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2015 - 02 - Applied Automation
2015 - 02 - Applied Automation
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Contents
A4 What does the Internet of Things
mean to people who make things?
Think: The connected machine.
From resource management to intelligent machine devices to
predictive maintenance, IoT offers plenty of things to do to make
manufacturing automation even more robust.
A4
A11
C OMMENT
Investing in automation opportunities
Jack Smith
Editor
ON THE COVER Manufacturing automation is about connecting machines to obtain more actionable information than ever before, regardless of how
you label it. Courtesy: B&R Industrial Automation Corp.
Applied Automation
February 2015
A3
A4 February 2015
Applied Automation
C O V E R S T O RY
Networked safety
Perhaps the biggest shift in mind-set for industrial
automation users is moving from hardwired safety PLCs
and relays to networked safety. It just plain scares
people to move from tightening down copper wires with
a screwdriver to consulting a software
display. Yet, we get on fly-by-wire airliners without a second thought. We
take driverless shuttle trains to the airport terminal. We dont think about it
because we cant see it, but even the
car we drive to the terminal depends
on networked devices, such as antilock brakes, airbags, and cruise control.
Networked safety holds perhaps the
greatest potential for improving productivity, along with functionality that
prevents workers from attempting to circumvent safety
systems. Networked safety has many advantages, including installed cost, testing, and diagnostic capabilities.
The concept is simple. Keep control and line power on
while ensuring that operating speeds, torques, directions,
and positions can cause no harm. Implementation is in
keeping with traditional safety implementations, comparing the primary control system status with a checksum on
an independent controller.
But instead of E-stops dropping out all power, networked safety calls for continued operation in safe
mode. Safe-mode operation is intended to prevent an
operator from being tempted to defeat a door interlock
to clear a jam, or to operate with machine guarding
removed to save steps. Instead, nip rolls cant turn in an
IoT: Things to do
IoT is much more than extending industrial networks to
the device level architecture. Its even more than distributing safety, motion, machine-to-machine intelligence, automated maintenance resources, and enterprise connectivity
to heretofore inaccessible manufacturing intelligence.
From resource management to intelligent machine devices
to predictive maintenance, IoT offers plenty of things to do
to make manufacturing automation even more robust.
C O V E R S T O RY
Figure 2: Condition-based monitoring uses networked sensors to
detect trends that could indicate
possible machine failure.
Predictive maintenance
Safe motion
Of the networked safety functions, safe motion is the
most powerful. Using intelligence and software embedded into servo/inverter drives with hardware, such as
safety encoders, it is possible for networked safety to
maintain operation of production lines, printing presses,
robots, and more in safe mode. This intelligence provides
not just the now-familiar safe torque off information, but
safe limited torque, safe limited speed, safe position, safe
limited acceleration, and much more.
Now, the machines on a line can continue to run in
safe mode when in the past an E-stop or a controlled
shutdown would be initiated to clear a jam, make a
repair, or replenish materials. The productivity potential is
enormous.
Networked E-stops
Speaking of E-stops, the E-stop button no longer
needs to be hardwired. Yes, E-stop buttons are now
available on the Ethernet network and integral to the
control panel. Enough said.
A6 February 2015
Applied Automation
Resource management
Think energy monitoringand not just electrical power
but water, steam, compressed air and vacuum, natural
gas, temperatureand you will recognize the immense
potential for improving sustainability.
Bring these monitoring activities into individual
machines and down to process unitsnot just branch
circuits or incoming power metersand the data become
much more actionable. Why does one shrink tunnel
or one shift use more energy than another? What is
the optimum line speed to balance energy costs with
throughput?
Autocompensation
Pushing more intelligence down to the device level
isnt just about communicating in the IoT. Its about inherently improving performance while removing the need
for human intervention. Leading-edge servo drives are a
good example.
Autocompensation within the drive lets it respond to
anomalies, predictively smoothing out disturbances without a technician fine-tuning the drive. No need to bring up
the oscilloscope function; no need to plug in a laptop.
Autoconfiguration
The same holds true for replacing an older component
with one that has a newer firmware version. In the past,
this has required manually resetting the new component, which often required software loaded on a PC.
Now its automatic, requiring no intervention on the part
of the user.
Onboard intelligence and Ethernet communications
between a controller and device today means that the
controller can query the new component and automatically downgrade its firmware to the version in use.
This means no need for a technician, no maintenance
software, no need to upgrade a software license, no
faults showing up, and importantly, no preconfigured
spares gathering dust on a shelf.
In Germany, and throughout Europe, technologists tend to sell technology to other technologists.
That is, as opposed to the U.S., where technologists
need to convince financial managers focused on
quarterly results that increased investment in technology is required to keep competitive and generate
organic growth. I believe this is why IoT proponents
in the U.S. tend to emphasize big data instead of the
connected machine. They are selling IT solutions to
chief financial officers.
Does this mean that 4.0 has a better chance
of actually happening in factory automation
than industrial IoT? Ive become convinced that
European industry collectively believes in the vision
of the connected machine. So perhaps machine
builders and technology providers that also believe
should target the European market first.
In Europe, call it 4.0, and when the technology
becomes established, next approach the overseas
subsidiaries of your European customers. There,
call the technology whatever they call it in those
markets. Dont let your organization be caught up in
the debate between 4.0 and industrial IoTtheyre
the same thingan Ethernet/Internet-based strategy for connecting machinery to deliver more effective operations than previously possible.
Lets make sure they use the same standards.
Applied Automation
February 2015
A7
C o v e r S t o ry
Does this unheard-of speed serve a practical purpose?
Think of firing a glue gun on a case packer more accurately,
high speed registration mark sensing, or shrinking the distance between sensor and reject station on a flow wrapper.
The I/O slices are programmed in the IEC 61131-3 languages, in the same project as the rest of the machine.
They just execute down at the slice level.
Distributed motion
Its not uncommon to see machine mounted, integrated motor/drives today, communicating over
Ethernet and providing onboard I/O. This concept
has been extended to machine mounted, distributed,
sealed drives operating conventional motors to meet
higher torque and speed requirements (see Figure 3).
Meanwhile, small drives, such as steppers used for
format changes, are taking the form of IP67-rated distributed I/O blocks.
Intelligent push-buttons
Even the lowly push-button is now a network node.
Instead of old-fashioned, hardwired, dedicated pushbuttons, push-buttons now plug into the same industrial
Ethernet cable as the I/O. They are multifunctional and
programmable, with multicolored LEDs indicating their
Autonomous maintenance
This kind of onboard intelligence, combined with inexpensive solid-state memory, leads to another big cost
saver that can make machines more efficient. The benefits
of using animation and video to walk operators and technicians through work instructions are well documented.
Why not tie those animations into the fault codes in the
control system, and walk the operator through first-echelon
troubleshooting? Using virtual network computing (VNC)
and Wi-Fi, the animations can run on the operators smartphone or tablet and they can walk around the whole line if
necessary, connected to their interactive troubleshooting
aid (see Figure 4).
This is known as autonomous maintenance. It means
that a maintenance technician may not be required to
bring the machine back on line because less experienced
operators can handle problems on their own, and that language and literacy barriers can be overcome.
Of course, if the problem cannot be resolved, the con-
Ethernet to Internet
Fundamental to IoT is the continuity of TCP/IP, HTTP,
FTP, and other universally accepted Internet communications standards across Ethernet-based industrial
networks to intranets and the Internet. Today, even a
low-cost controller is expected to provide a Web server and one or more Ethernet connections.
Network security
ISA/IEC-62443 (ISA 99) provides a comprehensive
overview of cybersecurity measures for industrial control systems. This is a complex topic requiring subject
matter experts. Suffice to say that just as IT has security standards, so does automation.
Secure VPN servers and hosted cloud services are
now widely available. Emerging now are secure services
catering to the specific needs of industrial automation.
Secure VPN capabilities are also being built into automation software suites. Large users and integrators with
extensive IT resources can apply their own solutions
across these interfaces. Machine builders and users can
source software-as-a-service solutions without investing
in additional IT infrastructure.
Services are available from third parties, control suppliers themselves, and machine builders and integrators.
A8 February 2015
Applied Automation
VNC access
Virtual network computing epitomizes the IoT. VNC
is an open-source sharing system that allows remote
access to an IoT-enabled controller without the vendors software suite. No licenses and no dedicated
communications software or hardware are required.
All you need is the controllers IP address.
OPC UA
Applied Automation
February 2015
A9
20 MILLION INVERTERS
10 MILLION SERVOS
300,000 ROBOTS
Yaskawa. Proven. Worldwide.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
VFD ISSUES
Drive selection
Drive overload
Drive overvoltage
Sources of noise
Electromagnetic interference (EMI)/electromagnetic
field (EMF) problems
Grounding issues
Incorrect configuration and/or parameter settings.
VFD loading
The main function of a VFD is varying the speed of a
3-phase ac induction motor. VFDs also provide overload
protection, start and stop control, and adjustable acceleration and deceleration. Programmable acceleration and
processor-controlled current limiting can reduce motor
inrush current at start-up, an important feature for controlling a factorys maximum instantaneous power load
and corresponding peak demand, which is often used by
the utility company to set rates or surcharges.
When specifying a VFD, its important to understand
the application and select the drive accordingly (see
Figure 1). The operating profile of the load must first
be considered. With both constant torque applications,
such as conveyors (see Figure 2), mixers, and compressorsand variable torque applications, such as
pumps, fans, and blowerscareful attention must be
paid to overload ratings.
For example,
attempting
to drive a
Figure 1: VFDs are available
fan
motor
faster
than
to fit almost any application
its base speed can
requirement. Understanding
significantly impact
these requirements helps ensure
the amount of power
optimal operation. All graphics
required as the fan
courtesy: AutomationDirect
horsepower varies with
the cube of the speed.
Running a fan too fast can thus consume
excess power and may overload the VFD,
while running it at half speed can reduce
horsepower requirements by 75% or
more, per the affinity laws, which apply
to pumps and fans.
Many applications can take advantage of this reduced power consumption at lower speeds to save energy.
An example is using a VFD to vary
VFD ISSUES
Figure 2: The photo shows a VFD installed in a conveyor systema common VFD application.
Overhauling loads
Another application that can cause issues is an overhauling loada high inertia load that must be slowed
faster than what would occur when coasting, or a load
that back-drives the motor during normal operation.
When overhauling loads are present, the motor becomes
a generator and the energy produced must be dissipated.
There are multiple options for handling this type of load.
In some instances, an oversized drive will help, but this
works only in marginal cases. A more common solution
is to use dynamic braking units with large resistors that
Applied Automation
Configuration issues
Theres no excuse for failing to
enter the correct motor nameplate
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VFD Issues
Figure 4: Modern
VFDs show faults
by displaying fault
names instead
of cryptic codes,
speeding and simplifyingw troubleshooting.
A common
configuration
parameter setting is activation
of the auto-tune
algorithm in a
vector drive, a
feature that often increases efficiency and improves control.
Understanding these configuration parameters and settings,
and adjusting as necessary from default values can ensure
proper operation, maximum efficiency, and optimal control.
Final checks
Figure 3: The photo shows an ac drive mounted and wired in a control enclosure. Oversizing a VFD enclosure aids in heat dissipation,
and can also help accommodate additional related components.
Applied Automation
Performing a few simple checks can help ensure effective application of VFDs. For any application, specifying
the correct input voltage and understanding the nature
of the load are critical. By understanding the load, most
overcurrent conditions can be easily eliminated. For most
applications, effective operation can be achieved by performing the following checks:
Ensure the input voltage is correct
Understand the nature of the load
Eliminate overcurrent conditions
Stretch out acceleration and deceleration time
if possible
n Get/keep the noise out of the VFDand the
rest of the plant.
n
n
n
n
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1. Developing ideas
2. Drafting concepts
3. Implementing solutions
4. Manufacturing machines
5. Ensuring productivity
With increasing engineering tasks and ever shorter time frames, its
good to know you have a drive and automation specialist at your side
who can make many of these tasks easy for you. We work with you
through the entire development process of your machine from initial
ideas all the way to after-sales, from the control system all the way to
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you will find more freedom to explore what really counts your ideas.
As easy as that.