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Volume 24, No. 2

table of contents

FEATURES

30

cover story

Designed to deliver Machines comprise components, and the automation supply chain really delivers for designers Rick Rice, contributing editor

24

machine input

Put your information in lights Operators and floor managers can get answers from stacklights

36

product roundup

Power where you need it Technology puts uninterruptible power supplies in their places

Mike Bacidore, editor in chief

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 [email protected] or call 1-800-553-8878 ext. 5020. To non-qualified subscribers in the United States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) Putman Media also publishes CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING, PHARMA MANUFACTURING, PLANT SERVICES, SMART INDUSTRY and THE JOURNAL. CONTROL DESIGN assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor information: World Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada N9A 6J5. Printed in the United States.

ControlDesign.com / February 2020 / 5

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Volume 24, No. 2

COLUMNS 9

editor’s page

13

ad index technology trends

Two partners create one focus

Make the best of an alarming situation

Mike Bacidore, editor in chief

Rick Rice, contributing editor

11

17

live wire

Simplify robots and automation

indiscrete

Smart-manufacturing goals translate into lives saved

Dave Perkon, technical editor

12

embedded intelligence

The eyes have it Jeremy Pollard, CET

table of contents

38

product showcase

42

automation basics

Document control systems in hazardous areas Dave Perkon, technical editor

AutomationDirect . . . . . . . . . . . . . . . . . . . . 2

B&R Industrial Automation . . . . . . . . . . . . 8

Beckhoff Automation . . . . . . . . . . . . . . . . . 4

Bihl+Wiedemann . . . . . . . . . . . . . . . . 28, 29

Digi-Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Dinkle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emerson Automation Solutions . . . . . . . 35

Newark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Do you know an influential woman in manufacturing? Nominate her to be part of Putman Media’s class of Influential Women in Manufacturing! For more information and to nominate someone by March 31, visit

Novotechnik . . . . . . . . . . . . . . . . . . . . . . . . 34

Opto 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Oriental Motors of America . . . . . . . . . . . 43

Phoenix Contact . . . . . . . . . . . . . . . . . . . . 33

SEW-Eurodrive . . . . . . . . . . . . . . . . . . . . . . . 3

Telemecanique Sensors. . . . . . . . . . . . . . 19

influentialwomeninmanufacturing.com Wago . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Yaskawa America. . . . . . . . . . . . . . . . . . . . . 6

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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

Two partners create one focus

Mike Bacidore [email protected] digital managing editor

Christopher Palafox [email protected]

A SINGULAR FOCUS often brings clarity and simplification to an otherwise complex is-

contributing editor

sue. When Rockwell Automation and Schlumberger combined forces to form Sensia, the

Rick Rice

two organizations easily could have run aground with added weight and a cumbersome

[email protected]

merging of cultures. But the recipe for the partnership included 500 people with automa-

contributing editor

Tom Stevic

tion expertise and 500 people with field-operations expertise, putting their minds to work

[email protected]

exclusively on oil-and-gas-industry optimization. “We are the unification of sensing, intelligence and action,” explained Neil Enright, vice

editorial assistant

Lori Goldberg

president, sales and marketing, at Sensia. “We’ve adopted a philosophy of simplicity. We

[email protected]

provide a solution at its base form to release value in our customers.”

columnist

Sensia has brought together about 1,000 professionals, operating with 11 legal entities

Jeremy Pollard

and a presence in more than 80 countries to combine competencies and create irreducibly

[email protected]

simple solutions.

design/production

“In the oil-and-gas industry,

senior production manager

Anetta Gauthier

automation has existed for a long

senior art director

time,” explained Enright. “We’ve

Derek Chamberlain

been providing automation across the value chain for many years. We

subscriptions

have installed systems, but there are

1-800-553-8878 ext 5020

islands of information. Sensia is able

email: [email protected]

to connect those isolated systems

circulation Industrial machinery manufacturing • Machine tools & metalworking

17,856 4,662

• Fluid handling & Conditioning

1,614

• Heating & cooling equipment

1,231

• Material handling & conveyance

1,230

• Power generatino & transmission

938

• Packaging machinery

718

• Other specialized machinery

7,463

Discrete & hybrid manufacturing

5,591

• Computers & electronics

2,199

• Food & beverage manufacturing

1,960

• Fabricated metals

905

• Pharmaceuticals & medical devices

696

• Transportation equipment

273

• Other manufacturing Engineering & integration services

Customers want not only increased production with reduced costs.

2,395 10,879

Other 2,857

for productivity gains.” The oil-and-gas market is facing numerous challenges, including price volatility, lack of available talent in geographic areas and desires to increase capacity while decreasing the capital to do it, said Enright. The same can be said for discrete manufacturing. Sensia’s customers want not only increased production with reduced costs, but they also want accelerated time to first oil, maximized use of existing assets and improved safety, he explained. “Automation is critical to facilitating the journey of digital transformation,” said Enright. “To enable that, we can provide data from disconnected systems to operators and help them to deploy the correct resources or improve the process. We have the capability to deliver process-manufacturing solutions.” Automation solutions, measurement solutions, digital solutions and lift-control systems are the core of Sensia’s offerings, putting intelligence into action via a four-stage process: sense, think, control, optimize. This can be applied to discrete manufacturing. “We take sensor information and analyze it using domain expertise,” said Enright. “We manage the process, and we continually improve performance. To create an insight is one thing, but you must create an action from the insight.”

TOTAL40,020

ControlDesign.com / February 2020 / 9

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live wire

Dave Perkon technical editor [email protected]

Simplify robots and automation AS MANUFACTURERS OF ALL TYPES PLAN, define and commis-

it out while the customer’s production suffers. The result is the

sion machine automation on the plant floor, there are many

system gets put in a bone yard. It’s painful when we hear those

things to consider. Not only must the machines hit the ground

stories, and it can set automation back years.”

running after the factory acceptance test, but they should be

The machine control systems are one of the keys to keeping

simple to support now and in the future. Changes in personnel

things supportable and simple, and the use of a PLC can lead

and product requirements will demand it.

the way. “PLC-centric integration simplifies control of motion

To ensure machines meet productivity, performance and qual-

and reduces intimation of the end user while easing long-term

ity requirements, there are some key things the machine build-

support of an integrator-designed robotic machine,” says Chris

ers, integrators and/or end users need to know about selecting,

Elston, chief robotics manager at YRG (www.yrginc.com), a mas-

integrating and commissioning robotic

ter distributor of Yamaha Robots.

and automation systems. Both machine builders and suppliers are aware of this, and they provided some examples. “We are using Augmented Reality for Remote Support presently—this

“The fancier the control system is,

Ensure machines meet productivity, performance and quality requirements.

this has the potential to be a game changer as it lowers the need for

the harder it is for technicians to keep up and be trained on how to keep a new automation line running in the manufacturing world.” Part of a simpler machine is that robots are getting smarter. “Firm-

technical resources on both sides of the support equation,” says

ware updates to robot controllers include enhancements that

Craig A. Souser, president/CEO of J.L. Souser & Associates, Inc.

start to predict arm motor overload conditions, for example,”

(JLS, www.jlsautomation.com) in York, Pennsylvania. “As part of

says Elston. “Robot controllers can now alert maintenance

our Next Gen machines, we have worked hard to make the sys-

personnel ahead of time via email or text message when a joint

tem simpler, not just from a hardware perspective, but also ease

in a robot is experiencing increased amperage load. This condi-

of use. We have eliminated a teach pendant, typical for a robot-

tion normally indicates some kind of a mechanical resistance or

controller-based system, and now, everything is on the HMI. We

lack of lubrication that could lead to downtime if not looked at,

have greatly reduced the amount of programming that our guys

so robot control systems with built-in predictive maintenance

do in configuring a system, which not only streamlines the pro-

features that can tie into a cloud system or an IoT are realistic

cess and eliminates coding errors, but it allows our customer

trends and features manufacturing engineers should invest in

with the appropriate training to do much more on their own in

now with increasing robot life expectancies on the rise.”

areas like adding recipes or making some basic changes.” Simpler hardware, development and operation have worked

Epson is very bullish on the introductory education of robotic automation to new users. “We’re finding there is a lot of inter-

for JLS as it has gone through rapid growth. New automation

est in this topic, says Scott Marsic, product manager for Epson

personnel have not had to learn how to program robots in the

Robots (epson.com). “Automation has always been a buzz word

traditional sense. The hardware and programming architecture

within manufacturing, and yet at a baseline we always want

already exist and Souser estimates it cuts the learning curve for

our customers to really ask themselves, ‘Why do I want to auto-

basic machines and applications in half.

mate?’ and ‘What am I looking to achieve by automating?’

As an end user selecting an integrator to provide the ser-

Once these questions are understood, there is an entire

vices, the customer needs to do a good deal of vetting. “Is the

network of distributors and system integrators who can help

potential provider truly capable of this project?” asks Souser.

customers better understand their current manufacturing pro-

“Do they do any field testing or validation of tooling or motion

cesses, associated automation requirements and then potential

simulations to address needs? What is their support capacity?

solutions. This is important to know, especially if a company

We have seen many projects go to the ‘newbie’ that has under-

does not have the experience or internal support to design and

priced a system, stumbled badly, spent months trying to figure

implement an automation program themselves.”

ControlDesign.com / February 2020 / 11

embedded intelligence

Jeremy Pollard [email protected]

The eyes have it MY VERY FIRST INTERFACE with machine-vision systems was

is probably better than any human can detect. The nuances in

working with a Canadian company that wanted to use a PLC

color are lost with the human eye, but not to technology.

to automate television CRT tuning using four high-resolution

Cognex, a vision vendor, can detect color variations down

analog cameras. The cameras were on a gantry system that

to the pixel level using its color model tool. Imagine produc-

would be placed in front of the CRT, and a pattern generator

ing cosmetics and scanning for imperfections in the finished

would provide the signal to display. The PLC was to automate

product based on color tones. The surface of the product has to

the setting of the RGB guns and convergence to provide for a

be uniform to within specifications, and the vision system can

color-accurate display that was sharp.

perform this task.

It didn’t work for reasons that have slipped past my recall,

Most machines have network connectivity these days, and

but it had something to do with the

IP cameras can play an important

lack of data coming to or from the cameras to allow the PLC to perform its duties. The project was in the 1980s while I was working for Rockwell Automation.

role in machine vision. An IP camera

Cameras can detect colors in 24-bit resolution, which translates into 16 million different color variations.

Machine vision has come a long

can be placed strategically on the machine to allow the operator to see certain operational locations that would be unsafe for them see natively.

way since then. My last interface

Machine vision covers a wide

was with a Keyence image color camera, which was detecting

assortment of options from a task perspective. I am sure that

whether or not a tube had been inserted into a bag for sealing.

if you take a look at a modern day assembly system you could

Detecting the orientation of the tube meant two things. First,

identify where a vision system could be employed.

was the tube inserted far enough into the bag? And, second, the

If you think it, it can be done. A vision system can detect

tube could vary in angle by 45°. The camera had to be very fast

anything with a very high degree of resolution and accuracy.

in determining the result.

The ability to interface with control systems has been greatly

And it was and worked flawlessly. It had to evaluate color, as well. Lots to do, and it did it well. We have come a long way. In the beginning, machine-vision systems were disguised

enhanced, as well as the ability to pre-process information and deliver that information directly to HMI/SCADA systems. The ability to be networked has expanded the application base,

as barcode readers as such. Reading barcodes and QR codes is

as well as the capabilities such as machine learning, operational

child’s play today.

learning and cloud interfacing. It truly is a different world today.

Heuft makes bottle inspectors. I saw it in action at a local

I learned that the automotive industry uses color-coded glues

brewery while it was scanning bottles at 120 bottles per minute

in manufacturing processes. There is no better way to have

for foreign objects that had been left in the bottle after washing.

quality control of the glue application than to have a vision sys-

It was fascinating to watch and to understand the technology

tem monitoring the application from the robot, as well as final

behind it.

inspection once the robot is done. Redundant quality checks are

It interfaced with a PLC for bottle rejection and control. It simply compared a black-and-white image to a stock pattern, and, if there was a difference, then it rejected the bottle.

paramount with these subassemblies. The ability to see using technology has been revolutionary. The incurred costs are miniscule compared to waste and lost

What a difference 20 years makes in vision.

production due to a failed process, which can be nipped in the

Black-and-white vision can do pattern recognition easily

bud using machine vision.

enough, and today’s cameras can go far beyond that by using color for part sortation and final inspection among other tasks.

JEREMY POLLARD, CET, has been writing about technology and

Some cameras can detect colors in 24-bit resolution, which

software issues for many years. Pollard has been involved in control

translates into 16 million different color variations, and that

system programming and training for more than 25 years.

12 / February 2020 / ControlDesign.com

technology trends

Rick Rice contributing editor [email protected]

Make the best of an alarming situation SIX MONTHS OF PLANNING and engineering, eight weeks of

Here is an example of how one might deploy a stack light. In

construction, 72 hours of commissioning, and your machine is

this situation, there is an alarm horn and a series of lights in red,

finally ready for production. Despite all your best intent, you’re

yellow (or amber) green and blue. The machine/process stops and

three minutes into the first run, and your pride and joy stops

a solid horn of 3 seconds draws attention to the fact that a stop

mid-cycle. What happens next has everything to do with how

has occurred. A flashing red beacon indicates a fault has occurred.

well you designed your controls and which features you built in

A solid red light might indicate that a safety device such as an e-

to help the operator get the machine back into operation.

stop, light curtain or door switch has been activated. The absence

The first thing that you want to happen is something that draws attention to the fact that the machine or process has stopped.

of a red light would indicate that a normal, operator-initiated stop has occurred. A solid yellow light indicates that the machine is in

The prevailing method of signaling

manual mode, and a flashing yellow

a process stop is sounding an alarm, followed by a light, or series of lights, to give some preliminary information about the source of the stop. Grouped together and commonly known as a

light might indicate that the machine

Horns or buzzers are used to provide an aural signal to draw the attention of the operator.

stack light, this device should be placed prominently on your machine or pro-

is in motion while in manual mode. A solid green light indicates that the machine is in motion, while a flashing green light can indicate two different functions. If the flashing green light is accompanied by an

cess. While little has changed over the years as far as the use of a

intermittent horn in the same sequence as the flashing light, then

stack light, the technology has moved along nicely.

the machine is preparing to start in automatic mode. If the green

Early light stacks utilized full-voltage, incandescent bulbs inside

light is flashing while the machine is in motion, then the machine

modules of different colored plastic or glass. Variations of the

is running, but a downstream device is preventing the machine

method of illumination have come forth over the years, using both

from producing product. A flashing blue light might indicate that

ac and dc voltages of a common theme to match similar control

a consumable material, such as glue or cartons or pouches, is at a

voltages. The advent of light-emitting-diode (LED) technology and

low level and, if not replaced, will cause the machine or process to

more recently the LED array have brought forth a product than

come to a stop. A solid blue light could indicate that the low-level

can be seen from great distances. One advantage of LEDs is they

condition has elapsed and the machine has come to a stop. As can

don’t burn out. Incandescent bulb filaments are weakened by the

be gleaned from the description above, much can be done with

very thing they are intended to do, emit light. The constant heat-

what seems like a simple device to provide immediate informa-

ing up and cooling down that happens when voltage is applied and

tion about the status of a machine and, if stopped, gives clues as

removed causes the filament to weaken and eventually fail. Ad-

to the source of the issue and how to respond in the most expedi-

ditionally, the use of filament bulbs in a process that is subject to

tious method to restore operation.

vibration will further reduce the life expectation of the filament.

The use of LEDs in stack light technology has many benefits.

The vibration on a relatively fragile element can cause it to break

An LED produces far less heat and, as such, the package used to

prematurely. LEDs are much more resilient and stand up much

house the light source does not have to be as big since there isn’t

better to the normal parameters under which machines function.

the need to vent the heat. This implies that the light module can

Horns or buzzers are used to provide an aural signal to draw

be totally enclosed, meaning it can be used in environments that

the attention of the operator to a significant event. This could be

might be subjected to dust or water vapor. LEDs are small and,

to signal a fault in the machine or system but could also be used

as such, can be in close proximity to other LEDs. This gives the

to signify the pending startup or change in operating speed. A va-

hardware provider the option to enclose LEDs of different colors

riety of sound-making technologies have been employed over the

in the same small module. Since LEDs last much longer than

years, culminating with products that can be directional, omni-

incandescent bulbs, replacing a traditional light stack with an

directional and totally enclosed for use in harsh environments.

LED version will result in less cost and the removal of the need to

ControlDesign.com / February 2020 / 13

technology trends

maintain the light modules. Further, LED

Many automation vendors have LED

uses of the devices. Some examples of

light modules are less costly to operate as

light stack products. The popularity of

this creativity are:

they are dc-powered.

the technology has prompted creative

• multi-color signal modules in a single dome-shaped lens with or without sound • traditional light stacks with alarm modules that have pre-wired pigtail connectivity • light stacks with M12 connectivity so that the light module can be easily swapped out by simply disconnecting the cable. Due to the low power consumption with LED technology, some manufacturers have come up with wireless light stacks. These units use Ethernet or Bluetooth technology to locate light modules on a machine or process that might normally be difficult to wire. One vendor has taken a different track with their light stacks. The traditional light stack would have a somewhat transparent plastic lens in the color of the desired output. Newer LED versions went with a similar approach where the lens is the color of the intended output. In a further advance more recently, manufacturers are going with an array of LEDs backed by a reflector with the LED in the color of the output. The net result is a light stack that can be seen at much greater distances with far more contrast and illumination than ever before. The convenience of small packaging for LED devices has opened up a whole new possibility for this technology. If palmsized devices can be so easily deployed, then the inclusion of touch-sensitive devices to provide input to the process is a natural addition. The same package that provides a multi-color status light can be used for a prompt to touch device where the light turns on to signal that a response is required. The user then touches the device to provide feedback. It’s not too hard to see where this is going when a pair of these devices is tied into a control system to provide a two-handed, anti-tiedown input.

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technology trends

Taking the above device into yet another progression, the

they aren’t placed appropriately on a machine. Further, if they

quick-connect M12 technology allows for a great way to make

aren’t relied on due to poor placement, they also get ignored from

a dual redundant e-stop button with LED annunciation. One

a maintenance standpoint and often go without getting the lights

manufacturer has even taken this a bit further by lighting up

replaced when they burn out during normal operation. With the

an LED array around the e-stop button to draw greater atten-

use of LED light stacks, especially with the new, mirror-backed

tion to the triggered device. These lights, in a ring instead of a

LED array technology, a well-placed signal device becomes an

simple light on the palm button, are visible from a distance and

integral part of a control system. Couple that with technology

are distinctive in that the untriggered device has a green ring

that doesn’t burn out or have issues with vibration and you get a

around it and the tripped state is annunciated with a red ring.

device that people tend to rely on. Our operators have embraced

In a trend that goes against the usual path of new is more

our standardization of the use of light stacks and often ask to

expensive, LED light stacks are significantly less expensive than

have them added or replace the original equipment that came

their incandescent predecessors. The great thing about this de-

from our machine vendors. We have taken their use even further

velopment is that more stack lights can be used in a design for the

and use subtle differences in the sound pattern of the alarm

same cost as a single light stack of the older technology. With the

horns on adjacent machines to help the operator avoid respond-

example of the use of a light stack in mind, it isn’t hard to imagine

ing to signals that aren’t relevant to their production line.

the impact on the ability to get the process back in operation if more lights are viewable around the perimeter of your machine. In my personal experience, light stacks tend to get ignored if

RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com), a dry-foods manufacturing and packaging company in Ashton, Illinois.

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Smart-manufacturing goals translate into lives saved MANUFACTURING AND not-for-profit are two terms you don’t often hear together. “But that’s what we’re doing,” explained Maria Kasparian, executive director of Edesia, a Rhode Island-based nonprofit that combats malnutrition around the globe. And by approaching its altruistic mission like a manufacturer—a modern, smart, digitally enabled manufacturer—it is optimizing its efforts. The ROI? Lives saved. During her presentation “Modernizing Technology to Save More Lives,” delivered to a rapt audience at Rockwell Automation’s Perspectives event at Automation Fair, Kasparian provided the backstory to Edesia—launched in 2010 and partnering with the likes of UNICEF and the U.S. government with the goal of eradicating starvation in the world’s most vulnerable cultures. The approach is comprehensive—from engaging with domestic farmers to produce their nutrient-dense food products to constant research-and-development efforts to quicken distribution and to educational efforts aimed at raising awareness and funds. All noble stuff, applauded spontaneous throughout. But what really resonated with this audience was the description of ef-

Nutritional ROI “Improved nutrition has one of the best ROIs you will ever see.” Edesia’s Maria Kasparian explains how automation has transformed the nonprofit’s abilities at Rockwell Automation’s Perspectives in Chicago.

forts Edesia launched four years ago to fully embrace digitalization and supercharge the good work. In short, embracing a data-driven approach. Sound familiar, manufacturers?

with our new production equipment we started using Rockwell Automation’s PlantPAx DCS for batch-process control.” Efficiency increases were quickly realized in addition to side

Data and more specifically numbers are now central to Ede-

benefits. Edesia has enjoyed a 20% increase in capacity in 2019

sia’s operations. Kasparian delivered some sobering figures to

alone. That’s a huge win, particularly considering that success

highlight the problem—3 million preventable deaths each year

like that means more than just increased earnings for share-

as a result of malnutrition. But she also noted encouraging sta-

holders, but rather more children fed and more lives saved.

tistics—the one-box-of-food-saves-one-kid ratio, the 10 million

Rather than replacing the 105 workers, many of whom are refu-

children Edesia has saved since launching less than a decade

gees from the countries the nonprofit serves, this automation

ago. And in the parlance of a profit-driven manufacturer, the

upgrade was, in Kasparian’s words, a game changer. Personnel

executive director broke it all down to return on investment—

embraced the new technologies. Workers learned new skills.

dollars and cents.

Pay increased, along with job satisfaction.

“Improved nutrition has one of the best ROIs you will ever

The smart approach at the nonprofit continues to evolve. In

see,” she boasted. “Every dollar spent on basic nutritional needs

the past 12 months Edesia has optimized new systems with

has a return of $16 on the local economy.”

data provided from machines. Employing six licenses donated

After six years of success, albeit relying on less-than-fully ef-

by Rockwell Automation, real-time data is now displayed

ficient approaches, Edesia made “huge upgrades” in 2016, scaling

throughout the factory, enabling constant access by staff,

production, expanding the size of its factory from 15,000 sq ft to

which can make immediate, informed decisions on the fly.

85,000, and aggressively automating processes that resulted in growth of output from 9,000 metric tons of food to 25,000. “We went from very manual processes to state-of-the-art,

Said Kasparian, “These innovations have helped us lower the cost of our humanitarian processes. This means reaching more children. We thank Rockwell Automation for its support and

automated processes,” she explained. One example: while

partnership. May we together continue to find ways to do more,

workers had previously dumped 50-lb bags into mixers, one-ton

to build a world where all children are well-nourished.”

bags are now loaded into sophisticated dosing hoppers. “And

One of the misconceptions about automation is that it

ControlDesign.com / February 2020 / 17

indiscrete

undermines the human element of manufacturing. It removes

Chairman and CEO Blake Moret celebrated the special rela-

man and woman from the work. This is a fallacy, of course.

tionship Rockwell Automation has with its partners. None is

Just look at the improved conditions for workers in the Edesia

likely as inspirational as this union with Edesia, which Moret

facility as an example.

described as “a truly remarkable organization.”

But this case study presented today is a particularly human

The results surely are remarkable. So is the overarching

one, a particularly warm example of using advanced manufac-

strategy—a nonprofit driven by the progressive mindset of a

turing to prompt true, positive change.

digitally transformative manufacturer. Heart, optimized by

During his keynote presentation, Rockwell Automation

smarts, filling bellies around the globe.

Siemens’ Capital software helps Groupe PSA digitalize after-sales documents

HPS opens new warehouse in Nevada

SIEMENS’ CAPITAL SOFTWARE electrical

which provides automated electrical docu-

HAMMOND POWER SOLUTIONS (HPS)

design product for its automotive after-

mentation through diagram synthesis.

opened a new warehouse in Reno,

sales documentation has been selected

“Using Capital for electrical design and

Nevada, effective January 13. The

by Groupe PSA, the second largest car

aftersales documentation has produced

new facility replaces the previous

manufacturer in Europe. Groupe PSA is a

tremendous time and cost savings,” said

warehouse in Compton, California,

manufacturer of five car brands: Peugeot,

Yves Bouvier, vice president of Diagnosis,

with plant operations in Compton

Citroën, DS, Opel and Vauxhall. The

Groupe PSA. “We have already achieved

being unaffected.

company has an established process of

a significant schedule reduction using

supplying its facilities with after-sales

Capital to deliver our complete schematic

accommodate HPS’ growing product

service documentation with several types

after-sales documentation and are target-

sales and provide improved ship-

of design deliverables aiding rapid diag-

ing above 30% schedule reduction.”

ping leadtime in select regions. The

nosis. Using Capital’s technology, Groupe

Siemens’ Capital E/E systems develop-

The new warehouse will better

Reno warehouse is triple the size of

PSA has replaced a largely manual pro-

ment toolchain spans the full electri-

the Compton facility at 36,000 square

cess and can now automatically render

cal system development process from

feet, and it will house an expanded

their electrical system diagrams using

system definition, through design and

number of product SKUs.

data that comes directly from the PSA

manufacturing and into automated ser-

“The investment in this new

electrical/electronic (E/E) engineering de-

vice documentation production. Digital

facility is part of a broader plan to

partment and their harness suppliers to

continuity of Groupe PSA’s electrical data

evolve our operations and customer

help provide correct-by-construction as-

using Capital enables aftersales docu-

service”, stated Larry Bell, director

surance. The result is accurate documen-

mentation driven directly by the actual

of supply chain. “Since the facility is

tation created using as-manufactured

engineering design data. This provides

within close proximity to major con-

data provided by Groupe PSA’s suppliers

data accuracy, efficiency and a reduced

sumption centers on the West Coast,

which helps ensure rapid and effective

time to market. Capital is part of Xcelera-

we expect lead times to be reduced

vehicle maintenance when required.

tor, an integrated portfolio of software,

to 1-2 days for stocked products in

services and application development

select regions”.

According to Siemens ,the Groupe PSA team needed a seamless, easy-to-use

platform that can be personalized and

technology to help ensure electrical data

adapted to fit customer and industry-

managed by experienced personnel

continuity. After exploring the software

specific needs to help companies become

from Baraboo, Wisconsin, ensuring an

tools available, it selected Siemens’ Capital

digital enterprises.

orderly transition for customers.

18 / February 2020 / ControlDesign.com

The new warehouse facility will be

Embedded Vision Alliance expands scope, rebrands as Edge AI and Vision Alliance THE EMBEDDED VISION ALLIANCE is

on-premise and it includes both hybrid

ating intelligent systems and applica-

expanding to encompass the full range

approaches where some processing

tions; building a vibrant ecosystem by

of edge AI technology and applications,

happens locally and some in the cloud.

bringing together technology suppliers,

including its traditional domain of com-

According to the Edge AI and Vision

end-product creators, and partners;

puter vision and visual AI. According

Alliance, the reason it is expanding is

and delivering timely insights into

to the alliance, to better reflect its new

because it is seeing the same challeng-

relevant market research, technology

scope it will be changing its name to the

es in edge AI that it saw in computer

trends, standards and application re-

Edge AI and Vision Alliance.

vision almost a decade ago.

quirements. The difference is that the

For the alliance, it defi nes edge

However, the organization remains

mission now includes not just vision

AI as AI processing that occurs lo-

committed to inspiring and empower-

but the full range of edge AI technolo-

cally, whether on a chip, device, or

ing the individuals and companies cre-

gies and applications.

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indiscrete

Eaton sells hydraulics business to Danfoss for $3.3 billion

The transaction is subject to customary closing conditions and regulatory approvals and is expected to close by the end of the year. According to Danfoss, the acquisition

POWER MANAGEMENT COMPANY Eaton

“Today’s announcement is part of the

is in line with its strategy to strengthen

has entered into an agreement to sell its

ongoing transformation of Eaton into

its core businesses and enhance cus-

hydraulics business to Danish industrial

a higher growth company with better

tomer value.

company Danfoss for $3.3 billion in cash.

earnings consistency,” said Craig Arnold,

This represents a 13.2 multiple of 2019’s

Eaton chairman and CEO. “We believe

years strengthened our power solutions

earnings before interest, tax, deprecia-

this transaction will create substantial

business through high customer focus, as

tion and amortization.

value for our shareholders and allow

well as through significant investments in

our hydraulics employees to be part of a

technology leadership,” said Eric Alström,

for 86 percent of its hydraulics seg-

company that has a strong commitment

president of Danfoss Power Solutions. “I

ment revenue in 2019. The business had

to the hydraulics industry.”

believe our customers will benefit from

Eaton’s hydraulics business accounted

sales of $2.2 billion in 2019 and employs

“Hydraulics is our core, and we have for

“By combining the knowledge and

combining these two businesses into a

approximately 11,000 people. Eaton is

experience of these two companies, our

full-line hydraulics player dedicated to

retaining the filtration and golf grip

customers will benefit from unmatched

innovation and with a broad offering of

businesses currently reported in its

expertise from a single partner,” said

products, robust distribution channels

hydraulics segment.

Kim Fausing, Danfoss president and CEO.

and tremendous geographic reach.”

Element14 launches ‘Connected Cloud’ IoT design challenge

PSoC specifically for IoT products and wearables that offer flexibility, in-field design tuning and faster time-to-market. Amazon Web Services will also be providing $25 Cloud Credit per sponsored

ELEMENT14 IS TEAMING up with Cypress

munity and social media for the element14

Semiconductor and Amazon Web Ser-

community. “We’re thrilled to partner with

vices to hopefully build a better future

Cypress Semiconductor and Amazon Web

least 10 blogs about their design process

with IoT. The “Connected Cloud” design

Services to offer our community members

and interface with Amazon Web Ser-

challenge aims to foster the communi-

the opportunity to expand their IoT design

vices incorporating photos, videos and

ty’s creativity by applying innovative IoT

knowledge using some of the best IoT tools

code samples. Those who complete 10

solutions to anything in their world that

available, all while working on a specific

blog posts and submit a featured project

needs improving, from monitoring traffic

challenge in their world.”

that meets the requirements will receive

conditions, to creating information hubs

The “Connected Cloud” Design Chal-

challenger for their AWS IoT Platform. All participants are required to post at

a Multicomp Pro Multimeter Set. One

for their communities or monitoring

lenge is open to everyone, but element14

first prize winner will receive a Desktop

flood waters. The latest design challenge

community members can apply to receive

3D Printer and the new, unannounced

from element14 encourages its members

one of 20 free PSoC 6 Kits. Challengers

PSoC6 Kit. One runner up will receive a

to learn new IoT development skills, el-

can choose a Cypress PSoC 6 WiFi-BT Pio-

HTC VIVE Pro Virtual Reality System and

evate their designs and think outside the

neer Kit (CY8CKIT-062-WIFI-BT) or PSoC

the new, unannounced, PSoc6 Kit.

box to solve everyday problems.

6 WiFi-BT Prototyping Kit (CY8CPROTO-

“Learning and advancing skills in IoT is

Applications for the free Cypress Kit

062-4343W) to build their projects. The

opened on January 27 and close on Feb-

one of the most frequent requests we get

Pioneer Kit enables designers to evaluate

ruary 24. The design challenge deadline

from our global community members,”

and develop their applications using the

is May 11. Winners will be announced in

said Dianne Kibbey, global head of com-

PSoC 6 MCU, Cypress’ ultra-low-power

June 2020.

20 / February 2020 / ControlDesign.com

Seeq expands Series B funding with $24 million to fuel advanced analytics growth strategy SEEQ, A MANUFACTURER of Industrial Internet of Things (IIoT) advanced analytics software, announced that is has secured a $24 million expansion of its Series B funding. This expansion round is led by Saudi Aramco Energy Ventures (SAEV), the corporate venture subsidiary of the world’s leading integrated energy and chemicals company, Saudi Aramco. It includes renewed participation by Altira Group, Chevron Technology Ventures, Second Avenue Partners, and other existing investors. Seeq enables engineers and scientists in process manufacturing organizations to rapidly analyze, predict, collaborate, and share insights to improve production

ics innovation,” says Steve Sliwa, CEO

companies using Seeq include pharma-

outcomes. Customers include compa-

and co-founder of Seeq Corporation.

ceutical industry leaders such as Merck

nies in the oil and gas, pharmaceutical,

“Through our direct sales personnel and

and Roche, as well as chemical industry

chemical, energy, mining, food and bev-

more than 50 channel partners, our cus-

leaders like Lonza and Covestro.

erage, and other process industries. The

tomer base has expanded to more than

In addition to cloud support, Seeq

funding will accelerate Seeq’s expansion

40 countries with deployments as large

partners with an extensive set of pro-

of development, sales, and marketing

at 5,000 users within one company.”

cess automation vendors for on premise

resources, and will also increase its presence in international markets.

In 2019, the company announced it

deployments by connecting to and

had achieved Amazon Web Services

working with systems sold by OSIsoft,

(AWS) Industrial Software Competency

Siemens, GE, Honeywell, Emerson Au-

provement in software for customers in

status and that its advanced analyt-

tomation Solutions, Inductive Automa-

process industries to accelerate insights,

ics solution was available in the AWS

tion, AVEVA, AspenTech, Schneider

action, and impact on their production

Marketplace. These achievements will

Electric, and others.

and business outcomes,” comments

enable Seeq customers to rapidly inves-

James Sledzik, venture executive at SAEV.

tigate and share insights from process

tum, in August 2019 Seeq ranked #369 on

“We are pleased to be leading the effort

manufacturing data stored either on

the Inc. 5000 list of fastest-growing pri-

enabling Seeq’s continued growth.”

premise or in the AWS cloud.

vate companies, and in November 2019

“Seeq is providing an important im-

Upon final closing, Seeq expects the

Seeq had previously made its ad-

Highlighting the company’s momen-

ranked #43 on the Entrepreneur 360 list.

Series B expansion to reach approxi-

vanced analytics software available as a

mately $30 million, which is in addition

software-as-a-service (SaaS) application

features enabling support for the integra-

Seeq’s new release, R22, introduces

to Series B funding led by Altira Group.

on Microsoft Azure and in the Azure Mar-

tion of structured data from SQL Server,

“With the backing of SAEV and our

ketplace. Cloud-based Seeq deployments

MySQL, and CSV files; easier distribution

existing investors, Seeq is positioned to

enable engineers at companies like Royal

of Seeq Workbench analyses to cowork-

continue its rapid growth by addressing

Dutch Shell PLC to access faster insights

ers; and an expansion of Seeq machine

market demand for advanced analyt-

and reporting on real-time data. Other

learning integration and features.

ControlDesign.com / February 2020 / 21

indiscrete

Essentium research shows manufacturers demanding open additive ecosystems ESSENTIUM, AN INNOVATOR in industrial additive manufacturing

North America and Europe to dominate in the airport kiosk industry during 2019 to 2029

(AM), announced the second in a series of findings from independent global research on the current and future use of industrial

ACCORDING TO A Fact.MR study, the global market for air-

3D printing. The study reveals that virtually all (99%) manufac-

port kiosks is expected to grow at value CAGR of 12.7% and

turing executives surveyed believe an open ecosystem is impor-

volume CAGR of 11.4% by the end of the assessment period.

tant to advance 3D printing at scale. While 85% of manufacturers

Over the forecast period, the market is expected to reach

reported that industrial-scale AM has the potential to increase

a market size of ~ USD 5.2 Bn by the end of 2029 from an

revenue for their business; 22% said their 3D printing efforts have

estimated USD 1.5 Bn in 2019. Across the globe, increase in

resulted in vendor lock-in that limits flexibility.

demand for more efficient management of airport activities

Until now, the industrial AM market has been dominated by

has led to a significant rise in installation of airport kiosks

closed systems where customers are locked into vendors’ hard-

and this increased demand is further expected to drive the

ware, processes and materials. As the technology obstacles around

airport kiosk market during the forecast period.

economics, scale, strength and speed of production fall away, the

In order to avoid delays, increased tendency of consum-

number of manufacturers using 3D printing for full-scale produc-

ers towards self-service solutions at airports is an impor-

tion has doubled compared to last year (40% in 2019; 21% in 2018).

tant factor to increase the demand for airport kiosk, world-

Manufacturers are now demanding open ecosystems to overcome

wide. Owing to such trends, investments in self-service

system inflexibility and use the materials of their choice—50% of

technologies will continue to witness a surge, with adop-

companies said they need high quality and affordable materials to

tion spreading to Tier II and suburban centers. According to

meet the growing demand for industrial 3D printed parts.

Fact.MR’s latest study, Self-service technologies including

An open additive ecosystem will see more partnerships focused

airport kiosk, have led to reduced waiting times and faster

on giving customers greater control of their innovation, more

processing, which has helped airport authorities in provid-

choice in materials, and industrial-scale production at ground-

ing a superior experience to consumers. In addition to self-

breaking economics. Market demand for Essentium’s open 3D

service check-in airport kiosk, airport authorities are now

printing ecosystem, developed in collaboration with multinational

focusing their attention towards self-bag tagging and drop

chemical company BASF and 3D software developer Materialise

off collection. Although these technologies are at a nascent

NV, is a clear indication that an open ecosystem approach is ad-

stage, it is expected that investments in these technologies

dressing unmet needs in the industrial additive market.

will witness a surge in the near future.

Blake Teipel, CEO and co-founder, Essentium, said: “At Es-

Among all the airport kiosk used at airport, the baggage

sentium, we strongly believe that an open ecosystem will be key

check-in kiosks are found in every airport across the globe

to the evolution of Additive Manufacturing. Being locked into

and is expected to witness the highest investment during

proprietary solutions that limit flexibility and choice is no longer

the forecast period. Baggage check-in airport kiosks were

an option if 3D printing is to become a serious contender as an

adopted by airport authorities a long time ago, and their

industrial process for end-use products. An open market focused

adoption is now spreading to Tier II and suburban areas. It

on developing new materials and better and faster machines is the

is expected that baggage check-in airport kiosk will remain

only way for manufacturers to unlock new applications and new

the largest segment in terms of revenue during the forecast

business opportunities. With this approach, the future belongs to

period, followed by automated passport control airport ki-

the customer, not to the OEM.”

osk. Owing to the increased demand for border management

22 / February 2020 / ControlDesign.com

solutions, the automated passport control airport kiosk is anticipated to show considerable growth during the forecast period. After installation of these kiosks at the airports, entry will only be permitted

Automotive firms must adapt or die, survey says

for authorized passengers to the passport control section. Across the globe, increasing incidences of

MARKET INTELLIGENCE FIRM Interact Analysis has released a new

terror attacks has boosted the demand for automated

market report focusing on automotive design, test and simulation solu-

passport control airport kiosk.

tions. This new market segment combines traditional software design

The airport kiosk market is analyzed across mul-

tools such as product lifecycle management (PLM) with test solutions

tiple regions, which include North America, Latin

and new, advanced simulation tools being used to model autonomous

America, Europe, South Asia, East Asia, Middle East &

vehicles and their behaviour.

Africa, and Oceania. Across the globe, North America

The report estimates the global automotive design, test and simulation

and Europe are most prominent markets for airport

solutions market to be worth around $5.1 billion in 2018, and forecasts a

kiosk. Both the regions together hold more than

compound annual growth rate (CAGR) of 11% to $8.6 billion in 2023.

50% share of the total airport kiosk market, across

This growth runs concurrently to major changes in the global auto-

the globe. While considering North America, high

motive market, as OEMs attempt to keep up with major changes in con-

penetration of technology, coupled with a strong push

sumer use habits and legislation. The report outlines how three major

by the public and private sector has meant that many

trends—electrification, autonomy and mobility—have emerged, forcing

airports are equipped with high-tech kiosks. The

the entire automotive community, from raw material suppliers to after-

relatively high number of airports in the US have also

market service centres, to rethink their strategies, products and futures.

been opportunity creators for kiosk market players.

OEMs are, the report states, facing major pressure on traditional

From a technology and investment perspective dur-

sources of profit like the manufacturing or servicing of cars. Instead,

ing the forecast period, the North American market

they are looking to simulation to speed up design processes and bring

will continue to be one of the most prominent regions

products to market far quicker than before. This is due in part to a

for the airport kiosk vendors and stakeholders across

new breed of OEM, who are not constrained by legacy processes, costly

the globe. On other hand, with increased investments

manufacturing facilities or shareholder oversight.

on infrastructure in Europe, Europe’s airports have

Increasingly, automakers are turning to simulation to speed up the

undergone a significant transformation in the past

design process and achieve more successful approaches. There are

decade. As aviation security receives marginal fund-

two main approaches that Interact Analysis has observed: first, using

ing from the state, the responsibility has fallen on pri-

simulation to reduce the need for physical prototypes and testing, and

vate investors to invest in security features, and they

second, bringing simulation much earlier into the design process to

have responded well. Investment in modern features,

help constrain and better define the end-product from the very start.

such as upgrades to all aspects of airport infrastruc-

Alastair Hayfield, research director for Interact Analysis and the

ture have been occurring at a significant pace. These

report’s author, said: “The days of cars being seen as ‘heavy metal’

factors have had a positive impact on the airport ki-

products are now in the past. Most of the value in a modern car is elec-

osk market in Europe and is further expected to drive

trical and the software used to control the functionality of the vehicles

the airport kiosk market.

is among the most complex ever developed by humans.

Leading companies concentrating on innovations

“This step-change in design and functionality has attracted new market

and new product development, while capitalizing

entrants from high tech industries, which has in turn brought new pres-

on rising demand, will have good future expansion

sures on the established players to increase their capabilities, and quickly.”

prospects in the global airport kiosk market. Key companies tracked by the report, which support the market expansion include Bolloré SA, Fujitsu Limited, Diebold Nixdorf AG, Embross Group,

“Investing in automation solutions will help bridge that gap. OEMS and suppliers which adopt simulations, for example, should find it possible to reduce development costs and improve their time to market.” “Our research points to one key trend: the automotive industry is in

Toshiba Corporation, NCR Corporation, Rockwell

the midst of a revolution, and automotive design, test and simulation

Collins and SITA SA.

solutions will prove the key weapons in the fight for market share.”

ControlDesign.com / February 2020 / 23

machine input

Put your information in lights Operators and floor managers can get answers from stacklights by Mike Bacidore, editor in chief

With advanced communication technology, what sorts of additional information are stacklights able to provide that can be of use to operators and floor managers?

Trey Gantt , product manager, Eaton (www.eaton.com),

Con-

nected devices can provide immediate indication of a fault and the data to diagnose and even prevent downtime from occurring. Connected technologies can impact productivity by improving efficiencies, saving time and costs.

John Curtin , director, automation solutions, Motion Industries

Tom Rosenberg , vice president of marketing and engineering,

(www.motionindustries.com), Advantages in wireless

Balluff (www.balluff.com),

communication have greatly enhanced the potential

point-of-use information. Stacklights and indicators

It’s a new world for real-time,

for stacklights to become far more helpful to operators and

can provide much more feedback to operators and plant floor

production managers. Traditionally, stacklights have been

managers than ever before. One popular form of information is

stand-alone indicators for a few specific functions of a single

continuously variable information also referred to as analog

process. Now, stacklights are able to be networked. This allows

information. This information can be used to indicate current

the production manager to identify and document faults and

level status in tanks, hoppers, feeders, flow racks and so on. Oper-

unproductive time throughout the plant. In addition to

ational status such as flow rates, pressure values and process

pinpointing the location of a fault, reducing response time and

speed are also popular. Another use for continuously variable

downtime, this information can also reveal opportunities to

information is pacing for operators in manual assembly areas.

improve processes and plant productivity.

They can quickly see how much time each individual person has for their process step. If someone is struggling, others can visibly

Robb Weidemann , senior business development manager, lighting

see the situation and step in and help. The other piece of

and indication,, Banner Engineering (www.bannerengineering.

information that has been popular is simply displaying that the

com), Stacklights can be used to provide visual

machine is in idle state. This would typically suspend all other

indication of tank level, temperature level and warning

forms of indication. We are all familiar with the spinning icon on

thresholds, process status, takt time, current production level,

our computers, and now this is available for machines, as well.

alarm state, operator response time and more. With IO-Link or

Basically, it indicates the machine is not ready. Again, colors can

wireless communication, these statuses can be monitored

be used as part of a communication plan to indicate the reason

remotely to ensure prompt action to critical changes, and the

for the idle time and call for specific personnel to respond. As

data can be logged over time to identify trends, locate bottle-

soon as the machine is ready, the indicators and stacklights

necks, resolve process inefficiencies and even enable predictive

revert back to normal operations, just like your computer.

maintenance capabilities. Michael O’Neill, sales manager, Werma (www.werma.com), The Alvaro Sanchez , product manager, Rockwell Automation (www.

wireless transmission of the indication from a stack-

rockwellautomation.com), Device-level communication

light can notify equipment status to people anywhere

protocols such as IO-Link are being integrated into

through the use of SMS texts and/or e-mails sent to cell phones;

more field devices every day. IO-Link and similar enabling

display data for all to see on a shop floor via flat screens mounted

technologies allow field devices to easily integrate into the

in the production areas; store performance data as machine

Connected Enterprise, delivering plant/device data and

history; provide summary reports from real-time data; schedule

diagnostics from the device directly into a control system to

and track production via counting that the stacklight can make;

help minimize downtime and increase productivity.

and indicate failure of signal communication links.

24 / February 2020 / ControlDesign.com

machine input

Peter B. Gasparini , sales manager, Werma (www.werma.com),

If

alarms with a notification that goes to the phone or other

we are talking about wireless monitoring and free

wireless device improves the response time, especially with

software/SQL, the solution time-and-date-stamps

larger plants or during times of reduced staffing, such as third

every critical process or condition or status or timely email or texts, which can be analyzed for lean initiatives and continu-

shift or holiday production. In addition to wireless technology, we are seeing stacklights

ous improvements. Werma has clients gathering all types of

that have auditory alerts to supplement the visual indicators.

information with stacklights. And the classic low-hanging-fruit

These are moving beyond the traditional blaring alarms to

data is uptime; downtime/faults, or reasons for stoppage; QC

include different tones, MP3 files with music or voice annuncia-

processes using vision sensors; production cycles/counting;

tors that identify the machine and the type of error.

transparency of production facility—what’s the current status of my machinery or manual workstations or pumps or chillers;

Lyon Lee , product marketing manager, IDEC (www.idec.com),

identify more productive capacity; initiate processes, such as

Stacklights can show a wide range of information

start/stop machinery; document time to respond. Werma clients are very creative and have come up with very

such as alarms, throughput, speed, flow rate, temperature, pressure or tank level.

interesting applications for our stacklights with communication—wireless—technology.

Steve Olson, IIoT technical specialist, Hilscher (www.hilscher.com),

member of Control System Integrators Association Lee Clore , owner/controls designer, Onyx Industries (www.

onyx-industries.com), As microprocessors make their

(CSIA, www.controlsys.org), Audible signals and scrolling message displays have been combined with stacklights.

way into these devices, the options open up. They could act as a large vertical bar-graph display as an example.

Danny Weiss , senior product manager, Newark (www.newark.

Stacklights are quite useful for awareness indicators—an

com), Many of our customers use stacklights with

active laser is in the area or an exposed surface is heated. This

communications to provide personnel with detailed

is especially true if the indicator light will allow for backlit

fault information via the communication network, but quick

symbols. 5S lean initiatives make use of indicator lights for

visible or audile information via the stacklight.

production purposes. Long visibility is useful for schedulers and production managers to monitor multiple work cells.

Jim Krebs , engineer,, AutomationDirect (www.automationdirect.

com), With the newer communications technology, Juergen Duemmler, manager, product management & engineer-

information such as runtime or downtime of a

ing, Siemens (www.siemens.com), Communication

machine or the motion of an operator in a work cell can now be

capability allows stacklights to send diagnostic

easily sent to a central database to help develop efficient plans

information through sensors on the machine to the operator

to increase uptime and provide other benefits.

regarding the condition of the machines. This data can be used to schedule maintenance or repairs that could possibly prevent more costly damage to equipment if it went unmonitored. Todd Mason Darnell , Ph.D., marketing manager of services and

In lieu of a stacklight, what types of applications can benefit from an illuminated pushbutton or indicator?

safety,, Omron Automation Americas (www.omron247.com), The

Danny Weiss , senior product manager,, Newark (www.newark.

addition of Bluetooth or other wireless technology to

com), One indicating light can show machine run,

the stacklight can significantly improve its effectiveness. The

ready or fault, as well as a really good example

stacklight, by itself, is a simple visual indicator that provides

demonstrating a heating element coming up to temperature. As

only basic information about the machine status. With the

we all know, pushing a button is what workers do to tell the

additional of wireless connectivity, the stacklight can push an

machine how to operate while indicating lights tell the worker

error notification to plant personnel enabling a “smart first

what the machine is doing or failing to do. To save space and

response” to machine. Even if the control system does not

money, you can combine pushbuttons with indicating lights, so

support the push of an error code, supplementing the visual

that if you push the button a light inside the button turns on.

26 / February 2020 / ControlDesign.com

Alvaro Sanchez , product manager,, Rockwell Automation

Robb Weidemann , senior business development manager, lighting

(www.rockwellautomation.com), An illuminated

and indication, Banner Engineering (www.bannerengineering.com,

pushbutton or indicator can benefit any applica-

While stacklights are effective to signal supervisors,

tion requiring visibility of real-time machine and process

even at a distance, lighted buttons and indicators are ideal at the

status indication. The type of technology used is based on

operator level. These buttons can be mounted in the operator’s

the requirements of the application including user/

normal sightlines, which improves ergonomics and saves time

operator proximity to the machine, the type and number of

by letting the operator keep eyes on the work. Assembly and

conditions that must be indicated and the environment,

machine-interface applications benefit from illuminated

just to name a few.

pushbuttons because two-way communication is enabled.

Todd Mason Darnell , Ph.D., marketing manager of services and

Juergen Duemmler, manager, product management &

safety, Omron Automation Americas (www.omron247.com),

engineering, Siemens (www.siemens.com), Pilot device

Typically stacklights are used for plant personnel

opportunities are everywhere. Any application that

other than the operators of the machine. Illuminated

requires a motor can use a pilot device to control the motor.

pushbuttons should never replace stacklights, since only the

Adding illumination to the pushbuttons or using indicator

operators can see the status of the pushbutton while the

lights also provides a visual indicator that allows the operator

stacklight is easily observable by other plant personnel.

to monitor the status of the motor/machine from the control

Illuminated pushbuttons and indicators, however, can be

panel. These devices are often used to show when a machine

helpful when there are multiple operators or to assist in

is powered on, running, off or overload tripped. Emergency-

troubleshooting. They can provide the status of a subsystem

stop pushbuttons can be illuminated to give a visual indicator

or alert other operators on large production equipment to

when the pushbutton has been actuated. This is particularly

problems. For example, if an e-stop is not actuated, it could

useful in locating the source of an emergency shutdown when

be illuminated to assist an operator with locating it. Once

there are multiple emergency stop pushbuttons on the same

pressed, all others could go dark, and the actuated button

production line. The addition of Profinet, AS-Interface or

could flash so that maintenance personnel can easily locate

IO-Link to a pushbutton provides digital feedback. For critical

it, remedy the problem and know which button to reset.

processes and applications, pushbuttons with communication offer visibility down to the lowest level when incorporated

Tom Rosenberg , vice president of marketing and engineering, Balluff (www.balluff.com),

into the manufacturer’s network.

This is all about process

efficiency. Operators and other personnel need real-time information at the point of use. Attention must be focused on the task, not looking outside of the work

Peter B. Gasparini, sales manager, Werma (www.werma.com),

Manual workstations, self-checkout kiosks, forklifts, and escalation—for example, a Werma client escalates

envelope for guidance. This creates the need for machine-

four times for one call for action from their manual workstations;

mounted indicators and pushbuttons. A central or even

every 5 minutes—three times—and, if after 20 minutes the

decentralized enclosure is not adequate. Indicators and

problem is not resolved, the fourth-escalation automation turns

pushbuttons need to be mounted within the machine,

on a 105 dB sounder outside the GM’s office. This was our client’s

inside the work envelope, where guidance is required.

idea. Since deployment, I don’t believe the alarm has gone off.

Trey Gantt , product manager, Eaton (www.eaton.com),

Pilot

devices are relied on to operate panels, pendant stations, control panels and other equipment.

John Curtin , director, automation solutions, Motion Industries

(www.motionindustries.com), Stacklights are designed to

alert people to a change in process status at a

Machine and panel builders use these devices to simplify

distance. Illuminated pushbuttons and indicators can serve a

operation, control and protection. Like stacklights, these

similar function but are best suited to applications where the

devices are used across a host of applications, including

system operator maintains close proximity to the location of

food and beverage, commercial construction, healthcare,

these devices—typically on the door of a control panel, in the

industrial and utility, to name a few.

operator control console or on a remote operator station.

ControlDesign.com / February 2020 / 27

SPONSORED CONTENT

The next generation of AS-Interface

FABRICIO GRANADAS Director of International Sales, Bihl+Wiedemann

Since the 1990s, AS-Interface (ASi) has become an integral part of modern industry, with more than 37 million installed notes worldwide. Customers can benefit from the economically reasonable fieldbus/wiring system for the first automation level, used to easily, reliably and economically connect sensors and actuators and attach them to the higher control level. The yellow ASi cable transmits power and data at the same time. The easy wiring process is doable even without training. Now a new generation of the ASi standard has been presented for the new requirements in times of Industry 4.0. ASi-5 easily enables faster transmission of larger data volumes and effortless integration of intelligent IOLink sensors. Fabricio Granados, director of international sales at Bihl+Wiedemann, shares his candid thoughts about the advantages of ASi-5 and how easy it is to use ASi-5 slaves together with ASi slaves of any previous generation.

Q: Is ASi-5 a completely new technology? A: No, ASi-5 is the evolution of the well-proven ASInterface standard. ASi-5 offers all the advantages that have already made ASi so special in the past. The greatest challenge during the development of ASi-5 was to keep all the known advantages of ASi. AS-i 5 had to be at least as good as ASi-3 in every aspect. Customers still benefit from the simple wiring scheme with just one cable for both power and data, the ability to connect slaves to any desired location of the yellow profile cable and the high flexibility due to the use of application-specific slaves. ASi-5 offers both a high bandwidth—process data size from 16 bits to 32 bytes per slave— and short cycle times—up to 384 digital inputs and 384 digital outputs in just 1.27 ms—making it possible to transport more and more data, without restrictions, to where they can yield valuable information.

Q: Why is it time for the next generation of ASInterface?

Q: In what way does the higher data bandwidth influence the usability of ASi-5? Is it more complex now for the users?

A: The main reason for evolving ASi was the changed situation for our customers. With the rise of a connected digital industry, more data needs to be transmitted. ASi-5 now allows us to transfer larger quantities of data at higher speed, while making integration of intelligent IO-Link sensors easier than ever. Intelligent sensors and actuators are responsible for an increasing number of control functions in distributed systems. ASi-5 was developed by seven renowned automation companies, including Bihl+Wiedemann. The complete project took more than 200,000 developer hours. Bernhard Wiedemann, CEO of Bihl+Wiedemann, was the technical leader of this cross-company development group.

A: The main advantages of AS-Interface are incorporated in the new generation. Long story short, our products are still as easy to use as before. Each network is controlled by one ASi-5 master that transmits data via fieldbuses such as EtherNet/IP or Profinet to a central control system or via OPC UA to the cloud. The connection technology, such as connectors and wires, stays the same. Additionally, to the same usability, the user benefits from increased diagnostics; for example, a channel diagnostics is possible now. This is a new generation of AS-Interface, which means that the technology still needs to prove its usefulness. When are the first ASi-5 products available?

28 / February 2020 / ControlDesign.com

SPONSORED CONTENT

IO-LINK

ASi-5 now allows us to transfer larger quantities of data at higher speed, while making integration of intelligent IO-Link sensors easier than ever. Bihl+Wiedemann is already offering the first ASi-5 gateways and modules. Our goal is to develop quickly a wide product range to meet all of our customers’ needs. The all-rounders in our portfolio are three new gateways that run on ASi-5 and ASi-3 and thus are able to communicate on both networks. If you want to read more on the technical specifics you can find the information on our website. As with all new technologies, it will take some time to develop all products that are available on ASi-3. ASi-5 enables a more efficient incorporation of intelligent sensors in the AS-Interface, which was worth all the invested effort. Many of the new features will be playing an increasingly important role as digitalization continues. This is an iterative process, which I am very much looking forward to see what will come out of it. Q: Can customers use their existing ASInterface devices together with ASi-5 products?

A: The greatest advantage of ASi‑5 is that it’s completely compatible with all earlier ASi devices and components. ASi-5 slaves can be combined with ASi slaves of any generation in existing as well as in new ASi networks. All ASi generations work parallel on the same cable—intelligent slaves, standard slaves and safety slaves on one network. In an existing ASi network, you can simply connect additional new ASi-5 slaves and easily continue to use existing ASi slaves. To use ASi-5 slaves all you need is a new Bihl+Wiedemann ASi-5 / ASi-3 gateway. Here’s another advantage: As before, AS-Interface in its ASi-5 expression remains a standard that guarantees compatibility between components of any manufacturer, not just the development partner. Any product with the ASi logo can work together with all the others in a common network and communicate seamlessly. Thus, for each problem there continues to be an ASi solution.

Q: In what applications is it worthwhile to switch to ASi-5 right now? A: From our perspective that would be, above all, applications characterized by high transmission speeds or elevated data quantities—for example, at locations where much I/O data needs to be collected in a tight space. ASi-5 also makes incorporating intelligent sensors, such as IO-Link sensors, much easier. And the new, high-performance standard modules with up to 16 inputs can replace one or another expensive fieldbus solution in the field.

For more information about Bihl+Wiedemann and its AS interface (ASi) devices for automation and safety equipment, visit www.bihl-wiedemann.de/us/asi-5.html.

ControlDesign.com / February 2020 / 29

cover story

Country

Voltage

Frequency

# of Wires

Argentina

380 V

50 Hz

3,4

Australia

400 V

50 Hz

3,4

Canada

120/208 V / 240 V / 480 V / 347/600 V

60 Hz

3,4

Germany

400 V

50 Hz

4

Mexico

220 V / 480 V

60 Hz

3,4

United States

120/208 V / 277/480 V / 120/240 V / 240 V / 480 V

60 Hz

3,4

Note that while the United States and Canada share power grids, especially near border states, Canada has a unique voltage of 347/600 V available and most manufacturing facilities use that voltage as a default. Note also that some countries have threeand four-wire circuits not including the ground wire. It’s extremely important to establish the available power at the end-user location before commencing the design to avoid costly errors later in the process. Grounding is something that is often overlooked as well. On systems where people will be interacting with the equipment, the lack of an earth ground on the supply voltage to the equipment can cause serious injury or even death. This is a very serious matter. On an ungrounded system, the failure of an electrical component will direct power to the shortest path to ground. That is often found through the electrical component housing

Country

Voltage

Frequency

Argentina

220 V

50 Hz

control panel, directly into the equipment frame itself. A per-

Australia

230 V

50 Hz

son touching that frame could be subjected to a shock powerful

Canada

120 V

60 Hz

enough to stop their heart or cause a serious burn.

Germany

230 V

50 Hz

Mexico

127 V

60 Hz

United States

120 V

60 Hz

and, by virtue of the method of mounting the component to the

Always include a proper ground system, including both chassis and earth grounds, to provide adequate protection for the people operating the equipment. As a secondary measure, ensure that the power distribution system from which your con-

In the above example, the numbers don’t look all that dif-

trol system will supplied also has a proper grounded system.

ferent. Some are 50 Hz while, others are 60 Hz. Some are 120 V,

This type of power distribution is called a delta-wye system

THE AUTOMATION SUPPLY CHAIN provides all the components

will be installed, or, worse, you don’t have an ample power sup-

while others are 220 V or 230 V, and one, Mexico, is 127 V. While

where there are three power phases and a grounded neutral leg

necessary to create effective and innovative machinery. The first

ply voltage to accomplish the intended task.

most modern components can handle the variance between

through which a dead short can travel.

step is to examine the electrical landscape for your design. Deci-

A consideration that is often overlooked is where the ma-

120 and 127 V or between 220 V and 230 V, what is hiding in the

The selection of a control voltage is more than a matter of

sions made at this juncture have implications all the way through

chine or process will, ultimately, end up. Don’t assume, just

weeds here is the fact that while Argentina and Australia look

taste. There are serious safety risks involved, as well. For ex-

the design, build and commissioning of the control system, so it

because you are building the machine in the United States, that

nearly identical, the Line and Neutral wire are reversed. That is

ample, prior to the invention of semi-conductors, most control

makes sense to take a good look at what the future will look like.

your clients will have that same voltage available where they

a surprise that could have deadly consequences.

systems used 120 Vac for the control voltage. This meant that

Many a project has been launched only to realize that the primary power supply voltage isn’t available where your system

30 / February 2020 / ControlDesign.com

are. For discussion purposes, here is a small sample of residential voltage and frequencies found around the world.

When examining three-phase industrial power options around the world, the options are even more diverse.

not only was the power in the electrical enclosure 120 Vac but so too was the field wiring on the machine or process. Operators

ControlDesign.com / February 2020 / 31

cover story

and technicians were exposed to those same voltages as a normal part of the work day. As anyone who has made incidental contact with an ac plug can attest, running 120 V through your body is not a desirable act. well as how many peripheral devices,

barcode scanner into a controls package,

ent control voltages and components

such as additional racks of I/O, barcode

one must set up a data exchange table of

have been offered to reduce the risk of

scanners and encoders, can be attached

some sort to exchange key data between

injury to personnel but none has been

to the controller.

the PLC and the barcode scanner. This

Over the years, a number of differ-

as effective as the advent of low-voltage

Think of a programmable automation

requires logging on to the barcode scan-

dc, specifically 18-24 Vdc. Most controls

controller (PAC) as a PLC on steroids.

ner with a laptop and setting up the

designers have settled on 24 Vdc as a

While it has the same input and output

function and communications to enable

control voltage because it provides an

capabilities as a PLC, a PAC is scalable

the PLC to talk to the barcode scan-

adequate voltage and current to operate

with multiple functions (via modules)

ner. With the use of a soft PLC comes

devices while not exposing personnel to

and information-enabled capabilities.

the ability to imbed part or all of that

the perils of higher voltages and the as-

These systems utilize a common

third-party configuration software right

backplane to add specialty modules to

there in the soft PLC. The advantage to

independently manage important func-

an operator or maintenance technician

tion like motion and temperature con-

to be able to launch the barcode scanner

There are a number of common terms

trol. Multiple I/O racks can be attached

configuration software right there on the

out there in the marketplace, and differ-

and smart devices such as variable fre-

HMI has obvious advantages.

ent types of controllers suit your applica-

quency drives and servo controllers can

tion differently.

be added directly to the I/O table using

be incomplete without bringing up the

industrial communications protocols to

safety controller. Early safety control-

easily integrate these components.

lers were really little more than regular

sociated risk of electrical shock.

Take control

A programmable logic controller (PLC) or programmable controller is a digital computer in a more robust

A soft PLC has all the capabilities of a

Any discussion about PLCs would

controllers painted red. While this is

container. It has been adapted for the

PLC/PAC but all the functions normally

oversimplification, the safety controller

purpose of controlling a machine or

residing in the PLC or PAC are encapsu-

of today is right on top of the latest in

manufacturing process. Some PLCs

lated in software running on a commer-

safety regulations and provides protec-

have all the inputs and outputs (I/O) all

cially available operating system.

tion that conforms to EN 954-1 Category

in the same housing as the controller.

The benefit of a soft PLC is that by run-

These are called shoebox PLCs. Other

ning the software on an operating system,

EN 954-1 Category 4 circuits ensure

PLCs separate the I/O from the control-

non-PLC-related programming languages

that the safety function is always avail-

ler, and these are called modular PLCs.

can be brought into the control algorithm.

able even in the case or one or more

The choice of shoebox versus modular

Programmers now have the option to

faults, usually by employing both input

is determined by the size of the appli-

leverage the power of programming lan-

and output redundancy, together with a

cation, but, generally speaking, a shoe-

guages such as C or C++ to code complex

feedback loop for continuous monitoring

box PLC would be a good choice where

routines that would be very cumbersome

of the outputs.

there are a few inputs and outputs,

in the common ladder logic (LAD), func-

while a modular PLC would suit itself

tion block (FB), sequential function block

fined as a relative level of risk reduction

to a larger project where many inputs

(SFC) or statement list (STL) languages

provided by a safety function, with SIL

and outputs are required.

available with industrial PLC or PACs.

4 being the most dependable and SIL 1

Packages of this type are relatively

A soft PLC also allows for the integra-

4 and SIL 3 requirements.

The Safety Integrity Level (SIL) is de-

being the least. The Functional Safety

limited as far as the number of inputs

tion of third-party software into the con-

of Electrical/electronic/programmable

and outputs that can be addressed, as

trol solution. For example, to integrate a

Electronic Safety Related Systems (IEC

32 / February 2020 / ControlDesign.com

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cover story

EN 61508) applies SIL as a measure of

compiled code unless all of the dots are

reliability and/or risk reduction.

connected. This means that you can’t

Safety PLCs are programmed using

produce a partially completed circuit

5. Choose the PLC or PAC type that best suits your application, based on the I/O count.

graphical function blocks instead of lad-

and download it to the safety controller.

der logic. The importance of this is it pre-

With a regular PLC or PAC, as long as the

vents an output from being activated if

code entered doesn’t produce an illegal

the programmer hasn’t connected all the

syntax, it will allow the compiling of

choose meets your requirements for the

required elements in the function blocks

code that might produce an unexpected

project and you can live with it for five to

that make up the safety programming.

or dangerous output.

10 years down the road.

For example, the programmer drags and

The selection of a suitable controller, at

6. Pick your favorite automation supplier and give them the criteria. Make sure the brand of controller you

The first criteria is obvious but, let’s

drops various types of safety devices into

face value, might seem simple enough.

face it, we don’t want to pick a controller

the program. Space is automatically cre-

1. Make a list of inputs and outputs.

today that is obsolete three years from

ated to fit the associated function block

2. Add to that list any communications

now. What happens if we have a hardware

with arrows to indicate the configuration

network and protocols to communi-

failure? Will we or your client be able

points that must be completed before the

cate with your system.

to get replacements? Let’s say you find

safety circuit is complete. Finally, unlike the compiler on a regular PLC, the programming software on a safety controller won’t produce

3. Add the data input/output devices that you need in your design. 4. Make sure to add the operator interface devices.

yourself moving on to another opportunity a couple of years down the road. Will someone else be able to pick up where you left off and support the product that you chose? Most automation suppliers should be able to have an honest conversation with you about these concerns and help you make an intelligent decision. Finally, and this is very important, if you have access to the programming software, build your PLC or PAC configuration in the software and make sure all the devices and peripherals fit your intended architecture. Here are some things to watch for: • know the limitations on number of I/O modules in the main or remote racks • make sure that you can connect to a remote rack if you need one • double-check the number of nodes that you can connect to on the chosen network architecture • make sure that your modules suit your expected sensor and output voltage levels • check for PNP versus NPN • make considerations for inductive loads. Inducing a voltage can wreak havoc on a relay. Better to use a sourcing output module for devices that have inductive properties.

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product roundup

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36 / February 2020 / ControlDesign.com

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power supply without the need for a tester.

include short-circuit protection, encapsulated construction and

Models range from 30 to 480 W.

conservative design for long-term reliability. All models are UL

Omron Automation / 800-556-6766 / automation.omron.com

60950-, UL 508- and CE-recognized or listed components. Acopian / 800-523-9478 / www.acopian.com

Single-phase ac DIN-rail switch mode power supplies Two Slimline single-phase ac DIN-rail switch mode power

Compact power supply

supplies are available in compact housings. The SPDM general-

This compact power supply is a 3.2-in-wide, 960-W, 3-phase, 40-

purpose family offers industry-standard features in common

amp, 24-Vdc unit. Technical highlights include an input range

output configurations. The models are available in ranges from

of ac 340 to 550 V, maximum output overload current at 60

30 up to 240 W, in 12- and 24-V outputs. The SPDC series fea-

amps for 5 seconds and 94% efficiency with minimal tempera-

tures efficiency levels above 90%

ture rise. This DIN rail-mountable unit

and built-in power factor cor-

features power factor correction (PFC)

rection. The models can provide

and an output alarm relay. Also available

150% power boost for up to 3 sec-

are 48- and 72-Vdc versions in the same

onds, making them well-suited

footprint.

for applications with high inrush

Lutze / 800-447-2371 / www.lutze.com

currents. With built-in parallel function and an output-ready relay, they help ensure power always is available for critical functions. They are available in

Energy-efficient ac/dc power supplies

120-, 240-, and 480-W output versions.

These CP series energy-efficient ac/dc power sup-

Carlo Gavazzi / 847-465-6100 / www.gavazzionline.com

plies are available in 12 models ranging from 192 to 480 W with output voltages from 12 to 56 Vdc. The 39-mm-wide CP10 series (240 W) has a power den-

Switched-mode power supply

sity of 1 W/4.7 cm3, offers efficiencies to 95.2% and

The high-performance and durable

a power loss of only 12.1 W at full load. The 48-mm

Promax switched-mode power

CP20 series (480 W) has efficiencies up to 95.6%

supply units are designed for de-

with a power loss totaling only 22.1 W. Both units reduce the

manding requirements. They can

mounting space needed in control enclosures and because of their

handle continuous overload of up

low heat losses may allow the use of smaller control enclosures.

to 20% or transient peak loads of

Puls / pulspower.us

ControlDesign.com / February 2020 / 37

product showcase

CONTACT US [email protected]

Stepper- and servo-motor-driven rotary stages

jogging, homing, read inputs and write outputs. They are ap-

The low-profile 400-mm AY110-400-01 (step motor-driven) and

plicable for communications between Ethernet TCP/IP Lexium

AY110-400-02 (servo motor-driven) rotary stages feature a 180-

MDrive products and Rockwell RSLogix 5000, Siemens S7 series

mm (7.087-in) open aperture. The stage’s height is 71 mm (2.795

and Schneider SoMachine and SoMachine Motion.

in). A precise pattern of 16 threaded holes in two bolt circles

Schneider Electric Motion USA / motion.schneider-electric.com

allows for easy mounting of custom tooling and fixtures, and easily accessible mounting holes in the base enable easy integration into new and existing applications.

Absolute rotary encoders

The rotary table’s diameter is 400 mm

The NR60E2 series of networked absolute rotary

(15.748 in) and the range of travel is a

encoders has been updated with such

full 360° of continuous rotation. The

features as a Profinet interface, E2

table is driven by a smooth 360:1 worm

technology, hub shaft (blind shaft)

gear, and it has a resolution of 0.0005°.

option and stainless steel units.

Optimal Engineering Systems / 888-777-1826 / www.oesincorp.com

These rotary sensors provide an overall measuring range of 16 bits (single-turn resolution) plus 14 bits (number of revolutions), for 30 bits total.

Convergent Modeling technology for mixed models

They are 100% compatible with Allen-Bradley, Siemens and

Parasolid software enhancements include Convergent Model-

Schneider PLCs that support EtherNet/IP, Modbus TCP/IP or

ing technology, which can operate on models containing a mix

Profinet. The series also has an IP67 ingress protection and is

of facet B-rep surfaces and classic B-rep surfaces, helping to

offered in either a 63-mm-diameter package with hub/blind

enable more efficient workflows in a range of applications. For

shaft mounting style or a 58-mm package with flange or servo

example, in generative design, in which new products au-

mount options.

tonomously are developed to

Advanced Micro Controls / 860-585-1254 / www.amci.com

satisfy design constraints, the technology can restore precise, classic mating surfaces to a

Halogen-free single cables

model that has undergone

The Allen-Bradley 2090 single cables include halogen-free PUR

facet-based topology optimiza-

and PVC options. The halogen-free options are suitable for

tion. In reverse engineering processes, it can be used to add

applications in which users want to reduce exposure to toxins

precise analytic surfaces to scanned data of parts for remanu-

and for applications looking to meet IEC 60754-1. The cables

facture. The Parasolid geometric modeling kernel is used in

are designed for systems that use Kinetix 5500 and 5700 servo

Solid Edge and NX software.

drives, Kinetix VP-Series servo motors and Kinetix VPAR elec-

Siemens / www.siemens.com

tric cylinders. The cables also have a smaller bend radius for continuous-flex and static applications and are available in a range of cable AWGs, types

Add-on instructions for use with Siemens, Rockwell and Schneider PLCs Three automation libraries are available to help simplify inter-

and connector options. Rockwell Automation / www.rockwellautomation.com

facing Lexium MDrive integrated motors with PACs and PLCs from Siemens, Rockwell and Schneider Electric. The library

Thermal flowmeter with Profibus DP

add-on instructions (AOI) for

The ST80 series thermal flowmeter has been expanded to

motion control reduce the work

provide a Profibus DP solution along with its existing Profibus

of writing software programs

PA capability. The Profibus DP protocol expands communica-

to execute move profiles such

tions options between a plantwide Profibus communications

as relative and absolute moves,

system for air and gas flow metering measurement and con-

38 / February 2020 / ControlDesign.com

trol. The flowmeter can be configured

face uses a more visual approach designed to simplify coding

as either a field instrument PA device

and reduce syntax errors.

or a system RS-485-based DP device.

AutomationDirect / 800-633-0405 / www.automationdirect.com

It provides air/gas flow rate, totalized flow, temperature and instrument health diagnostics over the Profibus

Fully redundant mobile angle sensors

digital bus. In addition to Profibus I/O,

The RSA3200 series of Hall effect angle sensors feature auto-

it includes standard output options of

diagnostics, fully redundant versions and ultra-EMC tolerance

dual 4-20 mA analog (NAMUR NE 43-compliant), HART (Ver-

for use in harsh environments and

sion 7) I/O and Modbus RTU.

high-reliability applications. The

Fluid Components International / 800-854-1993 / www.fluidcomponents.com

measurement angle is factory-programmable for a range maximum between 60° to 360°. An optional

Enclosure air conditioners

linkage lever that attaches to the

The SoliTherm Progressive series of enclosure air condition-

shaft provides additional mount-

ers is UL-listed for Types 12, 4, 3R and 4X and includes an

ing options. Output versions are CANopen, SAE J1939 as well

integrated condensate evaporation

as analog: 0.25 to 4.75, 0.5 to 4.5 V and 4 to 20 mA. Resolution is

package for no-drip operation. A pro-

12 or 14 bit, and repeatability typically is ≤ ±0.36° for CANopen

grammable digital controller that is

output and ≤±0.1° for all other outputs.

viewed and operated from inside the

Novotechnik U.S. / 508-485-2244 / www.novotechnik.com

enclosure and a weight-bearing metal flange support for easier mounting are among the features. Cooling capacities are from 1,000 to 21,170 BTU/hr, and the operating tem-

Blind plates for sealing enclosure openings The KDS-BP screw-on blind plates are designed for quick and reli-

perature range is -40 to 131 °F. The temperature controller is

able closing of preconfigured enclosure

adjustable from 68 to 122 °F and has settable high-temperature

openings with standard dimensions of

alarms. Forty-four models are available, and units can be pow-

86 mm x 36 mm and 112 mm x 36 mm.

ered by single- or three-phase ac at 120, 230 or 480 V at 60 Hz.

The plates are made of impact-resistant PA 6.6 and feature an all-round injected

Seifert Systems / 401-294-6960 / www.seifertsystems.com/us

TPE gasket. They protect the insides of machines or control cabinets from dust and strong jet water according to IP66.

Arduino-compatible controller

Conta-Clip / www.conta-clip.com

The open-source ProductivityOpen platform provides all the features of a standard Arduino plus the added power and reliability of an industrial controller. The P1AM-100 Arduino-

Wafer mapping sensor

compatible CPU’s processor circuit is designed to mimic the

The BOH00EZ wafer mapping sensor uses

Arduino MKRZero microcontroller. It is compatible with most

a precise photoelectric sensor for quick

available Arduino MKR format shields and the industrially

and reliable detection of semiconduc-

hardened ProductivityOpen shields and can use most Arduino

tor wafers and slotting errors in front

sketch programs found on

opening unified pods (FOUPs). Especially designed for use

open-source websites. Using

with extremely thin end effectors, it features a controlled and

the Arduino integrated devel-

focused light spot, allowing it to detect wafers just a few μm

opment environment (IDE), the

thick. Based on photoelectric Micromote technology, it features

CPU is programmed using C++

a small LED sensor that measures 2.4 mm x 1.5 mm x 7 mm.

code; the ProductivityBlocks

This allows it to deliver precision even in small spaces.

graphical programming inter-

Balluff / www.balluff.com

ControlDesign.com / February 2020 / 39

product showcase

Online 3D model library of LVDT position sensors

all divisible cable entry frames (KEL, KEL-U, KEL-ER, KVT and

This online 3D model library of LVDT position sensors helps to

KEL-FG) that accommodate large KT cable grommets. They are

ensure proper fit and seamless integration into a new or exist-

made of elastomer, achieve IP54 and are suitable for a tempera-

ing application. Offered in .stp (STEP) and .igs (IGES) formats

ture range of 40 to 100 °C.

for near universal acceptance in CAD programs, the 3D models

Icotek / www.icotek.com

help OEMS and end users to visualize space requirements for position sensors to optimize layouts for different sensing systems. The models also help engineers choose the right LVDT as replacements for existing sensors. The 3D models

Slant-polarized, four-port omni antenna This four-port OMNI antenna is well-suited for

are available for such sensors as the company’s

WISP, cellular and fixed wireless applications. The

miniature ac-operated LVDTs, high-tempera-

27-in antenna provides 360° coverage with 13 dBi

ture (200 °C) ac-LVDT, hermetically sealed

prebeam-forming antenna gain, making it ideal for

right-angle ac-LVDT and spring-loaded ac-

micropop deployments. It optimizes 4x4 MU-MI-

operated LVDTs. NewTek Sensor Solutions / www.newteksensors.com

MO’s full capabilities with the Cambium ePMP3000, using the antenna’s two overlapping bidirectional dipole-like pattern. These patterns provide high gain to maximize coverage area and low side lobes to improve isolation between MIMO chains. The an-

Smudge-resistant coating for optical lenses and sensors

tenna includes a Cambium ePMP3000 radio mount

Sureco 2320 transparent fluoropolymer coatings protect optical

with an aluminum cover that protects the radio and cables from

lenses and sensors from oil, dust, water and fingerprints without

the environment. Depending on the radio and terrain, coverage

sacrificing clarity. They minimize smudges and enable easy

spans within 2 to 5 miles of the antenna.

cleaning without altering the appearance of the object’s surface.

KP Performance Antennas / 855-276-5772 / www.kpperformance.com

A thin layer can be applied on a glass or optical surface using a wet process such as

I/O system for small motor control

spray, dip or spin coating or

The u-remote I/O system is designed for control of small motors

a dry process such as vapor

with current requirements of 0.5 to 2 A. It also can be used for

deposition. A monomolecular

valve flap control. The switching frequencies are adjustable

layer (