A&D Aug-Sep 2014

AUTOMATION & DRIVES
VOL 07 | AUG-SEP 2014 | ` 100

www.AandD24.in
A U T O M AT I O N & D R I V E S
Engineering design
Enabling flexible design experience

Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
AUG-SEP 2014 I VOLUME 07
FOCUS Semiconductors & electronics P. 36, 42
A&D - Interview ROUND-TABLE Ushering in the robo era P. 30

Patrick Schwarzkopf
Managing Director,
VDMA Robotics + Automation
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Other product and company names listed are trademarks or trade names of their respective companies. 07926
e d i to r i a l
The next big

disruptive technology MORE PRECISION.
Robotics is said to be the next big disruptive technology in the manufacturing
sector with increasing demand for both industrial and service robotics. Although
automotive industry has emerged as the biggest customer for industrial robotics,
there has been a growing demand for robots from sectors like electronics, machine LASER SENSORS
tools, plastics, pharmaceuticals, food & beverage, etc.
Largest selection worldwide
According to a recent market report, the global demand for industrial robots from low-cost up to highest precision
reached an all-time-high of about 1,68,000 units in 2013 and the global industrial Measuring ranges from 2 to 1000mm
robotics market revenues are expected to cross US$ 37 billion by 2018. According
to industry experts, the basic reason for the continuous growth in the use of NEW High-End series optoNCDT 2300
robotics is its continuous technological development in relation with market and 49kHz; Outputs: Ethernet, EtherCAT, RS422
Handling via Web Browser
industrial requirements, accounting for product quality and competitiveness as
well as safe processes. Also, the software to work with and run robots and
automation cells has developed rapidly over the last few years and the ease of use
has transcended into more applications under a very demanding and dynamic
manufacturing landscape. This has enabled manufacturers to provide products to
the market quicker and with flexibility of variations to meet consumer demand
and at the same time ensure the quality required and the performance
demanded.
Check out the Round-table feature in this issue that highlights the market
dynamics, technology trends, innovations and new application areas in the global
industrial robotics sector.
Please do write to us with your feedback.
OPTICAL MICROMETER
Measuring ranges up to 100mm
Frequency response up to 100kHz
Resolution <0.1µm
Shekhar Jitkar Repeatibility <1µm
Publisher & Chief Editor
Diameter, gap, width and
shekhar.jitkar@publish-industry.net position measurement
editorial advisory board
Vijay Srinivasan Ganapathiraman G Dr KLS Sharma

Partner, Effectus Consulting LLP Vice President & GM Advisor
(South and South-East Asia) Automation Education & Training
Anup Wadhwa ARC Advisory Group
Director – AIA (Automation Mandar Phadke
Industry Association) Ravi Agarwal CEO, Abhisam Software
Director, Pepperl+Fuchs Former Head – Process Control
P V Sivaram (Factory Automation) Lanxess India Pvt Ltd
MD – B&R Automation
Member – AIA Raj Singh Rathee Arcot Rajabahadur
Managing Director Automation Consultant
Anant Maheshwari Kuka Robotics India
President Thampy Mathew
Honeywell India Jasbir Singh Chairman, Fieldbus Foundation India
Vice President – Electrical & Regional Sales Director,
Instrument Pepperl+Fuchs (Process Automation)
Essar Project Management
Consultants
Overseas Partner:
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China, Taiwan, Hong Kong & South-East Asia Phone contact: +91 20 2674 1009
Email: pragnesh.mori@micro-epsilon.de
A&D India | Aug-Sep 2014 3
editorial_Aug-Sep14.indd 3 8/18/2014 8:01:08 PM

CONTENTS
Market Management Focus
Semiconductors
& Electronics
10 NEWS 24 “We are looking at professional 36 MEMS vibration monitoring
service robotics” A read into the inertial MEMS
18 “Creating trained resources across Interview with Patrick Schwarzkopf, technology which is ushering in a
India” Managing Director, VDMA Robotics new era of vibration monitoring
Interview with Subash Nambiar, + Automation Association
Country Manager, PTC 42 Semiconductor test system
ROUND-TABLE An application story on how IDT
TRENDS 30 Ushering in the robo era lowered test cost by using NI
26 Strategic approach to global Industry experts in discussion on semiconductor test system
sourcing activities technology and market drivers in
An article on how TÜV SÜD industrial robotics sector
Chemie Service ensures the
implementation of quality-assurance
measures for global sourcing
Technology
EVENT REPORT
88 Creating information driven Cover Story
digital enterprises
A post-event report on ARC 20 Enabling flexible design experience
Advisory Group’s 12th India Forum The article focuses on the latest
functionalities added in Synchronous
Technology, ST7 – the latest version
of Solid Edge
CONTROL & REGULATION

48 Open core engineering 54 Evolution of switching interfaces
The article on open core engineering The article details on ultra-slim relay
that increases application flexibility interface modules that provide a
and engineering efficiency across low-cost, space-saving solution for a
value chain host of industrial applications
ULTRA FAST AUTOMATION

1μs RESPONSE TIME
www.br-automation.com/reACTION
Phone: +91-20-41478999 Email: sales.in@br-automation.com
content page_Aug-Sep14.indd 6 8/18/2014 8:52:26 PM

CONTENTS
Technology
Advt
WIRELESS AUTOMATION 76 FIELDBUS & NETWORKS
58 Applying wireless to Ethernet/IP Remote eavesdropping
An article on the use of wireless An application story on how an
technologies in Ethernet/IP based American manufacturer of equipment
networks for industrial automation for concrete pipe production added
systems remote maintenance capability
66 Wireless technology for utility
monitoring 80 M2M COMMUNICATION New Products
A feature on how wireless technology Transforming industrial & energy
from Emerson helped Hindustan Zinc systems with IoT 93 OPC Unified Architecture for
improve visibility in real-time A feature highlighting the challenge in industry 4.0; Signal
translating intelligence in connected conditioners; Screw clamp fuse
MOTORS & DRIVES embedded devices to new products terminal blocks; Heady duty
68 Out-of-the-box ideas encoder
The article highlights on how Universal MACHINE VISION 94 Intelligent earth leakage relay;
Robots aims to establish the flexibility 83 Keys to successful multicore Data portal; Relay interface
of articulated-arm robots in industrial optimisation modules; Pressure transmitters
production A read into how to optimise machine & sensors made of titanium
70 Intuitive engineering vision application for multicore PCs 95 IT powered automation; Linear
A read into how thermoforming through field-testing modules; Handheld barcode
machines can be equipped with 86 Revolutionary simple & readers; Eddy-current
efficient synchronous motors ingeniously fast measuring system
Article on the new 3D vision
72 ROBOTICS & HANDLING automation for greater flexibility &
Designing cable management higher productivity
systems for 6-axis robots Columns
An article on designing cable 92 TECH TALK
management systems for 6-axis robots Cable trolley solution 07 Editorial
An insight into cable trolley system 08 Contents
used to support, protect and manage 96 Highlights - Next issue
flat & round cables for the transfer of 96 Company index
electrical energy & data
Advt
< Replaces dedicated hardware reACTION

TECHNOLOGY Find out more.
< Freely programmable
< IEC 61131, Function Block Diagram
< Reduces CPU load
< Reduces machine cycle time
content page_Aug-Sep14.indd 7 8/19/2014 3:36:05 PM

market | news
Manufacturing PMI rises to 17-month high in July Providing modern automation solutions for the Indian market
According to HSBC Purchasing Managers' Index (PMI), manufacturing SPS Automation India will take place on February 5–7, 2015, in Ahmedabad,
activities in India in Gujarat. The show will be
July 2014 was the organised by Messe Frankfurt
maximum compared to Trade Fairs India. Focused on
the past 17 months on modern automation solutions
increased orders. PMI for the Indian market, SPS
was up by 53 points in Automation India will cover a
July 2014 from 51.5 in wide range of topics from
June 2014. As per automation products to
Markit Economics, services and solutions, in The trade fair, will represent a leading
which co mpiles PMI order to meet India’s demands platform for advancements in automation
data, output grew at as one of the fast growing and their cost optimising and latest
the quickest rate in line automation markets in the technologies in factory and process
with the headline world. The trade fair, will automation
indicator, in the past 17 represent a leading platform
months (since Feb 2013), marking a 9-month period of increased production. for advancements in automation and their cost optimising and latest
Among the monitored sub-sectors, makers of intermediate goods raised technologies in factory and process automation. Commenting on India’s
production at the sharpest pace. The eight core sector industries, which high-growth path over the next decade, Raj Manek, MD, Messe Frankfurt
have a combined weight of 38% in the IIP, increased by a 9-month high of Trade Fairs India, says “India, has established itself as an economic
7.7% in June 2014, signalling that IIP and manufacturing could see better powerhouse and has the potential to become the world’s 5th largest
recovery in the month. consumer market by 2025.”
> MORE@CLICK ADI03514 | www.AandD24.in > MORE@CLICK ADI03515 | www.AandD24.in
Siemens PLM software used at Toyota Turck opens assembly line in Pune
Toyota Motor Corporation has expanded its vehicle safety information Turck India Automation recently inaugurated a new warehouse-cum-
management system based on Siemens’ Teamcenter® software. The assembly line at Hinjewadi industrial area and shifted to a new office at
system has been in use since January 2013 as part of a comprehensive Baner – Balewadi Link Road, Pune.
initiative to produce safe vehicles for its Announcing the new facility,
customers. Teamcenter was selected Pradeep Arora, MD, Turck India,
based on its widespread usage said, “The assembly line is a small
throughout the global manufacturing start for Turck’s manufacturing
industry. Market requirements regarding footprint in India. This has been
safety compliance for vehicles are possible with the able support of
The company’s successful deployment constantly increasing. In 2011, the our customers, vendors and the Turck officials announcing the
of Teamcenter has allowed it to International Safety Organisation (ISO) channel partners”. He also launch of its India manufacturing
enhance collaboration between published the ISO 26262 Functional thanked Ulrich Turck for showing operations
multiple divisions and significantly Safety standard which defines functional confidence in Turck India
improve traceability management safety for automotive equipment operations. On the occasion, Ulrich Turck, MD, Hans Turck GmbH, shared
applicable throughout the lifecycle of all the company’s technological vision for the growing needs of factory &
automotive electronic and electrical systems. In order to ensure compliance process industrial automation. Turck said, “In the expansion mode, apart
with ISO 26262, Toyota decided to implement a new safety information from sales, we have added expertise in terms of integrated solutions for
management system based on PLM that would standardise processes customers; system integration together with hardware combination,
across multiple divisions. After evaluating several PLM software systems, including 3rd party products; and value added solutions on-site. We have
Toyota selected Teamcenter. Toyota cited the widespread adoption of also added sourcing of components from the Indian market. As India has a
Teamcenter by the global manufacturing industry and Siemens’ open policy vast engineering talent pool, we are also planning to use India as an
for PLM technology as important factors in its decision. engineering pool for our activities.”
10 A&D India | Aug-Sep 2014
Market_news_Aug-Sep14.indd 10 8/19/2014 3:39:10 PM

market | news
Bhadresh Dani Joins Bharat Bijlee Fieldbus Foundation & HART Communication Foundation join hands
Bhadresh Dani has recently joined Bharat Bijlee as Vice President & Head Fieldbus Foundation and the HART Communication Foundation join hands
– Drives & Automation Division. A to create a new industry organisation dedicated to the needs of intelligent
Power Electronics Engineering devices and their integration in the world of process automation. The
graduate, he completed his combined power of both these organisations will serve to protect the
management education from investments that end users in process
Henley Management School, UK automation have made in HART® and
and IIM - Ahmedabad as well as a Foundation fieldbus communication
leadership development program technologies. The mission of the
from the Scandinavian Management combined organisation is to develop,
Institute, Denmark. Prior to joining manage, and promote global standards
Bharat Bijlee he was with Danfoss for integrating devices into automation-
Bhadresh Dani, Vice President & Head Industries, and he brings with him system architectures, providing
– Drives & Automation Division domain expertise and rich functional solutions for process
experience to realise Bharat automation suppliers and end users. Suppliers will also profit from the
Bijlee’s ambitious growth strategies in the Drives and Automation segment. increased efficiencies in resource utilisation, procedure consistency and
Bharat Bijlee is one of the leading professionally managed companies member service and support improvements. These two organisations will
engaged in the manufacture & marketing of transformers, motors, pump continue to exist individually, and evolve into the future. Each protocol will
sets, industrial electronics products, drives & automation and execution of retain its own brand name, trademarks, patents, and copyrights. The new
turnkey electrical projects. The company's manufacturing facilities are organisation will continue development, support, and promotion of the two
located on a 1,93,000 sq m campus, with a working area of approximately existing protocols, and will direct the development, incorporation, and
50,000 sq m, in Airoli (Navi Mumbai). implementation of new and overlapping technologies.
Republic of Rwanda – the partner country for AUTOMATION-2014

IED Communications Ltd in its continual endeavour of promoting Indian East Africa, ranked 3rd in African countries as per the Global Competitive
automation industry on the global platform, has now Index Report 2013-2014. In Rwanda, new special
reached African countries. Republic of Rwanda, one of economic zone has been developed and operational.
the rapidly growing countries on economical and More zones are planned on the districts level. Rwanda’s
infrastructural levels is the partner country for workforce has demonstrated increasing capacity for
AUTOMATION-2014 exhibition. The 9th edition of knowledge-based industry. “The Govt of Rwanda is very
AUTOMATION-2014 will be held on 15-18 October 2014 investor-friendly and committed to market the economy,
at the Bombay Exhibition Centre, Mumbai. Other African which is very inspiring for Indian industry and especially
developing countries are also expected to come on the for the automation industry. Indian industry should grab
board as bilateral partner countries for the event. The the potential opportunities for investment abound,
Govt of Rwanda and other African countries will have a particularly in the sectors such infrastructure, energy,
strong presence at the event with participation from the information and communication technology, mining,
Govt representatives and business delegations. “We are M Arokiaswamy, MD, IED manufacturing, real estate and construction & financial
proud to serve Indian industry for its economical growth Communications suggests that services & agriculture,” added Arokiaswamy.
through business development on the platform of India should grab the potential AUTOMATION-2014 will also be organising knowledge-
AUTOMATION-2014”, said M Arokiaswamy, MD, IED opportunities for investments based technical conferences, in-depth discussion with
Communications. abound experts on various subjects like innovations in
Republic of Rwanda is an attractive destination for technology, Foundation Fieldbus technology, safety and
foreign investments. There is a great opportunity for Indian industry to security, tank automation & metering.
develop business in Rwanda, the most competitive place to do business in > MORE@CLICK ADI03520 | www.AandD24.in

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market | news
Shaping the future of embedded design MathWorks conducts MATLAB EXPO 2014
National Instruments recently announced NI SOM, the first global product Mathworks recently conducted MATLAB EXPO — the 5th edition of its
launch from India, with the company introducing a major transformation in annual user conference in Bengaluru and Pune to cater to a growing
embedded technology for the world at Chennai. It combines the Xilinx Zynq customer base in the country. The two-city event welcomed more than
All Programmable system on a chip (SoC) with supporting components such 1000 participants from the commercial,
as memory on a small PCB and features a complete middleware solution government and academia sectors.
and ready-to-go Linux-based real-time operating system (RTOS) already Design engineers, professors and
integrated. With this industry experts were in attendance from
launch, it is paving across the aerospace & defense,
the way for its automotive, computers, electronics and
e m b e d d e d semiconductors, industrial automation
technology to be a and machinery and technology services
game changer for industries. Jason Ghidella, Product The two-city event welcomed
With this launch, it is paving the way for its embedded the future. “The NI Manager — Simulink platform & controls, more than 1000 participants from
technology to be a game changer for the future System on Module MathWorks, delivered the keynote the commercial, government and
(SOM), combined address titled ‘Behind today’s trends: The academia sectors
with powerful LabVIEW libraries, enables engineers to transform their ideas technologies driving change.’ The
into embedded products faster than any other tool available on the market. highlights of the two-city event included Simulink and LEGO MINDSTORMS
Healthcare devices, smart machines and other applications that require NXT workshops that demonstrated the potential for project-based learning
embedded technology will benefit as the NI SOM not only speeds up, but techniques while teaching undergraduate technical courses. Participants
also bridges design, prototyping and deployment with a single platform,” worked through lab modules with examples of sound tone control, line-
says Joel Shapiro, Leader for Marketing, Emerging Markets Region. following robots.
Frost & Sullivan to host a forum on enhancing manufacturing competitiveness

Frost & Sullivan’s Industrial Automation & Process Control (IPC) Practice tracked the manufacturing sector in India for more than a decade, Frost &
will host Industrial Technologies summit 2014 Sullivan is confident that the current slowdown
titled, “Enhancing manufacturing in the Indian manufacturing sector is a
competitiveness: Reality of adopting global temporary phenomenon. India has the
trends and technologies in the Indian context”, potential to be a manufacturing powerhouse
on October 8, 2014, in Mumbai. The summit of the world”, says Niju V, Director, Automation
will highlight the mega trends in the Indian & Electronics, Frost & Sullivan. He further
manufacturing industry and the evolving adds “Advanced automation and control
imperatives that enable companies capitalise solutions are expected to play an important
on short term growth opportunities. The part in this transition.”Apart from knowledge
summit will focus on sharing best practices gathering on future prospects for the market
and ideas on how to leverage innovative and evolving dynamics, the event is poised to
technologies and best-in-class solutions as a facilitate business interactions that can evolve
resource to address the evolving challenges Representational image from the last edition of enhancing into long term rewarding relationships.
for a better tomorrow. It will examine the manufacturing competitiveness event hosted by F&S Participants would benefit from insightful and
reality of adopting global technologies and strategic discussions involving industry
following international trends in the unique context of India. Success stories experts and the opportunity to meet and network with peers and potential
will be showcased and key challenges will be examined with respect to customers. The event will also have an awards evening and witness the
implementing state-of-the-art technologies and solutions. It will bring coronation of the industry's best-in-class companies at the Excellence in
together solution providers and solution adopters in a true meeting of Industrial Technologies Awards, India banquet.
minds, to collectively deliberate on the key steps to be taken to catapult the
process, discrete, and batch industries into a new growth era. “Having > MORE@CLICK ADI03523 | www.AandD24.in

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market | interview
“Creating trained resources across India”

Subhash Nambiar, Country Manager, PTC, discusses Indian manufacturing industry and how
companies are looking at creating and delivering smart, connected products to their customers,
during an interview with Srimoyee Lahiri. Excerpts…
How crucial is the Indian market for PTC? University Academy program supports this initiative and many
India is a very important market for PTC. We offer products customers are enjoying the benefit of the product through this
in CAD, Application Life Cycle Management (ALM), Service knowledge.
Lifecycle Management (SLM), and Product Lifecycle
Management (PLM) and now, we also have a platform for As the new leader at PTC India, what are your strategies to
Internet of Things (IoT) to meet customer expectations. We enhance performance during this fiscal year?
have customers in India who have invested in our flagship 3D I am excited to join PTC which owns a long history of
product and Pro E for the past 20 years. Like any other industry, technology innovations and is the leader in technology
manufacturing industry, particularly automobile, faces a lot of solutions that transform the way companies create and service
competition from both domestic and international companies. products. India is one of the fastest growing markets in the
Most of the companies look at reducing their manufacturing world with a significant customer base for us. As a strategy, we
cost and India is no different. In the last three decades, we have always looked at changing environment and industry needs
grown from a CAD company to a software and offered products and services to help our
product and service solution provider for customers achieve competitive advantage.
manufacturing companies. Many Indian The company has pursued an aggressive
companies are using our products for meeting strategy of acquisitions and rapid organic
their industry transformation. development to expand its offerings into fast-
growing markets. We currently have huge
What are your views on cloud computing in focus on creating well-trained resources
CAD space? across India.
There are mixed responses from the
customers on cloud computing due to What are the latest technology & demand
security, bandwidth, uptime, dependency, trends in your domain?
etc. At present, based on the customer Indian manufacturing industry contributes
requirements, we have been offering Creo more than 50% of export revenue and is
software in CAD space on our perpetual 15% of India’s GDP. All the manufacturing
license model. If customers are looking at a companies are looking at how they can
managed service, we are in a position to offer them a private create smart, connected products. In the IoT era, customers are
instance model, offering a better performance and uptime at a bringing to market increasingly smart and connected products
lower cost compared to the customer hosting the solution in which can generate value in new ways as streams of real-time
their infrastructure. operational data are captured, analysed, and shared to deepen
a company’s understanding of its products’ performance, use,
How is PTC pursuing its service strategies in India? and reliability.
We have been encouraging our partners to imbibe enterprise Acquiring ThingWorx will allow us to accelerate and help
consulting using our service advantage program to drive value our customers capitalise on the market opportunity that the
based selling to enterprises. The customer gets a complete IoT presents. The opportunity, however, goes well beyond this
solution either directly from PTC or through partners immediate pragmatic application. Industries of all types are
from consulting, product positioning, implementing and poised to see disruption from the Internet of Things and the
getting the solution advantage - meeting/exceeding customer expanding networks of connected sensors and devices, and
expectations. a growing ecosystem of ThingWorx partners is forming to
Apart from consulting and implementation, we also capitalise on this growth. ☐
provide high-end training to adopt our e-learning tools
supported by trainers in precision learning programs. Our > MORE@CLICK ADI03524 | www.AandD24.in
PTC_Market Interview.indd 18 8/14/2014 8:59:40 PM

Page 19_CST 210X273.pdf 8/19/2014 4:50:14 PM
CM
MY
CY
CMY
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c o v e r s to r y | t e c h n o l o g y
Engineering design
Enabling flexible
design experience
For manufacturers to realise more profitable

innovation, they need to consider opportunities to
optimise & accelerate designs, improve validation
earlier in the development process, enable faster
product to market, reuse 2D & 3D at maximum, and
improve visibility to program execution and risk
management. Siemens PLM Software’s Solid Edge has
been able to address these needs, and ST7 - the latest
version of Solid Edge with Synchronous Technology Sumedha Mahorey
Deputy Editor
brings in breakthrough innovations in this area. sumedha.mahorey@publish-industry.net
coverstory_Aug-Sep.indd 20 8/18/2014 6:58:59 PM

t e c h n o l o g y | c o v e r s to r y
Blank body functionality
Manufacturers have to rely on a combination of design that were possibly unnecessary or redundant. This was the
innovation, more electronics and embedded software content principle applied when Dynamic Dimensions were added.
to meet the demands of the marketplace, today. They are also This allows users to key in dimensions as they sketch without
required to demonstrate and provide increased responsibility stopping to click an icon. In the case of a rectangle, users can
for the design, development, prototyping and final production apply multiple dimensions, just by using Tab to move between
of parts. Siemens PLM Software was able to respond to these fields. If they don’t want to use the Dynamic Dimensions, one
challenges with Solid Edge, a hybrid 2D/3D CAD system that can ignore them without the need for extra steps (or turn them
uses Synchronous Technology (ST) for accelerated design, off altogether).
faster revisions and better re-use of imported geometry to help Part of focusing on the user is certainly making the
companies design better. Packed with over 1,300 user- interface more intuitive with more “heads-up” functions.
requested enhancements, the latest version of Solid Edge – ST7 Heads-up interface elements have enabled the user to keep
has grabbed the attention of its existing as well as new adopters focus on the work area while helpful cursor symbols or other
worldwide. With its remarkable attention to detail, newly- visual feedback help to indicate items such as selections or
added functionalities and ease of use, ST7 was introduced in automatic sketch relations.
May, this year during the Solid Edge University 2014. One of the new enhancements where this is most evident is
Based on four major pillars of development – accelerated in the Quick View Cube, displayed in the lower right corner.
3D modeling, streamlining design management, powering up One can select from dozens of view orientations directly from
with new apps and amazing user experience – ST7 features the cube. Select a corner for an isometric, or a face for a
some standout enhancements such as patent pending duplicate primary named view. Rotate with the arrows.
components command, blank from a 3D model, powerful New document templates have been organised by drafting
photorealistic rendering using KeyShot®, and enhanced standard as well as units, and document type (part, assembly,
Microsoft Surface Pro functions, among many others. draft, sheet metal). Using units in this way is new, and enables
Dan Staples, Vice President, Solid Edge Product users to have templates set up in various units for different
Development, Siemens PLM Software, while focusing on the purposes rather than needing to do this at the time of creation.
product development strategy behind the new upgrade, During installation of the Solid Edge software, templates are
asserted, “The key thing in development is to ensure that with created and saved based on the language specified in a user’s
every function added, complexity is kept to the minimum. Operating System, and all templates for all standards are saved
There is saying, if I had more time, I would have written less. for later access. This allows multinational companies to easily
Similar is the trend in user-based design. It is very easy to work with multiple standards.
cover everybody’s needs, but to do that elegantly where it is Along with the new startup screen comes a new File Open.
simple to use, and caters to everybody’s requirements is quite Solid Edge has implemented the Microsoft File Open standard
hard. But we have successfully achieved this in ST7.” interface. This allows the user to reuse knowledge from other
Office applications such as Word, Excel, or PowerPoint, also
Enhancing users’ experience enabling tasks such as copy/paste, delete, rename, sorting, and
previews. Providing a consistent experience across the entire
A great deal of attention in ST7 has been applied to technical computing environment leverages shared skills and
streamlining the interface and trimming areas of the workflow saves time.

c o v e r s to r y | t e c h n o l o g y
Users can publish their designs to Drawing views of parts and subassemblies ST7’s user experience features an intuitive
GrabCAD Workbench for collaboration coexist with views of the top level product user interface which informs users’ work
with team members, suppliers and
customers
Tool tips have been enhanced to include short video clips allows users to continue to work that way. But in ST7, users
for simple actions. This is not only good for users migrating can now fence-select objects, and then select the sketch relation
from other CAD packages, but has been singled out by CAD which they want to apply. This is essentially Object-Action.
managers of larger organisations as being helpful in training What’s new here is the ability to do it either way. If a user has
and in reducing support inquiries. different types of geometry selected, for example, lines and
circles, Solid Edge automatically filters the entities for valid
Accelerated 3D modeling types (for example, circles cannot be made parallel).
3D sketch is a new function, and is available for all types of
First things first. In most cases, designers start off by entities. This used to be only available for pipe/wiring functions.
applying/choosing a relevant material for a part. ST7 has Making this available for general modeling (consistent in Part,
brought big changes to material tables. Users can now group Sheet Metal & Assembly environments), most specifically
materials, Table Primitives select them from a visual interface. wireformed products, will be a big time saver.
Material data can be imported from sources such as Matlab. 3D measure tool: A new and comprehensive 3D Measure tool
com using an Excel file. Materials include mechanical and is also part of ST7. The results of 3D Measure are visual, and
visual properties that are reused downstream by mass the window stays available until the user dismisses it. The text
calculations, stress analysis and even rendering applications. from the results can be copied to be used in other dialog boxes
or dimension entry boxes, which will save a great amount
Quick Shapes / Primitives of time.
Sheet metal: In ST7, sheet metal has got a fair bit of attention.
Quick Shapes are a set of primitives for box, cylinder and The “part to sheet metal” enhancement, which enables to wrap
sphere. For example, to create a sphere in ST6, one would have a sheet metal part around (outside or inside) a solid body, is a
to sketch a semi-circle on a plane and revolve it. In ST7, users remarkable feature. In fact, in one example, creating a particular
can click a keypoint or any point on a plane and drag a radius. sheet metal part has been found to be 5X faster than doing so
According to Dan Staples, this results in four times fewer in previous versions.
clicks. Blank body: Also noteworthy is the Blank Body functionality,
which flattens a punched, drawn or formed sheet metal shape.
Intelligent relationship filters This tool can also be used on lofted shapes, for example, on a
fabric seat cover. This tool replaces separate third-party
Another ease of use enhancement aimed at easing migration software that would cost thousands on its own.
from other CAD systems comes in the sketch environment. In Standards-based holes: One of the most exciting of the
ST6 and prior, to assign sketch relations to multiple sketch revamped Solid Edge ST7 tools is the Holes tool. In the past, a
elements, a user would have to click on each element user would need to have their Machinery’s Handbook available
individually, and use the Action-Object workflow. There was to reference hole sizes for particular bolts correctly, ST7,
nothing wrong with working that approach, so Solid Edge however, incorporates all of this information in an editable

t e c h n o l o g y | c o v e r s to r y
3D Sketch provides the users a fast Streamlined, graphical and intuitive Material selection is made easy with an
creation method for components bent in design management bought to you by intuitive interface presenting multiple
more than one plane Solid Edge SP libraries utilised by different departments
database, and enables one to select hole sizes based on screw Classic and Premium versions. A single click will take a Solid
size. Users can also specify edge breaks and bolt head clearance. Edge model with its visual properties into the Keyshot
This is a big step forward in automating machine design parts. environment. The Live Link function enables updates to the
Comprehensive material definition: A more intuitive, visual Keyshot geometry directly in Solid Edge, so users never have
interface for storing, categorising and applying material to start over again after re-importing.
specifications is also available with ST7. The interface has Improved productivity for working with massive assemblies:
enhanced material appearance preview capabilities and users Users now have more control over the extent to which an
can add their own properties. Material information can be assembly is recomputed during open and save operations using
imported from external sources and stored in multiple libraries the Limited Update option. This option speeds response times
to support the needs of different departments. when working with large assemblies. Users can also check for
Duplicate component tool: This functionality is “Patent out-of-date components within an assembly and update & save
Pending”. Turning to assemblies, a duplicate component tool them using the Component Tracker command.
has been added to ST7. This is like a pattern, but it works Users can also insert reference assemblies from a higher
where there are no identifiable regular patterns. For example, level of the assembly into the current level, enabling this data
if there is a set of parts that fit into every bracket in the to be used as part of the design process while maintaining
assembly, Duplicate Component will take the original set of correct bill of materials (BOM) generation. They can also
parts and duplicate them in every situation where it finds that designate assemblies as simplified assemblies that are treated
bracket, orienting the parts to match the original occurrence. as leaf parts and are not automatically expanded. This improves
Early trials found this to be 10X faster than doing the work performance when working with large assemblies, while users
manually, and results in fewer assembly relations. can still expand these assemblies as needed.
ST7’s new ability to rename a family of assembly (FOA)
member is another enhancement that’s sure to be a huge time ST in the future?
saver. In draft enhancements, the automatic placement and
arrangement of coordinate dimensions on parts is a new tool. With patent pending innovations & breakthrough tools
For this, the amount of time saved is a function of how many already included in the ST7, what should users expect in ST8
dimensions of this type are used. This new function actually next year? Answering this, Staples affirmed, “Some years ago,
makes coordinate dimensions feasible. we saw traction in direct modeling in ST, but then it was just
Enhanced Microsoft Surface Pro support & Keyshot: The not adequate. We thought that direct modeling needed to be
Microsoft Surface Pro offers full support for Solid Edge design addressed in a completely new way and we have been successful
tasks and expanded support for finger gestures is now included. in achieving it. We think there is a lot more potential in ST in
For example, a single finger drag enables a pan operation in the future and we will continue to explore it in unique ways for
2D and a rotate operation in 3D, and a two finger pinch enables all industry models.” ☐
a zoom-in operation. ST7 also features a significant inclusion
of Luxion’s Keyshot software available with Solid Edge Keyshot > MORE@CLICK ADI03525 | www.AandD24.in

management | interview
“We are looking

at professional
service robotics”
Patrick Schwarzkopf is the new
Managing Director of VDMA Robotics
+ Automation Association, which has
nearly 250 member companies. In this
exclusive interview with Megha Roy,
he stresses on the growth prospects in
the industry, foreign markets focus and
development opportunities for newer
applications
What are the recent developments in VDMA Robotics + exports. Naturally, we are supporting our member companies
Automation in terms of new managing board, new initiatives, in becoming more global through our VDMA representative
international activities, global strategies, standardisation offices in India.
plans, etc?
This year, we focused on the AUTOMATICA Fair in Munich, How do you look at the performance of the robotics &
which presented the latest trends in robotics and automation. automation sector, in Europe as well as globally? How are
The latest development is the direct cooperation between the the growth prospects in 2014?
industrial robot and the human worker. VDMA Robotics + The robotics and automation sector has been receiving a lot of
Automation has published a position paper that helps users attention recently. The European Commission has just launched
ensure that such solutions are absolutely safe. Another topic SPARC, the world’s largest civilian research programme for
that is high on our agenda is sustainability. We provide many robotics. AUTOMATICA 2014, the leading trade show of the
solutions for increased safety, the more economical use sector, concluded with record results. There is great demand for
of material and saving energy. We are also looking at new robotics and automation technology from high-wage as well as
application areas, such as professional service robotics. The low-wage regions across the world. Therefore, we expect the
robotics and automation sector is also expanding exports global turnover of the German robotics and automation sector
every year. Currently, some 55% of business is made through to grow by 7% in 2014.
Patrick_management_Interview_Aug-Sep14.indd 24 8/14/2014 7:57:25 PM

i n t e r v IE w | m a n a g e m e n t
“Industry 4.0 will be the next leap

development that will bring a
paradigm change”
Patrick Schwarzkopf
Besides automotive industry, what are the other major way through production and will book certain “services”,
industries being targeted globally? Do you plan to come up e.g. robot. The devices will communicate with each other,
with any new application in the near future? everything will be a network, all players uniquely addressed
For robotics and assembly technology, automotive industry (e.g. with an own IP address) and the production will become
accounts for some two third of sales. For machine vision, the much more flexible and efficient. This integration will pave the
situation is much more diversified, with approximately one way for new business models, in which the customer’s order
quarter of turnover going to automotive. Electronics is a major will trigger the manufacturing of an individualised product
application field. We believe there is a big growth potential that need not be more expensive than today’s mass produced
in the food and pharmaceutical industries. In machine vision off-the-shelf item. Robots will come out of their protection
applications “outside the factory” are the big growth drivers, cages and will collaborate directly with human workers. Each
such as intelligent traffic systems, surveillance or precision side will focus on their specific strengths and the outcome
farming. will be increased productivity. To reach this goal, the robots
must be made safe to work with in a shared work space. Our
How do you look at the business potential in India for the members are developing the necessary solutions.
robotics & automation sector? Any new initiatives/activities
planned from VDMA India office? According to you, where will be the focus of technical
The technology is indispensable for many products that developments for the next few years?
are miniaturised, safety-critical and of particularly high The application of robotics and automation will be made a lot
quality. If an economy wishes to play a major role in the easier and more intuitive. The result of it will look simple, but
high-tech segment, it needs to apply robotics and automation the technology behind it is complex. This requires new ways
in production. Currently, the so-called robot density (the of communication and collaboration between humans and
number of industrial robots applied per 10,000 employees in machines through gestures or speech recognition.
the manufacturing sector) is still very low in India. Thus, there
is still a very big potential which will gradually be tapped over How important is the networking of different areas of
the coming years with time. In the meantime, we will monitor industry as well as different countries so as to make a
the Indian market, provide information services and organise globalised technology approach?
a management meeting later this year. To employ robotics and automation to the benefit of the
companies, the workers and the customers, a thorough
What are the technological breakthroughs expected in knowledge is needed on the technology, specific market
the robotics & automation sector in the coming years, for requirements, skills of the workers and many more factors.
example, Industry 4.0, Big Data, Cloud Computing, Digital Those who are good communicators and networkers and those
factory, human-robot collaboration, etc? who share knowledge will be taking the lead and producing the
Industry 4.0 will be the next leap development that will bring a best solutions. ☐
paradigm change: If production systems are currently centrally
controlled; in the new scenario, the workpieces will find their > MORE@CLICK ADI03526 | www.AandD24.in
Patrick_management_Interview_Aug-Sep14.indd 25 8/14/2014 7:57:27 PM

market | trends
Strategic
approach
to global
sourcing
activities
For global sourcing in
the chemical and process
industries, quality assurance
schemes embracing the whole
supply chain are imperative.
This article highlights how TÜV
SÜD Chemie Service points out
such weaknesses and ensures the
implementation of quality-assurance
measures.
Kurt Schumacher
Global sourcing expert & Member of
Managing Board
TÜV SÜD Chemie Service GmbH
kurt.schumacher@tuev-sued.de
For companies in the chemical and process industries, considerable risk factors.
reducing the cost of materials is one of the essential strategies Globally sourced products do not always reliably fulfil the
to stay competitive. Known as ‘global sourcing’, medium-sized relevant legal, regulatory and standard requirements in the
enterprises are increasingly joining large multinationals in country of destination. Ultimately, quality or delivery issues
engaging in procurement management at international level, may use up the forecast savings. When quality-assurance
to identify lower-cost sources. The construction of world-scale aspects are not examined individually and in detail but only
plants, for example, is moving over to emerging markets, a across the board, opportunities and risks may become distorted.
trend accompanied by increasingly networked international A one-sided focus on purchasing prices may consequently
supply chains. Manufacturers purchase plant components – become expensive; all the more if extensive rework becomes
including process-engineering equipment and pressure vessels necessary in a country with high labour costs before a plant or
for the European market – at attractive prices in, say, India. piece of equipment can be placed into service.
Conversely, complex high-tech equipment such as process-
engineering devices made of special materials or process- Approaches
control systems are imported to the Asian market from
countries such as Germany. Against this backdrop, a more strategic approach to global
While the share of third-party costs in revenue has been sourcing activities by purchasing departments makes good
rising for years and numerous studies have raised awareness of sense. Such an approach must include all relevant types of
sustainable purchasing, practice shows that there is a common costs, e.g. investment costs, life cycle costs and total cost of
trend towards “Best cost sourcing”, which can involve ownership, in the purchase decision. To do so successfully,
Market-Trends_TUV.indd 26 8/14/2014 7:50:24 PM

Page _27_Hilscher A&D 210X273.pdf 8/14/2014 4:33:35 PM
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Hilscher_EH_gateway_210x297.indd 1 06.06.2014 14:10:42

market | trends
A systematic and complete

purchasing strategy that extends
along the entire supply chain is of
critical importance
quality assurance along the supply chain must cover the entire Success factors in global sourcing
manufacturing process up to shipping from the country of
• Systematic and complete overall strategy
manufacture. The devil is frequently in the detail when
• Individual opportunities and risks analysis, cost-effectiveness,
problems arise later on. In these cases, statutory and singular empirical values
tests will not be enough to identify and eliminate critical issues • Comprehensive project specifications (design, materials,
before they turn into problems. Furthermore, many purchasing manufacturing, testing, quality assurance, documentation)
experts underestimate supply chain dynamism, which renders • Manufacturer selection and evaluation
adequate process design next to impossible without in-depth • On-site quality assurance (in-line and pre-shipment inspec-
familiarity with the local market situation in the country of tions)
origin. • Familiarity with the local situation (language, culture)
Given this, a systematic and complete purchasing strategy • Flexibility in supplier management (high dynamism in some
that extends along the entire supply chain is of critical supplier countries)
importance. This strategy must consider economic and
technical aspects, but also supplier relationship management,
including monitoring of production conditions. First and
foremost, this means thorough selection and evaluation of of Bayer, Dow Olefinverbund and Hoechst, the specialists are
manufacturers, watertight specification of product on-site at all major chemical and industrial centres in Germany
characteristics and differentiated control of implementation. and accompany their clients to international markets,
expanding their worldwide presence. This ultimately created
End-to-end quality management the Team of Global Networking, a group of specialists dedicated
to intensive exchange of know-how and experience.
The central element of an optimised procurement strategy To ensure that the materials used will also meet the
is quality assurance that primarily aims at ensuring that the ambitious requirements, the experts combine conventional
design of the purchased systems or components is in conformity and innovative non-destructive testing procedures. Based on
with the rules. Project specifications, too, must be decades of experience in the chemical and process industries,
comprehensively clarified to ensure end-to-end quality the experts have adopted the indispensable high level of quality
management. This includes, for example, the traceability of as a core value, supporting purchase decisions in global
materials and the completeness of the required documents sourcing to ensure far-sighted planning and keep the risk of
such as drawings, plans and documentation. service interruption to a minimum. ☐
At what point does TÜV SÜD Chemie Service support
global sourcing? Originating from the former user inspectorates > MORE@CLICK ADI03527 | www.AandD24.in
Market-Trends_TUV.indd 28 8/14/2014 7:50:26 PM

Page 29_Bosch Rexroth 210X273.pdf 8/18/2014 7:46:16 PM
CM
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m a n a g e m e n t | r o u n d - ta b l e
USHERING IN THE ROBO ERA

With the number of robots in the world crossing well-over
1,000,000 mark, this feature aims at analysing the various
technology & market trends emerging in industrial robotics while Sumedha Mahorey
Deputy Editor
assessing the key challenges the industry is facing globally sumedha.mahorey@publish-industry.net
As per a recent report by International Federation of emerging technologies, market drivers and understand the
Robotics (IFR), in 2013, about 1,79,000 industrial robots were issues faced by manufacturers in this industry.
sold worldwide, an all-time high and 12% more than in 2012.
Robot sales have reached record levels in Asia/Australia, Market drivers
Americas and Africa. Almost 1,00,000 new robots were
installed in 2013 in Asia/Australia, 18% more than in 2012. The use of industrial robots has increased steadily in the
The European market also increased by 5% to more than 43,000 recent years. In the past, industrial robots were used almost
units almost reaching the all-time-high of 2011. exclusively in the automotive sector and in series production.
With this in the backdrop, A&D India analyses the views of Rathee notes, “The continuous on-going development of robot
industrial robotics experts – Arturo Baroncelli, President, IFR; and control technology has enabled robotics to establish itself
Rajesh Nath, Managing Director, VDMA India; Sunil Raibagi, across a broad spectrum of different markets in sectors outside
Managing Director, GÜDEL India; and Raj Singh Rathee, the automotive industry. In the general industry, the primary
Managing Director, KUKA Robotics India – to gauge the objective of development work is to tap into new markets,
Round-Table_Aug-Sep 14.indd 30 8/14/2014 9:10:50 PM

m a n a g e m e n t | rou n d - ta b l e
particularly in the fields of foodstuffs, plastics, metalworking, CAGR of 4.38%. One of the major drivers in this market is the
foundry, electronics, medical technology and the entertainment increased automation across industries. The growing need to
industry.” As per Nath, “Automotive and metal industries are reduce human effort and errors in the production process has
the main drivers of growth in industrial robotics. The led to the adoption of SCARA robots across industries. In
automotive industry increased robot investments continuously many industries, workers performing repetitive tasks cause
and considerably between 2010 and 2013, by 22% on average errors in the production process. However, the adoption of
per year. The main countries involved were China, Germany SCARA robots that can perform repetitive tasks with
and the United States. In 2013, robot sales to the automotive unmatched efficiency can lead to a drastic reduction in
industry increased by 5%. Also, the metal and machinery production errors. Another major growth driver is the low
industry had an average annual growth rate of 22% in the same maintenance cost of SCARA robots.” As per a recent study, the
period. In 2013, robot sales to this industry were up by 17%. global SCARA robot market is witnessing an increase in the
The food industry as well as the pharmaceutical industry adoption of articulated robots as a substitute for SCARA
increased robot investments substantially in 2013. The robots. Nath stresses, “The market is witnessing the replacement
electrical/electronics industry - which had reached a peak level of SCARA robots with articulated robots in the automotive
in 2013 - increased robot orders by 9% in 2014.” Quoting industry. Further, the integration of artificial intelligence with
statistics, Nath adds, “The trend towards automation fuels articulated robots has led to the high demand for such robots
further growth in robotics. The main drivers of automation are globally.”
energy-efficiency and new materials, e.g. carbon-composites, With the demands growing for all kind of robots, Raibagi
requiring new productions; global competiveness requiring highlights, “As we manufacture more gantry robots, we are
increased productivity and higher quality; growing consumer seeing that articulated robots are mounted on gantry systems
markets requiring expansion of production capacities; to increase work envelope and reach. These combi robots are
decreasing life-cycles of products and increasing variety of giving lot of application functionality and reduce overall
products requiring flexible automation; and robots improving costs.”
the quality of work by taking over dangerous, tedious and dirty Increasing demand for robots with higher speed and
jobs that are not possible or safe for humans to perform.” advanced vision system for pick & place applications has also
Sharing a similar thought, Baroncelli points out, “The been seen in the food and pharmaceutical industries.
incentives to automate are forcing manufacturing industries Identifying major demand trends in such sectors, Baroncelli
worldwide to improve their production processes continuously states, “Increasing demand for robots used in hygienic areas
to be competitive in a global market. This is true for traditional, such as in the food and pharmaceutical industries; in the
emerging markets and low-wage countries. The demand for assembly of cars; increase of multi-axis-robots, i.e. robot arms
consumer goods is increasing especially in the emerging with 7, 8 axis instead of 6 for better maneuverability; increase
markets; and the life-cycles of many of these products are of riveting technology in the automotive industry; increase of
decreasing.” welding for high tension and zinc coated material, because the
automotive customers try to use lightweight and rust proof
Demand trends material, among others, have emerged.”
With huge demand for industrial robotics, let’s analyse the Emerging technology trends
latest demand trends in articulated robots, SCARA(Selective
Complaince Assemby Robot Arm) robots and gantry robots. The new industries are built around areas of robotic
Nath elaborates, “The global SCARA robot market is expected automation cells. Due to this, there are new requirements for
to witness moderate growth during the period 2013-2018 at a the development of robots and industrial production benefits

rou n d - ta b l e | m a n a g e m e n t
“The biggest challenge today is the

possibility that human operators and
robots cooperate”
Arturo Baroncelli, President, IFR
“Automotive & metal industries are

the main drivers of growth in
industrial robotics”
Rajesh Nath, Managing Director, VDMA
from these recent technological trends in robotics. Raibagi use of robots. Therefore, emerging technologies are in general
explains, “Robots, and even the control units, become smaller oriented towards this issue: capability of robots to react to
and more compact. That minimises the required floor space unexpected collisions, definition of interference regions where
and offers opportunities to integrate more robots and increase robots can choose automatically max kinematical parameters,
the productivity.” sensors to detect the presence of operators and so on.”
Multi-functional robots and combi robots can take over With multiple evolving technologies, which influencers are
additional tasks which are needed for a complete robot-based affecting the innovation roadmap of industrial robotic
automation solution, such as process control, motion control technologies? Answering this, Baroncelli elaborates, “Software
of additional axis, NC-motion, logic control, safety control. and man-machine interface, besides being a key part of a robot,
Integrated solutions reduce investment costs, reduce the are obviously influenced by key trends in information
communication effort between the different components, lead technology. Main issues in this perspective are: more intuitive
to an improved process quality (since motion and process programming, easier operator interface, interaction with smart
control are optimally synchronised), and facilitate configuration devices, image recognition. Anyway, when applications of such
and diagnosis since the operator has only one user-interface. general trends are to be when applied to industrial robotics,
Identifying key innovation drivers like fast performance very specific issues are to be considered: safety and reliability.”
growth, alterations in classical fields and enhanced product
diversity combined with reduced product life cycles manifest Challenges
themselves in specific innovation trends, Nath elaborates,
“Some major trends in industrial robotics are increased The global trend towards adoption of robotic automation is
adaptability of robot cells and robot periphery; vanishing increasing in India, but is still in early stages. Nath explains,
boarders between simulation and reality; smart robot “Automation still being in its infancy in several sectors is a
controllers; advanced Human Machine Interfaces (HMI); reflection of being in the ‘low value-addition’ zone. India is
redundant kinematics and cooperative robots; advanced sensor required to leap-frog to ‘higher value-addition’ manufacturing
performance and sensor fusion; energy efficiency; service processes. The real drive for automation started only in 1997
robotics becoming innovation motor for industrial robotics and India is lagging behind in comparison to the world growth
and human robot collaboration.” in automation sector. The factors affecting automation sector
Commenting on the future technology developments, in India is the political scenario, the economy conditions
Rathee says, “Technological trends, such as robot-robot prevailing and the social & technological challenges.” As per
cooperation, human-machine cooperation, production Baroncelli, “The biggest challenge today is the possibility that
assistants or modular, interactive robot generations, will all human operators and robots cooperate. Traditionally industrial
serve to secure the market of the future. Cooperating robot robots have always worked in operating areas protected by
systems, for example, are modifying and optimising fences and safety devices which separated them from human
manufacturing processes.” beings. Now, all the robot producers are trying to solve this in
Adding on the safety front of industrial robotics, Baroncelli different ways but all with the same objective: man and robots
stresses, “The most important challenge is connected with safe working together in a safe way.” While for Raibagi the main

Ajay Kumar Gard Engg.pdf 8/14/2014 3:14:03 PM
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“The continuous on-going

development of robot & control
technology has enabled robotics to
establish itself across a broad
spectrum”
Raj Singh Rathee, Managing Director,
KUKA Robotics India
“The end-customer-friendly-
integration of robots in machine
tools provides an enormous
potential for new robot installations”
Sunil Raibagi, Managing Director,
GÜDEL India
challenges lie in achieving energy-efficiency and lightweight from the ones having found solution for service robots can be
construction to reduce energy costs. He avers, “The potential usefully employed in factories. Frankly speaking, it is difficult
of the use of industrial robots in the general industry will to forecast today the limits of robotics, but the direction is
substantially grow when robots will collaborate with workers clear towards technical developments and new fields of
and when the integration of the robot will become easier. application.”
Especially, the end-customer-friendly-integration of robots in Building a technology roadmap, Raibagi asserts, “Even
machine tools provides an enormous potential for new robot with primitive intelligence, robots have demonstrated ability
installations.” to generate good gains in factory productivity, efficiency and
quality. Beyond that, some of the “smartest” robots are not in
Future outlook manufacturing; they are used as space explorers, remotely
operated surgeons and even humans – like Asimo. In some
With robotic intelligence, artificial intelligence, the need ways, some of these other applications show what might be
for increased factory productivity, efficiency, safety and quality possible on production floors if manufacturers realise that
resulting in many technology breakthroughs in the robotics industrial robots don’t have to be bolted to the floor, or
sector, how does the technology outlook for the industrial constrained by the limitations of yesterday’s machinery
robotics sector in the next decade? Replying to this, Baroncelli concepts.”
affirms, “Robotics has, among others, the fantastic feature of Indeed with rapidly increasing power of the microprocessor
being a synthesis of many technologies: mechanics, material and artificial intelligence techniques, robots have dramatically
science, electronics, mathematics, software, control…all these increased their potential as flexible automation tools. Raibagi
disciplines, at various paces, are naturally evolving bringing notes, “The new surge of robotics is in applications demanding
sound innovation to the market: the combined effects of such advanced intelligence. Robotic technology is converging with
improvement would result in an overall better and better a wide variety of complementary technologies – machine
performance of a robot.” Moreover, robot has the feature of vision, force sensing (touch), speech recognition and advanced
being able to interface with other equipment, in turn subject to mechanics. This results in exciting new levels of functionality
technological evolutions: sensors, vision systems, inspection for jobs that were never before considered practical for robots.
systems. The integration of these technologies with the robot Additionally, the introduction of robots with integrated vision
can create new performing systems to be applied in more and and touch dramatically changes the speed and efficiency of
more segments, therefore, populating areas where robotics is new production and delivery systems. Robots have become so
not applied yet. Adding further, he says, “Finally, there can be accurate that they can be applied where manual operations are
a cross fertilisation of technologies between industrial robotics no longer a viable option. Semiconductor manufacturing is
and the younger discipline of service robotics. Service robotics one example, where a consistent high level of throughput and
is a relatively younger branch having as a target to use robots quality cannot be achieved with humans and simple
(of different kinds) in environments different from factories, mechanisation.” ☐
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MEMS vibration monitoring

The inertial MEMS technology is ushering in a new era of
vibration monitoring and enabling a wider user base for this
type of instrumentation. Through functional integration and
ease of adoption, MEMS devices are gaining increasing
attention in new vibration monitoring applications as well.
New adopters of vibration sensing are also finding that quick
deployment and the reasonable cost of ownership are good Mark Looney
Senior Applications Engineer
Analog Devices - Greensboro, North Carolina
reasons to evaluate fully integrated MEMS devices. mark.looney@analog.com
Focus- Semiconductors & electronics.indd 36 8/19/2014 2:43:53 PM

F o c u s | S e m i c o n d u c to r s & E l e c t r o n i c s
Inertial MEMS(micro-electro-mechanical system) sensors for a normal wear-out mechanism. Although it takes time and
play a significant role in the massive expansion of today’s experience to develop this type of relationship, a well-
personal electronic devices. Their small size, low power, ease correlated vibration signature can be a cost-saving alternative
of integration, high level of functionality and superb to regular maintenance that follows short cycle times. Using
performance encourages and enables innovation in gadgets actual observations, such as vibration, provides an opportunity
such as smartphones, gaming controllers, activity trackers to take quick action when warning conditions are detected
and digital picture frames. In addition, inertial MEMS sensors (red curve), while avoiding premature maintenance on
have substantially improved reliability and reduced cost in machines that have more life remaining (blue and green
automotive safety systems, allowing them to be deployed in curves).
most automobiles. Sometimes, these three zones of operation (normal,
The continuous advancement in functional integration warning, critical) can correlate to the three stages of a machine’s
and performance has also helped MEMS accelerometers and maintenance cycle: early life, midlife, and end-of-life, in which
gyroscopes find their way into many different industrial case they may influence the vibration monitoring strategy. For
systems. Some of these applications offer lower-cost example, during early life, an instrument might only require
alternatives to present products and services, while others are daily, weekly or monthly observation of key vibration attributes.
integrating inertial sensing for the very first time. Vibration As it moves into midlife, this might change to hourly
monitoring is emerging as an application that has both types observation, and as it approaches end-of-life, vibration
of users. Traditional instruments that monitor machine health monitoring might occur even more often, especially in cases
for maintenance and safety often use piezoelectric technology. where people or the asset are at risk. At this stage, machines
High-speed automation equipment monitors vibration to that monitor vibration using portable equipment will
trigger feedback control of lubrication, speed, or belt tension— accumulate recurring costs that might become prohibitive
or to shut down equipment for quick attention from when compared to the cost of maintenance. While major assets
maintenance staff. can justify special attention, many other instruments cannot
Although piezoelectric devices have a mature user base, bear the recurring cost. To complement manual measurements,
MEMS accelerometers offer easy integration and reduced cost embedded MEMS-based sensors provide a more cost-effective
to an emerging group of new users. In addition, their advanced approach for equipment that requires real-time vibration
functional integration allows devices such as the ADIS16229 data.
digital MEMS vibration sensor with embedded RF transceiver Nature of vibration:Vibration is a repetitive mechanical
to provide a complete solution including signal processing motion. A number of attributes are important for developing
and communications. This type of programmable device can a vibration-sensing instrument. First, an oscillating motion
wake itself up periodically, capture time-domain vibration often has both linear and rotational components. Most
data, perform a fast Fourier transform (FFT) on the data vibration-sensing relationships tend to focus on the magnitude
record, apply user-configurable spectral analysis on the FFT of the oscillation, not on absolute position tracking, so linear
result, offer simple pass/fail results over an efficient wireless sensors such as MEMS accelerometers are sufficient for
transmission, provide access to data and results and then go capturing motion information. When the motion is mostly
back to sleep. New adopters of vibration sensing are finding linear, understanding the direction can be important,
that quick deployment and the reasonable cost of ownership especially when using single-axis sensors. Conversely, a 3-axis
are good reasons to evaluate fully integrated MEMS devices. sensor can offer more mounting flexibility, as the orthogonal
orientation enables pickup on one or more axes regardless of
Vibration monitoring applications the vibration direction. Since vibration is periodic, spectral
analysis offers a convenient way to characterise the vibration
When using vibration to observe machine health, the profile (the relationship between vibration magnitude and
objective is to correlate observable vibration with typical frequency). The profile shown in Figure 2 has both broadband
wear-out mechanisms, such as bearings, gears, chains, belts, and narrow-band components, with primary vibration at
brushes, shafts, coils, and valves. In a typical machine, at least ~1350 Hz, four harmonics, and some low-level wideband
one of these mechanisms require regular maintenance. Figure content. Every piece of moving equipment will have its own
1 shows three examples of the vibration v/s time relationship vibration profile, with the narrow-band response often

Figure 1: Example of vibration v/s time
representing the natural frequencies of the equipment. frequency does not interfere with a frequency of interest. The
Signal processing: The sensor selection and signal-processing measurement range and frequency response are related by
architecture depends on the application’s objectives. The Ap-p=Dp-p × ω2 where D is the physical displacement, ω is the
manufacturer’s insight into the mechanical design aids with vibration frequency, and A is the acceleration.
the band-pass filter design, specifically with the start frequency, While the frequency response and measurement range
stop frequency and pass-band roll-off rates. Rotation speed, place upper boundaries on the sensor’s response, its noise and
natural frequencies of the mechanical structure, and fault- linearity place limits on the resolution. The noise will establish
specific vibration behaviours can all influence the band-pass the lower limit of the vibration that will cause a response in
filter. While this type of approach is simple, vibration the output, while the linearity will determine how much false
monitoring requirements can change as historical data from a harmonic content is generated by a vibration signal.
particular machine becomes available. Changes in monitoring Analog filter: The analog filter limits the signal content to
requirements can lead to changes in the filter structure, which one Nyquist zone, which represents one half of the sample
can present a recurring engineering cost. Developers can rate in the example system. Even when the filter cut-off
trade complexity for flexibility by digitising the sensor frequency is within the Nyquist zone, it is impossible to have
response, implementing key signal processing functions such infinite rejection of higher-frequency components, which can
as filter, rms computation, and level detectors, and leveraging still fold back into the pass band. For a system monitoring
auxiliary I/O outputs to control indicator lights or provide a only the first Nyquist zone, this fold-back behaviour can create
numerical output. false failures and distort the view of the vibration content at a
Core sensor: The core sensor for either approach can be a particular frequency.
MEMS accelerometer. The most important attributes for Windowing: Time-coherent sampling is often not practical in
selecting a core sensor will be the number of axes, package/ vibration-sensing applications, as nonzero sample values at
assembly requirements, electrical interface (analog/digital), the start and end of the time record result in large spectral
frequency response (bandwidth), measurement range, noise leakage, which can degrade the FFT resolution. Applying a
and linearity. While many triaxial MEMS accelerometers window function before calculating the FFT can help manage
support direct connection with most embedded processors, the spectral leakage. The best window function is dependent
capturing the best available level of performance might require on the actual signal, but in general, the trade-offs include
single or dual-axis solutions that have analog outputs. For process loss, spectral leakage, lobe location and lobe levels.
example, the ADXL001 high-performance wideband iMEMS® Fast fourier transform (FFT): The FFT is an efficient
accelerometer leverages its 22-kHz resonance to provide one algorithm for analysing discrete time data. The process
of the widest available bandwidths, but it is only available as a transforms a time record into a discrete spectral record, where
single-axis, analog-output device. Analog outputs can enable each sample represents a discrete frequency segment of the
a quick interface in systems that have an available analog-to- Nyquist zone. The total number of output samples is equal to
digital channel, but the present trend of development seems to the number of samples in the original time record, which in
favour those sensors that have digital interfaces. most cases represents a number in the binomial series (1, 2, 4,
The core sensor’s frequency response and measurement 8 … ). Spectral data has both magnitude and phase information,
range determine the maximum vibration frequency and which can be represented in either rectangular or polar form.
amplitude that it can support before saturating the output. When in rectangular form, one half of the FFT bins contain
Saturation degrades the spectral response, creating spurious magnitude information, while the other half contains phase
content that can cause false alarms, even when the saturation information. When in polar form, one half of the FFT bins

ERI 210X273.pdf 6/12/2014 5:15:08 PM
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Figure 2: Vibration profile,

natural frequency ~1350 Hz
contain the real result, while the other half contains the lifetime enables analysis of a variety of behaviours that may
imaginary result. lead to a wear-out curve, which contributes to maintenance
In some cases, both magnitude and phase information are and safety planning. In addition to compiling historical
helpful, but the magnitude/frequency relationship often vibration data, some will find value in capturing condition
contains enough information for detecting key changes. For data associated with parameters such as power supply,
devices that offer only magnitude results, the number of FFT temperature, date, time, sample rate, alarm settings and
bins is equal to one half of the samples in the original time- filtering.
domain record. The FFT bin width equals the sample rate Interface: The interface depends on the existing infrastructure
divided by the total number of records. In a way, each FFT bin in a particular plant. In some cases, industrial cable-ready
is like an individual band-pass filter in the time domain. communication standards such as Ethernet or RS-485 are
provides an example of an actual MEMS vibration sensor, readily available, so the interface between a smart sensor and
which samples at 20480 samples per second (SPS) and starts the communication system might be an embedded processor.
with 512-point records. In this case, the sensor only provides In other cases, that same embedded processor might be used to
the magnitude information, so the total number of bins is 256 interface the smart sensor with an existing wireless protocol,
and the bin width is equal to 40 Hz (20480/512). such as Wi-Fi, ZigBee, or a system-specific standard. Some
The bin width is important because it establishes the smart sensors, such as the ADIS16000 wireless gateway node
frequency resolution as the frequency shift from one bin to an for remote sensors and the ADIS16229, come with a ready-to-
adjacent bin, and because it determines the total noise the bin deploy wireless interface that is available through common
will contain. The total noise (rms) is equal to the product of embedded interfaces such as SPI or I2C.
the noise density (~240 μg/√Hz) and the square root of the
bin width (√40 Hz), or ~1.5 mg rms. For low-frequency Conclusion
applications, where noise tends to have the most influence on
resolving vibration, a decimation filter prior to the FFT Inertial MEMS technology is ushering in a new era of
process can help improve the frequency and magnitude vibration monitoring and is enabling a wider user base for this
resolution without requiring a change in the ADC’s sample type of instrumentation. Performance, packaging, and
frequency. familiarity may contribute to continued use of piezoelectric
Spectral alarms: One of the key advantages of using an FFT is technology, but vibration monitoring is clearly growing and
that it enables simple application of spectral alarms. The evolving. Through functional integration and ease of adoption,
warning and critical levels correspond to the levels in the MEMS devices are gaining increasing attention in new
machine-health vibration vs time profile. The start and stop vibration monitoring applications. Convenience, through
frequencies complete the process variable definition advanced signal processing at the point of sensing, reduces
represented by this relationship. When using an embedded the monitoring burden to a simple state (normal, warning,
processor, the spectral alarm definition variables (start/stop critical) for most situations. In addition, remote data access
frequencies, warning/critical alarm levels) can be in through convenient communication channels is creating new
configurable register locations that use digital codes for applications for vibration monitoring instruments. Future
configuration. Using the same scale factors and bin numbering advances in key performance metrics (noise, bandwidth, and
scheme can greatly simplify this process. dynamic range) and the high level of functional integration
Record management: One of the key functions associated will help this trend to continue in the near future. ☐
with process variable relationships is record management.
Storing FFT records from different stages of each machine’s > MORE@CLICK ADI03529 | www.AandD24.in

Semiconductor test systems

An application story on how IDT lowered cost of test by adopting
the NI semiconductor test system. The solution creates a wide
range of mixed-signal semiconductor solutions from Glen E Peer
Director of Test Engineering
low-power to high-performance devices. Integrated Device Technology Inc
IDT faced a major challenge in keeping pace with Test System (STS) to achieve flexibility and the ability to
continuously increasing test performance requirements in a reconfigure and grow its test platforms in parallel with their
fast moving environment where device performance is rising performance needs. They also built on their original
constantly pushing the limits of ATE system capabilities and investment rather than throw it away like with traditional
thereby, accelerating tester obsolescence and driving test costs ATE systems, which generally require major costly reboots of
higher. the test floor as generations of test systems advance.
Solution Project details

IDT used the open PXI architecture of the NI Semiconductor IDT creates a wide range of mixed-signal semiconductor
Focus- Semiconductors & electronics NI.indd 42 8/14/2014 7:17:04 PM

Figure 1: Combination of a low-cost

commercial ATE system with IDT’s
enhancement system
solutions from low-power to high-performance devices. A This methodology worked well, but IDT eventually faced
worldwide leader in timing devices (clock ICs), IDT offers a hardware obsolescence that required replacing its chosen ATE
broad portfolio for networking and communications, and, therefore, a system redesign. Secondly, though the
consumer, and computing applications. company’s hybrid approach was successful from an engineering
As the performance of IDT’s devices increases, it becomes and performance perspective, it was not always production
more difficult to maintain the pace in the production test friendly. In general, as novel engineering enhancements get
environment. Traditional ATE systems capable of meeting “bolted” onto ATE systems, the systems become more difficult
IDT’s high-performance measurement requirements are to support in high-volume manufacturing. Adding cables,
expensive and often include extra capabilities that are not hardware, and sometimes device under test boards with
used but add to the cost. Additionally, within the traditional extravagant electronics to ATE systems increases the potential
ATE environment, upgrading a tester to improve its for possible failure points in high-volume manufacturing
performance often requires upgrading to the next-generation environments.
test platform and phasing out the current platform. This is The most ideal solution is to create or find a test platform
both expensive and wasteful because a large portion of the with an open architecture that allows users to build on their
engineering investment made during previous generations investments from within the tester rather than through bolt-
can be lost. on enhancements or reinvestments in high-dollar big iron
To combat this, IDT typically engineers its own solutions ATE. The company needed an architecture that was resistant
on top of the installed base of test systems. Having used to hardware obsolescence and could be reinvented as
various models from nearly every ATE vendor, the company technology improved. The NI STS provided this architecture.
have become proficient at extending the useful life span of STS’s PXI platform is perfectly suited to solve these
these ATE platforms while controlling costs and enhancing its problems. The system offers multiple PXI chassis inside a
measurement capabilities. tester mainframe to offer expansion capabilities so the user
can add enhanced test features within the tester itself. The PXI
Evolution of test open standard gives users the flexibility to select instruments
from a variety of vendors based on their needs instead of from
The evolution of test within the timing business unit at the limited choices of a single ATE hardware vendor.
IDT is the perfect example of this approach. The company STS works well for IDT as the natural extension of the
began with an off-the-shelf, high-dollar ATE system. Soon company’s tester evolution. With it, IDT can continue to build
they realised that this approach was too expensive, so the high-performance, low-cost test platforms using only the
company built its own internal test system(s). These modules and components we need to meet our performance
homegrown systems met the high-performance requirements targets. The open architecture of the NI STS makes this even
but sacrificed some of the benefits of using a commercial easier.
platform such as high parallelism and external support. The During the past year of STS deployment at IDT, the
company therefore migrated to a hybrid of these two company already enhanced the systems from their original
approaches and combined a low-cost commercial ATE system configuration to meet its evolving test needs. Through careful
with its own performance enhancement system as shown planning during the startup phase, the company ensured that
in Figure 1. despite these enhancements, these systems maintained 100 %

Page _ePLAN_210x273.pdf 8/14/2014 3:17:12 PM
CM
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STSs running production test within IDT’s

manufacturing facility
backward compatibility with the initial target solution(s). All NI STSs provide high-performance measurement features
of the company’s initial investment was preserved as it across multiple test sites with true parallel test capabilities to
expanded the testers to enable a broader usage base throughout further reduce the cost of test.
IDT. The NI STS is a scalable tester family with models available
using one (STS T1), two (STS T2) and four (STS T4) internal
Benefits of using an NI solution PXI chassis. IDT designed its NI STS beginning with the T2
model with upgrades and enhancements in mind. The ability
IDT took advantage of many benefits to using NI solutions. to grow the test platforms in response to the company’s own
First, unlike its previous hybrid approach, IDT could needs is one of the strongest selling points of these systems.
consolidate the test head, which reduced the number of Previously, it was difficult or impossible to share test systems
potential failure points within manufacturing, downtime for across internal business units, but the company now have
maintenance and repair, and floor space requirements. The other teams evaluating its NI STS. These groups’ test needs
company also increased its ability to test a wide range of are different from those that the company’s systems are
devices with the same configuration because the system has currently configured to handle, but with the open architecture
interchangeable interface boards, and IDT can use the same of the PXI platform, these users can add capabilities to the
tester configuration for different device types. The multisite original IDT system definition, which have been already
system allows for higher test throughput because it is a true proven in production.
parallel test system with high-accuracy performance Though no single ATE platform is ideal for all situations,
parameters for hardware optimisation. Lastly, this solution for the first time the company saw the possibility of maintaining
was lower in cost compared to alternative integrated solutions an ATE platform that can be reconfigured and reused across
because the company needed to build only one set of multiple business units through the simple swapping of
instrumentation and had fewer individual systems to interface boards or internal instrumentation modules. With
maintain. the NI STS, IDT believes that it can define one or two system
configurations and use these systems on its production test
Growing for the future floor to satisfy the different needs of all the businesses within
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to 25% range, enhanced measurement capability and accuracy, overall test operations and help further drive down the total
and cleaned up footprint on the test floor, which made its cost of test.
testers much more production friendly. Using the NI STS, the Finally, the company can break away from the big iron
company not only increased its test performance but also ATE vendors and their hardware obsolescence cycles and
reduced its overall cost of test by retiring older, difficult to determine the best test strategy based on their own overall
support and maintain test systems. Some of these older needs. The current and future investments in test hardware
systems had expensive power and cooling requirements, but and software are preserved and reusable for the foreseeable
the NI STSs simply plug into any 110 V outlet with no extra future. ☐
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systems were as much as twice that of the NI STS. Additionally, > MORE@CLICK ADI03530 | www.AandD24.in

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Wednesday, June 18, 2014 4:32:56 PM
C O N T R O L & R E G U L AT I O N | T e c h n o l o g y
Open core engineering

A read into open core engineering that combines a high degree
K R Raghunandan
of engineering efficiency and future-readiness, which increases Application Dept
Bosch Rexroth India
the application’s flexibility and engineering efficiency along the raghunandan.kr1@boschrexroth.co.in
entire value stream
Machinery manufacturers and users require more lower cost and increased future-readiness based on open
engineering efficiency for a faster time to market and future- industry standards. At the same time, it also provides new
proof automation solutions in order to protect their investments. degrees of freedom for customisation and flexibility for various
At the same time, they are looking for possibilities to customise programming languages and device classes. This engineering
their machines economically with new automation ideas for uses the Open Core Interface to connect previous engineering
machine processes and functionalities to meet the needs of that is based on the newest IEC standards.
individual customers. This is how they can set themselves
apart from the competition. As a result, the wish for more Engineering efficiency
flexibility to implement these customised concepts rounds out
the list of new requirements. Open core engineering accelerates engineering efficiency
Rexroth meets these requirements with open core decisively with software tools, function packages and multi-
engineering, which represents the company’s comprehensive technology solutions. It makes contributions at every step,
package of solutions that increases engineering efficiency from project planning to programming and parameterisation,
along the entire value stream for all drive and control commissioning to service. The engineering framework
technologies. Users benefit from accelerated engineering at IndraWorks provides all required tools for the engineering of
Control & Regulation_BOSCH_2014-aug.indd 48 8/14/2014 9:01:05 PM

Page _49_Dynalog India A&D 210X273.pdf 8/14/2014 4:40:18 PM
Optimizing PLC Network Deployment

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Moxa’s integrated industrial Ethernet solutions can optimize your PLC Industrial Ethernet Switches 200
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Download our 0QUJNJ[JOH1-$/FUXPSL1FSGPSNBODFBOE tInnovative one-click configuration for fieldbus
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Open core engineering replaces time-

consuming programming of complex machine
processes through simple parameterisation of
customised technological functions
all technologies. In complex projects and tasks, innovative topologies, which allow machinery manufacturers to create
function packages accelerate the work processes. For example, customised versions with regionally preferred communication
the “Generic Application Template” (GAT) creates the optimal systems without additional effort.
requirements for the development of modular machine Thanks to the library concept in engineering and the
software. Based on templates, GAT uses wizard support to scalability of the automation portfolio, machinery
automatically generate an executable machine program to manufacturers can reuse entire programs or individual
match the specifications of the project planner, thereby program modules on larger or smaller versions of their
significantly increasing engineering speed. Interfaces such as machines with a control unit that complies with the
the Automation Interface further increases engineering requirements. They can place the corresponding content into
efficiency. With this interface, engineering tasks can be carried the new project via drag and drop, hence saving time. Today,
out in an automated manner according to a script, and open core engineering safeguards major investments in
interfaces to eCAD systems. modern, software-based solutions and in the future too.
Open core engineering replaces time-consuming
programming of complex machine processes through simple Individualisation
parameterisation of customised technological functions. For
example, the FlexProfile: with this function, machinery In the past, applications requiring access to all functions of
manufacturers can easily fulfil their customers’ requests for the control core, could only be accomplished by the drive
more flexibility and retrofits at the push of a button. Based on manufacturer. With the Open Core Interface, Rexroth opens
two analytical motion profiles, it automatically adapts all drive the door into a new world of automation and offers machinery
movements to changed parameters in the production process. manufacturers entirely new degrees of freedom, with room for
individual solutions.
Future-proof solutions In order to increase productivity, increasing amounts of
information from various sources at the production and
Choosing an automation system means big investment for control system level must be exchanged quickly. By adapting
machinery manufacturers. Open core engineering protects Ethernet-based communication for fast production processes
this investment through the consistent use of open standards and integrating it into automation systems, as happened with
and uses the IEC 61131-3 and PLCopen standards for open Sercos, the data network stemming from the IT environment
PLC programming. The automation bus Sercos can be has become the current backbone of modern machines.
homogeneously integrated into all solutions to this end. With The Open Core Interface also expands the software tools
its high performance, application flexibility and the number of and function packages of open core engineering and creates
available field devices on the market, a highly functional and additional degrees of freedom in the engineering of machines
more future-ready Ethernet field bus is available as the and systems. Rexroth opens its drives down to the core and
backbone for state-of-the-art machine concepts. Open core provides methods for economically creating individual
engineering continues to integrate the newest standards such functions oneself. With the Open Core Interface, applications
as FDT/DTM for tool integration or OPC UA for M2M based on high-level programming languages on external
communication. Through multi-Ethernet interfaces, Rexroth devices receive flexible access to all control and drive functions
drives can also be integrated into heterogeneous automation down to the core. Applications become executable based on

Page _HMS.pdf 8/13/2014 3:43:50 PM
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“Netbiter has saved us many

service trips, which means
savings in time and money.”
Yashar Mailov, Service Manager, NetService, Azerbaijan
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that enables you to remotely control and supervise the
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ĚŽǁŶƟŵĞ
Save time, save energy, save resources™
HMS Industrial Networks India Pvt. Ltd.

“Corporate Plaza”, Unit 1A & 1B, Ground Floor, Senapati Bapat Road,
Near Chaturshrungi Temple, Pune – 411016 (M.S.), INDIA.
Email: sta@hms.se, Mobile No:+ 91 83800 66578
URL: www.hms.se
Netbiter_building_HMS_India_11_8_5_inc.indd 1 2013-08-05 14:17:56

With the Open Core Interface, Rexroth opens the

door into a new world of automation and offers
machinery manufacturers entirely new degrees of
freedom, with room for individual solutions
C/C++ directly in the real-time environment of the drives. calculated in which the lubricants are to be renewed or topped
Machinery manufacturers can use the Open Core Interface to and warnings are displayed. All these functions can also be
implement firmware expansions of the Rexroth motion logic simulated, so this app can also be used to show the functionality
drives by themselves. without a connected control. Apps for smart devices also
increase the efficiency of maintenance work in the production
Flexibility arena. Unlike in the past, the user needs no special consoles
with a physical connection to the control unit. For example, a
The penetration of smart devices into the consumer world technician can simply use his/her smart device to scan a QR
has also opened up new communication channels between code on the machine. The app immediately provides the user
humans and machines. In the future, intelligent control systems with wireless access to this control unit and allows him or her
will adapt even more easily to human communication, thereby to call up all diagnostic data. With the appropriate infrastructure
making interaction at the user level faster, more intuitive, moreand authorisation, diagnosis can be performed from any
intercultural and more flexible. desired site. In the event of a malfunction, for example, the
The Open Core Interface is already turning such innovative control unit can send error messages directly to the smart
machine concepts into reality. The wide support for open device per SMS or email and allow the technician to access the
programming and data interfaces in the IT world enables a control unit directly for remote troubleshooting.
high degree of flexibility in the selection of programming For commissioning, diagnosis and operation, in the long
languages and device platforms. Hence, the user is free to term, smart devices will therefore replace the HMI devices that
choose between C/C++, C# (.NET), Visual Basic, VBA (Office), were necessary in the past. For example, users will be able to
LabVIEW G, Objective-C, Java as well as all programming use a tablet PC to operate several machines, which in turn no
environments that support the integration of Microsoft COM longer need their own dedicated HMI devices.
libraries.
The Open Core Interface supports Apple® iOS and Google® Conclusion
AndroidTM, currently the two most important operating
systems for smart devices such as smartphones and tablets. Open core engineering combines a high degree of
Machinery manufacturers can, therefore, implement native engineering efficiency and future-readiness with same degrees
apps for Apple iPhones®, iPads® or Google Android smartphones of freedom available with modern high-level languages and
and tablets. Users can simultaneously connect to several IT-based technologies in new production machines. This
control units or access a control unit from various user combination enables the customisation of machine concepts
applications at the same time. and increases the application’s flexibility. For commissioning,
With the Operation App for Handling, one can operate a diagnosis and operation, in the long term, smart devices will
machine using tablet PCs. Setting up and commissioning the therefore replace the HMI devices that were necessary in the
system is possible via functions for teaching, jogging and past. For example, users will be able to use a tablet PC to
referencing. There exist manual functions to execute user operate several machines, which in turn no longer need their
specific switching functions of the system. Machine specific own dedicated HMI devices. ☐
programs can be selected, started, stopped and debugged. With
maintenance functions for linear systems, the cycles are > MORE@CLICK ADI03531 | www.AandD24.in

Evolution of switching interfaces

This article briefs on a number of interface relay modules that are made
available to provide the bridge between the industrial controller and Dr Ashish Manchanda
Managing Director
the increasing number of real-world control scenarios Finder India
As processes, machine control and automation become ever meant the use of external interface relay modules that has
more complex, industrial controllers have become more of a become the de facto solution.
commodity item, offering an amount of ‘control power’
sufficient to handle most applications. However, controllers Concern
invariably provide fixed and inflexible electrical interfaces.
This inflexibility is almost inevitable since no single interface The common concerns of the system integrators and end
can satisfy the disparate needs of switching both thermocouples users these days are of different nature when it comes to relay
and high power contactor coils. And since the provision of interfaces. An end user has a need for easy diagnostics, faster
optimised plug-in interfaces is seen as too costly a feature for uptime, redundancy/standby features for easy replacements
the standard industrial controller, no ‘easy fix’ exists within and above all longer electrical life under the harsh industrial
the controller. This point, combined with the need for quick environment. Whereas an integrator apart from the above also
and easy replacement of worn or damaged interfaces, has looks forward to solutions which are able to save costs directly
Control & Regulation_Finder_2014-aug.indd 54 8/14/2014 9:16:08 PM

Page _Kubler.pdf 8/13/2014 4:02:23 PM
CM
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Relay interface in control panels
or indirectly by saving space, less wiring, faster installation & The replaceable relay type also offers quick and easy
commissioning, etc. maintenance for those applications where exceptional longevity
The relay boards as a concept thus got initiated almost two is paramount. Development of this approach has led to further
decades ago and later got spread in the nooks and corners of benefits in cost and time-saving through innovations such as
the industry due to its easy availability at local assembly units multi-way jumper links for simple common circuit
near to the cabinet builders. At one time the most common interconnection between adjacent interface relay modules, and
style simply incorporated multiple PCB relays on a single the inclusion of identification labels to aid commissioning and
board, which was in turn mounted on a 35 mm rail. This was maintenance.
helpful where an enhanced current rating was needed across a
block of outputs, but it tended to hinder the tailoring of outputs The new approach
from channel to channel and be inflexible & bulky.
However, lately, some more of the concerns with these relay By identifying a relatively limited number of relay/socket/
boards have come to light. Some of these issues are non- module combinations, the technology has now advanced to a
availability of a common industry standard on the quality of level where the designer of the control panel has even better
the PC board design & soldering, PCB insulation strength, flexibility for selecting and using a combination of single part
electrical creepage, temperature withstand capabilities, MTBF numbers. The new technology Ultra Slim Relays in Solid State
values, behaviour under failures, consistency of components (SSR) as well as Electro Mechanical (EMR) has now provided
used, international test standards for finished product and last the design engineer access to a range of ideally matched
but not the least the compatibility of the soldered sockets with components that are assembled and ready to accept wiring –
respect to the requirement of the relays. offering the additional benefits of reduced inventory,
purchasing time, wiring time, space inside the cabinet
Evolution and cost.
However, there are small but significant differences in the
To overcome these elements of doubts, a number of ideal feature set of an interface relay, depending on whether
interface relay modules were made available to provide the the device is on the input or the output side of the controller.
bridge between the industrial controller and the increasing Until now this aspect of design had not been fully addressed,
number of real-world control scenarios. but of-late new solutions have even made the life easier by
Today, the preferred solutions are of an ultra-slim single reducing control cabinet foot print, wherein the regular set of
pole module type, particularly those equipped with a terminal blocks can be avoided which saves a lot of space and
replaceable relay element. Different versions can be selected wiring cost too! ☐
channel-by-channel to match the particular requirements of
the load, without any kind of over or under-specification. > MORE@CLICK ADI03532 | www.AandD24.in
Control & Regulation_Finder_2014-aug.indd 56 8/14/2014 9:16:13 PM

Page _57_ICP Das 210X273.pdf 8/14/2014 4:45:20 PM
CM
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drink
drink
Coffee Coffee
Coffee Coffee Coffee
Coffee
T e c h n o l o g y | W i r e l e s s a u t o m at i o n
Applying wireless to EtherNet/IP

An article on the use of Ethernet which is growing rapidly in factory automation, process control
and SCADA systems. The ODVA EtherNet/IP network standard is gaining popularity as a
preferred industrial protocol. Plant engineers are recognising the significant advantages that
Ethernet-enabled devices provide such as ease of connectivity, high performance and cost savings
While EtherNet/IP has many advantages, cable installation An important part of the EtherNet/IP standard is definition
is often expensive, and communications to remote sites or of Common Industrial Protocol (CIP) messaging. CIP defines
moving platforms may not be reliable or cost-effective. Wireless the information packet with recognition that the message
Ethernet technologies have emerged that can reduce network attributes will vary as applications do. Thus CIP message
costs while improving plant production. definition takes into account a wide range of applications
However, applying these technologies is not a simple matter including programming/diagnostics, data collection, PLC data
as industrial Ethernet systems vary greatly in terms of exchange and I/O communications.
bandwidth requirements, response times and data transmission
characteristics. Wireless as an alternative to cable installation
Features The cost of installing cable in industrial plants is a function

of the material costs plus the labour charges. Cable installation
Ethernet Industrial Protocol (EtherNet/IP) is a network costs have been estimated as ranging from $20 to $2,000 per
protocol defined by Open DeviceNet Vendor Association foot depending on installation challenges (distances, obstacles),
(ODVA). As an open standard, vendors may implement environment and local labour costs. Factors that impact total
EtherNet/IP communications in their devices without licensing cable installation costs include distance and number of
fees. Many vendors have adopted EtherNet/IP including locations; conduit design and installation; trenching; fibre optic
Rockwell Automation, who selected the protocol as one of three cable & infrastructure and hazardous location regulations.
preferred networks on their popular Logix controllers Once the total cost of cable installation is calculated, a
(DeviceNet and ControlNet are the other two). comparison can be made to wireless. Similar to cable installation
A&D India | Aug-Sep 2014

58
Wireless Automation - Prosoft.indd 58 8/14/2014 6:50:28 PM

W i r e l e s s a u t o m at i o n | T E C H N O L O G Y
Festoon and slip ring

communication systems
though, the total cost of wireless should be examined. This not shutdowns become more frequent. Designing wireless into the
only includes the wireless hardware (including wireless nodes, system upfront could have reduced installation costs and
antennas and cables), but also antenna installation (if applicable) increased plant production.
and personnel training. However, even when factoring in these
additional costs, the savings realized by wireless is often Industrial Wireless Considerations
dramatic and significant.
Additionally wireless (when implemented properly), offers TCP/IP or UDP/IP: Before selecting the wireless technology, it
better reliability than cabled systems because there are fewer is important to consider the EtherNet/IP application and
mechanical connections to fail. If the cable is broken by moving determine if it will be based on TCP/IP, UDP/IP or a
equipment, severed during construction or damaged by combination of the two. This is important because TCP and
vibration, production may be down for hours until the problem UDP protocols behave differently over wireless networks.
is located and corrected. Wireless also offers electrical isolation UDP/IP is typically used in implicit messaging systems
as fiber optics do, eliminating potential surge damage from where controllers communicate to I/O blocks over Ethernet
ground plane transients. media. TCP/IP is much more common as it is the basis for
Finally, a significant benefit of wireless is reducing project explicit messaging between controllers, HMIs, remote
time. Wireless systems are typically much quicker to install programming and data collection. Ultimately the automation
than wired systems. This is especially beneficial in systems that architecture will determine the EtherNet/IP protocol type and
move over time such as mining operations or the reconfiguration appropriate wireless technologies.
of production equipment on the factory floor.
Proprietary FHSS v/s 802.11 DSSS/OFDM: The most common
Wireless in motion approach to wireless Ethernet is RF transmission in the spread
spectrum bands. Globally, the 2.4 GHz and 5.8 GHz bands are
Where wireless can significantly benefit production is in available for license-free use in most countries.
processes using motion such as material handling systems Direct sequence and Orthogonal OFDM offer the fastest
where controllers and I/O are on moving platforms. Examples spread spectrum data rates as the wide channel permits
include overhead cranes, transfer cars, stacker/reclaimer cranes, transmission of complex modulation schemes. OFDM uses a
automatic guided vehicles (AGVs), conveyor systems and complex modulation technique and is capable of high data rates
rotating packaging machines. and low latency (the transmission time a packet takes from one
Mechanical methods of Ethernet communications (Figure end to the other). OFDM is also significantly more immune to
2) such as festoon cable systems, flex cable, slip rings and rails multipath fading, a problem due to RF reflections that high
are prone to frequent maintenance and sudden failures. These data rate systems frequently have.
systems are often relatively expensive, especially when Direct sequence and OFDM are the methods used by all
supporting Ethernet. popular open Wi-Fi standards including IEEE 802.11b, 802.11g
Wireless may be less expensive and, if implemented correctly, (both transmitting in the 2.4 GHz band) and 802.11a
significantly more reliable. Today, many of these mechanical (transmitting in the 5 GHz band. The wide band modulation
systems are being retrofitted with wireless as production offers high speed, it unfortunately is more prone to noise

59

T echnology | W i r e l e s s a u t o m at i o n
Wireless TCP/IP system for HMI connectivity
problems when multiple systems are operating in close A common error though is assuming that faster technologies
proximity. For example, IEEE 802.11b/g has thirteen available are better. If the application can handle slower speeds, then
channels (eleven channels in North America), but only three using relatively slower frequency hopping technology may be
channels don’t overlap. the best approach. Frequency hopping is the most robust
Due to overlapping channels and the popularity of Wi-Fi especially regarding communications in high RF noise areas,
systems in plants, band crowding and RF saturation can lead to and easier to implement. As applications demand higher
poor wireless performance. Frequency hopping is a very speeds, then more considerations and engineering challenges
popular technique for industrial systems because it has are typically encountered.
outstanding noise immunity techniques. Unlike direct sequence
and OFDM, Frequency Hopping uses many smaller channels in Wireless for explicit messaging between PLCs
the spectrum and rapidly changes channels or hops around
from channel to channel. One of the most popular uses of wireless is in sharing I/O
The disadvantage of Frequency hopping is that it is slower information between PLCs. Because these messages are
than Direct Sequence/OFDM and has longer data latency. Most unscheduled at the protocol layer, slower wireless Ethernet
Frequency Hopping systems are limited to 1 Mbps or less RF technologies may be used. MSG blocks in PLC ladder code
may be programmed to accept long delays in transmission. If
data rate. But if the data rate is fast enough for the application,
the application (process) is not time-critical, then a slower (but
the reliability of frequency hopping is tough to beat especially
in high noise environments. robust) frequency hopping technology may be the best choice.
There are many factors influencing how fast an explicit
Frequency Band Selection: There are many considerations MSG may be executed. Generally, applications requiring 200
when selecting the frequency band for EtherNet/IP ms response time or slower are a good candidate for FHSS.
communications including required data rate, distance, line- Faster response times may require faster technologies such as
of-sight obstructions, modulation technique, band availability OFDM available in IEEE 802.11a and 802.11g standards.
(government regulation) and band saturation (crowding).
There are also spectrum management issues to consider if Wireless for HMI networks
wireless is already in place or planned for the future.
The major consideration is band usage and management. Another popular application for wireless is connecting
Many industrial plants use the 2.4 GHz extensively for IT and Human Machine Interfaces (HMIs) to plant networks or
inventory systems. Therefore, the 900 MHz band (for slower machines. HMIs use TCP/IP communications and are not time
speed systems) or 5 GHz band (for higher speed) may be the critical other than to meet the needs of the process and, most
best choice for industrial wireless systems. importantly, the operator.
While HMI screens may look very complex and data
Wireless EtherNet/IP Reliability & Performance intensive, usually the actual data being transmitted (updated)
is minimal. If programmed efficiently, slower wireless
Industrial wireless applications can be divided into two technologies (such as Frequency Hopping) may be used. The
broad categories: Those requiring high speed, low latency key consideration is update times and the amount of information
performance, and those permitting slower speed with longer actually being transmitted.
packet latency. Wireless technologies are available to FHSS may be the best choice if appropriate. However, if
accommodate both. portable computers or PDAs are used, then the industrial

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T echnology | W i r e l e s s a u t o m at i o n
EtherNet/IP protocol stack
wireless network must support the standard built into these successful customer installations. The following information is
portable devices. 802.11b and 802.11g (Wi-Fi) are the most provided only as a guideline towards predicting wireless
common. This technology supports mobile operators while performance and should not be relied upon for any other
providing high speed, low latency communications. purpose. Prosoft Technology always recommends field testing
to confirm wireless performance and reliability.
Wireless for Ethernet I/O (implicit messaging)
Predicting Wireless I/O Performance
An emerging application for wireless is communications to
distributed I/O blocks using EtherNet/IP. Wireless offers many Because EtherNet/IP I/O messages are scheduled, it is
advantages in these applications including elimination of possible to predict scan time performance over industrial
mechanical coupling methods used in moving systems (e.g. wireless systems if the following conditions are met:
rails, slip rings) and general cost savings due to reduction of • Packets per second performance of wireless technology
Ethernet infrastructure. • Wireless behavior in multipoint systems (handling of UDP
Communication to EtherNet/IP I/O blocks can also reduce Multicasts)
automation costs compared to using remote PLCs. Programming • Number of CIP connections
is simpler using I/O instead of remote PLCs because MSG The first step in designing a wireless EtherNet/IP system is
blocks are not required in the main controller’s ladder program. calculating packets per second which determines minimum
But remember that Implicit Messaging is UDP/IP based, not wireless bandwidth requirements. Start by counting the number
TCP/IP. Wireless networks must be carefully designed, and the of CIP connections.
plant RF environment more closely managed to ensure reliable To calculate how many connections are in an I/O system,
communications. sum up all direct connections and rack optimized connections.
Several factors should be carefully considered before To determine how many packets per second the system will be
choosing this architecture including: using, multiply each connection by two. It is multiplied by two
• L ack of remote PLC control (intelligence) in case of because each CIP connection is bi-directional meaning that
communication failure during every Requested Packet Interval (RPI), a produced
• A mount of I/O and required scan times (network traffic) packet is sent by each end of the connection.
• P acket handling ability of wireless technology For example, if there are five direct connections and two
• E fficiency of the RF technology with multicast UDP rack optimized connections (with six digital modules in each)
packets equals 7 total CIP Connections, the total number of packets is
• 8 02.11 clear channel availability then calculated:
However if circumstances are right, wireless EtherNet/IP 7 CIP Connections x 2 = 14 Packets
I/O can be a significant cost saver and actually improve system Note that the six modules in each rack that are rack
reliability when correctly implemented, especially in moving optimized only count as one connection. Rack optimization (if
systems. available in the I/O hardware) can significantly reduce wireless
Prosoft Technology has performed extensive tests of its traffic.
Industrial Hotspot technology with EtherNet/IP and has many Then multiply the packets by scan time (derived from RPI

62

Page _63_IMTMA 210X273.pdf 8/14/2014 4:46:37 PM

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T e c h n o l o g y | W i r e l e s s a u t o m at i o n
setting) to calculate packets per second (pp/s). Let’s assume paper, 802.11n promises several features that are attractive for
that in the above example, the required RPI time is 20 EtherNet/IP communications including dual band (2.4 GHz, 5
milliseconds (actual RPI time is application dependant), we GHz) support, significantly faster packet transfer rates with a
know that there are 50 packets per second at an RPI time of 20 reported throughput up to 300 Mbps and RF propagation that
ms (1 / 0.02). We then multiply the 14 connections by the 50 actually takes advantage of reflected signals (quite common in
packets per second to get the over all packets per second rate: industrial plants with lots of metal) using multi-input, multi-
14 Packets x 50 per second = 700 packets per second (pp/s). output (MIMO) antenna systems.
The overall packets per second rate for 802.11 a/g radios IEEE 802.16 (WiMax): While popularly known as an
can be in the thousands. However it is best practice to not emerging cellular technology, WiMax technology will soon be
operate the radio network at maximum capacity. Rockwell available in the spread spectrum (license-free) bands including
Automation suggests reserving 10% of each adaptors bandwidth 2.4 GHz. WiMax offers high speed (up to 70 Mbps) at potentially
so it is possible to use its RSLogix 5000 software for remote long range. WiMax technologies may dramatically improve
programming. data rates to remote industrial sites and SCADA systems.
The next step is to determine a reliable packet per second ISA100.11a: The ISA is working on the ISA100.11a standard
(pp/s) rate that the wireless technology will reliably support for wireless enabled devices, such as sensors. Operating in the
while keeping in mind that at least 40% should be reserved for 2.4 GHz band, the technology will “sense” existing 802.11b/g
other applications and RF overhead. systems and work around them. While designed primarily for
embedded devices, EtherNet/IP adapters and gateways will
Emerging Wireless Technologies likely be supported. ☐
Courtesy: Prosoft
IEEE 802.11n: Not a ratified standard yet at time of this > MORE@CLICK ADI03533 | www.AandD24.in
Electric Automation
Systems and Components
International Exhibition and Conference
Nuremberg, Germany, 25 – 27 November 2014
Answers for automation

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64 +49 711 61946-828 or sps@mesago.com A&D India | Aug-Sep 2014

SPS_ANZ_2014_E_210x148_END.indd 1 30.06.14 11:48
W i r e l e s s a u to m at i o n | T E C H N O L O G Y
Wireless
technology
for utility
monitoring
The article discusses how cost-
effective measurements based on
wireless technology have helped
Hindustan Zinc to improve
visibility with real time, online,
accurate process monitoring and at
the same time enhancing flexibility
for future needs.
Improving process performance is all about understanding to improve visibility, optimise the production cost, reduce
what is happening and being able to respond quickly. There is energy consumption, congregate real time process variables
always a paradigm shift in the manufacturing industry which is from the fields, ensure safety and compliance. Moreover, it was
periodic in nature. Today, the shifts seem to be towards smart first time ever in Hindustan Zinc that it was conceptualised to
factories where information generated in the virtual world use wireless mass flowmeters for mass reconciliation at
flows into real manufacturing processes to make the production Chanderia Smelting Complex(CSC).
environment more intelligent, flexible and attuned to the
necessary specifications and standardisation. This will enable Challenges & issues
devices and systems to communicate with one another more
smartly and exchange information precisely. There was a huge shortfall of High Speed Diesel (HSD)
By introducing cost-effective measurements based on consumption v/s receipt ratio, which was identified in the
wireless technology has helped Hindustan Zinc to improve month of May 2012. Soon after one task force team was formed
visibility with real time, online, accurate process monitoring to find out the various causes for this variance. Also, an external
and at the same time enhancing flexibility for future needs. auditor was appointed to assist in finding out the probable
To remain competitive amid a fluctuating market condition causes.
and wobbly economic scenario, utility monitoring is identified As per the outcome of the auditor report as well as the task
an area in the plant with more than 50% of energy consumption. force, it was recommended to install mass flow meters to
Hence the decision to implement wireless technology in the measure the HSD consumption at major locations which was
facility for utility monitoring is a strategic choice as it will help one of the implementation part of the report submitted by the

66
Wireless Automation - Emerson.indd 66 8/14/2014 7:53:06 PM

T E C H N O L O G Y | W i r e l e s s a u to m at i o n
A complete device communication status
auditor. In existing HSD circuit, mechanical type meters were installation and commissioning is excellent in terms of HSD
being used to measure the HSD consumption that has lower reconciliation at CSC complex from May 2013 onwards.
accuracy levels (upto +/- 2%). There were total 15 such meters
in existing scheme. Also wiring the meters would prove to be Technology advantages
highly cost prohibitive and time consuming.
Wireless technology offers several advantages such as review
Inspired by technology of historic trend of consumptions; cost savings with no cable
laying and associated hardware; faster startup; web/network
Many industries are deploying wireless networks for based secure and safe data monitoring at centralised location;
targeted applications. Hindustan Zinc thus chose Emerson accurate data with accessibility from remote location; fully
Process Management’s wireless technology to monitor flow and automated system with no manual intervention; ability to add
level of High Speed Diesel (HSD) for mass consumption/ devices ‘at will’ for future expansions/debottlenecking and
reconciliation at CSC complex. Both the requirements of online predictive maintenance due to availability of advanced
accurate and real time monitoring and measurement of main diagnostics.
HSD tank is now possible and highly accurate HSD consumption
& reconciliation of data for different areas of the plant. Start anywhere
The new wireless solution with mass flow meters can deliver
accuracy level of +/- 0.1%. A proposal to deploy 10 numbers of With current wireless network now in place, additional
highly accurate mass flow meters to bring the consumption and devices can be added anywhere in the plant at much lower cost
receipt difference within (+/-1.3%) as an overall system than if they had to be wired in and without having to worry
accuracy of HSD volume handled has been made. The system about the existing cable infrastructure. Potential applications
needs no site survey or line of sight requirement for deploying where the benefits of wireless technology can be extended in
wireless & is reliable, safe and secure. future could be pump health monitoring, steam trap/relief
The mass reconciliation wireless system at the CSC complex valves monitoring, temperature profiling, moving/rotating
is based on 10 mass flow meters, 1 set of inventory radar equipments, water intake monitoring, waste water treatment,
gauging system, 1 set of smart wireless gateway and wireless fire, gas, smoke, spills & leaks, heat exchangers & filters,
components. It is seamlessly integrated to the system and corrosion and many more. ☐
complete device communication status is available as shown in Courtesy: Emerson
the above figure. The performance of wireless network after the > MORE@CLICK ADI03534 | www.AandD24.in

67
Wireless Automation - Emerson.indd 67 8/14/2014 7:53:10 PM

d r i v e s &&cDRIVES
MOTORS o m p o n e| natpsp l| i cat
T E C iHon
NOLOGY
Out-of-the
box ideas
The article highlights how Universal Robots
aim to establish the flexibility of articulated-
arm robots in industrial production by
developing UR 5 and UR 10 models for SMEs
in particular
Ian Young
Key Account Manager
Kollmorgen, Ratingen
Universal Robots has developed the UR5 and UR10 models Modular design
for small and medium-sized enterprises in particular. The
handling units lift a payload of five and ten kilograms, but The exceptional ratio of dead weight to loading capacity is
only weigh 18 and 25 kg themselves, respectively. This low the result of a sophisticated lightweight construction that
weight makes it possible to move the units easily without does not contain anything that is not required. With the drive
complex subcomponents. The multi-functional robots are just technology, this minimalist strategy means integrating the
as flexible in operation given their user-friendly software. It company’s frameless kit motors directly into the articulation
supports the Danish company with a user-friendly piece of axes. In doing so, the robot takes on the function of the motor
software. Using this, the six-axis lightweight robots are ready housing, while the gear unit simultaneously serves as the
for new tasks in no time. No special knowledge of robotics is primary bearing of the rotor. Viewed as a whole, the
necessary for the programming. components used by UR frequently take on multiple functions
Technology_Motors & Drives _Kollmorgen.indd 68 8/13/2014 7:59:56 PM

T E C H N O L O G Y | MOTORS & DRIVES
The KBM motors offer a great deal of

freedom to configure the servo axes
in space-optimised way due to their
variable, modular design
and this ultimately reduces the number of mechanical The improved temperature behaviour also prevents the
components such as ball bearings, couplings, or shafts entire construction from heating up. “The motors we used in
considerably, thus decreasing the overall system weight and the past became pretty hot when in continuous operation. For
form factor. In addition, with their high power density, it also the lower losses, the KBM motors simply stay colder. We can
increases the lifting capacity of UR5 and UR10 platforms. therefore run our robots in continuous operation without
The KBM motor series offers advanced electromagnetic derating”, says Östergaard. He also refers to test procedures
designs for optimised torque and minimal cogging & harmonic with long operation periods and comparatively high loads.
distortion. These benefits are offered over a large operating The KBM series is an innovative direct drive frameless
speed range. The electromagnetic technology with a high motor technology provided by Kollmorgen. The frameless kit
packing density in the stator increases torque and keeps motors offer mechanical and plant engineering a wide range
thermal losses low. High strength rare earth magnets are used of solutions for creating applications with a maximum degree
in the rotor, which allow a continuous torque of 1.45 to 3,445 of flexibility, power density, dynamics, and durability. In
Nm along with a peak torque of 4.91 to 12,812 Nm. “The high addition to the technical advantages provided by this product,
quality of these motors was a reason why we opted for it includes 14 frame designs and many pre-engineered
Kollmorgen”, explains Esben H Östergaard, Technical Business standard options with competitive lead times. “We can
Manager, Universal Robots. basically order as many motors as we want, when and how we
want,” emphasises Östergaard. This aspect is of particular
Operation without noise but importance because Universal Robots is growing strongly.
high energy efficiency “We therefore need a partner in drive technology who is a
good fit for us.” In this regard, Kollmorgen was able to impress
One of the advantages of the robots is its low-noise and the Danish robot specialists with delivery reliability and has
energy-saving operation. From a total-cost-of-ownership since established a UR-specific production line at the Czech
perspective, the economical use of resources directly increases location in Brno. “We can expand our business channels,” says
the efficiency of the overall robots. Thus, the competitiveness Östergaard. This development is accompanied by the fact that
of this technology also increases. An additional benefit of due to sophisticated safety technology both models are even
high energy efficiency is closely linked to reduced losses in able to be employed without additional shielding. This opens
the motors. Since efficiency is high, less heat is produced. the path to a safe and comfortable cooperation between staff
This means the motors stay cooler, operate below their and technology. ☐
maximum ratings and consequently achieve a longer
service life. > MORE@CLICK ADI03535 | www.AandD24.in
Technology_Motors & Drives _Kollmorgen.indd 69 8/13/2014 7:59:58 PM

M OTO R S & D R I V E S | T E C H N O L O G Y
Intuitive engineering
The article illustrates how thermoforming machines can be equipped with efficient
synchronous motors. These machines are used in food packaging, industrial products and
medical pharmaceuticals.
The global population is growing and by 2050, the need for also industrial products or medical pharmaceutical products
food will double. This means not only the production of food, are packaged and sealed by thermoforming machines.
but also transport and storage are the important areas that Although the energy consumption of thermoforming machines
will have to be taken into consideration. Even today, an is not particularly high, it is still worthwhile to take a look at
enormous portion of food does not reach the consumer this aspect. Due to the tight calculated costs and low profit
because it spoils en route or in storage. Approximately 1.2 margins for packaging materials, significant benefits for the
billion tonnes of food is wasted worldwide per year. The machine operators can be achieved by small optimisations.
packaging industry, therefore, needs to offer solutions that
provide better storage and safer transport of food worldwide. Higher degree of effectiveness
Thermoforming machines in particular is very important. with synchronous motors
Cheese, meat, fresh fruit and vegetables are the food categories
packaged by thermoforming machines. Not only food, but Considering these factors, Baumüller, a Nuremberg
Tech Motors & Drives- Baumüller.indd 70 8/18/2014 10:28:28 PM

T E C H N O L O G Y | M OTO R S & D R I V E S
specialist for automation systems & drive technology, equipped consumers in thermoforming machines. With the most precise
thermoforming machines with efficient synchronous motors. regulation possible, this consumption, which is unavoidable
In comparison to asynchronous motors currently preferred in thermoforming machines, can be reduced as much as
for such machines, synchronous motor has a higher degree of possible. Using software modules, for precisely recording
effectiveness, and thus more efficiency, due to the use of print marks, can also quickly regulate positions. This saves
permanently excited magnets. The DS synchronous motors material since the plastic shells are cut very precisely. Via
from the company also offer high torque precision and controls using cam disc technology with a virtual guide axis,
provides machine builders more flexibility in machine design sporadic movements in the machine are avoided which in
and decrease the necessary space thanks to their compact turn protects the mechanisms, reduces wear and tear and, due
structural shape. In conjunction with the energy efficient to the optimised motion control, increases the energy
inverters b maXX 5000, which are also available as feeder and efficiency of the machine. By using EtherCAT, the high-
regenerative units and the scalable b maXX controller PLC, performance real-time ethernet bus system, Baumüller
the company supplies an efficient and reliable automation achieves coordinated motion control in real time.
system for thermoforming machines. One of them has been
installed, for instance, at the Indian manufacturer — Rajoo. Benefits
The stackable inverter b maXX 5000 offers the benefit of
flexibly expanding and modifying entire drive lines without All software modules are integrated into the ProMaster
disconnecting the line thanks to the integrated drive-connect Engineering Framework. The machine builders can depict the
system. In addition, pluggable safety modules are available for entire machine in this intuitive and comprehensive automation
these inverters, so they can be flexibly adapted to the suite. This saves an enormous amount of time as a system
requirements of the applicable national regulations and the diagnosis can be performed during commissioning. In
respective application. The safety controls for controlling the addition, during programming, different machine models can
respective application and the safety-related programming in be designed which simplifies the variant handling for the
accordance with the machine directive are included in the machine builder as the correct version is automatically created
portfolio of the Nuremberg manufacturer. for the respective machine type. This is an enormous advantage
for the machine builder for designing different machine
Faster and more efficient software modules concepts. In addition, the company has integrated a service
and production technology which reduces the system down
Comprehensive software module kits offer special benefits time to a minimum.
to machine builders. The technology modules significantly
shorten the time-to-market since these provide pre- Conclusion
programmed and validated software modules to the
automation technician. The existing library is so comprehensive When it comes to efficiency in thermoforming machines,
that the movement processes in thermoforming machines can there are a number of options for reducing energy consumption
be executed using pre-programmed modules. These standard and increasing the overall efficiency of the system. The
modules include modules for automatic roller changes, improvements include selection of the right motor, movement
energy-optimised adaptations of the movement profiles in the optimisation via software and precise control of the heating
machine or for regulating heating elements. The heating elements. Such improvements increases energy efficiency and
elements integrated in the machine, which warm the laminate also reduces material wear & tear along with increasing the
for processing are controlled centrally or locally via software product quality and productivity. ☐
modules. Here, in particular, significant savings are possible Courtesy: Baumüller
because heating elements are by far the largest energy > MORE@CLICK ADI03536 | www.AandD24.in
Tech Motors & Drives- Baumüller.indd 71 8/18/2014 10:28:31 PM

R o b ot i c s & H a n d l i n g | T E C H N O L O G Y
Designing cable management

systems for 6-axis robots
This article deals with designing cable
management systems for six-axis robots
including cables, hoses, tubing, carriers, and Jörg Ottersbach
Head of Industry Management, Automotive & Robotics
connectors in three separate sections igus GmbH
In recent years, cable management has come into the best practice that robotics engineers and integrators can apply.
limelight because machine reliability has increased dramatically, It centers on designing cable management systems for six-axis
even though robots have grown more complex. Unfortunately, robots – including cables, hoses, tubing, carriers, and connectors
the methods used to attach and guide cables have not quite – in three separate sections.
followed suit. While managing cables and hoses is often an
afterthought in most designs, it is truly a vital part of any well- Overview of industrial robots
functioning robot. Since the 1960s, cable management methods
for robots have not changed dramatically. Most experts agree The term robot is defined as a machine capable of carrying
that one of the top blunders made is underestimating cable out a complex series of motions automatically. It was first
management issues. For instance, during a conference hosted introduced in a Czech science fiction play and then in 1942,
by the Robotic Industries Association (RIA), a group of leading the term “robotics” was coined by Isaac Asimov, a well-known
system integrators cited cable issues as the number one reason American author and professor of biochemistry at Boston
for downtime in robotics cells. Headaches range from tangled University.
and corkscrewed cables, to complete breaks that cause By 1970s, robotics had made its way into most manufacturing
downtime, lost revenue and damaged reputations. This is why facilities, predominately in the automotive industry, and by
the ways in which robot cables are attached and guided is 1980, more than 4,000 robots were being used in the US. Fast
important. The less is more approach to cable management is a forward 30 years, and more than 1.3 million industrial robots
Robotics & Handling IGUS Aug-Sep.indd 72 8/14/2014 8:54:44 PM

T E C H N O L O G Y | R o b ot i c s & H a n d l i n g
Corrugated tubing is available in a wide range of

size and styles
have made their way into manufacturing plants throughout the This breakdown is the key to longer-lasting cables. Each
world. During this robotic evolution, many different types of cable section needs a minimal dress pack, strain relief with
robots emerged. Some of the most common include cartesian service loops, and a junction box that contains and protects the
(gantry / linear) that are rectangular arms described as using X, electrical connectors joining the cables.
Y or Z axes spherical (polar) 1 linear axis and 2 rotational axes Use of a strain relief mechanism can eliminate stresses and
around the vertical shoulder joints. Jointed-arm (6-axis / extend the service life of a moving cable. This strain relief may
articulated) that are rotating shoulder and elbow in horizontal consist of standard elements such as tie wrap plates or clamps.
axes. SCARA (selective compliance assembly robot arm) the Engineers should ensure the cables are in the neutral axis, not
special jointed-arm version and cylindrical (post-type) 3 touching the inner or outer radius of the cable management
degrees of freedom, Y and Z linear movements, rotating base. system.
What do all these robots have in common? The cable From the sixth to third axis
management system is typically left to the last minute, but • Strain relief cables on the moving end (sixth axis) with a
without it, unprotected cables are likely to fail. Cable damage one- to two-foot service loop.
can shut down the most important robot on the line, which • Protect cables and hoses with a modular, multi-axis cable
leads to costly downtime. carrier.
• Separate cables at the third axis and install a junction box
The less is more approach for six-axis robots for diagnostics and cable replacement.
From the third to second axis
Current systems try to keep the cables on a six-axis robot • Strain relief cables on the third axis with a one- to two-foot
static while everything operating around them is dynamic. service loop.
Using one, long restrictive cable package prevents movement in • Use a modular, multi-axis cable carrier.
sync with the robot. Restrictions stress cables, which accelerates • S eparate cables and install a junction box at the second
failure. Often technicians severely bind cables with excessive axis.
dress packs (protective coverings on cables), cable ties, and From the second to first axis
even duct tape. The goal is to minimise tangling and interference • Strain relief cables on the second axis with a one- to two-
with the machine, but these types of solutions cause foot service loop.
corkscrewing and failure. • Multi-axis, reverse bend radius (RBR) cable carrier,
Instead, consider a six-axis robot as three separate sections: protecting and guiding rotating cables.
the sixth to third axis; the third to second axis; and the second • S eparate cables and install a junction box at the first axis.
to first axis. Separating the dress pack into three shorter sections

R o b ot i c s & H a n d l i n g | T E C H N O L O G Y
Robotic cable carriers offers additional benefits

not available with other systems
prevents it from wrapping, catching or snagging on machines minimal torsion resistance, and can only be fixed at two points
and minimises stress on cables and hoses. This approach with a defined length. The tubing can also stretch as the robot
applies to any six-axis robot, regardless of manufacturer or moves, which puts undue stress on the cables. Tooling
application. While other fixes such as duct tape and ties wraps interference sometimes occurs because there is no control path
might cost less and work temporarily, in the long run, properly for movement.
designed dress packs reduce unnecessary downtime and
maintenance costs. Enclosed dress pack
Six-axis robots can be found in applications such as robotics
/ automation, machine tools, handling machines, packaging An enclosed dress pack mounts directly to the robot and is
machines, and many more. In addition to the appropriate dress available in multiple configurations. It uses corrugated tubing
pack, it is imperative that six-axis robots use dynamic cables installed inside a plastic-reinforced housing to protect cables.
specifically designed for continuous flexing. Two important The system’s spring-loaded design minimises catch and pinch
features to take into account are a cable’s torsion-resistance and points.
shielding. Shielded cables face a greater risk of failure because Due to the completely enclosed housing, cable maintenance
constant movements can easily compromise the cable jacket. is difficult, and because it is not modular, the entire unit must
Use unshielded, high-flex cables whenever possible to avoid be replaced if one component breaks. Problems can also arise if
problems. If this is not an option, turn to special “rolling-flex” the programming or movements of the robot change. This is
cables. because an enclosed dress pack does not prevent the cables
from exceeding their maximum bend radius.
Cable management options
Robotic cable carriers
There are different options available for guiding and
protecting cables on six-axis robots. Three well-known Robotic cable carrier systems are at the core of the less is
solutions include flexible tubing, enclosed dress packs and more approach, and can be used universally for six-axis robots.
robotic cable carrier systems. The system mounts directly to the robot and is available in
multiple configurations. Like an enclosed dress pack, it has a
Flexible tubing spring-loaded design, which minimises catch and pinch points.
However, robotic cable carriers offer additional benefits not
Corrugated- or flexible-tubing is one option for protecting available with other systems. They can come equipped with
cables on six-axis robots and is available in a wide range of strain relief options to extend the service life of the cables;
sizes and styles. It has superior tear resistance at connection cables can also be quickly added or removed without
points and a long service life, even with reverse-bend cycles. dismantling the system. The defined bend radius of a robotic
However, corrugated tubing has its limitations. It delivers cable carrier protects cables from exceeding their maximum

T E C H N O L O G Y | R o b ot i c s & H a n d l i n g
bend radius. The limitations of the system include minimal any two cables or hoses and cables and hoses need to move
resistance to high-concentration acids and caustic chemicals, freely inside the carrier.
and the inability to handle circular movements with heavy The less is more approach also eliminates some safety
loads. Robotic cable carriers are well suited for welding robots concerns within a robotics cell. Cables are able to move more
in tight areas, multiple-tool applications, material-handling freely, but are protected and guided properly so that they will
jobs, and de-burring operations. For added flexibility, robotic not injure workers.
cable carriers are available in a fully enclosed design, a pull- Ideally, a robotic cable carrier system should guide cables in
through design for easy cable access, or as a lightweight, low- one continuous path; eliminate loose, unmanaged cables;
cost system for applications that do not require cables to be control the bend radius of cables to avoid pinching; have the
completely enclosed. ability to quickly add or remove cables and be available as a
fully enclosed design for extremely harsh environments.
Additional tips The Triflex® RS robotic cable carrier system from igus® was
designed with the less is more approach in mind. It ships and
Ideally, a robotic cable carrier system should allow sufficient installs as one piece and has an integrated fiber rod that returns
clearance inside the cable carrier for electrical cables, pneumatic cables to a home position after the robot completes a cycle. The
hoses and tubing for other media. This compensates for relative system includes mounting plates and brackets, protection links,
forces between cables and hoses. Cable carrier suppliers and a pre-engineered fiber-rod assembly. It is a modular,
typically provide this data. For instance, general rules of thumb compact system, but with only one piece to install for complete
for the line of robotic cable carriers from igus® include total end-of-arm tooling guidance. ☐
cable and hose diameters must not exceed 60 percent of the
carrier diameter; leave at least a 10 percent clearance between > MORE@CLICK ADI03537 | www.AandD24.in

Fieldbus & Networks | technology
Remote eavesdropping
An American manufacturer of equipment for
concrete pipe production added remote
maintenance capability for its machines located
at other location which enabled a fully
transparent information flow of the automation C
system of the production facility. R
Armin Beck
Product Manager,
Hilscher GmbH,
abeck@hilscher.com
When it comes to servicing and maintaining a production concrete pipes, the others serve to produce the required steel
system, speed is of primary importance. For this reason, an reinforcement. “All three systems run with Siemens S7 PLCs
American manufacturer of equipment for concrete pipe and offer practically fully automated operation. Manual
production wanted to add remote maintenance capability to intervention is limited to minor aspects, such as changing
three systems at one of its customers. But in order to be able to recipes and updating software”, said Bob Fehr, an Hawkeye
monitor the local data stream all the way down to PLC level, a Pedershaab automation engineer. For process automation of its
major communication obstacle needed to be removed. systems, it has opted for the Siemens process control system
Fortunately, Hilscher has a solution that was ready out of the SIMATIC S7®.
box. HawkeyePedershaab is a world leader in the market of
machines for the production of concrete pipes. Safety at a high level
In 2011, HawkeyePedershaab installed three fully automatic
production systems at a concrete factory in the province of An equipment to produce concrete components represents an
Quebec in Canada. One of them is used for the production of assembly of impressive dimensions and handles products
Red
76 A&D India | Aug-Sep 2014 netw
Feildbus&Networks _ Technology_Hilscher.indd 76 8/14/2014 8:56:12 PM

technology | Fieldbus & Networks
weighing several tonnes. So, HawkeyePedershaab uses industrial communications protocol and translate it into any
additional IM151 7F safety PLCs positioned between the other protocol. Power supply is accomplished either directly
individual S7 PLCs and several distributed Siemens ER200 S via the terminal of the device it is connected to or via a separate
I/O units used for each equipment. 24 VDC connection. “The Hilscher netLINK proved to be the
perfect solution. It allows us to reach the factory via the
Translating between protocols Internet and access the IM151 modules via their individual
MPI terminals without having to obtain costly S7 Ethernet CP
The solution is called netLINK (model NL50-MPI) provided components from Siemens”, adds Fehr.
by Hilscher. The German-based company is specialised in
communications solutions for factory and process automation Remote-controlled safety
and operates its own subsidiary in India. It is an intelligent
gateway in the form factor of a data bus plug that can be Due to the netLINK, the complete information flow of the
plugged directly into the S7 PLC. It is based upon the versatile automation system of a production facility becomes fully
netX chip from Hilscher and is able to read practically any transparent and is available via a conventional Ethernet
Connect, collect, create and display KPI data and Andon messages | Remote monitoring and control
Real-time performance monitoring | Built-in web server and data logging | Convert over 250 protocols
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Fieldbus & Networks | technology
As a 100% replacement of expensive

Ethernet-CP, NL 50-MPI allows control,
programming, remote maintenance
and connection of visualisations such as
WinCC over Ethernet
network. Where Ethernet is available, Internet and VPN also company now plans to extend this time and cost saving remote
represent no problem. It was therefore rather simple for maintenance system to additional manufacturing locations.
HawkeyePedershaab to realise the desired remote maintenance
for its machines located in Canada. Conclusion
“If access to a machine is required, its MPI terminal only
needs to be connected to one of the netLINKs. It only uses one As a 100% replacement of expensive Ethernet-CP, NL 50-MPI
IP address, which makes it easier than using three separate allows control, programming, remote maintenance and
netLINKs, for we do not have to worry about assigning IP connection of visualisations such as WinCC over Ethernet. As
addresses. Since we are dealing with a safety issue, we need to a real highlight, the device allows the Ethernet coupling of
be extremely careful. However, the netLINK lives up to our Ethernet port less S7-PLCs over their MPI or PROFIBUS
requirement 100 per cent, making it rather easy for us to interface with automatic DP/MPI baud rate detection. To
download and upload data in order to solve problems – just as configure a PLC to PLC connection NetPro in STEP®7 is used
if the machine would be located right here at our premises.” as usual. Also routing across multiple and networked PLCs is
possible. The protocols RFC1006, DHCP and NTP time
Small component with far reaching effect distribution to a PLC are part of the comprehensive scope of
services supported. The device is configured either in STEP7®
By now, the remote maintenance solution of the three machines with an embedded driver or via a web browser. The driver is
HawkeyePedershaab installed in Quebec is live and running Windows 7® and STEP®7 64-Bit compatible and supports
for more than two years and works without any problems. Siemens TIA Portal already along with all S7 Engineering tools
Sometimes the key to a solution is simply the right translator for full access to Profibus diagnostics and services in STEP7®.
to overcome communications problems and add the In addition, Hilscher also provides the DIN rail mountable
functionality to a manufacturing system that will save costs at version of NL 50-MPI device called as NT 50-MPI where 16
a considerable level, by eliminating the need to send a service simultaneous Ethernet connections and the access to maximum
technician on site. HawkeyePedershaab is fully satisfied with 32 PLCs in parallel are supported. ☐
their new solution, which seamlessly integrates with its
Siemens SIMATIC S7 process automation environment. The > MORE@CLICK ADI03538 | www.AandD24.in

Page 79_ SPS 210X273.pdf 8/14/2014 4:53:01 PM
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M 2 M c o mm u n i c at i o n | t e c h n o l o g y
Transforming Industrial
& Energy Systems with IoT
With billions of units generating more than $1 trillion in revenue
today, the Internet of Things (IoT) market is already big—and it’s
growing fast. Analysts predict the market will grow with a double-
digit compound annual growth rate (CAGR), and IDC forecasts
that revenues will double by 2015. This feature highlights the
challenge to translate the intelligence in connected embedded
devices into new products and services that solve customer
problems, drive customer engagement and loyalty, and deliver Thilak Kumar
Regional Engineering Manager
even higher value to the economy. Wind River India
Analysts are unanimous about one aspect of Internet of systems will outpace any other mainstream system type,
Things (IoT): the opportunity is huge. Experts predict that reaching 8.9 billion unit shipments by 2015 with 75% of
there will be anywhere from 20 billion to 50 billion connected revenue opportunity. Machine-to-Machine (M2M) technology
devices by 2020. IDC forecasts that the volume for embedded adoption is also spiraling upward. There are already more than
M2M Communication _ Technology_Windriver.indd 80 8/14/2014 8:36:21 PM

t e c h n o l o g y | M 2 M c o mm u n i c at i o n
a billion M2M devices at work in sensors, smart meters, industrial and energy markets. These are so heavily mechanised
industrial control systems, mobile healthcare assets, video and automated that they very well understand the role that IoT
surveillance systems, automotive and telematics solutions, can play in transforming business. These industries have been
smart buildings, and more. Wireless M2M connections alone incorporating sensors and automation into workflows for
increased by 37% last year to reach 108 million, according to a decades; yet less than 10% of their legacy systems are connected,
report from market analyst firm Berg Insight. leaving valuable data localised in devices and equipment, from
The seemingly sudden arrival of IoT and its network of HVAC sensors to manufacturing robots to building elevators.
intelligent systems have actually been emerging for years. Once connected this data enables operators to track output
Innovations in network connectivity, mobile and wireless based on real-time and trended data analysis to optimise for
technologies, multi-core processing, M2M communication, power efficiency, performance, and operational life. Smart IoT
sensor technologies, cloud computing, and data analytics have devices can manage the distribution of energy across the smart
converged to create an entirely new form of intelligence—and grid based on real-time data and provide situational awareness.
astonishing new capabilities to optimise the productivity of They will also connect once-discrete systems and allow for
processes and efficiency of decision making. communication across the factory floor to IT and management.
Early adopters of the IoT, sometimes referred to as Industry Industrial systems are becoming connected information hubs.
4.0 or Machine to Machine (M2M) communication, are the From real-time logistics and supply chain management to

M 2 M c o mm u n i c at i o n | t e c h n o l o g y
Smart devices in the Internet of Things (IoT) will manage the

distribution of energy across the smart grid based on real-time
data and provide situational awareness
production planning to automated quality control, converged operators with connectivity and communication, both within
networks deliver visibility across the entire process and enable the factory floor and to enterprise IT, to optimise efficiency
centralised control. In addition to transforming existing and reliability. Device-level data aggregation alleviates
operations through productivity gains and economies of scale, bandwidth strain by reducing machine-generated data sent to
IoT presents entirely new lines of business and services the cloud-based central control systems and back. Algorithms
otherwise not possible. analyse the data to identify factors affecting overall performance.
Let’s consider some of the key elements within IoT that can Operators utilise this data to make the adjustments necessary
transform the way industrial and energy systems are managed to keep production running smoothly and at optimal capacity
today. while maintaining quality.
Sensor data Cloud-based central control system

With critical sensor data, operators are able to schedule and A cloud-based central control system provides operators with
manage efficient repairs, performance adjustments and real-time equipment transparency and visibility to monitor
maintenance. New equipment with sensors can alert operators and analyse consumption patterns, predict impending failure
when a machine is not performing properly or showing signs risks, and evaluate any piece of equipment at any time.
of stress, and maintenance can be scheduled accordingly. With Predictive maintenance capabilities help mitigates outage and
all of the real-time data available, operators rely on data and downtime. An example on this context is Wind River® that
automation to ensure safety and reduce costs. In the IoT, data provides industrial and energy customers the tools and
is available whenever and wherever required, making planning technology to meet stringent real-time determinism
and spotting potential problems more efficient, triggering requirements while taking advantage of the flexibility and cost
preventive maintenance routines, and reducing downtime. benefits of open standards. In highly regulated industries and
Smart devices in IoT will manage the distribution of energy mission-critical applications—where security is paramount
across the smart grid based on real-time data and provide and failure is not an option the company delivers intelligence
situational awareness. They will also connect once-discrete where it’s needed, supplying the foundation that enables IoT
systems and allow for communication across the factory floor networks and connected devices to perform reliably, safely,
to IT and management. and efficiently. ☐
Whether incorporated into your new factory equipment or
as a bolt-on solution to a legacy system, gateways provide > MORE@CLICK ADI03539 | www.AandD24.in

technology | machine vision
Keys to successful multicore optimisation

Optimising a machine vision application for multicore PCs can
be a complex process with unpredictable results. To achieve best
overall system, it is necessary that developers pay close Didier Lacroix
attention. Field-testing under actual conditions is the only way Vice President — International Sales &
Marketing
Cognex Corporation
to fully measure system throughput. didier.lacroix@cognex.com
Machine vision speed increased automatically with Multicore PC architecture

increasing microprocessor speeds. However, with multicore
PC architectures, it is different, as it requires software design Earlier, to handle bigger and complex application, vision
changes to take advantage of parallel processing architecture. applications depended on advances in PC hardware. However,
A multicore strategy for machine vision can be implemented this requires higher heat dissipation, where cooling has become
at multiple levels. Independent high-level tasks — especially a limiting factor. Manufacturers like Intel and AMD use
those with hardware dependencies, such as acquisition and multiple processors instead of a single processor. These
I/O — can be written to run asynchronously on separate cores, processors are packaged on a single chip. Each processor is
leaving processor free to do those tasks that are not blocked. called a ‘core’, and new chips are called multicore processors.
Individual vision tools can also be parallelised so that they Two, four and eight-core processors are now common, while
divide their processing task among several cores. much higher density models are also being designed.
Machine Vision Cognex Didier..indd 83 8/18/2014 10:34:40 PM

machine vision | technology
Figure 1: Example of partitioning an image

across multiple threads
Optimised software is the key software at application layer to take advantage of a multicore
PC is usually only justified in very demanding applications.
It is not possible to move an existing machine vision Off-the-shelf solutions may not be efficient as custom code,
application from a single-core PC to a multicore PC and expect but can provide significant benefits at very low cost.
performance improvement. Some applications may not run 1. Application optimisation: Application-level software
any faster on a multicore machine due to operating system can be optimised for multicore PCs in three ways. Firstly, by
overhead and other inefficiencies. Programmes must be creating separate threads for tasks with hardware dependencies,
rewritten to speed up their applications, as many algorithms such as image acquisition, accept/reject results, operator
do not lend themselves to parallel processing. Here are four interaction and are often designed to minimise unpredictable
keys to successful multicore optimisation for machine vision hardware delays. Secondly, by creating separate threads for
applications. These are application optimisation; vision tool each camera in a multi-camera application, allowing each
optimisation; tuning for overall system performance, and thread to run as soon as its camera is triggered. And thirdly, by
software portability. creating separate threads for different machine vision tasks
within a vision application. However, this works if the tasks are
Processes & threads not dependent on each other, and the benefit will be small if
one task is much shorter than the other.
PC operating system manages programs as separate Some commercial machine vision products have built in
processes. Each process has an associated context and when these features. For example, CognexVisionPro™ software create
process is blocked the operating system saves current context separate threads for image acquisition and vision processing
and swaps in another process. System processes responses to a and can detect number of cores in a PC and create threads
range of demands, which is invisible to the user. based upon it. This type of scalability is advantageous in
A multithreaded program can be written so that different multicore PCs for applications with multiple image acquisition
sections run simultaneously and independently. These are and vision processing tasks, which need to be performed
much lighter and share the same address space, allowing it to simultaneously. It is beneficial on single-core PCs, because
switch quickly making it easy for them to share data when image acquisition does not use much CPU time and can
running in parallel. Multithreaded applications do not require therefore run in parallel with image processing operations.
a multicore architecture. They are efficient on a single-core 2. Vision tool optimisation: In addition to application-
machine, but rely on operating system to manage hardware level optimisation, it is possible to optimise machine vision
resources for them. Multithreading is suited for multicore PCs tools by parallelising their algorithms so they use multiple
and algorithms that ran sequentially, can be partitioned into cores simultaneously.
separate threads that now run in parallel on separate cores. However, not all vision tools can be easily parallelised.
Parallelisation is helpful for image processing filters or other
Commercial multithreaded software vision tools that run local operations on small regions of the
image. Commonly used filters include median, Gaussian and
Writing multithreaded application code is not simple and morphology operations can be optimised by dividing image
requires underlying machine vision libraries to be written in a into different pieces and assigning each one to a separate
re-entrant manner that allows multiple instances of the thread (Figure 1). The final speedup depends on algorithm
program to execute in parallel. For this, writing custom and number of cores. Because of overhead, there will always be

Figure 2: A vision application divided into Figure 3: One vision thread per core may
three threads running on a four-core PC not be the optimum choice. This application
finishes later than the one in Figure 2, even
though this one has one thread per core.
Depending on the application, more or fewer
threads may be better
some inefficiencies, so even a well-optimised vision tool may number of cores in the system. Redeploying existing system on
not run eight times faster on an eight-core PC. Many vision a different PC may require recompilation or rewriting
applications spend most of their processing on tools that are application software, which is high cost as development
more complex than simple image processing filters. It is not stations are modified and developers move on to other projects.
always possible to parallelise complex vision tool algorithms CVL and VisionPro™ libraries can automatically detect number
such as alignment and optimising the tool might only benefit a of cores on a PC and dynamically adjust number of threads
small portion of the algorithm. that they create allowing applications written for a four-core
The PatInspect™ tool has been redesigned so that inspection PC to run efficiently on an eight-core PC without touching the
steps are divided among available cores. Even when percentage source code or recompiling.
improvement is lower than for simple image processing filters,
overall application may benefit more, since complex machine Summary
vision tools generally consume large portion of overall
application. Optimisng a machine vision application for multicore PCs
3. Tuning for overall system performance: Fastest vision can be a complex process. It is clear that developers must pay
application would be one that control every processor core in attention to achieve best overall system performance. Field-
the PC and create one thread to run on each core. The PC must testing under actual conditions is the only way to fully measure
also support operating system, machine control and other system throughput. To maximise benefits of multicore PC
background tasks. In practice, optimum number of threads for technology in machine vision applications, developers should
vision application may not necessarily be the same as the consider several key questions when evaluating machine vision
number of cores in the PC, and may not make sense to assign software products. These should include points such as whether
each thread to a specific core. image processing filters have been optimised for multicore, as
The only way to determine optimum number of machine also other factors that can impact the performance of overall
vision threads is to test it under realistic conditions.Cognex’s application, including:
CVL™ and VisionPro™ software libraries give users a simple • Can the software product automatically create separate
method to set the number of threads for multicore-aware acquisition and processing threads to speed system
vision tools in an application. This top-level ability lets users throughput and responsiveness?
easily tune the system for best overall performance. • Does the software allow users to write their own
4. Software portability: Another concern is software multithreaded application?
portability from one PC to another. PC hardware changes • Can users tune the number of threads for best overall
quickly that vision applications will be deployed on multiple system performance?
PC models, either when new vision stations are deployed or • Does the software have the ability to automatically detect
needs to be replaced. Machine vision application is usually and adjust the number of threads, based on the number of
developed on a different PC than on which it is deployed and cores, without having to rewrite the application?
replacing PCs deployed in manufacturing lines is a constant By keeping these points in mind, users can maximise their
maintenance issue. options (and minimise their work) to take full advantage of
Since number of cores available may change over time, multicore PC technology. ☐
there should be a vision application, which can account for any > MORE@CLICK ADI03540 | www.AandD24.in

machine vision | technology
Revolutionary simple and ingeniously fast

The new 3D vision automation makes it significantly easier for users to install and integrate them
into their systems and processes. The automated processes using 3D robot guidance achieve
greater flexibility and higher productivity
With its innovative standard product line, ISRA Vision has sectors. The technology was too sophisticated and too
integrated its 25 years of industry experience, making 3D robot complicated. We have now passed that stage. For any application,
guidance possible without expert knowledge. Production from 2D to 6D, an easy to use product line consisting of sensors
managers on the factory floor are able to quickly and easily and software, scalable in terms of resolution and accuracy and
integrate ready-to-use sensors into their systems all on their ready for use is now available for 3D robot guidance: install,
own. In today’s world, 100 per cent monitoring and fully and connect. Instead of wasting countless hours programming,
automated processes using 3D robot guidance are key elements now you will only need to set a few parameters.
to achieve greater flexibility and higher productivity.
Machine vision systems make the use of robots even more GigE based sensors
flexible, which have demonstrated that they can reduce costs
and also provide documentation of the manufacturing quality The GigE based sensors can be used in either stationary or
that without them would not have been possible. Until recently, mobile applications and provide the highest rate of accuracy
users stayed clear of 3D robot guidance in many industry even for large components. For example, MONO3D will make
Machine Vision-ISRA.indd 86 8/14/2014 9:14:49 PM

Sensor for web-supported robot

guidance with structured light from
the new range of ready-to-use GigE
sensor products for highly precise 3D
positioning and orientation determination
– with integrated 3D form matching.
it possible to perform 3D measurements of position and advantages, because the need for mechanical feed components
orientation with a single sensor. The sensor determines all six is significantly lower. The following applies to all sensors: The
degrees of freedom for a three-dimensional object using only standard Gigabit-Ethernet (GigE) interface lets data be
three attributes. The lighting is already integrated in the exchanged at extremely fast speeds. In addition, many other
sensor’s enclosure. The stereo sensor uses two sensors for standard communication interfaces are supported, such as
stereoscopic vision and with them determine the object’s 3D Profinet and Profibus. The robust sensors are supplied quickly
coordinates or defined image segments. More areas that are and easily via Power over Ethernet (PoE). The sensors are
difficult are illuminated using the integrated lighting. combined with new software technology. It offers a modern
graphic user interface that allows the user to navigate intuitively
Sensor for web-supported robot guidance on the touch screen to operate the system.
SHAPEMATCH 3D makes use of multiple projected lines. 3D vision automation

Its primary application, when combined with 3D form
Matching, is for web-based robot guidance. Robust and highly The new 3D vision automation will make it significantly
accurate results are achieved because of the high redundancy easier for users to install and integrate them into their systems
of measuring lines. and processes. “Plug & automate” means that workers will now
Several single sensors can be combined to a sensor group. have the capability to install 3D robot guidance on their own
The SHAPESCAN3D sensor is designed to allow robots to and put it into operation immediately. The software is available
perform bin picking, meaning to reach into the box. Even in in combination with the sensors, but is also sold separately.
the most difficult lighting conditions, the positions of lower Users can determine for themselves exactly what they need for
level, randomly distributed objects can be determined three- their systems. You can easily start working with 3D robot
dimensionally in different depths of large bins. The robot can guidance in a flash, because instead of complicated
remove unsorted parts directly from the transport bin and - programming, all you need to do is set a few simple parameters.
without the need for complicated mechanical structures - can With its new philosophy, ISRA will be pioneering new
then feed them into the production process. application areas for 3D machine vision. The days when users
had to rely on experts to efficiently automate their systems is
Benefits now a thing of the past. With “plug and automate”, users now
have the freedom to use automation solutions of the
As compared to mechanical separation, the robot’s ability future today. ☐
to directly reach into the box brings with it the benefits of Courtesy: ISRA Vision
flexibility in the range of parts as well as cost reduction > MORE@CLICK ADI03541 | www.AandD24.in
Machine Vision-ISRA.indd 87 8/14/2014 9:14:52 PM

EVENT | report
Creating information
driven digital enterprises
For a successful business transition, it is imperative for
industries to adopt new information technologies, such as
cloud computing, mobility, social technologies, Internet of
Things, Big Data/analytics, and 3D visualisation. ARC
Advisory Group’s 12th India Forum discussed this transition
for the process and discrete industries at Bengaluru, recently. Sumedha Mahorey
Deputy Editor
A post event report… sumedha.mahorey@publish-industry.net
Market forces, such as globalisation, resource constraints Advisory Group’s 12th India Forum for the process and discrete
and environmental concerns, changing demographics, and IT industries, on the theme ‘Industry in transition: the information
trends are influencing manufacturing companies and their driven enterprise in a connected world, was organised on July
dynamic market ecosystems and value networks. India’s 10-11, 2014, at Bengaluru.
economic growth has temporarily decelerated due to the global
headwinds and domestic rumblings; but industry analysts Highlights
predict that it’s just a matter of time before the growth engine
is back on track. However, for a successful transition it is The day 1 began with the welcome address by
imperative for industries to adopt new information technologies, Ganapathiraman G, Country Manager India, ARC Advisory
such as cloud computing, mobility, social technologies, Internet Group, followed by keynote presentation by Ralph Rio,
of Things, Big Data/analytics, and 3D visualisation. Information Research Director, Enterprise Software, ARC Advisory Group,
driven digital enterprises leverage new technologies to achieve on “Industry in transition - the information driven enterprise
agility and sustain a competitive edge. With the focus on in a connected world.” Rio focused on predictive maintenance
maximising productivity and increasing RoI by channelising and how automation is bringing about a business transition.
relevant information and investing in technologies, ARC Arundhati Bhattacharya, General Manager, NTPC, in her
Event Report - ARC - Aug-Sep 2014.indd 88 8/18/2014 10:36:00 PM

report | EVENT
Ganapathiraman discussed integrated and interconnected

enterprise. He spoke on the rise of cyber physical systems and
the various industrial challenges to Internet of Things (IoT) –
cyber security, technology standardisation, IP ownership, and
socio-political issues. In the subsequent presentation on
“Predictive analytics - maximising profitability in operations”,
Sayantan Roy, Director - Software Sales, GEIPS, highlighted
on industry’s first predictive diagnostic solution and the
industry’s transition to brilliant machines. This was followed
presentation on “The Information Driven Enterprise – NTPC by a panel discussion and Q&A session.
experience,” highlighted the processes automated at NTPC, The second session started on the theme – advancement in
various advancements in HMIs, connectivity in automation control, network strategies, and MES, with the presentation on
systems and the need for business analytics. Bhattacharya said, “Industry in transition: information driven manufacturing -
“Embracing IT & automation technologies is not a mere exercise India specific challenges” by K Nandakumar, President, AIA.
but the need for business excellence today. Only such enterprise He shared the roadmap for modernisation of automation
will have the competitive edge in complex and dynamic future which included need for recognition to IPR, innovation &
business scenarios. The concept of information driven technology upgradation, technical collaboration, industry-
enterprise will change the business ecosystem.” institute partnership, standardisation, addressing technology
Next, Sameer Prakash, Head - Automation, Siemens, obsolescence, setting up additional R&D labs and joint
detailed on “Future of manufacturing – Siemens perspective” ventures.
and the digital enterprise platform as a basis for Industry 4.0. Presentations by BT Narasimha, Sr Director – Software
He said, “Integrating product and production lifecycle can Sales, Schneider Electric, on “Getting the most out of an MES
reduce time-to-market by up to 50%.” He also shared an investment” and Dinesh Mungi, BDM – Packaging, B&R
example of BMW-Brilliance manufacturing unit at Shenyang, Automation, on “A new high in control solutions: scalable and
China, which uses electrical and mechanical turnkey solutions ultra-fast automation” followed. Next, Sunil Mehta, Chairman,
as part of totally integrated automation. This was followed by a CLPA India, highlighted the topic “CC-Link IE and a trend for
presentation on “Connected enterprise: amplifying value with the future”, supported by Haruyuki Otani, CLPA – Technical
integrated control and information” by K Srinath, GM, Task Force Chairperson.
Rockwell Automation. He said, “Context building of data is Another presentation on “PLM software as key component
very important. Legacy system, control system and many layers of the digital enterprise platform” was presented by Gautam
prevent Big Data from becoming accessible. Companies need Dutta, Director – Marketing, Siemens PLM. He shared trends
to have networks for Big Data.” He also stressed on the in PLM, manufacturing engineering and point cloud data
connected enterprise and how it can be optimised for rapid management. The next theme of discussion was strategies to
value creation. achieve asset performance management and MES. Under this
On the theme of automation & enterprise trends, topic, presentation on “Asset maintenance and management

EVENT | report
Dignitaries on the dais during the

inauguration of ARC Advisory Group’s
12 th India Forum
using FDT/DTM – an end user perspective”, was given by for process industry” by Jayant Kapoor, GM - Manufacturing
Mouleswara Reddy, Sr Manager Quality, India Engineering IT, Ranbaxy and Manish Kumar Singh, Head - MES, Siemens;
Centers, Flowserve, FDT Group, while Vivek Gupta, Head “Integrated information management for operational excellence
Instrument, DCM Shriram, highlighted on “Advanced Process - ports information management system” by Vipul Shah,
Control (APC) in fertiliser plant including safety Associate VP, Chairman’s Office, Adani; and “End user survey
instrumentation”. The last presentation of day 1 was featured responses on engineering services by GSPs” by Neelam Singh,
by Chandrasekhar, MD, Pioneer CT, ACE Micromatic Group, Senior Analyst, ARC Advisory Group. A panel discussion and
who discussed “Machinery manufacturing trends”. Another Q&A session was held post these presentations.
round of panel discussion and Q&A session followed his The last session of the forum was based on the theme
presentation. information management. Under this, Rio shared insights on
Day 2 began with a presentation on “Manufacturing asset lifecycle information management, while Sanil
challenges in aeronautical industry” by Dr B Ashok, Deputy Namboodiripad, Assistant VP - Operations, Reliance Power,
Project Director, ADA, under the theme – Industry in discussed integrating plant control systems with business
transition: information driven manufacturing. He pointed out applications. Namboodiripad detailed on centralised
the various challenges that lie in the Indian aerospace monitoring and SAP journey of Reliance Power. The concluding
manufacturing sector. This was succeeded by an interesting presentation was given by Srinivasan Thiagarajan, Senior
topic “Engineering the Internet of Things” discussed by Raja Consultant, TCS on ETO2WIN: information driven ‘engineer
Shan, Head - Strategy, Engineering, & Industrial Services, TCS. to order’ enterprises, followed by a panel discussion and Q&A.
He stressed on IoT to improve the solution value chain and
analytics driven design. Key takeaway
The next theme was on control strategies and energy
optimisation. D P Majakar, AGM (EDN), BHEL & V Ramesh, The forum provided a platform to suppliers to disseminate
SE, KPCL, presented the total automation solutions for super and share new processes & technologies; and the end users
critical power plants, followed by a presentation on software- gathered information about new technologies that could be
based optimisation in power plants by Peter Deeskow, Head – deployed. With nearly 300 delegates, the two-day forum was
Product Development, STEAG. He spoke on how automated reminiscent to the fact that to remain competitive & achieve
detection of deviations can support in decision making. operational excellence, organisations must sift through the
Then, under the theme: strategies to achieve operational information glut and adopt appropriate technologies. The
excellence, Rainer Lamping, VP - Construction Management presentations made it clear that adopting new processes and
Strategy, Product Strategy Group, AVEVA, discussed the technologies is not an option - it is mandatory to achieve
importance of construction management in project execution. operational excellence and sustainability. ☐
This was followed by presentations on “Operational excellence > MORE@CLICK ADI03542 | www.AandD24.in

T E C H N O L O G Y | TA L K
Cable Trolley Solution

The article deals with cable trolley system that is used to support, protect and manage flat
and round cables for the transfer of electrical energy and data.
Cable and hose systems are available Application range

in various different industrial applications
as supply lines. They are only conceived Cable trolley system caters to
for flat and round cables. To transport moving applications in key
liquid and gaseous media, the round industries like process industry,
cables are replaced by hoses. These food and beverages, textile,
systems are employed in festoon automation, material handling and
application. To begin with, festoon mining. Additionally, these are
application generally caters to material used in machinery and equipment
handling. Festoon cable is flat cable that are permanently exposed to
designed for power and control the weather; conveying and
applications, particularly suitable for hoisting equipment; construction
demanding environments, such as in machinery; shipyard machinery. Cable trolley solutions have been engineered and
mills and at port facilities. The flat These are suitable for use in special tested to be oil, coolant and chemical resistant and
construction allows for stacking multiple conditions such as industrial or withstand dry, damp and wet conditions and
cables where space is at a premium. sea water. Cable trolley solutions therefore allow you to save money on downtime
Additionally, festoon cables are best suited have been engineered and tested and lost production
for meeting the requirements of to be oil, coolant and chemical
applications facing engineering and resistant and withstand dry, damp
design problems. These systems are ideal and wet conditions and thus, allowing by the following factors.
for overhead cranes, gantry cranes water you to save money on downtime and lost Flat cable: Travel distance less than 20 m
treatment systems, car wash systems, bulk production. × 1.25 = cable length; travel distance 20-
material conveyors, plating lines, and 50 m × 1.20 = cable length and travel
many other types of moving equipment. Key factors that determine the distance greater than 50 m × 1.50 = cable
selection of cable trolley system length
Key features of cable trolleys Round cable: Travel distance × 1.50 m =
The factors include travel distance, cable length
Parts used are made of special cable package-design (flat & round) and
galvanised steel and consist of four dimension. Support bracket-wall of roof How many trolleys do I need?
guiding rollers with special high-life ball mounting, I-beam with distance and
bearings for smooth running. Cables are beam dimensions are necessary to Divide the cable length by the double
clamped with rubber plates of Neoprene, accommodate the trolley wheel diameter. cable sagging which will give you the
appropriately shaped that prevents sharp Type of system: Provide a brief drawing number of trolleys including the towing
bends at the camping point. This ensures of the placement of cable clamps. Choose trolley. Standard cable sagging is 0.75 m.
long life of cables. Flame retardant as per type of system you would like to use (wire, Cable trolley length x number of trolleys +
highest industry standards IEC; weather c-profile, I-beam, etc) with regards to towing trolleys length = parking space.
resistant for harsh environments; high cable weight, size, bending radius and The equation of number of rails and track
data capacity and low electromagnetic environment. couplers is travel distance + parking space
interference; flat cables need less space Cable length: Find out the cables length = total track length. ☐
than round cables and cost-savings you have to use in your system. Here fore Courtesy: Lapp Cables
through quality and constant innovation. consider the travel length multiplicated > MORE@CLICK ADI03543 | www.AandD24.in
Tech Talk Lapp Aug.indd 92 8/14/2014 7:31:29 PM

news | technology
OPC Unified Architecture for industry 4.0 Signal conditioners

B&R has advanced the integration of OPC UA in the automation studio Pepperl+Fuchs’ SC-system is a new development that combines the
development software. Automation studio supports OPC UA clients and most powerful features of comparable products in a family of devices. For
servers directly on the controller, thus, example, calibration is performed by
allowing vertical communication to fully automated laser trimming of
SCADA, MES and ERP systems as well fixed resistors. This means the best
as vendor-independent communication calibration results without production
from PLC to PLC. With new PLCopen- spread, and the risk of interference
compliant OPC client function blocks, from trimming potentiometers due to
this communication can be easily their slider contact point is
implemented in the application eliminated. Electrolytic capacitors
These controllers can be software regardless of the hardware have been omitted, and alternative The 6 mm system modules are
implemented as OPC UA servers being used. Through the support of components are used instead. The mounted on a DIN rail
and as OPC UA clients OPC UA subscriptions, larger amounts temperature-dependent reduction of
of data can be transferred faster. OPC the capacitance values observed with electrolytic capacitors, as well as
UA is standardised in accordance with IEC 62541 and offers easy-to-use signs of aging, is thus effectively counteracted. By replacing the
functions for vendor-independent data exchange. This makes it easy for electrolytic capacitors, the SC-system signal conditioners can be operated
software developers to engineer complex systems with high data at an ambient temperature of up to 70 °C. The low-power design, which
communication demands. Implementing flexible and modular automation ensures low self-heating, contributes to the wide temperature range in
solutions more easily is the result. With POWERLINK, openSAFETY and which the products can be operated. The SC-system uses high-quality
OPC UA, the company offers its customers the perfect tools to meet the 3-way isolation between input, output, and supply which withstands a
high demands of Industry 4.0. working voltage of up to 300 V and a test voltage up to 2.5 kV.
Screw clamp fuse terminal blocks Heavy duty encoder

Connectwell’s screw clamp fuse terminal blocks are used in electrical CST Sensors’s BEI heavy duty encoder is specially designed for heavy
and control systems which require protection. The CF series terminal duty applications: steel & paper mills, lumber,
blocks accept industry standard cranes, etc. With solid shaft of 12 mm or 11
5 X 20 mm and 5 X 25 mm glass mm with RE0 115 mm flange (Euro flange
cartridge fuses. These blocks B10) for tacho generator type mounting it has
are completely closed and do not a resistance to shocks/vibrations and to
need separate end plates. CF4SP extreme axial/radial loads. With a high
series fuse terminal blocks have protection level of IP67 it has a connection
a thickness of 6 mm with a with terminal box (cable or connectors output
provision for using internal also available). It is electronic compatible
shorting links. In control and with industrial standards and electronic
The CF series terminal blocks accept automation wiring circuits it can permits to drive different inputs (PLC +
industry standard 5 X 20 mm and 5 X be used in an alternating display, for example). With digital
25 mm glass cartridge fuses configuration with some of the incremental output, optional analogue The encoder has a mechanical
feed through terminal blocks output (tachoencoders, optotacho) or sine over-speed switch option
CTS2.5UN, CTS2.5UE, CTS4UN and CF4SPFT. The CF4UL & CF4SPL series output its resolution is up to 10000 ppr. It with protection against short
terminal blocks are used for offline indication in case of fuse blow out. has a mechanical over-speed switch option circuits for electronics
These blocks can be used in AC & DC voltages. The width × length for with protection against short circuits for
CF4U is 8 × 57; CF4UL is 8 × 57; CF4SP is 6 × 58.5 and CF4SPL is 6 X 58. electronics. Option “Max control’’: the encoder gives on real time its
The voltage range of CF4UL is 6 – 60 V AC/DC 110 – 240 V AC/DC and physical environment parameters: shocks and vibrations, too high or too
CF4SPL is 6 – 60 V AC/DC 110 – 240 V AC/DC. low temperature, too low or too high supply, quality of the output signals.
Tech_news_Aug-Sep-2014.indd 93 8/18/2014 10:25:39 PM

technology | news
Intelligent earth leakage relay Data Portal

ElMeasure’s microcontroller based Intelligent Earth Leakage Relay (IELR) The latest version of the Eplan Data Portal will enable users to benefit
with 4-digit 7-segments RED bright digital from enormous time savings and increased
display, is unique as compared to project quality. The current 470,000 part
conventional ELRs. Its features include data, including schematic macros,
inverse curve; continuous leakage current geometric dimensions and documents, can
display (Programmable); continuous display be imported to engineering automatically.
of trip leakage current (Programmable); This is made more simple thanks to
continuous scrolling display for set current innovative functions such as a newly
and set time; field programmable through integrated 3D viewer, which enables users
front panel keys with password protection; to view and assess components quickly and Around 470,000 part data
Its features include wide input range 60 mA to 12 A and the easily. It is possible to call up several different including schematic macros,
inverse curve; continues trip time programmable from 300 ms to views such as front, page or isometric views geometric dimensions and
leakage current display 30 seconds and manual test and reset very easily with a click of the mouse. Free documents can be imported
(Programmable); continuous keys. Its specifications include second rotation and zooming functions allow that to engineering automatically
display of trip leakage update; auxiliary supply 80 to 300 VAC; individual detailed views can be generated in a using the Data Portal
current (Programmable); burden 4VA max; panel mountable 96 x very flexible manner. The advantages for the
continuous scrolling display 96 x 45; accuracy class 1.0 FS; relay user are obvious: e.g. when placing the part in the project, they receive
for set current and set time contacts; CBCT standard size – 40, 65, reliable decision support as to whether the component is suitable for the
and field programmable 100, 150, 200, 250, 300 mm tape wound proposed control cabinet. The surface of Eplan Data Portal has also been
through front panel keys with and weight (Approx): Unpacked – 250 gms optimised. The view of the 66 manufacturers that are currently involved
password protection Shipping - 350 gms. has been adapted to the design of Data Portal App.
Relay interface modules Pressure transmitters & sensors made of titanium

Finder has introduced the 39 series MasterINTERFACE range of ultra-slim Keller AG für Druckmesstechnik has offered titanium versions of its
relay interface modules that provide a low-cost, space-saving solution for a products for use in heavily corrosive media. This metal has a host of
host of industrial applications. This series incorporates an innovative, advantages for applications under very
replaceable fuse for output circuit protection, plus busbars and terminals special conditions. Titanium is used as a
that simplify input and output replacement for steel in the aerospace
wiring. Housed in a compact 6.2 industry, mainly for reasons of weight. In the
mm wide package, this series medical devices sector, the fact that titanium
offers integral coil protection is chemically and biologically neutral is
circuitry, as well as a secure especially important. This property is due to
retention and ejection clip. Five a permanent layer of oxide on the surface
dedicated module types are of the material. Thanks to its presence,
offered to meet the requirements components made of titanium will not
The 39 series MasterINTERFACE of basic, enhanced, input, output and corrode even in salt water or chlorinated Titanium is more frequently chosen
incorporates an innovative, replaceable timer interface functions. water, unlike the high-grade steels that are for process measurement technology
fuse for output circuit protection, plus The enhanced MasterPLUS module normally used in the sector. This is why applications involving waste water
busbars and terminals that simplify adds the option of a quick connection titanium is more frequently chosen for that may be contaminated with
input and output wiring replaceable output fuse and special process measurement technology unknown corrosive substances
leakage current suppression versions applications involving waste water that may
to mitigate detrimental effects caused by residual current in the input be contaminated with unknown corrosive substances. A titanium housing
circuit. Both the MasterINPUT and MasterOUTPUT incorporate additional makes it possible to carry out hydrostatic level measurements effectively
busbar jumper links and terminals necessary for the full connection of 2 or in brackish water, or even in iron chloride. The development of an
3-wire input devices and output devices respectively. implantable sensor (Ø 9 mm) made of titanium has caused a sensation.

news | technology
IT powered automation Linear modules

To avoid breaks in technology and ensure the future capability of the SCHUNK has recently presented the Delta 145C, a particularly compact
automation solution, Phoenix Contact has offered components and module that enables powerful
systems that use mainstream strokes up to 4,000 mm. Its
technologies from IT area. In inner dual-profiled rail guide
addition to the already proven ensures maximum rigidity and
automation protocols, precision, thus, exhibiting
international IT standards are superior performance in
integrated into the control absorbing heavy loads. To
system. The web server increase the reliability and the
provides a free website for all service life of the module, a
100-series controllers. These specially fixed plastic cover strip With a spindle drive, the series
These web pages can be displayed using web pages can be displayed protects the guidances, and drive enables driving forces up to 6,000 N,
the WebVisit software and linked to the PLC using the WebVisit software elements from dirt. The Delta series is speeds up to 2 ms-1 and a repeat
program using data and linked to the PLC finely graded and comprises a total of accuracy of +/- 0.03 mm
program using data. The web four sizes with profile widths between
panels with integrated browsers display the pages and allow them to be 110 mm and 240 mm and strokes up to 7,720 mm (Delta 240C). With a
visualised without any knowledge of Java. Using the FTP (File Transfer toothed belt drive, a maximum driving force of 2,200 N, a maximum speed
Protocol) server of the 100-series controllers, any type of file can be of 5 ms-1 and a repeat accuracy of +/- 0.08 mm are achieved. With a
stored or uploaded to the flash file system of the PLC — for example, for spindle drive, the series enables driving forces up to 6,000 N, speeds up
exchanging parameters, log files, recipes, or for storing the current to 2 ms-1 and a repeat accuracy of +/- 0.03 mm. These can be flexibly
version of the PLC source code during servicing. integrated into systems by means of T-nuts or mounting strips.
Handheld barcode readers Eddy-current measuring system

Cognex has introduced the DataMan 8050 and 8050X handheld barcode Micro-Epsilon’s turboSPEED DZ140 is optimised for thin turbine blades
readers, which are designed with a rugged made from aluminium or titanium.
polycarbonate housing to handle harsh factory floor The system is thermally stable
conditions and feature 1DMax+ with Hotbars barcode and very well protected from
reading algorithms. The 210 mm x 115 mm x 85 mm external interference. It is the
readers feature a 752 x 480 global shutter sensor, fourth generation of eddy current-
integrated LEDs with near/far optics, and DataMan based revolution counters for
setup tool software, which enables image viewing, turbochargers. The sensor system
Java scripting, and data formatting options. Available is suitable for speed
with both corded and wireless measurements of 200 to 400,000
communication modules, these series rpm. The sensor is just 3 mm in The DZ 140 eddy-current measuring
Available with both corded and support industry-standard communications diameter, yet it provides the system is resistant to oil and dirt
wireless communication modules, including USB, USB Keyboard, RS-232 and highest immunity to interference
these series supports industry- Bluetooth wireless communication to a base in harsh test conditions. The integrated temperature measurement feature
standard communications station. Built for tough work environments, records among other data the actual ambient temperature near to the
including USB, USB Keyboard, these series have durable and industrial sensor. It provides much higher immunity to interference than other eddy
RS-232 and Bluetooth wireless product features as well as a range of current-based revolution counters. The DZ140 eddy-current measuring
communication to a base station industrial cables and accessories to system is resistant to oil and dirt. The maximum operating temperature of
complement the product. These barcode the miniature sensor is 285°C, which is a key advantage compared to
readers read 2-D DPM codes as well as 1-D and 2-D label-based codes optical speed measuring systems, as this helps to achieve high precision
quickly and easily. These are optimised for reading 1-D and 2-D measurements on a continuous basis. The well engineered design also
label-based barcodes with the fastest performance. enables easy sensor replacement without further adjustments.

h i g h l i g h t s | c o m pa n y i n d e x | I m p r i n t
Highlights - (Oct/Nov 2014)

impRINT
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»»Automotive & Machine Tools »»Sensors & Encoders »»Robotics & Handling
Keeping competitiveness in The rapid progress of sensor Once guardians of large- and Advertising Sales 
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Many automation service providers cost-to-performance ratio. The Vision technology advances have led
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Bengaluru
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Contact: +91 9980432663
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AUTOMATION & DRIVES

VOL 07 | AUG-SEP 2014 | ` 100

Enabling flexible design experience

FOCUS Semiconductors & electronics P. 36, 42

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< Replaces dedicated hardware reACTION

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Republic of Rwanda – the partner country for AUTOMATION-2014

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For manufacturers to realise more profitable

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Blank body functionality

A&D India | Aug-Sep 2014 21

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22 A&D India | Aug-Sep 2014

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coverstory_Aug-Sep.indd 23 8/18/2014 6:59:02 PM

“We are looking

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A&D Aug-Sep 2014

A&D Aug-Sep 2014

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