis.

Corrugated tubing is available in a wide range of size and styles


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Robotic cable carriers offers additional benefits not available with other systems

prevents it from wrapping, catching or snagging on machines and minimises stress on cables and hoses. This approach applies to any six-axis robot, regardless of manufacturer or application. While other fixes such as duct tape and ties wraps might cost less and work temporarily, in the long run, properly designed dress packs reduce unnecessary downtime and maintenance costs.

Six-axis robots can be found in applications such as robotics / automation, machine tools, handling machines, packaging machines, and many more. In addition to the appropriate dress pack, it is imperative that six-axis robots use dynamic cables specifically designed for continuous flexing. Two important features to take into account are a cable’s torsion-resistance and shielding. Shielded cables face a greater risk of failure because constant movements can easily compromise the cable jacket. Use unshielded, high-flex cables whenever possible to avoid problems. If this is not an option, turn to special “rolling-flex” cables.

Cable management options

There are different options available for guiding and protecting cables on six-axis robots. Three well-known solutions include flexible tubing, enclosed dress packs and robotic cable carrier systems.

Flexible tubing

Corrugated- or flexible-tubing is one option for protecting cables on six-axis robots and is available in a wide range of sizes and styles. It has superior tear resistance at connection points and a long service life, even with reverse-bend cycles. However, corrugated tubing has its limitations. It delivers

minimal torsion resistance, and can only be fixed at two points with a defined length. The tubing can also stretch as the robot moves, which puts undue stress on the cables. Tooling interference sometimes occurs because there is no control path for movement.

Enclosed dress pack

An enclosed dress pack mounts directly to the robot and is available in multiple configurations. It uses corrugated tubing installed inside a plastic-reinforced housing to protect cables. The system’s spring-loaded design minimises catch and pinch points.

Due to the completely enclosed housing, cable maintenance is difficult, and because it is not modular, the entire unit must be replaced if one component breaks. Problems can also arise if the programming or movements of the robot change. This is because an enclosed dress pack does not prevent the cables from exceeding their maximum bend radius.

Robotic cable carriers

Robotic cable carrier systems are at the core of the less is more approach, and can be used universally for six-axis robots. The system mounts directly to the robot and is available in multiple configurations. Like an enclosed dress pack, it has a spring-loaded design, which minimises catch and pinch points. However, robotic cable carriers offer additional benefits not available with other systems. They can come equipped with strain relief options to extend the service life of the cables; cables can also be quickly added or removed without dismantling the system. The defined bend radius of a robotic cable carrier protects cables from exceeding their maximum


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bend radius. The limitations of the system include minimal resistance to high-concentration acids and caustic chemicals, and the inability to handle circular movements with heavy loads. Robotic cable carriers are well suited for welding robots in tight areas, multiple-tool applications, material-handling jobs, and de-burring operations. For added flexibility, robotic cable carriers are available in a fully enclosed design, a pull-through design for easy cable access, or as a lightweight, low-cost system for applications that do not require cables to be completely enclosed.

Additional tips

Ideally, a robotic cable carrier system should allow sufficient clearance inside the cable carrier for electrical cables, pneumatic hoses and tubing for other media. This compensates for relative forces between cables and hoses. Cable carrier suppliers typically provide this data. For instance, general rules of thumb for the line of robotic cable carriers from igus® include total cable and hose diameters must not exceed 60 percent of the carrier diameter; leave at least a 10 percent clearance between

any two cables or hoses and cables and hoses need to move freely inside the carrier.

The less is more approach also eliminates some safety concerns within a robotics cell. Cables are able to move more freely, but are protected and guided properly so that they will not injure workers.

Ideally, a robotic cable carrier system should guide cables in one continuous path; eliminate loose, unmanaged cables; control the bend radius of cables to avoid pinching; have the ability to quickly add or remove cables and be available as a fully enclosed design for extremely harsh environments.

The Triflex® RS robotic cable carrier system from igus® was designed with the less is more approach in mind. It ships and installs as one piece and has an integrated fiber rod that returns cables to a home position after the robot completes a cycle. The system includes mounting plates and brackets, protection links, and a pre-engineered fiber-rod assembly. It is a modular, compact system, but with only one piece to install for complete end-of-arm tooling guidance. ☐


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When it comes to servicing and maintaining a production system, speed is of primary importance. For this reason, an American manufacturer of equipment for concrete pipe production wanted to add remote maintenance capability to three systems at one of its customers. But in order to be able to monitor the local data stream all the way down to PLC level, a major communication obstacle needed to be removed. Fortunately, Hilscher has a solution that was ready out of the box. HawkeyePedershaab is a world leader in the market of machines for the production of concrete pipes.

In 2011, HawkeyePedershaab installed three fully automatic production systems at a concrete factory in the province of Quebec in Canada. One of them is used for the production of

concrete pipes, the others serve to produce the required steel reinforcement. “All three systems run with Siemens S7 PLCs and offer practically fully automated operation. Manual intervention is limited to minor aspects, such as changing recipes and updating software”, said Bob Fehr, an Hawkeye Pedershaab automation engineer. For process automation of its systems, it has opted for the Siemens process control system SIMATIC S7®.

Safety at a high level

An equipment to produce concrete components represents an assembly of impressive dimensions and handles products

Armin Beck Product Manager, Hilscher GmbH, [email protected]

Remote eavesdroppingAn American manufacturer of equipment for concrete pipe production added remote maintenance capability for its machines located at other location which enabled a fully transparent information flow of the automation system of the production facility.

© 2014 Red Lion Controls Inc. All Rights Reserved.

+91 - 9844876540 I [email protected] I better.redlion.net

ProducTVity StationReady-to-deploy visual management solution.Connect. Collect. Display.

Connect, collect, create and display KPI data and Andon messages | Remote monitoring and control

Real-time performance monitoring | Built-in web server and data logging | Convert over 250 protocols

ProducTVity Station

Create screens that provide KPI and Andon information at a glance

Transform any TV into a plant floor display. Red Lion’s ProducTVity Station™ is a ready-to-deploy plant floor visual management system that displays real-time Key Performance Indicator (KPI) data and Andon messages on large televisions to increase productivity. Quickly create sophisticated production scoreboards by using standard, consumer-grade LCD, LED or plasma TVs to drive performance improvements through real-time visibility.

Download our ProducTVity Brochureor visit www.redlion.net/PTVbrochure

Red Lion, the trusted name in automation, now offers Ethernet and Cellular networking solutions. Connect, monitor and control virtually anything, anywhere.

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weighing several tonnes. So, HawkeyePedershaab uses additional IM151 7F safety PLCs positioned between the individual S7 PLCs and several distributed Siemens ER200 S I/O units used for each equipment.

Translating between protocols

The solution is called netLINK (model NL50-MPI) provided by Hilscher. The German-based company is specialised in communications solutions for factory and process automation and operates its own subsidiary in India. It is an intelligent gateway in the form factor of a data bus plug that can be plugged directly into the S7 PLC. It is based upon the versatile netX chip from Hilscher and is able to read practically any

industrial communications protocol and translate it into any other protocol. Power supply is accomplished either directly via the terminal of the device it is connected to or via a separate 24 VDC connection. “The Hilscher netLINK proved to be the perfect solution. It allows us to reach the factory via the Internet and access the IM151 modules via their individual MPI terminals without having to obtain costly S7 Ethernet CP components from Siemens”, adds Fehr.

Remote-controlled safety

Due to the netLINK, the complete information flow of the automation system of a production facility becomes fully transparent and is available via a conventional Ethernet

© 2014 Red Lion Controls Inc. All Rights Reserved.

+91 - 9844876540 I [email protected] I better.redlion.net

ProducTVity StationReady-to-deploy visual management solution.Connect. Collect. Display.

Connect, collect, create and display KPI data and Andon messages | Remote monitoring and control

Real-time performance monitoring | Built-in web server and data logging | Convert over 250 protocols

ProducTVity Station

Create screens that provide KPI and Andon information at a glance

Transform any TV into a plant floor display. Red Lion’s ProducTVity Station™ is a ready-to-deploy plant floor visual management system that displays real-time Key Performance Indicator (KPI) data and Andon messages on large televisions to increase productivity. Quickly create sophisticated production scoreboards by using standard, consumer-grade LCD, LED or plasma TVs to drive performance improvements through real-time visibility.

Download our ProducTVity Brochureor visit www.redlion.net/PTVbrochure

Red Lion, the trusted name in automation, now offers Ethernet and Cellular networking solutions. Connect, monitor and control virtually anything, anywhere.


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network. Where Ethernet is available, Internet and VPN also represent no problem. It was therefore rather simple for HawkeyePedershaab to realise the desired remote maintenance for its machines located in Canada.

“If access to a machine is required, its MPI terminal only needs to be connected to one of the netLINKs. It only uses one IP address, which makes it easier than using three separate netLINKs, for we do not have to worry about assigning IP addresses. Since we are dealing with a safety issue, we need to be extremely careful. However, the netLINK lives up to our requirement 100 per cent, making it rather easy for us to download and upload data in order to solve problems – just as if the machine would be located right here at our premises.”

Small component with far reaching effect

By now, the remote maintenance solution of the three machines HawkeyePedershaab installed in Quebec is live and running for more than two years and works without any problems. Sometimes the key to a solution is simply the right translator to overcome communications problems and add the functionality to a manufacturing system that will save costs at a considerable level, by eliminating the need to send a service technician on site. HawkeyePedershaab is fully satisfied with their new solution, which seamlessly integrates with its Siemens SIMATIC S7 process automation environment. The

company now plans to extend this time and cost saving remote maintenance system to additional manufacturing locations.

Conclusion

As a 100% replacement of expensive Ethernet-CP, NL 50-MPI allows control, programming, remote maintenance and connection of visualisations such as WinCC over Ethernet. As a real highlight, the device allows the Ethernet coupling of Ethernet port less S7-PLCs over their MPI or PROFIBUS interface with automatic DP/MPI baud rate detection. To configure a PLC to PLC connection NetPro in STEP®7 is used as usual. Also routing across multiple and networked PLCs is possible. The protocols RFC1006, DHCP and NTP time distribution to a PLC are part of the comprehensive scope of services supported. The device is configured either in STEP7® with an embedded driver or via a web browser. The driver is Windows 7® and STEP®7 64-Bit compatible and supports Siemens TIA Portal already along with all S7 Engineering tools for full access to Profibus diagnostics and services in STEP7®. In addition, Hilscher also provides the DIN rail mountable version of NL 50-MPI device called as NT 50-MPI where 16 simultaneous Ethernet connections and the access to maximum 32 PLCs in parallel are supported. ☐


As a 100% replacement of expensive

Ethernet-CP, NL 50-MPI allows control,

programming, remote maintenance

and connection of visualisations such as

WinCC over Ethernet


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Analysts are unanimous about one aspect of Internet of Things (IoT): the opportunity is huge. Experts predict that there will be anywhere from 20 billion to 50 billion connected devices by 2020. IDC forecasts that the volume for embedded

systems will outpace any other mainstream system type, reaching 8.9 billion unit shipments by 2015 with 75% of revenue opportunity. Machine-to-Machine (M2M) technology adoption is also spiraling upward. There are already more than

Thilak KumarRegional Engineering ManagerWind River India

transforMing inDustrial & EnErgy systEMs with iotWith billions of units generating more than $1 trillion in revenue today, the Internet of Things (IoT) market is already big—and it’s growing fast. Analysts predict the market will grow with a double-digit compound annual growth rate (CAGR), and IDC forecasts that revenues will double by 2015. This feature highlights the challenge to translate the intelligence in connected embedded devices into new products and services that solve customer problems, drive customer engagement and loyalty, and deliver even higher value to the economy.

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a billion M2M devices at work in sensors, smart meters, industrial control systems, mobile healthcare assets, video surveillance systems, automotive and telematics solutions, smart buildings, and more. Wireless M2M connections alone increased by 37% last year to reach 108 million, according to a report from market analyst firm Berg Insight.

The seemingly sudden arrival of IoT and its network of intelligent systems have actually been emerging for years. Innovations in network connectivity, mobile and wireless technologies, multi-core processing, M2M communication, sensor technologies, cloud computing, and data analytics have converged to create an entirely new form of intelligence—and astonishing new capabilities to optimise the productivity of processes and efficiency of decision making.

Early adopters of the IoT, sometimes referred to as Industry 4.0 or Machine to Machine (M2M) communication, are the

industrial and energy markets. These are so heavily mechanised and automated that they very well understand the role that IoT can play in transforming business. These industries have been incorporating sensors and automation into workflows for decades; yet less than 10% of their legacy systems are connected, leaving valuable data localised in devices and equipment, from HVAC sensors to manufacturing robots to building elevators. Once connected this data enables operators to track output based on real-time and trended data analysis to optimise for power efficiency, performance, and operational life. Smart IoT devices can manage the distribution of energy across the smart grid based on real-time data and provide situational awareness. They will also connect once-discrete systems and allow for communication across the factory floor to IT and management. Industrial systems are becoming connected information hubs. From real-time logistics and supply chain management to


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production planning to automated quality control, converged networks deliver visibility across the entire process and enable centralised control. In addition to transforming existing operations through productivity gains and economies of scale, IoT presents entirely new lines of business and services otherwise not possible.

Let’s consider some of the key elements within IoT that can transform the way industrial and energy systems are managed today.

Sensor data

With critical sensor data, operators are able to schedule and manage efficient repairs, performance adjustments and maintenance. New equipment with sensors can alert operators when a machine is not performing properly or showing signs of stress, and maintenance can be scheduled accordingly. With all of the real-time data available, operators rely on data and automation to ensure safety and reduce costs. In the IoT, data is available whenever and wherever required, making planning and spotting potential problems more efficient, triggering preventive maintenance routines, and reducing downtime.

Smart devices in IoT will manage the distribution of energy across the smart grid based on real-time data and provide situational awareness. They will also connect once-discrete systems and allow for communication across the factory floor to IT and management.

Whether incorporated into your new factory equipment or as a bolt-on solution to a legacy system, gateways provide

operators with connectivity and communication, both within the factory floor and to enterprise IT, to optimise efficiency and reliability. Device-level data aggregation alleviates bandwidth strain by reducing machine-generated data sent to the cloud-based central control systems and back. Algorithms analyse the data to identify factors affecting overall performance. Operators utilise this data to make the adjustments necessary to keep production running smoothly and at optimal capacity while maintaining quality.

Cloud-based central control system

A cloud-based central control system provides operators with real-time equipment transparency and visibility to monitor and analyse consumption patterns, predict impending failure risks, and evaluate any piece of equipment at any time. Predictive maintenance capabilities help mitigates outage and downtime. An example on this context is Wind River® that provides industrial and energy customers the tools and technology to meet stringent real-time determinism requirements while taking advantage of the flexibility and cost benefits of open standards. In highly regulated industries and mission-critical applications—where security is paramount and failure is not an option the company delivers intelligence where it’s needed, supplying the foundation that enables IoT networks and connected devices to perform reliably, safely, and efficiently. ☐

Smart devices in the Internet of Things (IoT) will manage the

distribution of energy across the smart grid based on real-time

data and provide situational awareness



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Machine vision speed increased automatically with increasing microprocessor speeds. However, with multicore PC architectures, it is different, as it requires software design changes to take advantage of parallel processing architecture.

A multicore strategy for machine vision can be implemented at multiple levels. Independent high-level tasks — especially those with hardware dependencies, such as acquisition and I/O — can be written to run asynchronously on separate cores, leaving processor free to do those tasks that are not blocked. Individual vision tools can also be parallelised so that they divide their processing task among several cores.

Keys to successful multicore optimisation

Multicore PC architecture

Earlier, to handle bigger and complex application, vision applications depended on advances in PC hardware. However, this requires higher heat dissipation, where cooling has become a limiting factor. Manufacturers like Intel and AMD use multiple processors instead of a single processor. These processors are packaged on a single chip. Each processor is called a ‘core’, and new chips are called multicore processors. Two, four and eight-core processors are now common, while much higher density models are also being designed.

Optimising a machine vision application for multicore PCs can be a complex process with unpredictable results. To achieve best overall system, it is necessary that developers pay close attention. Field-testing under actual conditions is the only way to fully measure system throughput.

Didier LacroixVice President — International Sales & MarketingCognex [email protected]

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Optimised software is the key

It is not possible to move an existing machine vision application from a single-core PC to a multicore PC and expect performance improvement. Some applications may not run any faster on a multicore machine due to operating system overhead and other inefficiencies. Programmes must be rewritten to speed up their applications, as many algorithms do not lend themselves to parallel processing. Here are four keys to successful multicore optimisation for machine vision applications. These are application optimisation; vision tool optimisation; tuning for overall system performance, and software portability.

Processes & threads

PC operating system manages programs as separate processes. Each process has an associated context and when process is blocked the operating system saves current context and swaps in another process. System processes responses to a range of demands, which is invisible to the user.

A multithreaded program can be written so that different sections run simultaneously and independently. These are much lighter and share the same address space, allowing it to switch quickly making it easy for them to share data when running in parallel. Multithreaded applications do not require a multicore architecture. They are efficient on a single-core machine, but rely on operating system to manage hardware resources for them. Multithreading is suited for multicore PCs and algorithms that ran sequentially, can be partitioned into separate threads that now run in parallel on separate cores.

Commercial multithreaded software

Writing multithreaded application code is not simple and requires underlying machine vision libraries to be written in a re-entrant manner that allows multiple instances of the program to execute in parallel. For this, writing custom

software at application layer to take advantage of a multicore PC is usually only justified in very demanding applications. Off-the-shelf solutions may not be efficient as custom code, but can provide significant benefits at very low cost.

1. Application optimisation: Application-level software can be optimised for multicore PCs in three ways. Firstly, by creating separate threads for tasks with hardware dependencies, such as image acquisition, accept/reject results, operator interaction and are often designed to minimise unpredictable hardware delays. Secondly, by creating separate threads for each camera in a multi-camera application, allowing each thread to run as soon as its camera is triggered. And thirdly, by creating separate threads for different machine vision tasks within a vision application. However, this works if the tasks are not dependent on each other, and the benefit will be small if one task is much shorter than the other.

Some commercial machine vision products have built in these features. For example, CognexVisionPro™ software create separate threads for image acquisition and vision processing and can detect number of cores in a PC and create threads based upon it. This type of scalability is advantageous in multicore PCs for applications with multiple image acquisition and vision processing tasks, which need to be performed simultaneously. It is beneficial on single-core PCs, because image acquisition does not use much CPU time and can therefore run in parallel with image processing operations.

2. Vision tool optimisation: In addition to application-level optimisation, it is possible to optimise machine vision tools by parallelising their algorithms so they use multiple cores simultaneously.

However, not all vision tools can be easily parallelised. Parallelisation is helpful for image processing filters or other vision tools that run local operations on small regions of the image. Commonly used filters include median, Gaussian and morphology operations can be optimised by dividing image into different pieces and assigning each one to a separate thread (Figure 1). The final speedup depends on algorithm and number of cores. Because of overhead, there will always be

Figure 1: Example of partitioning an image

across multiple threads


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Figure 3: One vision thread per core may

not be the optimum choice. This application

finishes later than the one in Figure 2, even

though this one has one thread per core.

Depending on the application, more or fewer

threads may be better

Figure 2: A vision application divided into

three threads running on a four-core PC

some inefficiencies, so even a well-optimised vision tool may not run eight times faster on an eight-core PC. Many vision applications spend most of their processing on tools that are more complex than simple image processing filters. It is not always possible to parallelise complex vision tool algorithms such as alignment and optimising the tool might only benefit a small portion of the algorithm.

The PatInspect™ tool has been redesigned so that inspection steps are divided among available cores. Even when percentage improvement is lower than for simple image processing filters, overall application may benefit more, since complex machine vision tools generally consume large portion of overall application.

3. Tuning for overall system performance: Fastest vision application would be one that control every processor core in the PC and create one thread to run on each core. The PC must also support operating system, machine control and other background tasks. In practice, optimum number of threads for vision application may not necessarily be the same as the number of cores in the PC, and may not make sense to assign each thread to a specific core.

The only way to determine optimum number of machine vision threads is to test it under realistic conditions.Cognex’s CVL™ and VisionPro™ software libraries give users a simple method to set the number of threads for multicore-aware vision tools in an application. This top-level ability lets users easily tune the system for best overall performance.

4. Software portability: Another concern is software portability from one PC to another. PC hardware changes quickly that vision applications will be deployed on multiple PC models, either when new vision stations are deployed or needs to be replaced. Machine vision application is usually developed on a different PC than on which it is deployed and replacing PCs deployed in manufacturing lines is a constant maintenance issue.

Since number of cores available may change over time, there should be a vision application, which can account for any

number of cores in the system. Redeploying existing system on a different PC may require recompilation or rewriting application software, which is high cost as development stations are modified and developers move on to other projects. CVL and VisionPro™ libraries can automatically detect number of cores on a PC and dynamically adjust number of threads that they create allowing applications written for a four-core PC to run efficiently on an eight-core PC without touching the source code or recompiling.

Summary

Optimisng a machine vision application for multicore PCs can be a complex process. It is clear that developers must pay attention to achieve best overall system performance. Field-testing under actual conditions is the only way to fully measure system throughput. To maximise benefits of multicore PC technology in machine vision applications, developers should consider several key questions when evaluating machine vision software products. These should include points such as whether image processing filters have been optimised for multicore, as also other factors that can impact the performance of overall application, including:• Can the software product automatically create separate

acquisition and processing threads to speed system throughput and responsiveness?

• Does the software allow users to write their own multithreaded application?

• Can users tune the number of threads for best overall system performance?

• Does the software have the ability to automatically detect and adjust the number of threads, based on the number of cores, without having to rewrite the application?By keeping these points in mind, users can maximise their

options (and minimise their work) to take full advantage of multicore PC technology. ☐


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With its innovative standard product line, ISRA Vision has integrated its 25 years of industry experience, making 3D robot guidance possible without expert knowledge. Production managers on the factory floor are able to quickly and easily integrate ready-to-use sensors into their systems all on their own. In today’s world, 100 per cent monitoring and fully automated processes using 3D robot guidance are key elements to achieve greater flexibility and higher productivity.

Machine vision systems make the use of robots even more flexible, which have demonstrated that they can reduce costs and also provide documentation of the manufacturing quality that without them would not have been possible. Until recently, users stayed clear of 3D robot guidance in many industry

Revolutionary simple and ingeniously fast

sectors. The technology was too sophisticated and too complicated. We have now passed that stage. For any application, from 2D to 6D, an easy to use product line consisting of sensors and software, scalable in terms of resolution and accuracy and ready for use is now available for 3D robot guidance: install, and connect. Instead of wasting countless hours programming, now you will only need to set a few parameters.

GigE based sensors

The GigE based sensors can be used in either stationary or mobile applications and provide the highest rate of accuracy even for large components. For example, MONO3D will make

The new 3D vision automation makes it significantly easier for users to install and integrate them into their systems and processes. The automated processes using 3D robot guidance achieve greater flexibility and higher productivity

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a& D i n d i a | A u g -S ep 2013

it possible to perform 3D measurements of position and orientation with a single sensor. The sensor determines all six degrees of freedom for a three-dimensional object using only three attributes. The lighting is already integrated in the sensor’s enclosure. The stereo sensor uses two sensors for stereoscopic vision and with them determine the object’s 3D coordinates or defined image segments. More areas that are difficult are illuminated using the integrated lighting.

Sensor for web-supported robot guidance

SHAPEMATCH 3D makes use of multiple projected lines. Its primary application, when combined with 3D form Matching, is for web-based robot guidance. Robust and highly accurate results are achieved because of the high redundancy of measuring lines.

Several single sensors can be combined to a sensor group. The SHAPESCAN3D sensor is designed to allow robots to perform bin picking, meaning to reach into the box. Even in the most difficult lighting conditions, the positions of lower level, randomly distributed objects can be determined three-dimensionally in different depths of large bins. The robot can remove unsorted parts directly from the transport bin and - without the need for complicated mechanical structures - can then feed them into the production process.

Benefits

As compared to mechanical separation, the robot’s ability to directly reach into the box brings with it the benefits of flexibility in the range of parts as well as cost reduction

advantages, because the need for mechanical feed components is significantly lower. The following applies to all sensors: The standard Gigabit-Ethernet (GigE) interface lets data be exchanged at extremely fast speeds. In addition, many other standard communication interfaces are supported, such as Profinet and Profibus. The robust sensors are supplied quickly and easily via Power over Ethernet (PoE). The sensors are combined with new software technology. It offers a modern graphic user interface that allows the user to navigate intuitively on the touch screen to operate the system.

3D vision automation

The new 3D vision automation will make it significantly easier for users to install and integrate them into their systems and processes. “Plug & automate” means that workers will now have the capability to install 3D robot guidance on their own and put it into operation immediately. The software is available in combination with the sensors, but is also sold separately. Users can determine for themselves exactly what they need for their systems. You can easily start working with 3D robot guidance in a flash, because instead of complicated programming, all you need to do is set a few simple parameters. With its new philosophy, ISRA will be pioneering new application areas for 3D machine vision. The days when users had to rely on experts to efficiently automate their systems is now a thing of the past. With “plug and automate”, users now have the freedom to use automation solutions of the future today. ☐

Courtesy: ISRA Vision> MORE@CLICK ADI03541 | www.AandD24.in

Sensor for web-supported robot

guidance with structured light from

the new range of ready-to-use GigE

sensor products for highly precise 3D

positioning and orientation determination

– with integrated 3D form matching.

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E V E N T | r ep ort


Market forces, such as globalisation, resource constraints and environmental concerns, changing demographics, and IT trends are influencing manufacturing companies and their dynamic market ecosystems and value networks. India’s economic growth has temporarily decelerated due to the global headwinds and domestic rumblings; but industry analysts predict that it’s just a matter of time before the growth engine is back on track. However, for a successful transition it is imperative for industries to adopt new information technologies, such as cloud computing, mobility, social technologies, Internet of Things, Big Data/analytics, and 3D visualisation. Information driven digital enterprises leverage new technologies to achieve agility and sustain a competitive edge. With the focus on maximising productivity and increasing RoI by channelising relevant information and investing in technologies, ARC

Advisory Group’s 12th India Forum for the process and discrete industries, on the theme ‘Industry in transition: the information driven enterprise in a connected world, was organised on July 10-11, 2014, at Bengaluru.

Highlights

The day 1 began with the welcome address by Ganapathiraman G, Country Manager India, ARC Advisory Group, followed by keynote presentation by Ralph Rio, Research Director, Enterprise Software, ARC Advisory Group, on “Industry in transition - the information driven enterprise in a connected world.” Rio focused on predictive maintenance and how automation is bringing about a business transition.

Arundhati Bhattacharya, General Manager, NTPC, in her

88

Creating information driven digital enterprisesFor a successful business transition, it is imperative for industries to adopt new information technologies, such as cloud computing, mobility, social technologies, Internet of Things, Big Data/analytics, and 3D visualisation. ARC Advisory Group’s 12th India Forum discussed this transition for the process and discrete industries at Bengaluru, recently. A post event report…



Event Report - ARC - Aug-Sep 2014.indd 88 8/18/2014 10:36:00 PM

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presentation on “The Information Driven Enterprise – NTPC experience,” highlighted the processes automated at NTPC, various advancements in HMIs, connectivity in automation systems and the need for business analytics. Bhattacharya said,

“Embracing IT & automation technologies is not a mere exercise but the need for business excellence today. Only such enterprise will have the competitive edge in complex and dynamic future business scenarios. The concept of information driven enterprise will change the business ecosystem.”

Next, Sameer Prakash, Head - Automation, Siemens, detailed on “Future of manufacturing – Siemens perspective” and the digital enterprise platform as a basis for Industry 4.0. He said, “Integrating product and production lifecycle can reduce time-to-market by up to 50%.” He also shared an example of BMW-Brilliance manufacturing unit at Shenyang, China, which uses electrical and mechanical turnkey solutions as part of totally integrated automation. This was followed by a presentation on “Connected enterprise: amplifying value with integrated control and information” by K Srinath, GM, Rockwell Automation. He said, “Context building of data is very important. Legacy system, control system and many layers prevent Big Data from becoming accessible. Companies need to have networks for Big Data.” He also stressed on the connected enterprise and how it can be optimised for rapid value creation.

On the theme of automation & enterprise trends,

Ganapathiraman discussed integrated and interconnected enterprise. He spoke on the rise of cyber physical systems and the various industrial challenges to Internet of Things (IoT) – cyber security, technology standardisation, IP ownership, and socio-political issues. In the subsequent presentation on

“Predictive analytics - maximising profitability in operations”, Sayantan Roy, Director - Software Sales, GEIPS, highlighted on industry’s first predictive diagnostic solution and the industry’s transition to brilliant machines. This was followed by a panel discussion and Q&A session.

The second session started on the theme – advancement in control, network strategies, and MES, with the presentation on

“Industry in transition: information driven manufacturing - India specific challenges” by K Nandakumar, President, AIA. He shared the roadmap for modernisation of automation which included need for recognition to IPR, innovation & technology upgradation, technical collaboration, industry-institute partnership, standardisation, addressing technology obsolescence, setting up additional R&D labs and joint ventures.

Presentations by BT Narasimha, Sr Director – Software Sales, Schneider Electric, on “Getting the most out of an MES investment” and Dinesh Mungi, BDM – Packaging, B&R Automation, on “A new high in control solutions: scalable and ultra-fast automation” followed. Next, Sunil Mehta, Chairman, CLPA India, highlighted the topic “CC-Link IE and a trend for the future”, supported by Haruyuki Otani, CLPA – Technical Task Force Chairperson.

Another presentation on “PLM software as key component of the digital enterprise platform” was presented by Gautam Dutta, Director – Marketing, Siemens PLM. He shared trends in PLM, manufacturing engineering and point cloud data management. The next theme of discussion was strategies to achieve asset performance management and MES. Under this topic, presentation on “Asset maintenance and management


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using FDT/DTM – an end user perspective”, was given by Mouleswara Reddy, Sr Manager Quality, India Engineering Centers, Flowserve, FDT Group, while Vivek Gupta, Head Instrument, DCM Shriram, highlighted on “Advanced Process Control (APC) in fertiliser plant including safety instrumentation”. The last presentation of day 1 was featured by Chandrasekhar, MD, Pioneer CT, ACE Micromatic Group, who discussed “Machinery manufacturing trends”. Another round of panel discussion and Q&A session followed his presentation.

Day 2 began with a presentation on “Manufacturing challenges in aeronautical industry” by Dr B Ashok, Deputy Project Director, ADA, under the theme – Industry in transition: information driven manufacturing. He pointed out the various challenges that lie in the Indian aerospace manufacturing sector. This was succeeded by an interesting topic “Engineering the Internet of Things” discussed by Raja Shan, Head - Strategy, Engineering, & Industrial Services, TCS. He stressed on IoT to improve the solution value chain and analytics driven design.

The next theme was on control strategies and energy optimisation. D P Majakar, AGM (EDN), BHEL & V Ramesh, SE, KPCL, presented the total automation solutions for super critical power plants, followed by a presentation on software-based optimisation in power plants by Peter Deeskow, Head – Product Development, STEAG. He spoke on how automated detection of deviations can support in decision making.

Then, under the theme: strategies to achieve operational excellence, Rainer Lamping, VP - Construction Management Strategy, Product Strategy Group, AVEVA, discussed the importance of construction management in project execution. This was followed by presentations on “Operational excellence

for process industry” by Jayant Kapoor, GM - Manufacturing IT, Ranbaxy and Manish Kumar Singh, Head - MES, Siemens;

“Integrated information management for operational excellence - ports information management system” by Vipul Shah, Associate VP, Chairman’s Office, Adani; and “End user survey responses on engineering services by GSPs” by Neelam Singh, Senior Analyst, ARC Advisory Group. A panel discussion and Q&A session was held post these presentations.

The last session of the forum was based on the theme information management. Under this, Rio shared insights on asset lifecycle information management, while Sanil Namboodiripad, Assistant VP - Operations, Reliance Power, discussed integrating plant control systems with business applications. Namboodiripad detailed on centralised monitoring and SAP journey of Reliance Power. The concluding presentation was given by Srinivasan Thiagarajan, Senior Consultant, TCS on ETO2WIN: information driven ‘engineer to order’ enterprises, followed by a panel discussion and Q&A.

Key takeaway

The forum provided a platform to suppliers to disseminate and share new processes & technologies; and the end users gathered information about new technologies that could be deployed. With nearly 300 delegates, the two-day forum was reminiscent to the fact that to remain competitive & achieve operational excellence, organisations must sift through the information glut and adopt appropriate technologies. The presentations made it clear that adopting new processes and technologies is not an option - it is mandatory to achieve operational excellence and sustainability. ☐


Dignitaries on the dais during the

inauguration of ARC Advisory Group’s

12th India Forum


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T E CH N O LO GY | TAL K


Cable and hose systems are available in various different industrial applications as supply lines. They are only conceived for flat and round cables. To transport liquid and gaseous media, the round cables are replaced by hoses. These systems are employed in festoon application. To begin with, festoon application generally caters to material handling. Festoon cable is flat cable designed for power and control applications, particularly suitable for demanding environments, such as in mills and at port facilities. The flat construction allows for stacking multiple cables where space is at a premium. Additionally, festoon cables are best suited for meeting the requirements of applications facing engineering and design problems. These systems are ideal for overhead cranes, gantry cranes water treatment systems, car wash systems, bulk material conveyors, plating lines, and many other types of moving equipment.

Key features of cable trolleys

Parts used are made of special galvanised steel and consist of four guiding rollers with special high-life ball bearings for smooth running. Cables are clamped with rubber plates of Neoprene, appropriately shaped that prevents sharp bends at the camping point. This ensures long life of cables. Flame retardant as per highest industry standards IEC; weather resistant for harsh environments; high data capacity and low electromagnetic interference; flat cables need less space than round cables and cost-savings through quality and constant innovation.

Cable trolley solutions have been engineered and

tested to be oil, coolant and chemical resistant and

withstand dry, damp and wet conditions and

therefore allow you to save money on downtime

and lost production

CAbLE TrOLLEY SOLuTIONThe article deals with cable trolley system that is used to support, protect and manage flat and round cables for the transfer of electrical energy and data.

Application range

Cable trolley system caters to moving applications in key industries like process industry, food and beverages, textile, automation, material handling and mining. Additionally, these are used in machinery and equipment that are permanently exposed to the weather; conveying and hoisting equipment; construction machinery; shipyard machinery. These are suitable for use in special conditions such as industrial or sea water. Cable trolley solutions have been engineered and tested to be oil, coolant and chemical resistant and withstand dry, damp and wet conditions and thus, allowing you to save money on downtime and lost production.

Key factors that determine the selection of cable trolley system

The factors include travel distance, cable package-design (flat & round) and dimension. Support bracket-wall of roof mounting, I-beam with distance and beam dimensions are necessary to accommodate the trolley wheel diameter.Type of system: Provide a brief drawing of the placement of cable clamps. Choose type of system you would like to use (wire, c-profile, I-beam, etc) with regards to cable weight, size, bending radius and environment.Cable length: Find out the cables length you have to use in your system. Here fore consider the travel length multiplicated > MORE@CLICK ADI03543 | www.AandD24.in

by the following factors.Flat cable: Travel distance less than 20 m × 1.25 = cable length; travel distance 20-50 m × 1.20 = cable length and travel distance greater than 50 m × 1.50 = cable lengthRound cable: Travel distance × 1.50 m = cable length

How many trolleys do I need?

Divide the cable length by the double cable sagging which will give you the number of trolleys including the towing trolley. Standard cable sagging is 0.75 m. Cable trolley length x number of trolleys + towing trolleys length = parking space. The equation of number of rails and track couplers is travel distance + parking space = total track length. ☐Courtesy: Lapp Cables

Tech Talk Lapp Aug.indd 92 8/14/2014 7:31:29 PM

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93A& D I n d i a | A u g -sep 2014

OPC Unified Architecture for industry 4.0

B&R has advanced the integration of OPC UA in the automation studio

development software. Automation studio supports OPC UA clients and

servers directly on the controller, thus,

allowing vertical communication to

SCADA, MES and ERP systems as well

as vendor-independent communication

from PLC to PLC. With new PLCopen-

compliant OPC client function blocks,

this communication can be easily

implemented in the application

software regardless of the hardware

being used. Through the support of

OPC UA subscriptions, larger amounts

of data can be transferred faster. OPC

UA is standardised in accordance with IEC 62541 and offers easy-to-use

functions for vendor-independent data exchange. This makes it easy for

software developers to engineer complex systems with high data

communication demands. Implementing flexible and modular automation

solutions more easily is the result. With POWERLINK, openSAFETY and

OPC UA, the company offers its customers the perfect tools to meet the

high demands of Industry 4.0.

These controllers can be

implemented as OPC UA servers

and as OPC UA clients

Signal conditioners

Pepperl+Fuchs’ SC-system is a new development that combines the

most powerful features of comparable products in a family of devices. For

example, calibration is performed by

fully automated laser trimming of

fixed resistors. This means the best

calibration results without production

spread, and the risk of interference

from trimming potentiometers due to

their slider contact point is

eliminated. Electrolytic capacitors

have been omitted, and alternative

components are used instead. The

temperature-dependent reduction of

the capacitance values observed with electrolytic capacitors, as well as

signs of aging, is thus effectively counteracted. By replacing the

electrolytic capacitors, the SC-system signal conditioners can be operated

at an ambient temperature of up to 70 °C. The low-power design, which

ensures low self-heating, contributes to the wide temperature range in

which the products can be operated. The SC-system uses high-quality

3-way isolation between input, output, and supply which withstands a

working voltage of up to 300 V and a test voltage up to 2.5 kV.

The 6 mm system modules are

mounted on a DIN rail

> MORE@CLICK ADI03544 | www.AandD24.in > MORE@CLICK ADI03545 | www.AandD24.in

Screw clamp fuse terminal blocks

connectwell’s screw clamp fuse terminal blocks are used in electrical

and control systems which require protection. The CF series terminal

blocks accept industry standard

5 X 20 mm and 5 X 25 mm glass

cartridge fuses. These blocks

are completely closed and do not

need separate end plates. CF4SP

series fuse terminal blocks have

a thickness of 6 mm with a

provision for using internal

shorting links. In control and

automation wiring circuits it can

be used in an alternating

configuration with some of the

feed through terminal blocks

CTS2.5UN, CTS2.5UE, CTS4UN and CF4SPFT. The CF4UL & CF4SPL series

terminal blocks are used for offline indication in case of fuse blow out.

These blocks can be used in AC & DC voltages. The width × length for

CF4U is 8 × 57; CF4UL is 8 × 57; CF4SP is 6 × 58.5 and CF4SPL is 6 X 58.

The voltage range of CF4UL is 6 – 60 V AC/DC 110 – 240 V AC/DC and

CF4SPL is 6 – 60 V AC/DC 110 – 240 V AC/DC.

The CF series terminal blocks accept

industry standard 5 X 20 mm and 5 X

25 mm glass cartridge fuses


Heavy duty encoder

cSt Sensors’s BEI heavy duty encoder is specially designed for heavy

duty applications: steel & paper mills, lumber,

cranes, etc. With solid shaft of 12 mm or 11

mm with RE0 115 mm flange (Euro flange

B10) for tacho generator type mounting it has

a resistance to shocks/vibrations and to

extreme axial/radial loads. With a high

protection level of IP67 it has a connection

with terminal box (cable or connectors output

also available). It is electronic compatible

with industrial standards and electronic

permits to drive different inputs (PLC +

display, for example). With digital

incremental output, optional analogue

output (tachoencoders, optotacho) or sine

output its resolution is up to 10000 ppr. It

has a mechanical over-speed switch option

with protection against short circuits for

electronics. Option “Max control’’: the encoder gives on real time its

physical environment parameters: shocks and vibrations, too high or too

low temperature, too low or too high supply, quality of the output signals.

The encoder has a mechanical

over-speed switch option

with protection against short

circuits for electronics


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Pressure transmitters & sensors made of titanium

Keller Ag für Druckmesstechnik has offered titanium versions of its

products for use in heavily corrosive media. This metal has a host of

advantages for applications under very

special conditions. Titanium is used as a

replacement for steel in the aerospace

industry, mainly for reasons of weight. In the

medical devices sector, the fact that titanium

is chemically and biologically neutral is

especially important. This property is due to

a permanent layer of oxide on the surface

of the material. Thanks to its presence,

components made of titanium will not

corrode even in salt water or chlorinated

water, unlike the high-grade steels that are

normally used in the sector. This is why

titanium is more frequently chosen for

process measurement technology

applications involving waste water that may

be contaminated with unknown corrosive substances. A titanium housing

makes it possible to carry out hydrostatic level measurements effectively

in brackish water, or even in iron chloride. The development of an

implantable sensor (Ø 9 mm) made of titanium has caused a sensation.

Intelligent earth leakage relay

elMeasure’s microcontroller based Intelligent Earth Leakage Relay (IELR)

with 4-digit 7-segments RED bright digital

display, is unique as compared to

conventional ELRs. Its features include

inverse curve; continuous leakage current

display (Programmable); continuous display

of trip leakage current (Programmable);

continuous scrolling display for set current

and set time; field programmable through

front panel keys with password protection;

wide input range 60 mA to 12 A and the

trip time programmable from 300 ms to

30 seconds and manual test and reset

keys. Its specifications include second

update; auxiliary supply 80 to 300 VAC;

burden 4VA max; panel mountable 96 x

96 x 45; accuracy class 1.0 FS; relay

contacts; CBCT standard size – 40, 65,

100, 150, 200, 250, 300 mm tape wound

and weight (Approx): Unpacked – 250 gms

Shipping - 350 gms.

Relay interface modules

Finder has introduced the 39 series MasterINTERFACE range of ultra-slim

relay interface modules that provide a low-cost, space-saving solution for a

host of industrial applications. This series incorporates an innovative,

replaceable fuse for output circuit protection, plus busbars and terminals

that simplify input and output

wiring. Housed in a compact 6.2

mm wide package, this series

offers integral coil protection

circuitry, as well as a secure

retention and ejection clip. Five

dedicated module types are

offered to meet the requirements

of basic, enhanced, input, output and

timer interface functions.

The enhanced MasterPLUS module

adds the option of a quick connection

replaceable output fuse and special

leakage current suppression versions

to mitigate detrimental effects caused by residual current in the input

circuit. Both the MasterINPUT and MasterOUTPUT incorporate additional

busbar jumper links and terminals necessary for the full connection of 2 or

3-wire input devices and output devices respectively.

Its features include

inverse curve; continues

leakage current display

(Programmable); continuous

display of trip leakage

current (Programmable);

continuous scrolling display

for set current and set time

and field programmable

through front panel keys with

password protection

The 39 series MasterINTERFACE

incorporates an innovative, replaceable

fuse for output circuit protection, plus

busbars and terminals that simplify

input and output wiring

Data Portal

The latest version of the eplan Data Portal will enable users to benefit

from enormous time savings and increased

project quality. The current 470,000 part

data, including schematic macros,

geometric dimensions and documents, can

be imported to engineering automatically.

This is made more simple thanks to

innovative functions such as a newly

integrated 3D viewer, which enables users

to view and assess components quickly and

easily. It is possible to call up several different

views such as front, page or isometric views

very easily with a click of the mouse. Free

rotation and zooming functions allow that

individual detailed views can be generated in a

very flexible manner. The advantages for the

user are obvious: e.g. when placing the part in the project, they receive

reliable decision support as to whether the component is suitable for the

proposed control cabinet. The surface of Eplan Data Portal has also been

optimised. The view of the 66 manufacturers that are currently involved

has been adapted to the design of Data Portal App.

Around 470,000 part data

including schematic macros,

geometric dimensions and

documents can be imported

to engineering automatically

using the Data Portal


> MORE@CLICK ADI03548 | www.AandD24.in > MORE@CLICK ADI03549 | www.AandD24.in

Titanium is more frequently chosen

for process measurement technology

applications involving waste water

that may be contaminated with

unknown corrosive substances



n e w s | technology

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IT powered automation

To avoid breaks in technology and ensure the future capability of the

automation solution, Phoenix contact has offered components and

systems that use mainstream

technologies from IT area. In

addition to the already proven

automation protocols,

international IT standards are

integrated into the control

system. The web server

provides a free website for all

100-series controllers. These

web pages can be displayed

using the WebVisit software

and linked to the PLC

program using data. The web

panels with integrated browsers display the pages and allow them to be

visualised without any knowledge of Java. Using the FTP (File Transfer

Protocol) server of the 100-series controllers, any type of file can be

stored or uploaded to the flash file system of the PLC — for example, for

exchanging parameters, log files, recipes, or for storing the current

version of the PLC source code during servicing.

These web pages can be displayed using

the WebVisit software and linked to the PLC

program using data

Linear modules

SchUnK has recently presented the Delta 145C, a particularly compact

module that enables powerful

strokes up to 4,000 mm. Its

inner dual-profiled rail guide

ensures maximum rigidity and

precision, thus, exhibiting

superior performance in

absorbing heavy loads. To

increase the reliability and the

service life of the module, a

specially fixed plastic cover strip

protects the guidances, and drive

elements from dirt. The Delta series is

finely graded and comprises a total of

four sizes with profile widths between

110 mm and 240 mm and strokes up to 7,720 mm (Delta 240C). With a

toothed belt drive, a maximum driving force of 2,200 N, a maximum speed

of 5 ms-1 and a repeat accuracy of +/- 0.08 mm are achieved. With a

spindle drive, the series enables driving forces up to 6,000 N, speeds up

to 2 ms-1 and a repeat accuracy of +/- 0.03 mm. These can be flexibly

integrated into systems by means of T-nuts or mounting strips.

Eddy-current measuring system

Micro-epsilon’s turboSPEED DZ140 is optimised for thin turbine blades

made from aluminium or titanium.

The system is thermally stable

and very well protected from

external interference. It is the

fourth generation of eddy current-

based revolution counters for

turbochargers. The sensor system

is suitable for speed

measurements of 200 to 400,000

rpm. The sensor is just 3 mm in

diameter, yet it provides the

highest immunity to interference

in harsh test conditions. The integrated temperature measurement feature

records among other data the actual ambient temperature near to the

sensor. It provides much higher immunity to interference than other eddy

current-based revolution counters. The DZ140 eddy-current measuring

system is resistant to oil and dirt. The maximum operating temperature of

the miniature sensor is 285°C, which is a key advantage compared to

optical speed measuring systems, as this helps to achieve high precision

measurements on a continuous basis. The well engineered design also

enables easy sensor replacement without further adjustments.

With a spindle drive, the series

enables driving forces up to 6,000 N,

speeds up to 2 ms-1 and a repeat

accuracy of +/- 0.03 mm

The DZ 140 eddy-current measuring

system is resistant to oil and dirt




Handheld barcode readers

cognex has introduced the DataMan 8050 and 8050X handheld barcode

readers, which are designed with a rugged

polycarbonate housing to handle harsh factory floor

conditions and feature 1DMax+ with Hotbars barcode

reading algorithms. The 210 mm x 115 mm x 85 mm

readers feature a 752 x 480 global shutter sensor,

integrated LEDs with near/far optics, and DataMan

setup tool software, which enables image viewing,

Java scripting, and data formatting options. Available

with both corded and wireless

communication modules, these series

support industry-standard communications

including USB, USB Keyboard, RS-232 and

Bluetooth wireless communication to a base

station. Built for tough work environments,

these series have durable and industrial

product features as well as a range of

industrial cables and accessories to

complement the product. These barcode

readers read 2-D DPM codes as well as 1-D and 2-D label-based codes

quickly and easily. These are optimised for reading 1-D and 2-D

label-based barcodes with the fastest performance.

Available with both corded and

wireless communication modules,

these series supports industry-

standard communications

including USB, USB Keyboard,

RS-232 and Bluetooth wireless

communication to a base station




Highlights - (Oct/Nov 2014)

h Igh l Igh t s | compA ny InDex | Impr Int

company IndexName . . . . . . . . . . . . . . . . . . . . . . . . . Page

Ajay Kumar Garg Engineering College . . . . . . 41

Analog Devices . . . . . . . . . . . . . . . . . . . . . 36

ARC Advisory Group . . . . . . . . . . . . . . . . . . 88

B&R Industrial Automation . . . . . Cover, 8,9, 93

Baumuller . . . . . . . . . . . . . . . . . . . . . . . . . 70

Bharat Bijlee . . . . . . . . . . . . . . . . . . . . 12, 41

Bosch Rexroth . . . . . . . . . . . . . . . . . . 29, 48

Chanto Air Hydrantics Co . . . . . . . . . . . . . . . 13

Connectwell Industries . . . . . . . . . . . . . 11, 93

Cognex . . . . . . . . . . . . . . . . . . . . . . . . 83, 95

Contrinex Automation . . . . . . . . . . . . . . . . . 15

CST Sensors . . . . . . . . . . . . . . . . . . . . 19, 93

Delta India Electronics . . . . . . . . . . . . . . . . . 3

Dynalog India . . . . . . . . . . . . . . . . . . . . . . 49

Emerson . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Electronic Relays (India) . . . . . . . . . . . . . . . 39

Eplan . . . . . . . . . . . . . . . . . . . . . . . . . 45, 94

EIMeasure . . . . . . . . . . . . . . . . . . . . . . . . . 94

Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 4

Finder India . . . . . . . . . . . . . . . . . . . . . 54, 94

Fieldbus Foundation . . . . . . . . . . . . . . . . . . 12

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 14

Galil Motion Control . . . . . . . .Back Inside Cover

GUDEL India . . . . . . . . . . . . . . . . . . . . . . . 30

HART Communication Foundation . . . . . . . . . 12

Hilscher India . . . . . . . . . . . . . . . . . . . 27, 76

HMS Industrial Networks . . . . . . . . . . . . . . . 51

Hummel Connector Systems . . . . . . Back Cover

ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 57

IFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

IED Communications Ltd . . . . . . . . . . . . . . . 12

IFM Electronic India . . . . . . . . . . . . . . . . . . 61

Igus India . . . . . . . . . . . . . . . . . . . . . . . 2, 72

ISRA Vision . . . . . . . . . . . . . . . . . . . . . . . . 86

IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Keller AG . . . . . . . . . . . . . . . . . . . . . . 35, 94

Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . 68

Kubler Automation . . . . . . . . . . . . . . . . . . . 55

KUKA Robotics India . . . . . . . . . . . . . . . . . . 30

MathWorks . . . . . . . . . . . . . . . . . . . . . . . . 14

Messe Frankfurt . . . . . . . . . . . . . . . . . . 64, 79

Micro-Epsilon . . . . . . . . . . . . . . . . . . . . 7, 95

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Mifa Systems . . . . . . . . . . . . . . . . . . . . . . 75

MMI India . . . . . . . . . . . . . . . . . . . . . . . . . 53

National Instruments . . . . . . . . . . . . . 6, 14, 42

Omron Automation . . . . . . . . . . . . . . . . . . . . 1

PTC India . . . . . . . . . . . . . . . . . . . . . . . . . 18

Phoenix Contact . . . . . . . . . . . . . . . . . 43, 95

Prosoft . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Pepperl+Fuchs (PA) . . . . . . . . . . . . . . . . . . 93

Red Lion . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Renu Electronics . . . . . . . . . . . . . . . . . . . . . 47

Rockwell Automation . . . . . . . . . . . . . . . . . . . 5

Schunk Intec India . . . . . . Front Inside Cover, 95

Sesame Motor Corp . . . . . . . . . . . . . . . . . . 81

Siemens . . . . . . . . . . . . . . . . . . . . . . . .16,17

Siemens PLM . . . . . . . . . . . . . . . . . . . 10, 22

Turck India Automation . . . . . . . . . . . . . . . . 14

TUV SUD Chemie Service GmbH . . . . . . . . . 26

VDMA Robotics + Automation Association . . . 24

VDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Wind River . . . . . . . . . . . . . . . . . . . . . . . . 80

Robotics & Handling »once guardians of large- and heavy-part handling, robots are now involved in moving the smallest and most delicate of parts with dexterity. Vision technology advances have led to robots being able to pick and place randomly located parts. From three-dimensional bin picking to food-grade applications, robotics are moving into new manufacturing frontiers. also, the use of material-handling robots has increasingly become a solution to raise productivity and manufacturing versatility, while enhancing worker safety as they historically have. The next issue will feature articles discussing these trends.

Sensors & Encoders »The rapid progress of sensor manufacturing technologies allows the production of systems and components with a low cost-to-performance ratio. The recent advances and future development trends in the field of sensor technology focus on novel sensor structures, manufacturing technologies and signal processing methods in individual and multi-sensor systems. The predominantly observed future development trends are: the miniaturisation of sensors and components, the widespread use of multi-sensor systems and the increasing relevance of radio wireless and autonomous sensors. check out the next issue for more details.

Automotive & Machine Tools »Keeping competitiveness in this fast-paced industry means reacting quickly to changes in the marketplace and on the plant floor. many automation service providers have leveraged their combined capabilities to create integrated automation and information solutions that go beyond traditional meS to overcome corporate data organisation boundaries. By providing a unified view of processes and data, as well as providing data integrity, the new automation solutions deliver real-time connectivity, marrying meS and production systems to enable actionable response to a variety of automotive challenges. The next issue will highlight some of these trends.

ImpRInT

Publisher / Chief Editor Shekhar Jitkar [email protected]

Deputy Editor Sumedha mahorey [email protected]

Sub-editor & Correspondent

Srimoyee Lahiri [email protected]

Features Writer megha Roy [email protected]

Advertising Sales Sagar Tamhane (Regional Head - north & east) contact: +91 9820692293 [email protected]

dhiraj Bhalerao (Regional Head - West & South) contact: +91 9820211816 [email protected]

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Internet http://www.aandd24.in

Highlights_Aug-Sep_2014.indd 96 8/19/2014 3:29:02 PM

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A&D AUG SEP 2014

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