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Volume 24, No. 1
table of contents
FEATURES
32
cover story
The drive to improve printing production Data-driven smart system’s functionality settles a long-term problem with flexographic printing Rodney Pennings
28
38
43
How to choose between VFD and soft starter
Industrial automation with a mission
A sense of purpose
Applications dictate the pluses and minuses of each
A student design team developed a PLC-based control system to safely automate a test stand and prove out an engine prior to rocket launch
machine input
Mike Bacidore, chief editor
PLCs
product roundup Make production more effective and safer with presence sensing
Simon Bambey and Griffin Peirce, UBC Rocket Student Team
CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfield Rd., Suite 400N, Schaumburg, Illinois 60173. (Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at Schaumburg, IL, and at additional mailing offices. Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©Putman Media 2020. All rights reserved. The contents of this publication should not be reproduced in whole or part without consent of the copyright owner. POSTMASTER: Please send change of address to Putman Media, PO Box 1888, Cedar Rapids IA 52406-1888; SUBSCRIPTIONS: To change or cancel a subscription, email
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ControlDesign.com / January 2020 / 5
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Volume 24, No. 1
table of contents
COLUMNS 9
editor’s page
How to smarten up enclosures
14
technology trends
Wrap it up Rick Rice, contributing editor
Connection Technology for High Bandwidth Industrial Applications
Mike Bacidore, editor in chief
11
18 live wire
How to add jobs using robots Dave Perkon, technical editor
13
embedded intelligence
What will 5G do for you? Jeremy Pollard, CET
indiscrete
North America leads global piezoelectric motor market
45
product showcase
50
automation basics
How to secure cybersecurity Dave Perkon, technical editor
ad index Allied Electronics and Automation ...............................6
Murr Elektronik.....................................................................7
AutomationDirect................................................................2
Oriental Motors of America ..........................................51
Beckhoff Automation ........................................................4
Parker Pneumatic ............................................................16
Endress + Hauser ................................................................8
Pepperl+Fuchs ..................................................................19
Digi-Key................................................................................52
Phoenix Contact ...............................................................35
Festo .....................................................................................21
SEW-Eurodrive......................................................................3
Hammond Manufacturing .............................................31
SMC Corporation of America ........................................12
KEB America .......................................................................15
Telemecanique Sensors ................................................17
MTS Systems .....................................................................27
Yaskawa America .............................................................10
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editor’s page In Memory of Julie Cappelletti-Lange, Vice President 1984-2012
Mike Bacidore editor in chief
[email protected]
1501 E. Woodfield Rd., Suite 400N Schaumburg, Illinois 60173 630/467-1300 Fax: 630/467-1124
editorial team editor in chief
How to smarten up enclosures
Mike Bacidore
[email protected] technical editor
Dave Perkon
[email protected]
THERE’S BEEN A subtle shift in the market from conventional I/O to universal I/O. The
digital managing editor
savings on labor and materials seemed obvious, but Bechtel Oil and Gas decided to prove
Christopher Palafox
[email protected]
it out before standardizing on ready-made intelligent enclosures with configurable I/O. An
contributing editor
internal study revealed 15-30% savings on each Bechtel LNG project. “We get to see a lot of
Rick Rice
new technologies,” said Robert Resendez, control and automation team manager, Bechtel
[email protected]
Oil and Gas, who spoke about his company’s implementations at Schneider Electirc’s In-
contributing editor
novation Days in Austin, Texas. “We get to implement a lot of new technologies.”
Tom Stevic
In 2013, Bechtel had just come off of seven LNG projects. “One of the biggest challenges
[email protected]
was design development because of the changes,” explained Resendez. “We were at the fac-
editorial assistant
Lori Goldberg
tory acceptance test (FAT) for eight to 12 months on all of them because of design develop-
[email protected]
ment. What could we do to fix this problem? Universal I/O was a no-brainer. I don’t have to
columnist
increase cabinet size. The marshal-
Jeremy Pollard
ing cabinets were the big changer
[email protected]
because we didn’t have to rewire.” The obvious savings came to light
design/production
immediately, but Bechtel wanted to
senior production manager
Anetta Gauthier
know the overall impact on costs.
senior art director
Bechtel took a project it had just completed with 2,253 I/O signals going to four buildings.
The new system also increased
Derek Chamberlain
certain costs, but the net effect was
subscriptions
evident. “In 2013, we started vetting
1-800-553-8878 ext 5020
the systems and looking at them from an engineering standpoint,” said Resendez. “In
email:
[email protected]
the conventional system, we had a cabinet and then each I/O had to go to a marshaling
circulation Industrial machinery manufacturing
cabinet, then out to intermediate junction boxes and then copper cable out to the instru17,856
ments. This is the standard.” With the remote I/O, the intermediate junction boxes were replaced with intelligent en-
• Machine tools & metalworking
4,662
• Fluid handling & Conditioning
1,614
closures. “All the I/O is now moved out to the field,” explained Resendez. “The connection
• Heating & cooling equipment
1,231
back is now fiberoptic cable, so we’ve reduced the cable size and the structure by elimi-
• Material handling & conveyance
1,230
nating the copper cable. And the marshaling cabinets have all but gone away.”
• Power generatino & transmission
938
• Packaging machinery
718
Bechtel took a project it had just completed with 2,253 I/O signals going to four buildings. “We had an I/O rack room, a utility substation, compressor substation and propane
• Other specialized machinery
7,463
condenser substation,” said Resendez. “We replaced the junction boxes with the smart
Discrete & hybrid manufacturing
5,591
enclosures. Eighty field junction boxes were replaced with 39 Smart I/O boxes.” The major-
• Computers & electronics
2,199
ity of homerun cabling was eliminated, reducing 195 homerun cables to 16 cables.
• Food & beverage manufacturing
1,960
“We eliminated 21,000 homerun cable terminations,” said Resendez. “We eliminated
• Fabricated metals
905
almost 2 million linear feet of cable. We eliminated all 23 marshaling cabinets, and DCS
• Pharmaceuticals & medical devices
696
cabinets went from eight to five. Because we eliminated cabinets, we reduced the footprint
• Transportation equipment
273
from 864 sq ft to 234 sq ft. In some other projects, we’ve eliminated a whole building.”
• Other manufacturing Engineering & integration services
2,395 10,879
Other 2,857 TOTAL40,020
ControlDesign.com / January 2020 / 9
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live wire
Dave Perkon technical editor
[email protected]
How to add jobs using robots I HAVE SEEN WITH MY OWN EYES how automation and robots im-
manufacturer products,” says Bill Hennessey, CEO of ALIO
prove manufacturing and create better jobs on the plant floor.
Industries (www.alioindustries.com). “I assume they have not
However, I asked several machine builders and vendors how
noticed that we have already reduced our jobs and manufactur-
robots and technology in manufacturing will take peoples jobs.
ing drastically.”
The answers were very clear, they won’t. So don’t listen to that crap. Here is what a few of them said.
Since the 1980s manufacturing plants and small town America have been disappearing at very concerning and in-
“Robots are actually adding jobs, says Matt Wicks, chief
creasing rates. “In the early 80’s I remember the same negative
robotics solution architect at Honeywell Intelligrated (intel-
comments about robots we were placing in auto plants and
ligrated.com) in Mason, Ohio. “Robotic advances are shifting
construction equipment plants, that people would be put out of
the workforce to jobs that are more
work,” says Hennessey. “This nar-
uniquely suited for people to perform and away from dangerous, strenuous and less-rewarding tasks.” Today’s automation trends have a strong potential to benefit everyone,
row vision has returned. Lessons
If the USA had kept automation numbers up as other did, we would have a vibrant exporting economy.
continues Wicks. “There are encour-
than to improve their overall job prospects,” he says. “At the
the opposite which is that the infrastructure to automate created more and higher paying jobs than the ones replaced. As an alternative,
aging signs, both in the coming year and further out, that robots are far less likely to replace people
learned in the 80’s and 90’s support
consider what happens to small town America when that manufacturing plant leaves.” If the USA had kept automation numbers up as others did,
World Economic Forum in 2018, for example, it was estimated
we would have a vibrant exporting economy instead of a deficit
that by the year 2022, AI and robotics will have a net increase of
spending importing country, continues Hennessey. “It’s amaz-
more than 60 million jobs.”
ing that recently this job loss negativity related to robotics and
Far from replacing their human counterparts, robots are
automation occurred while industry was moving out of the USA
becoming their co-workers and collaborators — creating new
at the highest rates in our history to avoid high corporate taxes
opportunities for productivity, accuracy, cost savings and job
in the USA, only to automate in another country,” he said.
satisfaction. “As beneficial as these improvements are, chang-
Robotic automation is a must to build today’s and tomorrow’s
ing consumer expectations will make them critical to the sur-
products no matter which country it is manufactured in and no
vival of many retail and distribution operations,” says Wicks.
matter the hourly wage workers get. “Automation created jobs
Mobile robots are becoming commonplace in warehouses,
in Detroit in the old days and higher wages for techs and pro-
distribution centers, factory floors, etc. “With a projected 2
grammers, so automate or send jobs to China, where they auto-
million manufacturing jobs within the USA going unfilled in
mate more than any other nation all due to taxes and incentives
the next decade, robots are helping resolve this issue,” says
plus human workers lack of quality,” says Hennessey.
Mr. Nicolas Lauzier, VP of engineering at Robotiq (robotiq.com).
The past decade has been a growth period for the United
He provided the following quote from ‘The skills gap in U.S.
States. “While automation has been a big benefactor of this
manufacturing 2015 and beyond’ published by Deloitte Consult-
wave, the fear of the ‘job killing’ robot hasn’t quite panned
ing LLP and the Manufacturing Institute, “The benefits of cobots
out,” says Scott Marsic – product manager for Epson Robots
working alongside humans will become more apparent as the
(epson.com). “Interestingly as robot placements have increased
labour shortage persists because one benefit of cobots is that
over the past decade so have job openings (ITR 2019). What we
they supplement human output to boost overall efficiency.”
continue to see are that many industries still have significant
The robotic industry, which is primary now all manufac-
technical labor gaps, and those gaps present opportunities for
tured off shore, is booming. “The media and so called pundits
those trained—particularly in automation industries—to take
are warning of the reduction in jobs if we increase our robotic
advantage of them.”
ControlDesign.com / January 2020 / 11
embedded intelligence
Jeremy Pollard
[email protected]
What will 5G do for you? WHILE NOT THE fanciest of gifts, I bought my household an Instant Pot. It’s a high-class pressure cooker that promises to make me a better cook.
processed data to them in a form that is easy to interpret. This large amount of data will need a big transmission pipe so that the pipe doesn’t get clogged, and that’s 5G.
But the kicker is that it is Wi-Fi-enabled, so it actually counts as
The 4G bandwidth simply will not be big enough to handle
technology, yes? That way it doesn’t count as buying an appliance
the data that will be required. Another 5G advantage is the abil-
but an edge IoT device. That’s my story, and I’m sticking to it.
ity to use smaller antennas for smaller areas and larger anten-
In our sandbox, there will be a new kid in town that will
nas for larger areas, which can provide long-range data support.
change the face of Iot and IIot, and that is 5G mobile technology.
5G is not widely available in all areas, but, as the buildout
I think it is pretty cool that you can monitor your pot roast from
happens, customers will start demanding more data from their
your car or turn the device on so that
systems for maintenance, opera-
the pot roast is ready when you get home. 5G will make no difference in that situation. So what will 5G give us? First off, I have done a lot of reading on 5G and
tional issues and economic analyt-
5G will provide the data highway that big data will need as devices get smarter.
its health effects. Some say that the higher frequencies will cause an ab-
ics in real time. The old proverb applies here: Work expands to fill the time available. Replace work with data and time with bandwidth, and we have created a new one. There is a new technology that
normal amount of human disruption and cancers. You need to
enhances the 5G core called light fidelity (Li-Fi), which is based
be the judge for yourselves, but some of the information seems
on light waves. It is secure and not prone to interference, and it
quite credible. There is just as much credible information out
is similar to Bluetooth in its range.
there supporting the opposite. At 300 GHz it will have the fastest bandwidth available and is comparable to microwaves. The short wavelength allows for
This provides an ability to have a localized small, safe and fast network for devices that support Li-Fi. Fiberoptic cable could be used for connectivity, as well.
very fast communications between devices, routers, switches
I can envision M2M being based on Li-Fi due to the non-
and antennas. It just takes a shorter amount of time to travel
electrical nature of the technology. While not widely used in
the same distance as 4G does.
present time, this technology may grow with the rollout of 5G.
So, why all the hype? Edge devices can now process the data
Where 5G will excel will be when edge computing and IIoT
that they are supposed to and fire it to wherever they want us-
devices start proliferating in our applications. Edge comput-
ing whatever protocol they want. MQTT, HTTP or even FTP can
ing by definition suggests that the device that extracts and
be supported by 5G much better than 4G can do it.
processes data and information from devices is as close to the
This gives rise to almost real-time data for SCADA, edge
source of the data as possible. That data has to go somewhere,
devices, analytical data and cloud-based solutions. The new
and typically it has to get there in real time, which today can be
and improved SCADA and edge-located HMI/devices will be able
upwards of seconds or longer. Will new SCADA/HMI systems
to link to the cloud directly using Microsoft’s Azure platform or
support IIoT technologies natively to provide the need to have
Amazon Web Services (AWS).
this data? Absolutely. Depending on the amount of data that the
5G will provide the data highway that big data will need as de-
customer wants from this device at the edge of the domain, the
vices get smarter and provide more data to the user for real-time
distribution model and the definition of real time, 5G may be
display, historical as well as real-time analytics and pre-pro-
what is needed to accomplish the goal.
cessed information for the ability to make informed decisions. This can be important due to the fact that most companies do
JEREMY POLLARD, CET, has been writing about technology and
not have the staff or the wherewithal to perform these analyt-
software issues for many years. Pollard has been involved in control
ics on their own. They will need the devices to provide this pre-
system programming and training for more than 25 years.
ControlDesign.com / January 2020 / 13
technology trends
Rick Rice contributing editor
[email protected]
Wrap it up THE ELECTRICAL ENCLOSURE is essentially a metallic box with a lid. To mount components in the box, a back panel on standoffs is added to create the finished enclosure. The application and environment dictate the variations on this base concept. Starting with the enclosure itself, certain applications may
Generally, types 1, 4, 4X, 12 and 13 can be used indoors, while 3R, 4 and 4X can be used outdoors. For a full list of NEMA ratings, please consult www.controldesign.com/nemaenclosures. When choosing an appropriate enclosure, the NEMA rating
call for a different material of construction. Environments
should be considered before any other criteria. Once that deci-
where exposure to caustic or corrosive chemicals or extreme
sion has been made, the type of access to the component inside
weather is expected, making the box out of fiberglass or poly-
the enclosure will dictate the next step in the selection process.
carbonate ABS is a better option. In normal, dry conditions, a
Generally speaking, the risk to personnel when exposed to
mild steel enclosure is suitable and
the contents of the enclosure will
for wet environments a stainless steel enclosure is best. The National Electrical Manufacturer Association (NEMA), came up with a rating system to describe these applications and
determine the type of construction.
For enclosures that contain voltages higher than 48 Vdc, an interlocked disconnect is required.
environments and some of the main
A pushbutton station, for example, is primarily a low-voltage enclosure where the lid will rarely be removed. As such, a four-bolt, removable cover is appropriate. A
types are described as follows:
junction box might require infre-
Type 1 is a general-purpose enclosure constructed for indoor
quent opening (for troubleshooting or to add connections) and
use. This product protects against incidental contact from dust,
is generally mounted in a position where completely removing
light and indirect splashing but is not dust-tight.
the cover isn’t practical. For this purpose, an enclosure with a
Type 3R is intended for outdoor use. Deemed to be weather-
hinged door and clamps would be an appropriate choice. The
tight, this type of enclosure is neither rain-tight nor water-
clamps require a screw driver or wrench to loosen the clamps
tight, meaning that a direct stream of water or rain may
and would provide a degree of protection that is higher than the
breach the enclosure. For this reason, a Type 3R enclosure
same enclosure with hinged-lid that uses a quarter-turn latch
would be suitable for power or switchgear equipment but not
that could be operated with a coin, for example.
recommended for control circuits. Type 4 enclosures are considered weather-tight (weather-
For enclosures that contain voltages higher than 48 Vdc, an interlocked disconnect is required. Generally, there are two such
proof). They will protect the contents from falling rain, snow,
types of disconnect panels. The first uses a through-the-door
sleet, dirt, wind-blown dust, splashing or hose-directed water.
rotary actuator that locks the door in the closed position if the
These enclosures will not be damaged by the formation of ice
disconnect is in the ON position. The second uses a side-arm dis-
on the exterior surfaces but are not considered to be corro-
connect handle (lever-type) that uses a mechanical lever to prevent
sion-resistant.
the door from being opened while the disconnect is in the ON posi-
Type 4X enclosures are corrosion-resistant and are made of
tion. Both options protect unauthorized or accidental opening of
materials such as aluminum or stainless steel. They have the
the door while the power is on but have an override feature so that
same properties of the Type 4 enclosure but are intended for
the enclosure and contents may be accessed by trained personnel.
extreme environments. Type 12 enclosures are intended for indoor use and provide a
Always remember to follow proper arc-flash procedures when accessing panels above 48 Vdc. These procedures include the
degree of protection against solid falling objects, such as dirt,
wearing of proper personal protective equipment (PPE) includ-
dust, fibers, dripping or light splashing water. These are usually
ing clothing, face shield, gloves and footwear. The rules regard-
constructed of mild steel.
ing this type of access are much more restrictive than in years
Type 13 has all similar properties to Type 12 but adds a degree of protection against oil and non-corrosive coolants.
14 / January 2020 / ControlDesign.com
past, so make sure to review the regulations regularly to make sure you are compliant.
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technology trends
As a contract packager of food products, our manufactur-
Something that has been of particular interest to my orga-
ing processes dictate the use of pretty much the full spec-
nization of late has been the introduction of products in the
trum of NEMA types and our enclosures come in all sorts
NEMA 4X realm, particularly sloped-top enclosures used in our
of shapes and sizes. With any organization that has been
ribbon blender operations. These mixers are used for a great
around for a while, the use of enclosures was far less criti-
variety of products and, as such, require frequent wet washes
cal in earlier years, and this leads to a number of situations
between product families. The popularity of gluten-free and
where the type of enclosure has changed as improvements
organic products, as well as the ever-present allergens have
have been made to our systems. As with all projects, make
also increased our need to wash (and test on a micro-biologic
sure to consult the current rules governing such matters and
level) our blending equipment and rooms on a much more fre-
make sure that you are compliant with the rules as they exist
quent schedule than ever before. The existing equipment was
today. Generally, we stick to NEMA 4X for anything on our
installed in 2000 with a more recent addition in 2012. Both the
blending or dumping equipment while NEMA 12 works just
original and the addition use NEMA 4X enclosures, but we have
fi ne for our general production equipment. We don’t package
learned that continuous washing over a number of years has
any corrosive products, nor do we have to consider explo-
rendered the enclosure seals to be less than fully functional.
sion-proof equipment due to our current product mix. An
At the time we purchased this equipment, the enclosures came
evaluation of these criteria with each new product offering
with a permanent seal that is installed at time of fabrication.
does give us confi rmation that we are minimizing the risk to personnel when we introduce these new processes.
A new product (within the past year) has hit the market that directly addresses our current concerns. While still a NEMA
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4X product, these new enclosures employ features that help
down to the original metal and the application of a glue to lay
to reduce the possibility of getting moisture inside the panels
down a new seal in place of the old.
during the washing process. The fi rst feature is a sloped top
The new seal is not a match for the old seal but is, rather,
that, unlike previous version, extends the top surface of the
a roll of seal that must be applied one side at a time with ap-
enclosure over the top of the door. Previous versions employed
propriate cutting to length. In our experience, this process
a sloped top that stopped at the usual front face of the cabinet.
inevitably ends up with corners that are not continuous and
The door was then a separate assembly that was attached to
a means by which water can get into the panel. These new
a flange that was welded to the front face of the enclosure.
enclosure are sanitary-washdown-rated. The key feature is a
These new series of enclosures extend the top of the enclosure
replaceable FDA-grade silicone gasket. These gaskets do not
out over the top of the door to just past the front face. This
replace the existing seals on a non-washdown enclosure but
feature creates a roof or porch over the door to force any water
would be used to replace the gasket on a newly installed en-
stream out past the top ledge and seal of the door.
closure. The silicone construction resists bacteria growth and
The second feature is a new way of sealing the door. The
chemical absorption, and the ease of replacement makes them
traditional way of sealing an enclosure is a laid-in foam seal
an excellent choice for any new installation where NEMA 4X in
that is applied at time of manufacturing. If the seal fails, then
a washdown environment is likely.
one must either replace the whole door, if a current version of the enclosure matches the originals, or a kit must be applied
RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com),
that requires the removal of the old seal, cleaning of the surface
a dry-foods manufacturing and packaging company in Ashton, Illinois.
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indiscrete
North America leads global piezoelectric motor market PIEZOELECTRIC MOTORS ARE witnessing heightened demand, underpinned by their utilization in a wide array of appli-
Piezoelectric Motor Market Regional Overview
cations such as photonics, manufacturing process control, medical devices and metrology. Rapidly evolving production processes like 3D printing and advanced robotics are driving the need for motion control systems and miniature devices, which in turn will boost the growth of the piezoelectric motors market in the coming years. On the back of these factors, the global piezoelectric motor market is projected to grow at a moder2029, says Fact.MR. Application areas such as robotics and factory automation in various industries have resulted in the growth of
North America Asia Pacific (excl. Japan)
Latin America
Europe Japan Middle East & Africa
Standard LPM Vacuum LPM Non-magnetic RPM
Non-magnetic LPM Standard RPM Vacuum RPM
piezoelectric motors. The robotics and factory automation segment, combined, will witness an absolute dollar opportunity of US$ 37 Mn between 2019 and
semiconductor & electronics sector. Piezoelectric motors have high power
The piezoelectric motors have become a mainstream driving element in
2029. Additionally, medical equipment
to volume ratio with nearly zero noise
industrial and commercial applications.
and device manufacturers are rapidly
level and can achieve speeds up to 1 m/s
With continuous advancements in tech-
moving towards the adoption of piezo-
with 50 nm (nanometers) of resolution,
nology, the piezoelectric motor industry
electric motors vis-a-vis electromag-
which makes them suitable for applica-
has bolstered new capabilities within
netic motors. These include surgical
tions that requires higher operating
the nano- and micro-positioning space.
devices, 3D scanners, MRI compatible
force or torque in a small space.
The leading players in the piezoelectric
robotics, ultrasonic emitters, drug de-
Fact.MR says that North America is
motor market are focusing on product
livery devices, laser beam steering, and
projected to be the most prominent
innovation to meet the needs of various
devices used in dermatology, cosmetol-
market for piezoelectric motors and
sectors such as medical, automotive,
ogy, and ophthalmology.
estimated to account for more than 25%
robotics and other sectors.
There are some key takeaways of the global piezoelectric motor market.
of the global piezoelectric motor market
For instance, in 2019, Physik Instru-
throughout the forecast period on the
mente (PI) GmbH & Co. KG launched
According to Fact.MR, linear piezo-
back of growing demand for piezoelec-
piezoelectric linear motor for robotic
electric motor market is growing at a
tric motors in the aerospace & defense,
applications thus giving an impetus to
significant rate and is projected to wit-
medical, and robotics sectors.
its demand.
ness an absolute dollar opportunity of
Optics and photonics segment is
In 2019, Portecap launched rotary
$108 million during the forecast period.
anticipated to gather momentum due to
piezoelectric motor for the smart
Piezoelectric motors are preferred
increase in the application of piezoelec-
bone orthopedic application. Innova-
over electromagnetic motors, as piezo-
tric motors in cameras, telescope, and
tions have allowed these companies
electric motors offer various advantages
microscopes. The segment will witness
to expand their global reach in the
such as high operability in vacuum
an absolute dollar opportunity of $38
piezoelectric motor market. Fact.MR, in
environments suitable for aerospace,
million between 2019 and 2029.
its new offering, provides an unbiased
18 / January 2020 / ControlDesign.com
SOURCE: FACTMR
ate rate of over 4% between 2019 and
analysis of the global piezoelectric motor market, presenting historical demand data (2014-2018) and forecast statistics for the period, 2019-2029.
Compressor’s surge-control puzzle decoded by testing
The study divulges compelling insights
AN ENGINEERING STUDY was commissioned to provide a rigorous dynamic simula-
on the piezoelectric motor market on
tion of a fractionator and overhead vapor system. The model was constructed and
the basis of product type (Standard
validated against both steady-state and dynamic plant historical information.
LPM, Non-magnetic LPM, Vacuum LPM,
Unreliable compressor controls on a fractionator was causing some issues that
Standard RPM, Non-magnetic RPM, and
a refinery could not figure out. “It was the largest processing unit in the refinery,”
Vacuum RPM), where LPM and RPM
said Howard Jemison, PhD, dynamic simulation advisor, Aveva, who shared the
stands for linear and rotary piezoelec-
story of his investigation at Innovation Days in Austin, Texas. “Especially during
tric motors, end use industry (Micro
startups, there was a problem with the controls. They were looking at the funda-
Positioning Stages, Medical & Lab
mental causes of the trips, as well as whether they might make an improvement in
Automation Equipment, Automotive,
the control system.”
Aerospace & Defense, Robotics &
In the configuration, the suction throttle valve (STV) was used to control the
Factory Automation, Optics & Photon-
overhead on the fractionator. The compressor was more than 400 feet away. “You
ics, and Instrumentation), operating
have a lot of piping, and the anti-surge valve (ASV) was located at the top of the
force/ torque (0-20 N, 20-150 N, 150 -
fractionator,” said Jemison. “The pressure was affected almost immediately, and
225 N, Above 225 N, Below 10 mNm,
the trips were tied to this pressure.”
10 - 25 mNm, Above 225 mNm), across seven regions.
Jemison modeled the system to see if it could predict these trips and determine what to do about them.
2019
Ensuring process availability. Providing flexibility. Challenging expectations. VisuNet HMI Systems
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indiscrete
“When the event happened, it was already past the surge control line, and no action was being taken by the controller,” explained Jemison. “Nobody could give me a satisfactory answer why and how that could happen.”
Jemison took the responses from those valves every 20 milliseconds to see if it matched what he saw from the trends on the live data. Then he tested it by connecting to a Triconex control system.
During startup, the constant-speed compressor would fill with propane, so the molecular weight was lower. “The
in less than a minute. From the 30-second
The location of the ASV was at the
controller would not take action until
point, there was a buildup of the pressure,
top of the fractionator. “They wanted
the compressor started to surge,” said
when the reactor was ramping up.”
to eliminate condensation being blown
Jemison. “Then it would take very ag-
This client had standardized compres-
when it opened,” Jemison explained.
gressive action and guarantee it would
sor controls from another site, which
“If I want my ASV to respond quickly
trip. Once the valve would open, the
Jemison tweaked to match conditions for
to upsets in my compressor, I want to
pressure would go up, and it would trip.”
this site. “Within a week, they’d given
minimize the volume downstream of
me the controls, and they gave me the
the compressor. If it’s 400 feet away, I
change in the control strategy and run
PT2 file. I tested two different strategies
don’t have that. We could reduce the
different scenarios. “We had to build a
for the fractionator pressure control.”
discharge volume by 70% by moving that
Jemison decided to investigate a
dynamic model of that process and vali-
He tested the STV manipulation on the
valve, but what did the model say?”
date against the operation of the actual
compressor inlet, which was the existing
unit, which is not a trivial exercise,”
strategy, and he tested a variable-speed
it made it hard to go into surge. “I finally
explained Jemison. “We validated this
drive (VSD) on the compressor motor.
found something to delineate these two
model against two steady plant condi-
“We wanted to check this and see if
The Triconex controls worked so well
cases,” said Jemison. “We added a bunch
tions, summer and winter. We validated
this helped,” said Jemison. “The Triconex
of hydrogen, a low-molecular-weight
those based on their steady-state mod-
showed significant improvement with
gas, to push the compressor into surge.”
els. Now I’ve got the data from the re-
both of these implementations in avoid-
There were lots and lots of different
sponse curves on the performance map,
ing surge or trip conditions altogether. It
scenarios we would run. “The two worst
so I had to get to those trip conditions.”
was a very simple I/O connection from
ones we wanted to see were power fail-
Synsim to the Triconex emulation.”
ure and fail-open ASV to see how they’d
As the reactor would spin up, the compressor would fill with propane.
The VSD had quite a few advantages
respond,” said Jemison. “We wanted to
“Somewhere, I’ve got a set of conditions
economically. It could save money over
be sure we didn’t open any safety valves
causing this trip,” said Jemison, “but I
the course of several years, using fewer
and avoid these trips.”
didn’t have an emulation of the control
kW on the compressor, and it was less
system they were using. All I cared about
likely to open the anti-surge valve when
mance. “We tried not opening the ASV,
was what the valves were doing.“
running at high rates.
and we decided we didn’t need it,” said
Jemison took the responses from those
“But, when we went back and ran the
The Triconex showed superior perfor-
Jemison.
valves every 20 milliseconds to see if it
conditions that got them into trouble
matched what he saw from the trends on
in the first place, the VSD didn’t work
conex to replace the existing surge control
the live data. Then he tested it by con-
well at all,” said Jemison. “It was much
and decided to close the ASV when the
necting to a Triconex control system.
more prone to have trouble. The VSD
compressor trips. Keeping the STV control
was much slower to respond, especially
was the better option, rather than chang-
namic trip conditions were compared in
during that fast ramp-up. The STV actu-
ing to the compressor-motor VSD. They
a detailed model of process scope. “The
ally won the competition because it was
decided to move the ASV from the top of
results from the dynamic validation tests
already there, so there was no cost to re-
the fractionator to near the compressor
showed the time period was not long,”
place it, and because of its better control
and to modify the ASV to be fail-last or
said Jemison. “The whole thing was over
response in adverse conditions.”
fail-closed, rather than fail-open.
The two steady-state and two dy-
20 / January 2020 / ControlDesign.com
In the end, the refinery selected Tri-
PCB Completes $1 million clean room facility PCB PIEZOTRONICS, A wholly owned
further reduced down to ISO Class 3-4
subsidiary of MTS Systems Corporation
levels (less than 10 particles / cubic foot)
tally controlled clean rooms will further
(NASDAQ: MTSC), announced the comple-
due to usage of laminar flow benches,
enhance their pressure and force sensor
tion of new environmentally controlled
High Efficiency Particulate Air (HEPA)
manufacturing and assembly processes.
clean rooms totaling 4,300 sq. ft. at their
filtered fume extractors and other state
Higher efficiencies, increased through-
Walden Avenue headquarters. Earlier this
of the art clean room equipment.
put and improved quality are just some
year, the sensor manufacturer began as-
A second clean room area (3,100 sq ft)
PCB expects that the environmen-
of the expected benefits. PCB Design
sembly of all pressure and force products
is designated for final product assembly
Engineers are working on the next gen-
in this new state-of-the-art facility.
and calibration processes. This space
eration of high-performance sensors.
Sensor elements and other critical
is under even stricter humidity con-
“We are very proud of this new state-
assemblies are manufactured within a
trols to prevent electrostatic discharge
of-the-art facility and our continuous
1,200 sq ft room, which meets or exceeds
(ESD) damage to electrical components.
improvement initiatives to provide
ISO Class 7 cleanliness standard (less
Laminar flow benches for critical prod-
higher performing, quality sensor prod-
than 10,000 particles per cubic foot). This
uct assembly, and solder stations with
ucts to meet the demands of our valued
room is also humidity controlled within
HEPA filtered fume extractors are used
customers” said David T. Hore, president
a tight specification. Particle counts are
throughout this space.
of PCB Piezotronics.
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indiscrete
Swissbit opens state-of-the-art electronics production facility in Berlin SWISSBIT, A SPECIALIST provider of data-storage and security
turing of the latest memory and security modules for industrial
solutions for industrial applications and the Internet of Things
use. The plant boasts almost 2,600 square meters of dedicated
(IoT), opened its state-of-the-art electronics production facility in
production floorspace. Swissbit is ideally positioned for growth
Berlin, Germany. Swissbit has been manufacturing in Germany
markets, supplying the latest generation flash memory solu-
since 2002. Now, the company has further strengthened its
tions and innovative security products for embedded IoT ap-
long-term commitment to Berlin as a manufacturing base and
plications, including memory modules with integrated chips for
has tripled its production capacity for highly integrated electron-
authentication and data encryption. Digitalization will increase
ics. New technology trends, such as growing digitalization and
the demand for industrial memory products for industrial,
increased networking of devices in the Internet of Things, are
Netcom, automotive (for example autonomous driving) and
driving the demand for memory and embedded IoT solutions.
medical applications. Furthermore, increased networking of
Secretary of State, Dr. Frank Nägele, took part in the reception at
devices in the Internet of Things is seeing a dramatic rise in
the high-tech factory in the CleanTech Business Park in Berlin-
the requirements for the protection of data and devices and
Marzahn. Swissbit is set to increase the number of jobs in devel-
thus the demand for smart security products for embedded IoT
opment and production from 200 to up to 300 by 2023.
solutions. Counterfeit protection for cash registers, which will
Taking just over a year to construct, the factory has been in operation since October 2019 with complex precision manufac-
be mandatory in Germany from 2020, is one of the application areas of the new Swissbit solution.
PHOTOS BY SWISSBIT
With just under 2,600 square meters of dedicated production space, the sophisticated precision manufacturing facility produces state-of-the-art, industrial-grade storage and security modules.
22 / January 2020 / ControlDesign.com
Swissbit offers access to its state-of-the-art production technologies and processes to developers of high-tech products.
At the opening ceremony of Swissbit’s high-tech factory on December 4, 2019, guests enjoyed a tour to view the facility’s state-of-the-art production technologies.
At the opening event, a tour of the facility offered guests an insight into the latest manufacturing technology and processes. In future, Swissbit will also offer access to its technology and processes to other developers of high-tech products as a service. This includes highly automated production equipment for assembly and connection technology for highly integrated electronics products, with placement capacities of, for example, 80,000 components per hour (cph). With continuous 300mm wafer handling and advanced 3D packaging capabilities, Swissbit delivers future-proof technologies that only a few companies globally have mastered in this form. In total, Swissbit invested 20 million euros into the expansion and construction of the new production facility.
Lars Lust, Berlin site manager at Swissbit, welcomed guests for the opening of the new facility.
“At our new manufacturing site in Berlin, we are able to showcase our state-of-the-art advanced packaging technologies and demonstrate the precision we achieve for the production of our highly integrated packages and memory modules. Normally, to experience similar facilities in action you would need to fly to Asia”, commented Silvio Muschter, CEO of Swissbit AG. “Swissbit products have always been and will remain ‘Made in Germany’. Our plant in Berlin has it all: skilled developers, proven experience and the latest equipment. We’re excited to be close to an important developer and start-up scene and thrive on the cooperation opportunities with local research and educational institutions that the location offers. We have already been actively fostering our involvement in these communities since 2002 and want to continue expanding and that includes the creation of new high-tech jobs here in Berlin.”
Lars Lust (left), Berlin site manager at Swissbit, and Secretary of State Dr. Ing. Frank Nägele participated in the opening ceremony as a representative of the Berlin Senate Chancellery.
ControlDesign.com / January 2020 / 23
indiscrete
Universal Robots helps meet new-year goals during National Cobot Awareness Month in January JANUARY IS TRADITIONALLY a month
re-deployment, and affordability. Today,
orative robots, and an opportunity for
for new hope and new energy to meet
UR cobots allow employees to move from
manufacturers to get a jump on their
life and business goals. But for manu-
repetitive, low-value tasks to higher-
financial resolutions as well. Universal
facturers facing a new year with the
value activities that increase productivity
Robots customers around the world typi-
lowest unemployment rate in more
and quality as well as work conditions.
cally see ROI within the first year, with
than five decades, it can be a tough time
“We’ve been the frontrunners of col-
many seeing much faster return in just a
to expect workers to come back with
laborative robotics since the term was
enthusiasm from holiday celebrations
adopted. While safety is imperative,
to dull and menial tasks. That makes
that’s simply the cost of entry into the
automation, I was surprised to find that
January an ideal time for National Cobot
cobot market now,” says Shepherd. “We
we could afford a six-axis robot and
Awareness Month, says Stu Shepherd,
believe that being collaborative is just as
a collaborative one at that,” says Joe
regional sales director of Universal Ro-
much about being accessible, lowering
McGillivray, CEO of Dynamic Group, an
bots (UR) Americas division. “It’s been
the automation barrier by placing robots
injection molding company in Minneso-
more than 10 years since Universal Ro-
within reach of manufacturers who
ta that deployed UR cobots. “I assumed
bots sold the world’s first commercially
never thought they could deploy robots
those systems cost hundreds of thou-
viable collaborative robot, but the cobot
due to cost and complexity.”
sands of dollars, which was not the case.
market is still largely untapped. By
One such manufacturer was Toolcraft,
few weeks or months. “When we first started looking into
The return on investment on our first
making January National Cobot Aware-
a machine shop in Seattle, WA, that
ness Month, we want to send a signal to
found itself at a crossroad when a large
manufacturers that cobots are here to
order prompted the company to add a
worldwide and nearly 60% of global
solve the monotonous tasks they simply
third shift for 24/7 production. “No-
market share, UR is well-positioned
can’t staff. With an average payback
body wants to run on third shift around
to help manufacturers get started and
period of only six to eight months due
here. When you put an ad out, you’re
succeed with cobots. Free online UR
to increased productivity, quality,
not getting very many responses,” says
Academy training has helped more
and consistency, they can make their
Steve Wittenberg, director of opera-
than 85,000 users from 130 countries
investment back and then some before
tions at Toolcraft, who is in an area with
(and counting) quickly learn how to im-
year end if they start now.”
three percent unemployment. Toolcraft
plement, “teach,” and redeploy collab-
started looking at different automation
orative robots for almost any task. And
resolutions to improve our health and
options, initially considering traditional
the UR+ ecosystem provides over 200
well-being, to better manage our money,
industrial robots.
certified products and 400 approved
Most of us start the New Year with
to be more productive and satisfied, to
“If we looked at just the robot hard-
system was just under two months.” With more than 39,000 cobots sold
commercial developers that provide
help others, and to broaden our horizons
ware alone, that appeared to be a more
guaranteed plug-and-play compat-
and learn something new. Cobots can
cost-effective solution,” says Wittenberg.
ibility with UR cobots for fast and easy
help manufacturers and their valued
“But once we started factoring in the
implementation.
employees accomplish those goals.
savings on not having to erect a safety
While cobots’ built-in safety systems
Cobots are now the fastest-growing
cage, and the time saved on the ease of
segment of industrial automation,
that allow them to work side-by-side
use, avoiding a lot of complex program-
with the yearly revenue for cobot arms
with employees was the defining feature
ming, Universal Robots ended up being
expected to reach $11.8 billion by 2030,
of collaborative robots, UR has expanded
the right solution.”
up from $1.9 billion in 2018 according
that definition to include user-friendli-
Fast return on investment continues
ness, simple set-up, flexibility for easy
to be a significant advantage of collab-
24 / January 2020 / ControlDesign.com
to newly released analysis from ABI Research.
Collaborative robot market is increasingly competitive
and consolidate. The industry will see growing diversity in the coming years as startups bring their unique cobots to market to serve various applications.” Tractica expects demand to grow rapidly
ABB, FANUC, KAWASAKI Robotics,
The benefits of lower costs, increased
as more companies realize the benefits
Rethink Robotics, Techman Robot and
safety, greater flexibility, rapid setup,
of cobots, find new uses for them, and
Universal Robots have emerged as com-
and easier training are driving factors
adopt them for their processes.
panies to watch, according to a report
for global cobot demand. Traditional
from Tractica.
robot makers are moving to meet this
Market Radar”, examines six leading
The global collaborative robotics (cobot)
Tractica’s report, “Collaborative Robots
demand by adapting existing robots or
companies in the cobot industry that
market is experiencing a strong growth
developing and offering new cobots. This
should be on your radar - ABB, FANUC,
trend that is being driven by factors such
trend is a reaction to competition from
Kawasaki, Rethink, Techman and Univer-
as efficiency, quality, and automation of
cobot startups that established the cobot
sal Robots. It discusses the crucial market
production. According to Tractica, cobots
category and have begun to eat into the
drivers, challenges, and industry applica-
are being adopted in companies large and
market share of traditional robots. Ac-
tions for their products and provides a
small, looking to assuage labor shortages
cording to Tractica senior analyst, Glenn
heatmap that illustrates some of their
and meet the demand for high mix/low
Sanders, “The cobot market will be
relative strengths. Recommendations for
volume production.
fairly crowded until it begins to mature
vendors and end users are also included.
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indiscrete
Korea hits new record of 300,000 industrial robots in operation
Siemens partners with Arm to accelerate the future of mobility
THE WORLD ROBOTICS report presented by the International Federa-
SIEMENS DIGITAL INDUSTRIES Software announced
tion of Robotics (IFR) shows a new record stock of about 300,000
a partnership with global semiconductor IP leader
operational industrial robots in the Republic of Korea in 2018 (+10%).
Arm, that will bring leading edge IP, methodologies,
Within five years, the country has doubled its number of industrial
processes and tools together to help automakers, in-
robots. Following Japan and China, the country ranked third in 2018.
tegrators and suppliers collaborate, design and bring
But the dynamics of robot installations has decreased in recent
to market their next-generation platforms much
years and for 2019 a continued decrease is expected.
faster. This partnership was formed to address the
“Robot installations declined by 5% to 37,807 units in 2018,” says
increasingly complex challenges facing the indus-
Junji Tsuda, President of the International Federation of Robotics.
try in developing platforms to realize active-safety,
“Both, the electrical/electronics industry and the automotive industry
advanced driver assistance, in-vehicle infotainment,
reduced installations, together they account for 82% of total demand.”
digital cockpits, vehicle-to-vehicle/vehicle-to-infra-
South Korea is affected by the US-China trade dispute, but there
structure and self-driving vehicles. Key advances
could be positive as well as negative effects: China is an important
in computing and sensor technology are enabling
export destination for Korea´s intermediate products. The conflict
companies to redefine mobility beginning with the
could result in decreasing demand from China. In contrast, Korean
integrated circuits and software within automotive
products might substitute Chinese products. But currently, the
electronics systems. The combination of Siemens’
South Korean economy is in troubled waters. Declining demand
and Arm’s innovative technologies can help auto-
for electronic products and announcements of investment reduc-
makers and suppliers deliver tomorrow’s electronic
tions by major electronics companies point towards another year of
design and automotive solutions, today.
decreasing robot installations. In the long run, the extensive use of robots is vital in order to
Siemens’ PAVE360 digital twin environment, featuring Arm IP, applies high-fidelity modeling techniques
maintain competitiveness. Korea’s population is ageing rapidly. By
from sensors and ICs to vehicle dynamics and the envi-
the middle of this century, it will have one of the oldest popula-
ronment within which a vehicle operates. Using Arm
tions out of all OECD countries, just behind Japan, Italy and Greece.
IP, including Arm Automotive Enhanced (AE) products
In 2050, more than one third of the population will be over the age
with functional safety support, digital twin models
of 65 and around half of all workers will be aged 50 and over. This
can run entire software stacks providing early metrics
helps to explain why South Korea has already embraced robots, particularly in its manufacturing sector, where “robot density” ranks second place in the world - following Singapore. With 774 industrial robots per 10,000 employees, the Republic of Korea has more than twice the number of Germany and Japan. The Workforce Development and Training Act, updated in 2019, is one important initiative in a series of government- driven programs. People get support to develop skills of how to handle robots and automated machines. The “Smart Manufacturing Innovation Strategy” announced the build-up of 50,000 smart factory workers by 2022. And the Third Robot Basic Plan with a runtime of 5 years will support training of 2,200 workers for small and medium-sized enterprises by 2023.
26 / January 2020 / ControlDesign.com
of power and performance while operating in the context of a
rethinking IC design for the automotive industry, manufactur-
high-fidelity model of the vehicle and its environment, helping
ers can consolidate electronic control units (ECUs), leading
deliver a new future of mobility.
to thousands of dollars in savings per vehicle by reducing
“Developing future transportation solutions requires collabo-
the number of circuit boards and meters of wire within the
ration across complex ecosystems,” said Dipti Vachani, senior
vehicle design. This in turn reduces vehicle weight, which can
vice president and general manager, Automotive and IoT Line of
promote longer range electric vehicles.
Business, Arm. “Arm technology has been deployed in applica-
“In all we do at Siemens, our goal is to provide transporta-
tions across the whole vehicle for more than two decades, and
tion companies and suppliers the most comprehensive digital
our collaboration with Siemens redefines what is possible in
twin solutions, from the design and development of semi-
terms of safety-capable, scalable heterogeneous compute. We
conductors, to advanced manufacturing and deployment of
see this as an important catalyst for the next wave of automo-
vehicles and services within cities,” said Tony Hemmelgarn,
tive semiconductor innovation.”
president and CEO at Siemens Digital Industries Software.
Using Siemens’ PAVE360 with Arm automotive IP, automak-
“Siemens believes collaboration with Arm is a win for the
ers and suppliers can simulate and verify sub-system and
entire industry. Carmakers, their suppliers, and IC design
system on chip (SoC) designs, and better understand how they
companies all can benefit from the collaboration, new meth-
perform within a vehicle design from the silicon level up, long
odologies and insight now sparking new innovations.”
before the vehicle is built. Arm’s automotive IP is helping to
Siemens Digital Industries Software is driving transformation
democratize the ability to create safety-enabled silicon, bring-
to enable a digital enterprise where engineering, manufacturing
ing it within reach of the entire automotive supply chain. By
and electronics design meet tomorrow.
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machine input
How to choose between VFD and soft starter Applications dictate the pluses and minuses of each by Mike Bacidore, chief editor
Can you talk about the pluses and minuses of using a soft starter or an ac variable-frequency drive (VFD), as well as explaining the applications in which one might be a better fit than the other?
as Allen Bradley’s E3 electronic overload relays can give you feedback on how your device is running—current, torque, leg voltages—without having the added cost and setup of a VFD. These devices can also be set up with hardwired I/O or over communication protocols such as DeviceNet and ControlNet.
Greg Maryniarczyk , test engineer at DLS Electronic Systems (www.
VFDs offer more options on how you can fine-tune your process
dlsemc.com), Soft-start drives are used to limit inrush
and flow to optimize your facility or product. You also have consid-
current associated with electric motor startup.
erably more feedback available to you, if that is what you desire.
Soft-start drives lower the initial voltage by adding solid-state series impedance and ramp up until full speed is achieved.
Chip McDaniel, technical marketing at AutomationDirect (www.
Doing this extends the life of the motor and mechanical
automationdirect.com), For most applications, the choice
components that are connected to it. Large motor electric
between a soft starter and a VFD boils down to the need
inrush current also places a high demand on the electrical
for speed control. If across-the-line starting is not acceptable and
supply system, which often results in extra cost.
an application requires adjustable start and stop times for
VFDs deliver much higher frequency source power during
electrical or mechanical reasons, then a soft starter can be an
startup to reduce current due to the increased inductive imped-
excellent solution. Electrical reasons include limiting peak current
ance. This can be advantageous if control is desired after full
input, which may provide considerable energy cost savings, as
speed is reached. This control allows for continuing control as
well as avoidance of excess utility company billing for those plants
the load on the motor is changing. VFDs are more efficient and
and facilities being charged at peak demand level. Avoiding the
produce less heat, while being able to start motors under con-
shock of full-speed starts and stops on connected mechanical
siderable loads. In both methods, as the motor reaches operat-
equipment is also a compelling reason to apply soft starters.
ing speeds, the counter electromotive force (CEMF) increases to limit current to steady-state conditions.
VFDs provide all of these benefits and more, including powerfactor correction and low power consumption, along with full-speed control and not just start/stop control, but the ad-
Margie Rawlins , lead control systems engineer at Thermo Systems
ditional cost of the VFD must be justified. Other benefits include
(www.thermosystems.com), a Control System Integrators
dynamic braking, PID control, Safe Torque Off (STO), built-in
Association (CSIA, www.controlsys.org) member, The
I/O and logic, fire mode, circulatory control mode, multi-motor
main deciding factor between using a VFD or a motor starter is
control, communication interfaces and network control. The list
the ability to continuously change the speed of a motor. If your
goes on and on, depending on model and manufacturer.
application is going to be a set speed, then you should use a motor starter. They are generally much lower in cost and easier
Daniel Weiss , senior product manager at Newark (www.newark.
to setup. If you are going to need or want to be able to match the
com), In today’s competitive landscape of energy
speed of other machines, or have the flexibility to continually ensure optimal machine operation, then a VFD is the way to go. With a VFD, you can receive feedback using many types of
management, soft starters provide a valuable alternative to across-the-line motor starting. A soft starter helps to protect the motor and connected equip-
communications, from hardwired I/O points, if you just want
ment from damage by controlling the voltage supplied to the
minimum feedback, to Ethernet, if you want to have all the data
motor. This limits the initial inrush of current, extending the life
in the drive available to your controller.
of the motor, and reduces mechanical shock sustained during
With a motor starter, you can still get feedback. Devices such
28 / January 2020 / ControlDesign.com
starting by providing a more gradual ramp-up to full speed.
Soft starters are also applicable where electrical systems
speeds like a variable-speed drive (VSD). If you have an applica-
have limited current capacity. When using a soft starter, inrush
tion where the motor will run at full speed all the time, then an
current is more limited than conventional across-the-line mo-
RVSS is much smaller and less expensive than a VFD. But in
tor starting. By gradually increasing the voltage at the motor
many applications, there is a need to vary flow or pressure.
terminals, the soft starter produces a more regulated motor
With an RVSS, this is usually done by running the motor at full
acceleration up to full speed. Soft starters are also capable of
speed and then using a control valve to change flow or pressure.
providing a gradual ramp to stop, where sudden stopping may
Using a VFD, the need for a control valve is eliminated since we
create problems in the connected equipment.
just vary the speed of the motor to adjust flow or pressure.
Check out soft starters for applications where speed ramping
By not running the motor at full speed, we know from the
and torque control are desired for starting or stopping; where
affinity laws that the VFD method drastically lowers the energy
supply network issues or penalty charges may occur while
used. With many applications, the control valve can be expen-
starting a large motor—high inrush current; where a gradual
sive to maintain due to the need to constantly clean or unclog
controlled starting is required to avoid shock and tension in
the control valve. This is all eliminated using the VFD.
the mechanical system for applications such as conveyors,
Both the reduced-voltage soft starter and the variable-speed
belt-driven systems, gears and couplings; and where pressure
drive can ramp up the motor to eliminate harmful mechanical
surges or water hammer may occur in piping systems.
impacts of across-the-line starting. The soft starter does switch over to running across the line,
Steve Perreault , industrial drive product management at Yaskawa (www.yaskawa.com),
Both soft starters and VFDs
dramatically reduce starting current and potentially damaging levels of starting torque. Soft starters are often the
so it will be a linear load while running across the line. This means it will not inject harmful harmonic distortion into your plant’s ac power grid. The VFD is a nonlinear load and, therefore, does inject harmonics into your power grid.
most economical choice when considering only the starting
For most environments or locations, this isn’t an issue. In
condition. And, after the starting event, the motor receives
areas that require low harmonic content, as defined by IEEE519,
sinusoidal voltage, with zero added distortion. Although there
there are drives that have this functionality integrated as hard-
are methods for minimally controlling speed with a soft starter,
ware, so there’s nothing to set up, maintain or adjust. The extra
doing so is very inefficient and inaccurate.
cost of these “clean power” drives is far less than the energy
The cost of VFDs has decreased dramatically in recent years, and the benefits over soft starters are numerous. The main
savings gained through the variable-speed operation of pumps, fans and compressors mentioned.
disadvantages of VFDs compared to soft starters, are that, first, VFDs introduce a small amount of extra heat in the motor—im-
Tim Albers , director of marketing and product management at
perfect sine wave—and, second, VFDs draw nonlinear current,
Nidec Motor (acim.nidec.com),
known as harmonic distortion, from the power source.
drive can do everything a soft starter can do and
In most cases, the benefits of VFDs greatly offset these
An ac variable-frequency
more. The soft starter can only soft-start. There are different
things, and special VFD countermeasures exist to greatly
types of soft starters, but the most common controls the
reduce them when necessary. Not only do VFDs provide an
voltage and therefore the current of the motor as it starts to
extremely smooth and controlled start, but they also efficiently
limit the inrush of current.
control motors to nearly any desired level of speed, torque or position, including over-speed and full torque at zero speed. Special application and safety features are often included,
Based on that limitation, the motor will also start slower. The advantages of that are a cooler rotor at start and a slower or softer starting process on both the installed electrical power-
providing even greater benefit. In most cases, variable-speed
supply system and the mechanical structure of whatever
control greatly improves processes and yields impressive
equipment is being started.
energy savings.
A variable frequency drive can do the exact same things. The advantage of the variable -frequency drive is that it can do so
Chuck Fernandez , enclosed low voltage product manager at Siemens (www.siemens.com),
Obviously, the reduced-volt-
age soft starter (RVSS) cannot be run at different
much more after the motor is accelerated and up to speed. To be honest, soft starters have reached an economic cost point versus variable frequency drives so that, now, below
ControlDesign.com / January 2020 / 29
machine input
25-75 hp or so, the cost of a soft starter is not necessarily lower
erally lower purchase price compared to a VFD; and the ability
than the cost of a variable frequency drive.
to bypass the power electronics in the soft starter once the
The larger the load, the more cost advantage that a soft starter has, particularly for medium voltage. For an extreme example,
motor is up to full speed and operating. A VFD’s power electronics always operate when the motor
the market price of a 25-hp soft starter and a variable-frequency
is operating. The soft starter’s bypass will offer slightly lower
drive are very comparable. For a medium-voltage 4,000-hp, the
losses, and therefore energy, when the motor simply needs to
soft starter may be as little as 33% to 40% the cost of a variable-
run at full speed all the time. The advantage of a soft starter
frequency drive. In that case, it is not application-dependent,
over a standard contactor to start a motor is reduced demand
but, instead, power- and voltage-dependent.
on the electrical system during the starting of a motor.
In my opinion, the only advantage of a soft starter over a
A typical low-voltage motor will require six to seven times
VFD is cost. If process matching of the speed of the process to
its rated current during starting. The soft starter can typically
a variable process output is not required, then price should be
reduce those requirements to two-and-a-half to four times the
the only determining factor. If the process can be optimized or
motor-rated current during motor startup. Benefits of the re-
cost saved on electricity by matching the process speed, then a
duction of inrush current to the motor include lower torsional
VFD will always be the choice.
shock to the rotating system—motor, coupling and rotating load—during startup, lower peak current to motor, lowering
Jared Orlicki , engineering technician at Fuji Electric of America
the overall kVA demand on the electrical system during startup
(americas.fujielectric.com), Soft starters and VFDs can
and lower voltage dip—light flicker—that can occur when start-
both be used to control accelerate and decelerate ac
ing larger motor loads.
motors, reducing the starting current. VFDs provide the
VFDs offer several advantages over soft starters that can
additional advantage of controlling the output frequency, while
be substantial—speed control of the motor and application;
soft starters are fixed at line frequency operation. The VFD’s
energy savings; lower inrush current; and the option of full
variable-speed operation is referred to as variable voltage
torque or higher for starting the motor.
variable frequency (VVVF). Soft starters utilize silicon controlled rectifiers (SCRs) to perform phase angle control, while VFDs use insulated-gate bipolar transistors (IGBTs) to perform pulse-width-modulation (PWM) control. The advantages of the soft-starter design are lower Watt
VFDs also offer the ability to supply real-time process information and preventive and predictive maintenance information back to the control system. VFD speed control allows users to match process operation and output to changing demands for products. Substantial energy reduction is typical for pumps and fans. In those appli-
loss, no harmonics except during acceleration/deceleration,
cations, power demand drops off as a cubic function of speed
less maintenance and lower initial cost. However, there are
where a 10% reduction in speed relates to an approximate 33%
numerous advantages provided by the VFDs’ variable-speed
reduction in energy usage.
capability. VFDs are better-suited for advanced applications
Many users believe their pump just needs to run at full
that require speed control, torque control, PID control and
speed as the process can handle excess flow easily or there
dancer control.
is a control valve in place already. Using a drive allows users
VFD technology continues to evolve, while soft starters are considered a mature product by most engineers. Each new gen-
to turn back the pump to actual required flow or match the required flow to the process.
eration of VFDs provide higher performance, smaller size and
Users can also apply a VFD with the control valve set to wide
more advanced CPU control. VFDs enable the advanced motor
open and use the drive to set required flow at less than system
control that is required by many applications and can deliver
design, saving substantial amounts of energy.
operational cost savings in many others. Soft starters are only considered suitable for simple fixed-speed applications.
An additional benefit of VFDs is reduced valve and pump maintenance costs. Control valves and pumps are hardest pressed in service when operating at full speed or high pres-
Nisha Chandrasekharan , portfolio manager for low-voltage drives
sures, and VFDs can help to reduce that pressure and the
at Rockwell Automation (www.rockwellautomation.com), The
resulting maintenance needs. Some applications of VFDs can
primary advantages of soft starters are twofold—gen-
eliminate the control valve altogether.
30 / January 2020 / ControlDesign.com
Finally, some drives can act as a power converter. In some applications, VFDs can be operated with single-phase input power to operate a three-phase motor. Sizing of the VFD should be carefully considered for these kinds of applications. Common applications for soft starters include applications
Chris Jaszczolt , industrial drive product management at Yaskawa
(www.yaskawa.com), It all comes down to user intent.
The goal of each system is to reduce user cost. That can be initial cost or through year-over-year energy savings. Soft starters are meant to reduce the power surge that oc-
with low or medium starting torque; lightly loaded applica-
curs when you power on a motor across the line. Utility com-
tions; little or no speed control during run mode; control of
panies have demand charges or fees based on your peak power
inrush; and power monitoring.
demand. It behooves the user to eliminate their peak demands
Common applications for drives include single-phase ap-
as much as possible.
plications; speed control and system efficiencies operating at
Therefore, a soft starter can be used to reduce the utility
reduced speeds during the run mode; applications with high
company’s demand charge. More advanced soft starters pro-
starting torque; continuous feedback for critical position con-
vide a form of motor-overload protection.
trol; and holding motor at zero speed.
The operation of motor/application will dictate if the user
Load types for which a soft starter would not be recommend-
can overcome the added cost of a VFD compared to a simple
ed include extruders, positive displacement pumps, inclined
soft starter. If the motor will never operate at a different speed
conveyors, lifts and nonhydraulic elevators. Full torque is not
than line speed, say, 60 Hz, then the most economical choice is
available at zero speed or very low speeds with soft starters.
likely a soft starter. However, if the application will deviate in
However, an ac drive can produce rated torque from zero to
any way from rated power operation at line speed, then a VFD
rated speed and can typically handle all load types.
is the correct solution.
Die-cast Aluminum
Polycarbonate
Polyester
Industrial Wall-mount
Stainless Steel
cover story
Data-driven smart system’s functionality settles a long-term problem with flexographic printing by Rodney Pennings, PCMC
4.0 (i4.0) technologies is transforming
Applied technology to solve bounce
manufacturing across a broad range of
Printing is centuries old, with modern
industries, including packaging printing.
printing concepts invented by Gutenberg
with certain bounce jobs. In printing, the
Data-driven smart systems offer major
in the 15th century. Since then, printing
overall goal is to get the presses quickly
advances in manufacturing speed and
has been as much an art as a science,
up and running at full speed, keeping the
agility for increased productivity and
even with the advent of high-speed
amount of setup time and wasted material
less downtime and waste. All are part of
flexographic printing systems, a form of
as low as possible. Bounce leads to wasted
the requirements for a flexible factory-
rotary printing where ink is applied to
time and materials, and companies must
of-the-future production environment.
a variety of surfaces using flexible rub-
depend on experienced press operators
Many companies are actively explor-
ber or similar printing plates. Although
to fine-tune print settings and still get
ing and integrating i4.0 technologies in
these systems incorporate advanced
the press running at the highest possible
order to make the Factory of the Future
automation that enables printing
machine speed with quality output.
a reality today. This includes Barry-
complex jobs at speeds up to 2,000 feet
Wehmiller’s Paper Converting Machine
per minute, certain aspects of printing
incorporated i4.0 technology in its
Company (PCMC) in Green Bay, Wis-
operations often depend on an opera-
new SteadyPrint feature. This solution
tor’s artful manipulation—tweaking—of
reduces print setup time, increases
the press at startup in order to print a
quality and reduces print waste, even
perfect image.
with less-experienced machine opera-
The rapid introduction of Industry
consin (www.pcmc.com), a supplier of equipment for flexographic printing, bag and tissue converting, packaging, and nonwovens technology. Using advanced intelli-
effects on the print quality. Every flexographic printer struggles
To eliminate the tweaking, PCMC
tors. Working under a long-established
bounce is most often seen at the start
relationship, PCMC tapped into Bosch
of print runs with challenging graphics.
Rexroth for a unique array of resources
ties in the drives and controls platform
These challenging graphics often have
and capabilities to help develop
provided by Bosch Rexroth, PCMC
a hard leading edge on a printing plate
SteadyPrint, including:
recently introduced an award-winning
that meets the opposing impression roll,
• decades-long expertise and innovation
i4.0 smart technology solution called
causing an impact that affects print reg-
SteadyPrint that solves the longstanding
istration. This leads to poor print quality,
problem of bounce in flexographic print-
with uneven ink distribution or colors
ing. SteadyPrint is just one element in
that are out of registration. Press opera-
PCMC’s suite of SmartLink i4.0 technol-
tors typically tweak various settings on
ogy, which consists of smart features for
the press manually until they minimize
munications architecture for real-time
connected machines.
out the bounce effect, at times being
motion control advantages
gence and machine-learning capabili-
32 / January 2020 / ControlDesign.com
Waste associated with the issue of
unable to fully eliminate these negative
in printing and converting technologies • i ntelligent motion control technology that can learn and respond with torque offsets • support for high-speed SERCOS com-
ControlDesign.com / January 2020 / 33
cover story
(Source: PCMC)
•R exroth’s Open Core Interface tool that enables access to additional motion control functionality and analysis using third-party programming languages.
SteadyPrint solution delivers results PCMC worked with Bosch Rexroth and distributor partner CMA/Flodyne/Hy-
Before and after Figure 2: Before, the bounce in a complex job slowed the printing, but the Fusion press with SteadyPrint ran five times faster with no operator adjustment required.
dradyne (www.cmafh.com) in De Pere, Wisconsin, to develop the SteadyPrint
cel out the disturbance that generates
tomer’s print job is different, all of them
functionality for the company’s Fu-
bounce. When customers were given
doubled or tripled the speed or went to
sion and ELSMax flexographic printing
the opportunity to test the feature by
full speed much faster than ever before.
presses (Figure 1).
bringing sample jobs into PCMC, they
One customer had a complex job that
were able to improve press speeds
could only run at 300 feet per minute on
bance-canceling algorithm that uses
between 200% and 400% and reduce
the press due to bounce. It ran the same
the intelligence in the Rexroth servo
waste by up to 35%.
job on our Fusion press with SteadyPrint
SteadyPrint is based on a distur-
drives to learn the electronic signature of each print job and rapidly can-
We had multiple customers come in to do bounce trials and, while every cus-
A well-controlled flexographic press Figure 1: The Fusion flexographic press from Barry-Wehmiller’s PCMC features data-driven smart systems that offer major advances in manufacturing speed and agility for increased productivity and less downtime and waste. (SOURCE: PCMC)
34 / January 2020 / ControlDesign.com
at 1,500 feet per minute with no operator adjustment (Figure 2).
Challenge accepted We’ve got your back Our customers have relied on Phoenix Contact for almost 100 years. They trust us. They trust our products. And now we are elevating our commitment to that trust with our Limited Lifetime Warranty. This is our promise to you that the products you install in your control cabinets are built to last. Simply register and let us do the work. Learn more at www.phoenixcontact.com/warranty
© PHOENIX CONTACT 2020
cover story
A smooth drive
(Source: PCMC)
Figure 3: The capabilities of the servo drives enables the SteadyPrint feature to gather axis motion data and use in a drive-based algorithm to smooth out print quality and eliminate bounce.
How SteadyPrint stabilization works Each Fusion press system consists of a
automation platform for overall ma-
of the drives, the torque feedback had a
chine control.
signature that repeated once per rota-
To develop SteadyPrint, the capabili-
tion of the roll.”
large central impression cylinder, 8 to
ties inherent in the Rexroth IndraDrive
10 feet in diameter, surrounded by eight
servo drives were utilized to gather new
pattern, continues Schmidt. “We then
or 10 printing decks with two cylinders,
data about the motion on each axis. “Our
apply a compensation algorithm, to off-
one containing the image and the other
IndraDrive servo drive registers bounce
set the effects of the torque disturbance
applying the ink.
as a torque disturbance,” says Brian
significantly reducing position errors,”
Schmidt a motion control engineer at
he says.
The Fusion press, like other PCMC
We developed a concept to record this
presses, was already using Bosch
Rexroth. “The drive will counteract the
Rexroth drive and control technology,
disturbance and smooth out the motion,
job, it takes just a few rotations of the
including IndraDrive M servo drives
but, while the disturbance is happening,
cylinders for the drives to learn the nec-
(Figure 3) and IndraDyn T frameless
print quality is adversely affected. By
essary torque offset to apply; the Stead-
torque motors to control the cylinders,
capturing data on the torque feedback,
yPrint feature then engages the drive-
and the IndraMotion MLC motion logic
velocity feedback and position feedback
based algorithm and virtually eliminates
36 / January 2020 / ControlDesign.com
According to Schmidt, for each print
the need for operators to make manual mechanical adjustments to smooth out print quality and eliminate bounce. This also eliminates the wasted material from mechanical adjustment and enables full-speed printing almost from
They were able to improve press speeds between 200% and 400% and reduce waste by up to 35%.
the outset of each print run. Adding refinements to the Fusion press mechanical design to minimize deflection, including an improved
trol platform has also enabled PCMC to
to PCMC for the SteadyPrint system. I
mandrel support arrangement that
advance its connected machine concept.
credit the close working partnership our
increases deck stability, PCMC is using
With SERCOS, we have an expanded
people developed through multiple inno-
the IndraDrive drive-based torque offset
view of all the data that the drive cap-
vation sessions and system refinements
algorithm to implement its SteadyPrint
tures. “That lets us have a deeper look
for the success and recognition that
capability across the full line of Fusion
into the drive and allows us to imple-
SteadyPrint has accomplished.
press systems, as well as the company’s
ment system dashboards and predictive
ELSMax presses.
maintenance capabilities where we can
the project went as expected. I have
connect remotely through the cloud to
a very high view of what Rexroth and
support customers in real time to man-
CMA/Flodyne/Hydradyne bring to these
age their systems,” says Schmidt.
kinds of projects, and their capabilities
Intelligent drives deliver major advantages
The best compliment I can pay is that
The SteadyPrint feature confirms a core
Bosch Rexroth’s Open Core Interface
advantage of Bosch Rexroth’s approach
enhances PCMC’s flexibility to provide
degree. I couldn’t have imagined doing it
to automation and motion control: Using
connected machine functionality to its
with any other team. They are the gold
distributed, drive-integrated intelligence
customers. The Open Core Interface is a
standard in product and support. I also
to solve motion control challenges is
machine control programming interface
appreciate how our partners are com-
often the smartest and most effective
to create high-level, language-based
mitted to real-world applications of In-
approach, rather than depending on a
applications. PCMC utilized Open Core
dustry 4.0 technology and how they are
PLC to handle all the processing.
Interface to extract data from the drives,
helping PCMC to implement and expand
such as torque, position and veloc-
the SmartLink concept of smart features
intelligence wasn’t in the drive. Given
ity data and then made it available for
and connected machines. PCMC plans to
the speed and dynamics of how these
analysis using third-party programming
continue introducing new innovations
print jobs run 1,000 to 2,000 feet per
languages and data analytics packages,
like SteadyPrint and looks forward to
minute, with repeats as low as 12 inches
rather than going through traditional
working with Bosch Rexroth and CMA
long, it wouldn’t be possible to have the
PLC methods of exchanging data.
and to produce the next generation of
There is no way we could do this if the
controller handle the compensation. It has to be in the drive.
are always impressive to the highest
innovations.
Collaboration wins awards
Bosch Rexroth’s use of the high-speed
The Flexographic Technical Association
Rodney Pennings is the Printing, Coating
SERCOS Ethernet-based communications
(FTA) recently awarded its Technical In-
and Laminating sales director at Paper
bus as the backbone for its motion con-
novation Award, Heavy Metal Category,
Converting Machine Company (PCMC, a division of Barry-Wehmiller and a leading supplier of high-performance converting
While every customer’s print job is different, all of them doubled or tripled the speed.
machinery for the tissue, nonwovens and package-printing industries worldwide. He joined PCMC more than 21 years ago and also helps to direct the product line’s strategy and market plans.
ControlDesign.com / January 2020 / 37
PLCs
by Simon Bambey and Griffin Peirce, UBC Rocket Student Team
AT THE UNIVERSITY of British Columbia (UBC) in Vancouver,
ideal for the task. This article shows how they created a PLC-
Canada, a group of determined students faced a technical task
controlled rocket engine test stand, improving and adapting it
more challenging and with greater real-world implications
as requirements evolved.
than presented by typical homework or exams. They needed to safely test-fire an actual rocket engine to verify correct opera-
On-the-job learning
tion prior to launch.
The student team is made up of dedicated and motivated
The UBC Rocket student team consists of over 100 students
individuals who embrace the challenge even though it is over
working on multiple rocket projects. About one third of this
and above their normal school and work commitments. For
group are engaged in the UBC Rocket Spaceshot project, work-
many, it is one of the few opportunities for Canadian citizens
ing to build a sizable 25-foot-tall rocket powered by a liquid
to engage in this type of aerospace and rocketry program. The
propellant engine. The rocket alone would weigh about 450
UBC Rocket student team provides a professionally organized
pounds empty and 1800 pounds when loaded with propel-
way for the students to gain valuable aerospace and engineer-
lants. As part of designing and building the rocket, the project
ing experience.
required in-house creation of a custom propulsion system, the most complex part of the rocket. About a dozen students focused entirely on designing and
Actually launching the rocket is the ultimate goal for the team, but like any large project, this one is organized from smaller projects. The rocket engine test stand is one essen-
manufacturing evolving generations of the rocket engine,
tial piece of the larger rocketry project, with every element of
machined and assembled out of steel and aluminum parts.
the program critical to overall success. Much of the math and
Once each propulsion system was developed, the team
science behind rocketry is covered in the classroom, but for
needed to test the engine control, functionality and perfor-
real-world implementation the students would need to learn a
mance on the ground, so they could verify the overall rocket
lot on the job.
design before flight. This meant developing and qualifying
A few team members were assigned to find out the require-
some form of test stand and associated automation to control
ments for controlling the rocket engine, and to then specify and
and monitor test runs.
design control hardware and software to create the necessary
After some initial research, the team realized that control-
test stand system.
ling and monitoring a rocket engine on the ground was much like operating an industrial machine. This led them to conclude
It is rocket science
that a programmable logic controller (PLC) platform would be
For the team’s rocket, the engine size was specified early
38 / January 2020 / ControlDesign.com
(Source: AutomationDirect and UBC Rocket)
A hot rocket test stand Figure 1: The rocket engine, shown here attached to the test stand, must be controlled to carefully combine and ignite liquid oxygen and kerosene while monitoring results.
in the design. The liquid propellant engine combines liquid
already knew that PLCs and other industrial devices like control
oxygen with kerosene and a source of ignition, with the result-
valves and sensors could do the job if they selected the right
ing combustion developing about 3400 pounds of nominal
parts and programmed them properly. Here’s how the team
thrust. At full power, the engine consumes about 15 pounds
specified the required hardware and software.
per second of the fuel and oxidizer propellants combined, with the combustion chamber operating at about 200 pounds per
Control of real-world science
square inch of pressure.
After some initial investigation, the team targeted Automa-
The test stand would need to remotely, reliably, and safely
tionDirect products for the PLC platform, with the Automa-
control the engine for a test run (Figure 1). It also monitors and
tionDirect website’s features assisting in this decision. Online
stores the results of each firing for later analysis.
product selection guides quickly helped the team focus on the
Test stand automation operates valves and actuators, monitors sensors, initiates ignition, and provides various safety shutdown functions. The last item is critical because a properly
Productivity2000 micro-modular PLC platform as it had plenty of computing power, I/O options, and configuration flexibility. Selection of the Productivity2000 was reinforced by the
designed control system can recognize instrumented problems
wealth of online product documents, support information, and
within milliseconds and act to drive the system to a safe state.
training videos. Even though none of the team members had
No personnel were ever expected to be anywhere near the
ever programmed or even heard of a PLC prior to this project,
engine in operation, but the team also needed to protect the
many members were familiar with other contemporary lan-
equipment from damage.
guages such as C++ and Python.
Because the team was learning so many disciplines at once, there was a great desire to avoid re-inventing the wheel. They
Using the free software and online tutorials, the team quickly discovered how to configure and scale inputs and
ControlDesign.com / January 2020 / 39
PLCs
outputs, and create the ladder logic necessary to achieve control. This gave them plenty of confidence they could meet their goals. The team was very excited for the hands-on opportunity to work with real-world products and systems, which isn’t always possible at university. However, they needed to be mindful about incorporating the “minimum viable product”, engineering-speak for keeping it simple and economical.
Mission control The test stand design and development process evolved in several ways. Initially the design team tried using stepper motors to control valves, but they found this approach to be difficult and unable to provide the necessary feedback. They moved to using pneumatically actuated valves and electric solenoid valves, both easily interfaced with the PLC via relays. As development continued, more valves were progressively automated, eventually reaching a total of 12. For instrumenting the test stand and rocket engine, temperature and pressure sensors sourced from AutomationDirect were specified for the necessary ranges and service. Industry-standard 4 to 20 mA signals ensured straightforward connection to the PLC and provided reliable signals. (Source: AutomationDirect and UBC Rocket)
Core automation elements were assembled into a control panel mounted onboard the test stand (Figure 2). The team designed and fabricated the control panel using a variety of hardware and cables obtained from AutomationDirect. Test stand operation encompassed several types of functionality including: • valve control
Rocket control center Figure 2: The team designed, fabricated, and wired a control panel mounted onboard the test stand, featuring a PLC with connector cables installed at the top.
40 / January 2020 / ControlDesign.com
• ignition • auto-abort • status and data logging.
Figure 3: The test stand is remotely monitored by team members.
sequentially open to mix fuel and oxygen
anomaly will abort operation, driving
machine interface for monitoring and
The team developed a human-
in the igniter, a small chamber which
all valves closed and other devices to
control of test operations from a remote
shoots a flame into the main rocket
their safe state. The team has experi-
operating location, and also used video
engine. Following this, the PLC outputs
enced engine startup sequences that
recording (Figure 3). Complete valve
a 4-20mA signal to precisely command
were abnormal and the test was reliably
control is generally achieved through
positions of the main propellant valves
shutdown each time by the PLC.
timing sequences programmed into the
with better than 1° of precision as they
PLC so all actions can be performed re-
follow a pre-programmed profile to
and instrument data are data logged to
peatably and precisely once triggered by
ensure smooth engine startup. Once the
the PLC’s built in webserver. This allows
the operator. For a typical test session,
propellants enter the engine’s combus-
quick, remote access of data for export
an operator remotely actuates valves
tion chamber they mix and are ignited by
in CSV format after the run so the team
while a technician performs the propel-
the igniter, which is then shut off.
can perform more detailed analytics us-
lant filling. Once propellant tanks are
For each test run, all device status
As the test reaches completion the
ing other PC-based software. Being able
filled, the technician joins the operator
main propellant valves close and are
to remotely access the data from within
in the control bunker where they set the
followed by a sequence of valves auto-
the safety of a control bunker enables
test parameters.
mated to inject inert gas into the engine
the team to efficiently run back to back
and surrounding area to clear any
engine tests.
Before a test can begin, the PLC enforces that all valves are in the correct
residual propellants and suppress any
state. The operator initiates a test and
small fires. Closely tied with the normal
3-2-1 ignition
the PLC takes over automatic control of
valve and ignition functionality is the
In 1961 as the Mercury Freedom 7 launch
valves where timings are scheduled with
complementary auto-abort logic. The
experienced delays, an exasperated Alan
millisecond precision. To begin, valves
program is configured so any sensed
Shepard is said to have barked “light this
ControlDesign.com / January 2020 / 41
(Source: AutomationDirect and UBC Rocket)
Mission control HMI
PLCs
the UBC Rocket team to rapidly develop a reliable automation platform. It also gave them the ability to readily adapt the system to new and changing requirements. For instance, the team was able to progressively transition manual valves (Source: AutomationDirect and UBC Rocket)
over to automatic valve control. They also upgraded the propellant valves to pneumatic valve positioners, enabling them to throttle flow rates during key startup sequences. Currently the test stand is trailer-borne, but upcoming construction phases are adapting the design to fit in a shipping container, with more automation for fire suppression
Ignition
and propellant filling.
Figure 4: The testing regimen progressed from dry cycling, to water tests, to ignition tests, to the final live fire operation.
UBC Rocket team members began the project with plenty of passion, but perhaps somewhat less hands-on expe-
candle” to mission control. However, any
tiple fully operational test sessions,
rience. They were enthused to find how
rocket program has extensive tests lead-
with five total firings. All systems and
AutomationDirect systems and support
ing up to the proverbial candle lighting
automation elements have operated
helped them build skills and produce a
moment (Figure 4).
consistently and as expected.
reliable automation solution. The team
The UBC team members extensively
repeatedly found that AutomationDirect
and progressively tested their rocket
A platform for the future
offered the wide portfolio of products
engine test stand to ensure proper
Choosing and implementing commer-
they needed, suitable for the difficult
operation. Hundreds of test runs were
cially available AutomationDirect PLC
field operating conditions, at a good
performed, first operating dry to just
controls and instrumentation enabled
price point.
exercise the controls and the equipment. Later the systems were operated with water so certain control and monitoring could be safely achieved without introducing propellants. Because reliable ignition is a must, the team next performed over 60 igniter tests before ever filling the system’s supply tanks with propellants. Finally, the team conducted a series of cryogenic checks where the liquid oxygen plumbing was tested with liquid nitrogen to ensure that all sensors and valves operated nominally when exposed to cryogenic temperatures. Eventually the team performed
The UBC Rocket team includes more than 100 students, with more than a dozen on the Spaceshot project forming the propulsion testing group and tasked with developing the
actual and complete live fire tests. As
rocket engine test stand. This case study was authored by Simon Bambey, team lead, and
of this writing, there have been mul-
Griffin Peirce, propulsion testing lead.
42 / January 2020 / ControlDesign.com
product roundup
CONTACT US
[email protected]
A sense of purpose Make production more effective and safer with presence sensing TOF photoelectric sensors
multiple sensors to be installed close to one another without
E3AS series reflective-type photoelectric
the risk of cross talk, enlarging the overall detection area.
sensors use a time-of-flight (TOF) detec-
Configuration software is available with an easy-to-use graphic
tion method to maintain stable detec-
interface that allows users to install, maintain and perform
tion without being influenced by varying
soft adaptations on the sensor quickly and efficiently.
sensing distances, colors, materials or
Telemecanique Sensors / www.tesensors.com
surfaces. They have a sensing distance of 1,500 mm, and the full sensing range of 50 application. The sensors also have an antifouling coating on
Ultrasonic sensor with wide detection range and minimal dead band
the sensing surface to reduce false detection and minimize
The 31-mm-high UC-F77 sensor has a short dead band and a
maintenance needs in environments with oil, dust or steam.
detection range of up to 800 mm. Its simple configuration can
Omron Automation Americas / automation.omron.com
be carried out on the device itself or with the parameterization
to 1,500 mm eliminates the need for different sensors for each
software PACTware. The sound beam width can be calibrated based on the application at hand and suppresses false targets.
Capacitive proximity sensors with potentiometer adjustment
The sensor also provides an automatic synchronization feature.
These capacitive proximity sensors allow sensing of metal
nated without any external intervention,
and nonmetal objects through insulating materials such as
and the devices can be operated in prox-
wood or plastic and can be used to sense fill levels of liquids
imity to each other. An IO-Link interface
The ultrasonic pulses of as many as 10 sensors can be coordi-
or powders. The 18- and 30-mm
allows access to diagnostic data and
sensors have a simple potenti-
additional communication options.
ometer sensitivity adjustment.
Pepperl+Fuchs / 330-486-0002 / www.pepperl-fuchs.com
Operating voltages are 10 to 30 Vdc; shielded and unshielded versions and NO or NC units also
IP69K-certified capacitive proximity sensors
are available. CK2 series 18-mm
The CA18CA and CA30CA series capacitive proximity sensors
sensors carry IP65/IP67/IP69K ratings and provide an unshield-
are well-suited for automation applications in which sensor
ed sensing distance of up to 15 mm, while 30-mm dc-powered
flexibility or sensing performance needs to be monitored and
CT2 series sensors have metal (IP65-rated) or plastic (up to
logged constantly and accurately. The
IP69K-rated) housings with sensing distances up to 25 mm.
sensors are housed in Ecolab-approved
AutomationDirect / 800-633-0405 / www.automationdirect.com
IP69K-certified housings. An IO-Link communication mode enables functionalities such as quality of run (QoR),
Ultrasonic sensors for mobile equipment, material handling and conveying
quality of teach (QoT) and diagnostic parameters. With IO-Link sensor communications, each sensor
The OsiSense XX ultrasonic sensor has a detection
becomes fully programmable and customizable, allowing more
range of up to 1,000 mm, is available in a straight or
than half a million setting combinations. Other features include
90° head M18 cylindrical format and is E2-certified. Its
programmable sensing distance and hysteresis; single point, two
tilt angle and high sensitivity help to detect challeng-
point and window sensing modes; configurable input/output;
ing targets, even those previously troublesome to ultra-
and standard, plastic or level application modes.
sonic technology. A synchronization feature enables
Carlo Gavazzi / 847-465-6100 / www.gavazzionline.com
ControlDesign.com / January 2020 / 43
product roundup
Type 4 safety light curtain
integration. The sensors can be read and configured with a
Banner Engineering’s SLC4 safety light curtain
smartphone or tablet connected via Bluetooth.
protects small machine openings without re-
VEGA Americas / www.vega.com
stricting the operator’s normal motion. It comes with simple mounting and machine integration. Made primarily from polycarbonate, it is
Opposed-mode photoelectric sensor
sturdy enough to resist damage from contact
The QS18 Expert opposed-mode sensor
with parts being loaded or unloaded. Features
with IO-Link is a compact photoelec-
include a 2-m range, 14- and 24-mm resolutions,
tric sensor with infrared and visible
IP65 rating, a Type 4 safety level and defined
beam emitter/receiver pairs with a
areas from 160 to 320 mm in 80 mm increments.
range of 20 m (66 ft). Ambient light
Newark / www.newark.com
immunity prevents unintentional triggering and keeps the sensor from being tricked by ambient light sources, such as a lightbulb, flashlight
Reflex array sensors for polybag and flexible packaging detection
or other light-emitting industrial sensors. Optical synchroni-
RAY10 and RAY26 photoelectric sensors work with a 2-D light
channels so that three sensor pairs can be mounted side by
band that allows them to detect flat and location-tolerant
side with no cross talk. Teach and Set methods ensure optimal
objects on conveying systems. The compact RAY10 and the
gain and threshold for all applications, especially for high-
performance-oriented RAY26 are specialized for different
speed or partial beam block (low-contrast) applications.
installation and detection conditions.
zation allows each sensor to be set to one of three frequency
Banner Engineering / 888-373-6767 / www.bannerengineering.com
Instead of emitting a single beam of light, RAY10 sensors generate a 25-mm band—or array—of light
IP68 magnetic sensor
that hovers just above a conveyor or
The BIM-UNT magnetic sensor has been redesigned and has
sorter’s surface. The RAY26 emits an
an IP68 rating. The LED window has been removed to increase
even larger band of light at 55 mm
visibility and limit the point of ingress. As the sensor
to detect objects of varying heights.
is just 19.7 mm long, it is suitable for use in
This span of unbroken, continuous light allows the sensor to
pneumatic cylinders to move pis-
detect the position and location of the leading edge of an ir-
tons. This design also can be
regularly shaped object or part.
used in wet environments.
Sick / www.sickusa.com
Turck / www.turck.com
Compact pressure sensors with customizable ring color
Inductive sensors for harsh conditions
VEGABAR compact pressure sensors with switch function
The Sick inductive sensor portfolio is designed to perform
allow all sensor states to be seen from any direction. The il-
well under harsh conditions and includes speed and accelera-
luminated ring can be customized with one of 256 different
tion monitoring, 1%
colors, all of which remain clearly visible even in daylight. At a
hysteresis, IO-Link-
glance, users can see whether the
programmable sen-
measuring process is running, the
sors and safe position
sensor is switched, or any sensor
monitoring. Other fea-
management is required. IO-Link
tures include an IP69K
protocol ensures universal commu-
rating, 7,000 psi, 150 g shock resistance and chemical resistance
nication, so users receive seamless
to cutting fluids and solvents.
data transfer and simple system
Motion Industries / www.motionindustries.com
44 / January 2020 / ControlDesign.com
CONTACT US
[email protected]
product showcase
LVDT sensors for valve position monitoring
with threaded and quick-
These ac-operated LVDT position sensors are available in high-
locking metric connectors
temperature, miniature and hermetically sealed designs and
from other manufacturers.
are well-suited for valve applications. They enable accurate
The cable connectors have
monitoring and control of gas turbine valves that regulate the
a vibration spring, making
flow of fuel through different components of a gas turbine. By
them vibration-resistant up
knowing the posi-
to 20 g. They are rated for IP66/68.
tion of microfuel
Phoenix Contact / 800-322-3225 / www.phoenixcontact.com
valve openings, operators can operate turbines with mini-
Metal and nonmetal industrial enclosures
mal wasted energy.
Hammond Manufacturing enclosures are available in a variety
When implemented
of metals and nonmetals. The enclosures are rated NEMA 1,
as part of steam power plant rehabilitation projects, the sen-
3, 3R, 3S, 4, 4X, 6, 6P, 12 or 13 and are available in wall-mount,
sors can be used in a control system to monitor the position of
floor-mount and freestanding form factors. NEMA 1 enclosure
modulating governor and throttle valves. They also can moni-
units are suitable for basic
tor valve position at petrochemical plants.
protection. NEMA 12, NEMA
NewTek Sensor Solutions / www.newteksensors.com
4/12, NEMA 4 and NEMA 4X enclosures are gasketed to add a significant amount of protec-
Compact angle sensors
tion for indoor or outdoor use.
The Vert-X 1600 sensor series measures angular position in a
Enclosure types and styles
compact 16-mm-diameter housing base. These sensors convert rotational angle into an analog or digital output. Measurement
include wall-mount enclosures, junction boxes, pushbutton enclosures, floor-mount and
range is 0 to 360° with 14-
freestanding enclosures, disconnect enclosures, consoles and
bit resolution and repeat-
consolets and wireways and wiring troughs. Door and window
ability of 0.1°. Available
configurations and latch/lock options are available.
analog outputs are 10 to
AutomationDirect / 800-633-0405 / www.automationdirect.com
90% of supply voltage and 5 to 95% of supply voltage. Digital interface options
Fieldbus couplers for I/O system
include SPI and PWM. The
The 750-363 EtherNet/IP fieldbus coupler has
sensors are sealed to IP65, life is ≥ 50 million movements, and
a fast boot-up time that enables systems
MTTF is 668 years. Redundant versions of the sensor are avail-
to get online more quickly. Firmware
able. A 6-mm D-shaped shaft and two reinforced through-holes
updates can be accessed using the
enable easy mounting.
couplers’ onboard Web-based manage-
Novotechnik U.S. / 508-485-2244 / www.novotechnik.com
ment system. The coupler can be paired with Wago’s 500+ I/O modules to meet the needs of any I/O application. It sup-
Quick-locking circular connectors
ports a variety of protocols such as HTTP(S),
M23 PRO circular connectors offer uniform solutions for signal
BootP, DNS, SNMP and FTP(S). Other features
and power transmission. The OneClick quick-locking sys-
include dual Ethernet ports, eliminating the need for switches
tem makes it easy to connect devices quickly and safely. The
or hubs; support of as many as 250 I/O modules; and add-on
system enables users to see, hear and feel when the connec-
instructions to simplify the integration with Allen-Bradley
tion is made, ensuring that connectors are fully locked. The
master controllers.
connectors, available in M23 up to 17 positions, are compatible
Wago / 800-din-rail / www.wago.us
ControlDesign.com / January 2020 / 45
product showcase
Low-power prototyping board
control of output voltage/current, constant power limit and
The RL78/G14 fast prototyping board is a function-rich board to
arbitrary waveform generation. All models have three ac input
enable rapid product development for IoT endpoint equipment.
options, including a single-phase 230-Vac input (with 0.99 PF),
Users can combine
a three-phase 208-Vac input (with 0.94 PF) or a wide-range 400-
it with the RL78/G1D
/480-Vac input (with 0.94 PF) as well as conversion efficiencies
BLE module expan-
as high as 90.5%.
sion board to add
TDK-Lambda Americas / 800-lambda-4 / www.tdk-lambda.com
Bluetooth low-energy wireless communication functions. The
Compact safety magnetic sensors
prototyping board is
The MC36C series of compact safety magnetic sensors can be
based on the RL78/G14 microcontroller (MCU), which provides
used to monitor swinging, sliding or removable safety guards,
a rich set of functions in the low-power RL78 family, making
which keep personnel safe from dangerous areas, and to
it well-suited for motor control in portable equipment and IoT
monitor the position of sliding,
sensors, as well as industrial equipment.
hinged and removable safety
Renesas Electronics / renesas.com
guards, especially in dirty and dusty environments. The magnetically coded REED sensors
IP66 cable entries for all shapes and sizes
have a wide actuation range,
The tool-less KDS and KES cable entry systems enable easy
making them suitable for use in
routing and flexible rearrangement of cables and conduits
applications in which great tol-
in enclosures and control
erances are required, such as with safety gates or doors that
cabinets, with reliable strain
are aligned imprecisely. The sensors can work standalone or
relief and IP66 ingress protec-
in conjunction with a safety module to reach a safety category
tion. One-piece KES plates with
4, according to EN ISO 13849-1.
push-through membranes
Carlo Gavazzi / 847-465-6100 / www.carlogavazzi.com
enable high-density routing of as many as 32 unassembled cables, wires or conduits. The multipart KDS system features
Firmware with additional visualization and storage options
a frame that always can stay in place once it is installed. Re-
Groov Epic version 1.5.0 increases visualization and storage
movable sealing elements in different sizes can be inserted to
options to suit a wider variety of applications and hardware.
change the assembly as needed.
The embedded View server has been updated to version 4.2, with functions to create more
Conta-Clip / 732-564-0705 / www.contaclipinc.com
dynamic web and mobile HMIs, dashboards and Andon
Full-rack ac/dc programmable power supplies
boards. Shape gadgets allow
Ten models are available in the 1U full-rack Genesys 2.7-kW ac/
users to create custom SVG im-
dc programmable power supply series ranging from 10 V-265
ages and animations directly
A to 600 V-4.5 A. Built into a lightweight 19-in-wide (483-mmwide) rack-mountable chassis, the series offers five embedded
46 / January 2020 / ControlDesign.com
in View and to dynamically change their color and size (height and width) based on process
front-panel setup menus
variables or any other data source connected to the firmware.
with user-selectable
This version also introduces tag-driven conditional formatting
functions that include
for other gadgets, allowing users to make elements visible or
internal resistance
invisible, as well as change text color and formatting.
simulation, slew-rate
Opto 22 / 951-695-3000 / www.opto22.com
Position control hinge
gearheads have many
The E6 one-way constant torque hinge enables heavy doors
gear ratios with uni-
and panels to be lifted more easily by removing friction from
form distribution. As
the hinge in one direction, while providing high torque to hold
a result, motor power
them securely in place. The hinge provides reliable position-
can be used optimally:
ing with consistent operating efforts, eliminating the need for
a higher torque can
secondary support components such as gas struts and door
be achieved with the
stays to hold doors or panels in position. It also offers hold-
same input speed, and
open functionality that prevents it from closing on the user. Sealed for outdoor
a higher speed can be achieved with the same torque. Faulhaber Micromo / www.faulhaber.com
use and constructed from corrosionresistant materials, the hinge offers increased longevity and requires no
High-power-density outer-rotor brushless motor
maintenance or adjustment over the
The KinetiMax high-power-density series of outer-rotor
lifetime of most applications.
brushless motors is designed for high-torque, low-cogging applications. With an
Southco / 610-459-4000 / southco.com
efficiency rating of more than 85% and a
HMI for IIoT edge applications
high power-to-weight
Exor’s eX700 series combines a high-performance sunlight-
ratio, it’s suitable any
readable display with connectivity options such as OPC UA.
application in which
The product range also includes a controller with networking
weight and battery
capability. The HMIs are well-suited for demanding IIoT edge
life are critical. The series is offered in compact stator-rotors
applications in extreme environments. The glass-projected
sets. The motors are available in six frame sizes, with three
capacitive touchscreen and the 7-in widescreen display with
stack-lengths per size and three windings per stack length. The
800x480 resolution are bonded for high optical performance
series also features a large stator bore that allows cabling to
and resistance in such environments. The products run
pass through easily for applications such as robotic joints. The
JMobile software. JMobile runtime is
temperature sensor is mounted on the stator, and a Hall com-
included and requires JMobile V2.8
mutation board is available.
or higher. The HMI supports Corvina
Allied Motion / www.alliedmotion.com
Cloud secure connectivity with full network separation. CoDeSys V3 runtime is available with a choice
Industrial box thin clients
of EtherCAT, Profinet, Ethernet/IP
Designed to withstand high temperatures, shocks and vibra-
and Powerlink.
tions over long periods, the BTC14 industrial box thin client
Servo2Go / 877-378-0240 / www.servo2go.com
has four digital uniform DisplayPorts, enabling processes to be visualized on up to four Ultra-HD (4K) screens, thus giving an optimal overview of all information. Additional mounting
GPT gearhead family with numerous gear ratios
kits and a rugged design allow it to be installed in a num-
The metal GPT planetary gearhead family offers compact
ber of ways. The preinstalled VisuNet RM Shell 5 firmware
dimensions, high torque and fine graduations of numerous
simplifies both virtualizing host
gear ratios. The gearheads tolerate frequent and sudden load
systems and perform-
changes and operate with high efficiency, can be combined
ing quick and intuitive
with different motors and enable various shaft configurations.
configuration.
They are available with diameters of 22, 32 and 42 mm and
Pepperl+Fuchs / 330-425-3555 /
can be equipped with as many as four reduction stages. The
www.pepperl-fuchs.com
ControlDesign.com / January 2020 / 47
product showcase
Multiturn absolute kit encoders
film coating, gaskets for mechanical joints and an integral
The Posital miniature multiturn kit encoder for integrated
10-ft shielded cable that offers protection against the ingress
motor feedback has a 22-mm diameter and is 23-mm high (0.87
of dust and resistance to low-pressure waterjets. For improved
in/0.9 in). It features a self-powered
protection in high-humidity environments, an advanced coat-
rotation counter that eliminates the
ing is available as an option. The motors are available in NEMA
need for backup batteries or com-
sizes 23, 24 and 34. A double-shaft version is available with an
plex gear systems. The encoders are
optional IP65-rated encoder for applications requiring feedback.
designed for builders of servomotors,
Applied Motion Products / 800-525-1609 / www.applied-motion.com
feedback-controlled stepper motors, microdrives, miniature robots and other machines in which high-precision
Expandable vision controller
position feedback is required and space is at a premium. They
The 4Sight XV6 expandable vision controller is designed to
offer 17-bit electronic resolution and a multiturn measurement
handle intensive vision applications on the factory floor and
range of up to 32 bits. Vendor-neutral SSI and BiSS C interfaces
provides expansion capabilities for video acquisition. Powered
are supported.
by an eighth-generation Intel Core processor, the controller can
Electromate / 877-737-8698 / www.electromate.com
support intensive machine vision applications. It offers desktoplevel processing performance with support for as many as three displays, whether VGA, DVI-D, HDMI
Harsh application I/O modules
or DisplayPort. It features four full-
Allen-Bradley ArmorBlock I/O modules can operate in a range
height, half-length expansion slots
of temperatures and offer up to IP69K protection in harsh
for accepting frame grabber PCIe
applications. The modules can be mounted anywhere on a
cards operating at full performance.
machine for shorter cable runs. They use nickel-plated zinc die-
It pairs readily with Matrox Imaging
cast housing, have QuickConnect
frame grabbers to deliver customized video capture solutions for
functionality and offer diagnostics
Camera Link, CoaXPress, GigE Vision with Power-over-Ethernet
in an EtherNet/IP universal digital
(PoE) support, DisplayPort, HDMI and SDI interfaces.
I/O block to reduce commissioning
Matrox Imaging / www.matrox.com
and troubleshooting times. Three IO-Link hub blocks help reduce design complexity by allowing more
Temperature controller with smooth-touch keypad
devices through the IO-Link master. An M12 L-coded power
The PM Plus temperature controller has a bright, full-color
connector on selected blocks supports higher current, allowing
front-panel display with easy-to-read characters and color-cod-
more blocks to be daisy-chained.
ing, making the display visible from many angles. It also has a
Rockwell Automation / www.rockwellautomation.com
smooth-touch keypad, which eliminates rubber buttons that can wear out from use and harsh environments. The keypad also eliminates contamination points and creates a better seal
IP65-rated stepper motors for wet and dusty environments
on the front of the controller. It is backward-compatible with
These IP65-rated stepper motors are dustproof and resistant to
fers user upgrades such as an intuitive
water pressure impact, mak-
menu flow that allows the controller to
ing them well-suited for use
be configured easily. It offers Bluetooth
in wet and dusty applications.
connectivity with the EZ-Link mobile
Using advanced seal protection
app for remote access capability and
technology, the motors feature
full descriptions of parameters and
sealed laminations, an oil shaft
error codes.
seal, internal corrosion-resistant
Watlow / www.watlow.com
48 / January 2020 / ControlDesign.com
legacy EZ-Zone PM controllers but of-
The only magazine exclusively dedicated to the original equipment manufacturing (OEM) market for instrumentation and controls—the largest market for industrial controls.
1501 E. Woodfield Rd., Suite 400N
Wire-actuated encoder The SG121 wire-actuated encoder is suitable for measuring lengths up to 12
Schaumburg, Illinois 60173 630/467-1300 Fax: 630/467-1124
m. Its robust aluminum housing is coupled with impact-resistant plastic, so it survives harsh operating conditions. It can handle temperatures between
publishing team
-40 and 80 °C, high shock and vibration loads, dirt, dust and water. For
group publisher & vp, content
outdoor applications in low temperature ranges, a version with integrated
Keith Larson
[email protected]
water drain holes also is available. This prevents water that has penetrated
vp, sales & publishing director
the sensor from freezing at below-zero temperatures. The flexible 58-mm flange system can be used with almost any interface, be it an incremental or absolute interface.
sales team
Siko / www.siko-global.com
northeastern and mid-atlantic regional manager
Dave Fisher
[email protected] 508/369-6330 Fax: 508/543-3061
High-force linear voice coil motors
24 Cannon Forge Dr.
These high-force linear voice coil motors have an internal shaft and bearing. The three motors in
Foxboro, Massachusetts 02035
the GVCM-095-089 series features the same housing, measuring 3.5 in (88.9 mm) long by 3.75 in. (95.3 mm) diameter and the same threaded mounting holes for easy integration into new and ex-
midwestern and southern regional manager
isting applications. The GVCM-095-089-01 features a 2.5-in (63.5-mm) stroke
Greg Zamin
[email protected]
and a continuous force of 25 lb (111.2 N). The GVCM-095-089-02 features a 1-in
704/256-5433 Fax: 704/256-5434
(25.4-mm) stroke and a continuous force of 58 lb (257.7 N). The GVCM-095-089-03
1501 E. Woodfield Rd., Suite 400N
features a 0.5-in (12.7-mm) stroke and a continuous force of 63.9 lb (284.1 N).
Schaumburg, Illinois 60173
Moticont / www.moticont.com
western and mountain regional manager
Jeff Mylin
[email protected]
High-bus-voltage stepper drives and motors SureStep high-voltage ac drives are available with compatible hightorque motors. The drive is powered from 90 to 240 Vac and is intended for use with step motors designed to handle a high bus voltage of 340 Vdc. MTRAC motors are specially designed to work with high bus voltages, providing higher torque, especially at higher speeds. Stepper drive auto-setup measures motor parameters and configures motor current control and antiresonance gain settings. The drive uses ac input of 90 to 240 Vac. Output current is selectable from 0.6-2.5A/phase (peak of sine). Motors are available in NEMA frame sizes 23 and 34 with torque available from 75 to 1,841 oz-in.
847/516-5879 Fax: 630/625-1124
digital sales specialist
Jeanne Freedland
[email protected] 805/773-4299 Fax: 805/773-0451
classified manager
Lori Goldberg
[email protected] 630/467-1300 Fax: 630/467-1124
AutomationDirect / 800-633-0405 / www.automationdirect.com
executive staff
Power supply with remote monitoring capability The TPS4000-24 power supply delivers up to 4,080 W of output power (24 V at 170 A) in a 2U high
president & ceo
John M. Cappelletti cfo
package. It operates from a wide-range Delta or Wye 350–528 Vac three-phase input. The high-
Rick Kasper
voltage input avoids the requirement for step-down transformers and assists phase load current
vp, creative services, production
balancing. It is fully featured with isolated ac fail, dc good and dropped-phase signals, remote
Steve Herner
on/off, remote sense and a 12-V 0.3-A standby supply. A PMBus communications interface allows remote monitoring of the output voltage,
reprints
output current, internal temperature, status signals and fan speed. In
Foster Reprints • www.fosterprinting.com
addition, the output voltage, overcurrent limit and the remote on/off
Jill Kaletha
can be programmed by the PMBus.
[email protected]
TDK-Lambda Americas / 800-lambda-4 / www.tdk-lambda.com
866-879-9144 ext. 194
ControlDesign.com / January 2020 / 49
automation basics
Dave Perkon technical editor
[email protected]
How to ensure cybersecurity FOR EVERY CONSUMER electronic device I have, I wonder how effective its cybersecurity is, especially when I read news head-
has created with its new IoT Security Rating. “This IoT Security Rating provides a suitable and purposeful
lines such as “Amazon Ring hacker accesses camera in child’s
solution that meets a baseline level of security,” says Lamber-
room.” The hacker could see, hear and talk to a little girl. So, it’s
ink. “While it doesn’t promise an exhaustive level of security
clear, a minimum amount of cybersecurity at home, as well as
on a product, it looks for must have minimum security features
on the plant floor and in the control panel, is a requirement.
that any product should have.”
According to the news article, a “spokesperson” stated that
It’s a vast market place in need of cybersecurity. “There
Ring’s overall security was not compromised. Really? I would
are more and less mature manufacturers when it comes to
have unplugged the camera, and the family did.
security,” says Lamberink. “Industry leaders have very well de-
Clearly the best defense is to not
veloped cybersecurity methods and
become a target, and no one should have to worry about being attacked. Fortunately, it is possible to learn how not to become a target and a great way to do that as a manufacturer or
have been doing it for years. There
There are those who are not even aware yet of cybersecurity or don’t know where to begin.
integrator is to get a UL IoT Security
are those who are not even aware yet of cybersecurity or don’t know where to begin. In many cases, there are many products where security is lacking—it’s low-hanging fruit for
Rating. It’s the minimum required.
hackers.”
Whether it’s consumer tech products or industrial control
The UL IoT Security Rating is a leveled approach with five
systems, the demand for a reliable and secure IoT connection
levels from absolute minimum baseline to increasing levels of
is required. I talked with Gonda Lamberink, cybersecurity
requirements. “There is a need for an absolute floor and a need
senior business development manager at UL about UL’s newest
for manufacturers to start differentiating with UL labels for dif-
safety baseline for manufacturers and retailers.
ferent levels,” says Lamberink.
According to UL, it is the first organization to offer conformi-
This UL rating can potentially apply to industrial control pan-
ty assessment for all key security frameworks and a consumer
els. However, some of the end customers in the industrial market
labeling system to convey the level of security protection pro-
may have security requirements that go beyond UL’s highest rat-
vided to connected products. UL’s new IoT Security Rating solu-
ings. Because of that, UL provides certification for other security
tion evaluates critical security features of connected products
solutions including IEC 62443, a series of standards to address
against common attack practices and known IoT vulnerabili-
and mitigate security vulnerabilities in industrial automation
ties, to help make product security transparent and accessible
and control systems.
to consumers through UL’s Verified Mark.
The bottom line is control systems need cybersecurity. The
I used to work at a UL508 panel shop, and this UL mark is a
IoT Security Rating requirements are published in UL MCV 1376,
great label to place on a control panel. It shows it’s a quality and
which documents the five tested and certified secure-by-design
safe panel. What UL has seen over the past several years is an
levels of security capabilities that can be applied to many applica-
increasing interest in cybersecurity coming from manufactur-
tions. It documents the many base line options for verification of
ers across the board as any device with wireless connectivity
security capabilities such as software updates, data and cryptog-
is a potential target for cybersecurity hackers. Over the past
raphy, logical security, system management, customer identifiable
couple years there has been an increasing focus on preventing
data, protocol security, and process and documentation.
large-scale attacks, such as denial of service using botnet. All manufacturing facilities and control system integrators
“UL has also published a whitepaper titled IoT Security Top 20 Design Principles,” says Lamberink. “Most of these principles
must include at least a minimum amount of security. It’s not
have been translated into the requirements for the formal IoT
just security for critical infrastructure in an industrial complex
Security Rating assessment. It’s a good source for a quick sum-
but across the board down to the device level, which is what UL
mary of must-have security practices and principles.”
50 / January 2020 / ControlDesign.com
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