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ENERGY EFFICIENCY IN SMART FACTORIES: THE ROUTE TO LOWER RUNNING COSTS
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IN THIS MAGAZINE…
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NERGY EFFICIENCY IN SMART FACTORIES: THE ROUTE TO LOWER RUNNING E COSTS
10 ARTIFICIAL INTELLIGENCE SET TO IMPROVE ENERGY MANAGEMENT 11 DIGITAL SOLUTION FOR FACTORY ENERGY MANAGEMENT 12 FPT Industrial Records Positive Results in China at SFH 14 Interroll and Teknokom realize a fully automated and remotely monitored material flow system for Karaca Group in Turkey
16 Interroll presents new High-Performance Crossbelt Sorter 18 Survey reveals German production companies’ unrealized demand for automated material flow systems
20 Interview with CEO Ulrich Balbach 22 Less planning and project planning effort for material flow solutions 23 OPC UA Embedded Toolkit from Softing Now Includes Discovery Announcements 24 St. Joseph-Stift hospital in Dresden relies on networked solutions that secure the building envelope, but also much more
28 Rohde & Schwarz presents new test solutions for 5G base stations 30 New R&S NGP800 power supplies boost efficiency with up to four independent channels in a single compact instrument
32 Manual work meets modern automation to empower workers with handicaps 36 Will Teledyne Gas & Flame Detection bring differentiation to the market? 38 New Intesis gateway makes communication between PROFINET and BACnet easy 40 A lot of power in a very small space 43 Strong and established sales partners represent the German pump manufacturer WANGEN PUMPEN in Australia and New Zealand
44 Leuze and iTRACE Announce the Blockchain Integration of 2DMI with the DCR 200i Send your press releases to: editor@ipmediaonline.com To receive Industry Asia Pacific magazine free of charge, please subscribe online at www.industry-asia-pacific.com Industry Asia Pacific is the English-language magazine for engineers, published by INDUPORTALS MEDIA PUBLISHING. It contains the latest product and company news for industrial markets. Industry Asia Pacific edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used. www.ipmediaonline.com
Camera Based Code Reader
46 Always in front of the right rack: Less downtime for compartment fine positioning with camera-based positioning sensors
50 Muting reinvented - Smart Process Gating 57 More than 1500 autoclave cycles possible 58 AGV navigation: what are the possibilities? 60 Chain Condition Monitoring 63 Powerful CAN-FD multi-channel Ixxat PC-interface for automotive test systems and industrial applications
64 Magnetic encoder system with Drive-Cliq interface from Balluff 65 Red Lion Presents Layer 3 Gigabit Ethernet Switch 66 LogiDrive intralogistics solutions combine energy efficiency and the reduction of variants
68 Traceability in the medical sector, a technical challenge
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Steed WEBZELL
EDITORIAL
THE SMART MONEY IS ON ENERGY EFFICIENCY As Europe emerges from the grip of its COVID-19 crisis, manufacturers, process plants and other industrial facilities are awakening to a “new normal”. In recent weeks, machinery that had stood idle since March has begun whirring into life, and production staff have been making their way back to the shop floor, at a safe working distance, of course. Sure enough, things are different now, but for how long? This million dollar question is one that few are brave enough to call at this stage. However, judging by major disruptive events in history, time heals wounds … and economies. Confidence will return and investment levels will rise once more. In the meantime, the trick is to be smart about manufacturing and save on unnecessary outgoings. Within this remit, overheads are a key target as they typically constitute 30-40% of total production costs. Sure enough, there is little that manufacturers can do about certain overheads, such as the depreciation of plant and machinery, or the cost of insurance, for example. However, when it comes to energy costs, there are major savings to be had with the right approach. The convention of powering everything up in the morning and powering it all down in the evening is no longer appropriate in a highly competitive industrial landscape. Monitoring should be the first step in any energy-efficiency drive. Industrial facilities must be aware of how much energy is being used, and when, to ensure they make the right changes to their strategies and the right investments; ones that deliver the quickest return. Indeed, monitoring can sometimes provide surprising insights. For instance, it may become evident that certain machinery or plant equipment is idling for extended periods when it can instead be turned off. Similarly, data might reveal that some lighting circuits are being left on for entire shifts, when they can in fact be powered down for specific time periods. For this reason, the use of occupancy sensors has gained much traction in industrial settings over recent years.
With monitoring addressed, data trends will emerge that can be used to shape the energy strategy moving forward. Perhaps a manager or team leader can be appointed to take ownership and drive the project, with the best suggestions taken forward to implementation. Some ideas will be common sense and can be actioned successfully with relative ease. However, in the age of the smart factory, there is a growing train of thought surrounding energy. What if energy monitoring and control could be achieved using Industry 4.0 strategies, with consumption data for machines, plant, equipment, systems and lighting all metered, analysed and managed via the Cloud? Well, the good news is that the technology already exists to make this vision a reality. Moreover, a number of case studies have emerged of industrial facilities successfully adopting this technology. Such premises are not only saving money, but reducing their carbon footprint and, in turn, boosting their environmental credentials. The capabilities of Industry 4.0 and, subsequently, smart factories, have been mooted for a number of years, with a greater number of projects now coming to fruition. However, the nature of the Industry 4.0 ethos is intrinsically linked to scalability, so it perhaps comes as no surprise that concepts such as smart lighting, for example, are today being included in holistic “smart” strategies. Of course, the havoc, misery and tragedy that the pandemic wreaked across Europe should never be forgotten. Few people or businesses will have escaped its effects. But now the rebuilding starts. And although civilisation, including industry, can do little else but live with this virus in a pre-vaccine world, the time to start adapting to the new normal, is now.
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MARKET OVERVIEW
ENERGY EFFICIENCY IN SMART FACTORIES: THE ROUTE TO LOWER RUNNING COSTS Author: Steed WEBZELL
The concept of the smart factory has been steadily evolving over the past few years as it moves towards the goal of providing harmonious communication between shop-floor devices and enterprise-wide management systems. Ultimately, the ambition is to ensure productivity and quality are maximised, from quotation and order, to manufacturing and dispatch. Such a transition also provides the perfect opportunity to address a sometimes overlooked aspect of smart factory operations: energy efficiency.
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n recent years, a swathe of innovative, future-oriented solutions have come to market offering real-time smart metering capabilities for electricity, gas and water. By leveraging capability of this nature, energy efficiency can be seen as a core component of Industry 4.0. It is well documented that factories are among the world’s biggest consumers of energy, however, the use of power is clearly vital in ensuring the continuity and quality of end-toend production processes. With these thoughts in mind, it is critical to ensure energy efficiency at all times.
Most factories have a number of machines, systems and devices that consume energy, including machine tools, production lines, conveyors, motors, HVAC units, boilers, back-up generators and lighting, to list but a few. However, with the right smart technologies in place, plant managers no longer have to record samples of energy usage at predefined intervals, as is the case with traditional energy management systems. Although conventional systems help provide a snapshot of energy consumption, they do little to help curtail energy use, predict peak patterns or suggest what can be done to improve efficiency.
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In contrast, smart monitoring means that analyses can take place in real time, helping to optimise energy efficiency. Moreover, via the use of smart meters, it is possible to not only track energy use at its distribution point, but at various points of consumption throughout the smart factory. Transparent energy flows and data are clearly key for exploring optimisation potential. If these flows are also integrated into cloud-based IoT systems, valuable knowledge can be generated and used to optimise entire factory and business operations. 33 | Industry Asia Pacific | July 2020
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Advantech is using its solution to monitor and analyse factors such as energy consumption at the company’s own facilities. 33 | Industry Asia Pacific | July 2020
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NEWS MARKET OVERVIEW
Ultimately, adopting an ecosystem of intelligent and energy-efficient solutions for Industry 4.0 manufacturing delivers benefits that include energy management, remote connectivity and control solutions for smart factories. Sustainable solutions, such as the ones set out in this article, will facilitate more energy-efficient and productive manufacturing businesses, while simultaneously providing safer, more connected operations. A case in point can be seen at the Maisach, Germany warehouse and distribution centre of Rexel, a leading electrical wholesaler that is taking advantage of the latest cloud-based energy monitoring solutions from Siemens to help drive anticipated annual savings in electricity costs of 25-30%. “Increasingly distributed energy systems and renewable energy sources require new, intelligent solutions, and energy monitoring creates the basis for this,” states Ricardo Radowski, Director of Business Development at Rexel Germany. At Rexel’s site in Maisach, electrical energy data such as voltage, current and power for infeed is now being recorded around the clock. Data from electrical outgoing feeders – as well as individual consumers down to machine levels – is also being captured.
After data analysis the results are clearly displayed and can be shown on different devices – for maximum transparency in real time.
Using the MindConnect Nano interface, the energy data collected in Rexel’s facility is transferred directly into MindSphere from Siemens, a cloud-based, open IoT operating system. “We are now aware of where our energy is flowing,” says Radowski. “For instance, it was a surprise that such a large proportion of our energy consumption could be attributed to lighting. Making this discovery means, we will soon be replacing our conventional lighting system with a more intelligent alternative that consumes 80% less energy.” Rexel has also installed the same solution at its distribution centre in Weisskirchen, Austria, so the option of cloud connection proved very attractive. “We decided on cloud connection because of the crosslocation opportunities and other possibilities that are available,” states Radowski. “By way of example, it is now easy to benchmark energy efficiency between facilities and share information and best practices.” HOLISITIC MONITORING OF ENERGY EFFICIENCY
Ricardo Radowski, Director of Business Development at Rexel Germany now has an overview at all times of important energy data, analysed from the cloud.
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The power monitoring system from Siemens includes software and suitable measuring devices from the Sentron portfolio. In fact, more than 100 devices from the 7KM PAC series have been installed. Further to energy data, the devices provide precise status information on electrical power distribution, exact meter readings and better peak load management. The measured values can also be used to assess system status and network quality.
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The story is similar a little further south, at the home of the Slovenian smart factory, Salonit Anhovo. Thanks to the adoption of a solution based on LoRaWAN technology from Solvera Lynx, Salonit Anhovo has become one of the top 10% most energy-efficient cement factories in Europe. In order to comply with European energy regulation and meet reduction targets for power consumption, Salonit Anhovo decided to carry out an energy management project. “Our company wanted to understand, in detail, the energy flow through the factory, and we were looking for a system to handle energy consumption data automatically,” says Magda Gabrijelcic, Energy Manager at Salonit Anhovo. The project required a custom-made solution to optimise energy-intensive production processes: Salonit Anhovo uses over 90 GWh of electricity annually, more than 8 GWh of gas, and over 400,000 cubic meter of water. The cost of
NEW S MARKET OVERVIEW
The Salonit Anhovo factory covers a site of more than 6 square kilometres.
energy consumed by the company amounts to more than €6 million per year. An inhospitable industrial environment with high moisture rate, extreme temperature conditions and far-spread production areas – spanning an area of more than 6 square kilometres – made the project even more challenging. “Using LoraWAN devices from Solvera Lynx allowed us to focus on the energy-saving potential of the project, instead of hardware aspects such as cabling,” confirms Gabrijelcic. Data transmission is performed by ComBox. L communication equipment, which offers long battery life and suitability for harsh industrial environments. In total 36 ComBox-certified devices were installed, 11 of which are for gas metering, 10 are for water metering, five for compressed air, and 10 for electricity meters. The data is gathered and analysed by the GemaLogic software platform. After using the LoRaWAN-based EMS for over a year, Salonit Anhovo has achieved real results and accomplished its primary project goals: holistic monitoring of energy efficiency performance and the reduction of energy consumption.
reinvent the wheel every time. Every aspect of the hardware and software has already been field tested and is mutually compatible, so implementation is very fast.” The company pioneered and perfected this Industry 4.0 upgrade solution in its own factories, where significant productivity improvements were achieved, along with reductions in energy costs, giving a very fast return on investment. For instance, in Europe, Advantech has installed a service centre in Eindhoven, Netherlands, which is a great showcase for the potential of industrial automation and systems developed by the company. Warehouse management, real-time control and production systems are monitored through a digital dashboard, which has all the structure data under control in order to guarantee that the principal information is constantly analysed. In this way, Advantech shows customers and visitors how, in practice, it is able to obtain tangible results both in terms of productivity and energy efficiency.
“After 16 months of good operations, we are highly satisfied with our choice,” states Gabrijelcic. “ComBox. L CI devices with LoRaWAN and Gemalogic as the energy management system really work for us.” TANGIBLE RESULTS IN ENERGY USAGE REDUCTION
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At Advantech, a complete, integrated hardware and software solution has been pioneered that enables factories to be turned into more profitable smart factories, quickly and efficiently. What’s more, Advantech has successfully implemented the solution at its own facilities. “Our unique co-creation model of partnering with SRP providers means that we can provide a complete [hardware and software] tailored solutions for upgrading to Industry 4.0 almost off the shelf,” explains Advantech’s Managing Director Jash Bansidhar. “We don’t have to 33 | Industry Asia Pacific | July 2020
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NEWS MARKET OVERVIEW
ARTIFICIAL INTELLIGENCE SET TO IMPROVE ENERGY MANAGEMENT
ABB and Verdigris Technologies have developed machine-learning algorithms to predict unplanned peaks in power consumption, and identify strategies for prevention. To explain further, ABB is deploying artificial intelligence (AI) to help factories and other industrial buildings improve their energy management and tackle rising tariffs for peak electricity. The company has added two AI-powered apps to the ABB Ability Electrical Distribution Control System (EDCS): Energy Forecasting and Intelligent Alerts.
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he Energy Forecasting app enables users to reduce electricity bills by reducing peak demand charges, while the Intelligent Alerts app uses machine learning algorithms to help customers better manage their assets, identifying underlying issues before they become problems.
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ABB Ability Energy Forecasting leverages the capabilities of AI to give facility managers accurate power consumption predictions. In short, Energy Forecasting enables management to take timely actions and reduce unplanned consumption spikes by rescheduling or switching off noncritical loads – and take full advantage of Time of Use (ToU) tariffs.
The Energy Forecasting AI uses neural network methods to identify and learn patterns in a circuit or a factory’s energy consumption, while also considering weather data. Using weather forecasts and historical information, the Energy Forecasting app is then able to predict power consumption (kW) for the next 24 hours, updating its forecast every 15 minutes. ABB Ability Intelligent Alerts uses machine learning to help customers better manage critical assets. The app learns how various factors affect the factory and key assets so that it can minimise the distraction of false alerts and information overload, allowing facility teams to focus their time more productively. Intelligent Alerts also identifies the relevant circuits and makes potential recommendations to ensure any response can be swift and decisive. www.abb.com
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DIGITAL SOLUTION FOR FACTORY ENERGY MANAGEMENT
Mitsubishi Heavy Industries (MHI) recently launched ENERGY CLOUD Factory, a service package that utilises AI and IoT technologies. The solution is aimed specifically at factories within “Energy Cloud”, MHI’s dedicated energy solution service.
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sing data acquired by Netmation eFinder, MHI’s independently developed system for collecting data on equipment operations, the system enables the visual monitoring of production equipment operating ratios and energy consumption. Moreover, a factory’s overall performance can be evaluated in parameters known as ENERGY CLOUD Score, a newly devised KPI (key performance indicator) that integrates indexes used for measuring process productivity and energy consumption. Proprietary AI technology also enables the forecasting of future factory performance. www.mhi.com MORE INFORMATION 33 | Industry Asia Pacific | July 2020
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FPT INDUSTRIAL RECORDS POSITIVE RESULTS IN CHINA AT SFH
The COVID-19 pandemic continues to affect societies and operations around the globe. FPT Industrial, the global powertrain brand of CNH Industrial, has endeavored to mitigate these effects throughout its manufacturing and commercial network by abiding by the health and safety regulations set forth in the different international markets in which it operates. Currently the demand for industrial powertrains remains strong as the providing of essential equipment is something the world depends on to keep moving.
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n this challenging moment, positive signs of recovery have begun in China, the first nation to weather through the pandemic. With a gradual return to work and a ramping up of industrial activities, encouraging business results in the country are providing confidence to global players. Such encouragement was recently recorded during the month of April at SFH, FPT Industrial’s joint venture in Chongqing, China.
Following several weeks of shutdown due to the outbreak of the COVID-19 virus in late January, the plant resumed production in early February with extensive measures in place to ensure the health and safety of all employees. Following a carefully designed plan, it restarted at reduced capacity, gradually returning to full operation. Thanks to increased demand in China’s heavy truck market, SFH recorded a new, all-time high monthly production record for Cursor engines in April. It marked a 6% increase compared to the previous record achieved in 2018 when the heavy truck industry in China was at an unprecedented volume peak. As a leading engine supplier for commercial vehicle manufacturers, SFH counts four cylinders and head production lines and two assembly production lines. Among them, the cylinder and head production lines are equipped with 40 large-scale processors. The plant is operating 24
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NEWS
hours with extra shifts so as to guarantee supply for its customers, including SIH, parent Company CNH Industrial’s joint venture for heavy trucks in Chongqing, to meet the surging demand of the market which had been impacted due to the lockdown in force. Founded in 2007 by FPT Industrial in partnership with SAIC Motor and Chongqing Machine Equipment, SFH is one of the largest engine manufacturers in China and a pioneer in advanced low-emissions industrial engines. With some 700 employees, the joint venture manufactures the Cursor engine ranges for heavy-duty commercial vehicles and construction equipment for on- and off-road use - as well as power generation and marine applications at its Chongqing facility. The plant exports part of its production to markets around the world, and produces engines which Stage V and Euro VI emissions regulations for the North American and European markets respectively. www.fptindustrial.com MORE INFORMATION 33 | Industry Asia Pacific | July 2020
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INTERROLL AND TEKNOKOM REALIZE A FULLY AUTOMATED AND REMOTELY MONITORED MATERIAL FLOW SYSTEM FOR KARACA GROUP IN TURKEY
Interroll and Teknokom, an innovative system integrator for complete warehouse automation solutions, established an automated order picking system for Cookplus in Istanbul, Turkey. Essential elements of the new material handling solution are the RollerDrive EC 5000, MultiControl, and the Modular Conveyor Platform (MCP) from Interroll. The system combines advanced features such as travel control, automatic invoice printing, dynamic volume measurement, with cargo label applications and real-time monitoring.
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he order picking automation system which was delivered and installed by Teknokom is a key part of a modern, 6,000-square-meter distribution center of Cookplus in Hadimköy near Istanbul which serves customers all over Turkey. Cookplus is the e-commerce brand of Karaca Group, a leader in the tableware, kitchen and home textile market, operating with 2,700 dealers and shops in 27 countries. The zero-pressure-accumulation conveyors used for this material flow solution have a length of more than 220 meters interconnecting a variety of picking stations with the packaging and shipping areas on two floors of the facility. The efficient and extremely energy-saving conveying of totes and parcels uses about 190 RollerDrive EC 5000 units being controlled by 60 Interroll MultiControls cards connected to a programmable logic controller (PLC) and a warehouse management system.
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“With our new solution we dramatically increased the performance and capacity of our distribution and fulfilment center by avoiding a variety of complex manual internal processes. Just as important to us as increasing our efficiency was further improving customer satisfaction through very fast and reliable deliveries,” says Ertugrul Celebi, Chief Operating Officer, Logistics & Supply Chain, at Karaca A.S. The advanced conveyor system is entirely managed by software developed by Teknokom, a long-standing member of the Rolling On Interroll program, Interroll’s international partner network. The software applications use the data gathered by Interroll’s MultiControl cards for controlling and monitoring purposes. One example is an intelligent travel control feature which allows bypassing picking stations or a complete floor if no action from operators is needed. Moreover, at the end of the picking operation, before packaging, a printer automatically equips every order with the respective invoice. Upon entering the shipping area, a
The system combines advanced features such as travel control, automatic invoice printing, dynamic volume measurement, with cargo label applications and real-time monitoring. Software applications use the data gathered by Interroll’s MultiControl.
label applicator automatically pastes to each order a barcode label for the forwarding agent; this label contains all of the necessary information, including the order destination, volume information and a list of content.
www.cookplus.com www.teknok.com www.interroll.com
“To fulfill the demanding needs of our customer, we used our long-standing cooperation with Interroll and smoothly integrated different state-of-the-art technologies in this automated material flow system. The complete project was very carefully and holistically executed, from planning and installation up to maintenance and support. For example, our customer is now able to monitor the operation of his system in real time via an online application—whenever and wherever he wants,” declares Mustafa Hisim, Deputy General Manager at Teknokom A.S.
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Teknokom’s software application allows for monitoring the whole material flow process for maintenance and support purposes via a user-friendly interface which offers controlling as well as reporting features. For example, the locations of the totes, the actual status of the orders, and the picked items in a single tote can be seen for both floors. Moreover, operation managers can receive live as well as time-frame-based reports about order fulfillment capacity, bottlenecks in the picking stations, error reports, and detailed performance information.
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INTERROLL PRESENTS NEW HIGH-PERFORMANCE CROSSBELT SORTER
The width of the carriers was increased by an impressive 50 percent. This means an enormous gain in flexibility when sorting goods of different dimensions.
Interroll's new High-Performance Crossbelt Sorter can process up to 20,000 conveyed goods per hour.
Faster, more flexible and even quieter: With the global market launch of the new High-Performance Crossbelt Sorter MX 025H Crossbelt Sorter, Interroll extends its innovative portfolio of automatic sorting solutions to include a new high-performance system capable of handling up to 20,000 conveyed goods per hour. This new solution also allows much heavier and larger goods to be sorted. As a result, even the most demanding users can now enjoy the performanceand availability benefits offered by mechanically driven horizontal crossbelt sorters from Interroll.
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he new High-Performance Crossbelt Sorter MX 025H, offers an increased conveying speed of up to 2.5 m/s (8.2 ft/s) compared to 1.8 m/s (5.9 ft/s) for the still available Interroll Crossbelt Sorter ST 6160. The new sorter thus enables throughput rates of up to 20,000 conveyed goods per hour. At the same time, the HighPerformance Crossbelt Sorter MX 025H is able to transport goods weighing up to 50 kg. In addition, the width of the carriers has been increased by an impressive 50 percent. This means an enormous gain in flexibility when sorting goods of different dimensions.
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Maintenance for the HPCS is extremely easy and inexpensive. This is true for many reasons. First of all, the drive chain has been replaced with a rubber belt. This means there is no need for lubrication. Secondly, it is now much easier and faster to replace the belt. However, extensive tests indicate this will not need to happen for many years, even in the case of 24/7 operations. The carriers can also be replaced much faster, and wear parts are also less expensive; all this contributes to significantly lower maintenance costs – around 50% less than with a conventional Crossbelt Sorter. Thanks to the mechanical drive concept, the sorter operates extremely quietly—below 67 dB(A)—even at the highest throughput rates. In addition to extensive load and endurance tests in the in-house test center, the new sorter has already been in use for almost a year at selected
The terminals can be customized to the needs of the each user. The modular sorter platform also includes innovative infeed conveyors.
customers’ sites. The new product is officially available in the Asia-Pacific region on June 22, 2020. Over 400 Interroll automatic sorting systems already in use worldwide “With our entry into absolute high-performance sorting, system integrators can now offer users an innovative and at the same time proven technology range,” explains Jens Strüwing, Executive Vice President and Head of Products & Technology at Interroll. “Our unique, mechanical drive concept enables us to process an increasing number and variety of goods according to demand—with the highest reliability and economic advantages that are unparalleled in the world market.”
Energy savings of up to 50 percent Interroll Crossbelt Sorters operate on a direct drive principle, in which the drive units can be positioned flexibly. The entire drive system offers power efficiency rates of over 85 percent. It is designed redundantly so that if one drive unit fails, the sorting operation continues uninterrupted. Compared to electrical sorting systems operated with traditional linear motors, energy savings of up to 50 percent can be achieved. At the heart of the sorter are the crossbelt carriers with patented mechanical drives. The modular sorter platform also includes innovative infeed conveyors and terminals that can be customized to meet the needs of each user. www.interroll.com
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One important reason for this global success is the basic mechanical principle of Interroll's sorter platform. Today, more than 400 sorters are already in use worldwide by industry leaders such as Amazon, DHL, FedEx, UPS, Hugo Boss, Inditex (ZARA), Zalando, Swiss Post, Austrian Post and China Post. Unlike competing products, the number of electronic components in these sorters has been kept as low as possible. The unique design principle ensures maximum availability, very long lifetime, minimum operating costs as well as short payback periods.
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SURVEY REVEALS GERMAN PRODUCTION COMPANIES’ UNREALIZED DEMAND FOR AUTOMATED MATERIAL FLOW SYSTEMS
There is still a high potential for increasing productivity in medium-sized German manufacturing companies: Not even one in five manufacturing companies in Germany achieves a degree of automation of more than 75 percent in internal material flow. At the same time, end-users attach particular importance to simple and robust systems for pallet handling. These are some of the findings of the Production Logistics in Medium-Sized Businesses survey, which Interroll conducted in Germany in 2019 to identify what users want in terms of appropriate solutions.
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utomation and robotics are key technologies for greater competitiveness, quality and sustainability in industrial production. In order to optimally tap the productivity potential of these technologies, the internal flow of materials plays a central role. This applies not only to the supply of materials to assembly lines or robots, but also to the most seamless connection of storage and picking areas with incoming and outgoing goods. Most large companies have recognized this challenge. But what is the actual situation with automation in medium-sized companies?
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Only a minority is already highly automated Interroll's survey ”Production Logistics in Medium-sized Companies” identifies a clear need to catch up in this area: The average degree of automation of internal material handling at the companies surveyed is only 53 percent. Not even one in five companies (19 percent) achieves a level of automation of over 75 percent for these processes. Nearly one in 10 companies (9 percent) has been very reluctant to invest in these processes and has an automation level of just under 25 percent. In the case of handling processes, this even applies to every fifth company. This situation in the companies suggests that there is a backlog demand for the appropriate equipment. If this reluctance to invest is not broken, these companies are likely to face competitive disadvantages in productivity.
Interestingly, the survey also shows this situation in the susceptibility of warehouse processes to failures, which the respondents reported. For example, the number of companies with a degree of automation of less than 50 percent doubles to 48 percent compared to 24 percent of companies with a higher degree of automation. But even those who automate are naturally not completely safe from disruption. Here, software malfunctions (40 percent) and the incorrect operation of complex systems (32 percent) are among the most frequent causes of impairment.
In the survey commissioned by Interroll and conducted by the agency Faktenkontor (Hamburg), a total of 200 production companies in Germany were surveyed by telephone in 2019.. The focus was on companies with 50 to 500 employees and a turnover of up to 500 million euros. The companies came from a wide range of sectors, including mechanical engineering and the food and consumer goods industry. Technical decision makers, such as technical managers, production managers and production planners were particularly addressed.
Simplicity and robustness are particularly important for users Incidentally, easy operability of conveyor modules also plays an important role for the survey participants in pallet handling. Sixty-one percent of the production planners even consider this feature to be the most important factor in these processes. Across all those surveyed, the durability and robustness of pallet conveyor technology (58 percent) accounts for the decisive advantage of a solution. And those who believe that those responsible in medium-sized companies are not open-minded about future trends are mistaken: 67 percent consider predictive maintenance and professional service to be the most important criterion for ensuring smooth production processes, even before applications with a long service life (53 percent) and modularized products (50 percent).
With the results of this survey in mind, Interroll is actively working on a new solution - the Smart Pallet Mover, or SPM- to better organize and automate the “last mile� in manufacturing areas.
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This new interface will improve the connection between the different phases of the material flow, that is, the movement, organization, input and output of pallets. The SPM can be deployed not only in proximity of manufacturing machines but also between different production cells within the same manufacturing process. www.interroll.co.uk/products/spm/
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INTERVIEW WITH CEO ULRICH BALBACH
“Leuze – Forerunner. Yesterday. Today. Tomorrow.”
Leuze has recently changed its brand appearance. What are the reasons behind this?
The company is now simply branded ‘Leuze’. Are you no longer into ‘electronics’?
For more than 50 years, Leuze has been developing efficient sensor solutions together with our customers worldwide, tailored to their requirements and in an industry that is constantly evolving. Your success is our motivation. And the Leuze brand is the promise by which our values, messages and emotions are conveyed. The new brand image conveys determination and passion for technological advancement and change.
No, of course we are still very much into electronics – optoelectronics in particular is what we do. When the company was founded in 1963, the term ‘electronics’ had a very special meaning. That has changed. Nobody would question whether devices like our sensors use electronics. And from a practical point of view, ‘Leuze electronic’ is quite a long name that was often misspelled or shortened to ‘Leuze’ anyways. These are some of the points that prompted us to discard ‘electronic’ in our name. Above all, we think it’s important to have a clear identity.
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The word ‘forerunner’ also stands out in the new image. What message are you trying conveying with this? We actually consider ourselves to be forerunners for our customers. That goes well beyond being a pioneer. When we analyzed our technological milestones, it was obvious that we have been an innovative company for many decades. And we have always been a leader in terms of patents. For example, when you talk to one of our long-time 33 | Industry Asia Pacific | July 2020
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NEWS
requirements. The slogan underlines our role as a forerunner and our adaptability. Paving the way for someone else only makes sense if that party is willing to go down that path. How do you sell this to your customers? We are a high-tech company, we are adept masters of our technologies, and we aim to continue on the same track. To design technologies that are useful to our customers is what we call innovation. That’s what we’re good at. Another one of our strengths is application know-how. How you use a sensor for a specific application – that is critical for us. This determines the design that follows. We also take pride in designing user-friendly products, not only in terms of user operation, but also with very unique designs. And finally, high integration capability with plug-and-play is also very important to us. Let’s take a look forward: What will Leuze focus on in the next five years? developers, you’ll quickly find that we quite often spoke of the first, biggest, highest, smallest, or whatever. So for us this is quite an important revelation to recognize that we have been a forerunner in so many ways, without necessarily communicating it. And that’s what we want to change in the future. So that’s why the complete slogan is “Forerunner. Yesterday. Today. Tomorrow.” Correct? Correct. We want to be a beacon and show the way. This is also true for future-oriented topics such as Industry 4.0, IoT, or IIoT. This is why we thought really hard about this “forerunner” slogan, as you call it. Also the part “Yesterday. Today. Tomorrow.” This shows that we look at the entire picture, that we fulfilled this promise in the past and can prove so, and that we will continue to live up to it in the future.
From a constructive point of view, we have the usual suspects: reduce manufacturing costs, use other materials, observe potentially new guidelines. Sustainability, reuseability, which means designing products in a way that allows us to recycle them in some shape or form. That is certainly one issue we will focus on more and more. Particularly important is the issue of connectivity, which we call ‘sensors communication’. What I mean by that is not only the design of interfaces, but the big picture. That means collecting data, over to the edge, up to the cloud, retrieve, and analyze. None of that would make any sense without the necessary sensor technology and its further development. And another trend that has and will always be there: everything is getting smaller. With optoelectronics, the issue is that you can’t scale it. That is why we always have a team of engineers working on miniaturization. Many thanks Mr. Balbach. www.leuze.com
That sounds very ambitious. How do you make sure you will remain a forerunner for the long term? MORE INFORMATION
The role of a forerunner changes over time. A forerunner 40 years ago is not the same as today. And of course this role can have a different meaning tomorrow or the next day. Unfortunately, I don’t have a crystal ball to predict the future. But we are a nimble company and will remain flexible enough to quickly develop further and adapt to new 33 | Industry Asia Pacific | July 2020
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I N T R A LO G I S T I C S
LESS PLANNING AND PROJECT PLANNING EFFORT FOR MATERIAL FLOW SOLUTIONS
With the inclusion of the recently introduced flow storage and retrieval machines and transfer cars in its planning software, Interroll has once again expanded the range of applications of the popular Interroll Layouter tool.
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ith this application, which can be seamlessly integrated into the AutoCAD design program, planners and system integrators can now visualize even complex conveyor systems end-to-end at the click of a mouse and make them available for quotation and ordering processes. By digitalizing the necessary process chain, the effort required by customers is dramatically reduced—by up to 90 percent, depending on the initial situation.
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The ability to visualize technical planning has always been one of the central requirements in the project business with modern material flow solutions. But even today, the path from the first plant design to the detailed technical project planning, which leads to the preparation of a quotation and the concrete award of the contract, is in most cases still characterized by time-consuming breaks in the work processes. For example, initial visualizations of the overall solution must later be broken down to all the required individual components of the desired plants. The fact that this process step can be avoided is demonstrated by the Layouter tool that Interroll makes available free of charge to its customers worldwide.
“With our application, which can be seamlessly integrated into AutoCAD as a plug-in, planners and system integrators can not only visualize the planned conveyor solution based on the desired parameters,” explains Marcus Dörr, Global Product Manager for the Modular Pallet Conveyer Platform (MPP) at Interroll. “The Layouter also simultaneously specifies all the necessary technical components of the respective solution. In addition, the plug-and-play modularity of Interroll's conveyor platforms ensures that the engineering effort required to put together the overall solution is eliminated”. The advantages of this approach are impressive: Already with his first design, the AutoCAD user has all the technical information for the desired conveyor solution and, in the case of special framework agreements, even the necessary price information. This means that the planning data can easily be reused for the subsequent quotation or ordering process. The Interroll Layouter can be used for Interroll's modular platform offers, such as the Modular Conveyor Platform (MCP), the MPP, or the company's flow storage solutions. The free application is available as a plug-in for a full version of AutoCAD from version 2014. The Layouter is compatible with Windows 7 to Windows 10; Microsoft Excel is required on the workstation computer. www.interroll.com
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IT
OPC UA EMBEDDED TOOLKIT FROM SOFTING NOW INCLUDES DISCOVERY ANNOUNCEMENTS
Softings uaToolkit Embedded adds metadata and discovery announcements.
Version 1.31 uaToolkit Embedded adds metadata and discovery annoucements to OPC UA field devices which eliminates the need for preset information in the subscriber.
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ofting's uaToolkit Embedded for implementing embedded OPC UA Servers with client/server and publisher/subscriber communication just enhanced the OPC UA publisher and subscriber with metadata and discovery announcements. The publisher now sends the metadata for the published data set. The subscriber can use this data for the decoding of the published data set which reduces the need of preset information in the subscriber. V1.31 also supports the latest Long-Term Support version (LTS) V1.1.1 of OpenSSL. (LTS for OpenSSL V1.0.2 ended on December 31, 2019 but is still supported).
Softing's uaToolkit Embedded has been certified in the Compliance Lab of the OPC Foundation for the Nano Embedded Device Server profile, the Micro Embedded Device Server profile and the Embedded UA Server profile. The toolkit has a low memory footprint and requires little computing power. This makes it particularly suitable for firmware development of field devices, and also for use in control or remote I/O systems with limited resources. It also supports OPC UA Companion specifications with a tool for importing OPC UA nodesets. The toolkit is available on the Softing Website as full and trial version: https://industrial.softing.com/en/products/ protocol-software-and-sdks/opc-ua-embedded-toolkit. html
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“As industry 4.0 and IIoT continue to develop, we have seen a very significant and sustained increase in OPC UA adoption. The uaToolkit Embedded is our offering for customers who want to use OPC UA in sensors, small devices and low-end controllers,” says Thomas Rummel, Senior Vice President Engineering & Product Management at Softing Industrial. “Meanwhile there is an increasing amount of OPC UA Companion specifications for devices. The VDMA (Germany’s Mechanical Engineering Industry Association) alone coordinates the activities of over 26 working groups that define a common, cross-sectoral language between
machines and plants. And the new OPC UA FLC (Field Level Communication) initiative will further increase the demand for embedded OPC UA.”
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IT
ST. JOSEPH-STIFT HOSPITAL IN DRESDEN RELIES ON NETWORKED SOLUTIONS THAT SECURE THE BUILDING ENVELOPE, BUT ALSO MUCH MORE
St. Joseph-Stift hospital
From isoled solution to Multi-services platform.
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n its efforts to provide more security against unauthorized access and improved monitoring and control, the technical services department of the St. Joseph-Stift hospital in Dresden relies on the proven technology of the BMS manufacturer PcVue and the door and window specialist GEZE. Over time the originally isolated PcVue solution becomes an all-purpose tool.
In the 2019 major hospital rating of the Frankfurter Allgemeine Zeitung (Frankfurt general newspaper, FAZ), the St. Joseph-Stift in Dresden came top six in the category “150 to under 300 beds”: The patients surveyed were not only above average satisfied with the medical and nursing care, but the hospital also received top marks for the organisation of procedures and service. The hospital, which currently has 250 beds, treats around 35,000 patients a year. In order that the nursing and medical staff can concentrate fully on the patients, the hospital operator also regularly invests in the technical infrastructure. The new comprehensive control technology solution from PcVue and GEZE is an example.
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In the origin the visualization and control function of an existing intercom system was used for the building’s door and lock automation. Due to further requirements, especially with regard to scheduling and standardization of the data exchange with a heterogeneous field layer, the need for a comprehensive monitoring and control solution became apparent. This solution exists in the form of PcVue 12.0, which connects doors and locks from different manufacturers via the OPC, ICX and BACnet communication protocols. That generates a powerful abstraction layer, at instant. A particularly elegant 33 | Industry Asia Pacific | July 2020
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solution is the connection of GEZE door systems via BACnet/ IP, as the PcVue software includes a dedicated library with symbols and function blocks for various GEZE module types. Thanks to this simple integration, the connection can be carried out independently by the technicians on site. PcVue enables the implementation of complex, buildingspecific logic, which is necessary due to the existing building topology. Sequential control and flexible networking options are of fundamental importance in such scenarios. The same applies to the special purpose emergency switch in the emergency room. In the event of structural changes, it must be possible to convert escape routes at any time. Thanks to the use of a PcVue developer license, as well as the intuitive configuration interface of the PcVue software and the intensive on-site training, it is possible for technical staff to reconfigure the system at any time.
His own department also benefits from the system’s versatile functionality. Thanks to the 100% Wi-Fi coverage within the building area, which has been in place since 2019, technical staff have access to the PcVue Web visualization (WebVue) via notebook and tablet anywhere and at any time, which is a decisive advantage for mobile maintenance workers. An additional screen is available in the technical area, which also serves as an alarm monitor for the on-call service. A uniform architecture and extensive networking possibilities Torsten Klotzsche’s vision of “achieving intelligent control of neuralgic information and control points with manageable investments” is fulfilled by the solution in that the four main buildings and four annexes of the facility can be supervised with a simple yet flexible, future-proof architecture. The control system consists of a PcVue server station for up to 65,000 data points, five Web clients and a development and test station. All stations are networked with each other, so that new project versions can be created, deployed and distributed at any time. This happens almost in real time, as PcVue projects do not have to be compiled before deployment. Data and control commands are currently exchanged via several different communication protocols, including BACnet, OPC, Modbus, KNX and ICX. Also integrated into the project’s Web interface is the
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A multitude of benefits for various user roles Users of the system include medical and administrative staff. Using Web-based thin clients on 32” flat screens at the gate and in the emergency room staff can always keep an eye on the status of the building’s lock status. At off-peak times, the medical staff in the emergency room and receptionists are authorized to acknowledge certain alarms autonomously. Torsten Klotzsche, head of the building’s technical services department, describes the requirements for the system as follows, among other things “The aim is to […] facilitate the
daily work of the operating departments”. Above all, this could be achieved by relieving certain functional areas.
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WebScheduler, the user interface for managing PcVue’s native schedules and BACnet schedule objects. By now PcVue even monitors status messages from the intercom system by using the ICX protocol. Connecting the doors brings more transparency, comfort and safety Locking the doors in the evening once forgotten is a thing of the past. Thus, for example, unwanted visitors remain outside, which could cause a lot of damage in such a property. Instead, the doors are now automatically locked by the system after a certain time using sophisticated scheduling. The controlled admission of persons is easily possible at any time.
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Other functions that have changed as part of the integration are: - Temporarily putting indoor doors into “permanently open” state; reducing the door cycles (movement of the door) - Connecting the weather station; enabling the doors to be opened and closed accordingly (e.g. in strong winds) or to switch into automatic mode.
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The first GEZE doors are now connected to the PcVue system thanks to the simple integration. This creates more transparency, offers more comfort and above all makes the building safer. Thanks to that technology, the conversion measures were changed while the building was still in operation without affecting the regular operation of the building. It was possible for the technical team on site to create an intelligent door control system with manageable investments. In the first stage of the expansion, three-door control units, three sluice systems, a revolving door and several other automatic doors were activated. This also relieves the staff, doors no longer must be locked manually, unexpected visitors have no access and the technician on site has an easier time managing the building. During the next round of door maintenance, a check is made to see which door systems can be connected to the PcVue system with little effort to use BACnet. This simplifies to connect the subsystem “doors” step by step. Further system expansion After the planned handover of the control system to the IT department of the hospital and the associated virtualization of the system, the connection of further GEZE automatic doors, the integration of blind controls, as well as critical and non-critical power supply lighting over KNX into the system are planned for the near future. The incorporation of remote branch offices via the IOT protocol LoRa, as well as the integration of video surveillance systems in PcVue, also play a role in the considerations of the technical team.
Schematic representation of the door lock subsystem.
Furthermore, a new part of the building is planned, where the entrance door will also be connected via BACnet. All this is easy to implement with the versatile PcVue solution. The technicians on site therefore now have a true all-purpose tool at their disposal. www.pcvuesolutions.com
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MEASUREMENT
ROHDE & SCHWARZ PRESENTS NEW TEST SOLUTIONS FOR 5G BASE STATIONS
Rohde & Schwarz is continuously extending its portfolio of test solutions for 5G base stations and the associated massive MIMO antenna arrays and amplifiers. Highlights include an OTA test solution with frontend modules specifically for the 5G FR2 range and a solution for speed-optimized tests of 5G base stations. Both are ideal for use in production. There is also a new, innovative test solution that allows developers to perform cross-channel measurements with up to 4x4 MIMO in the FR1 range.
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s a leading manufacturer of wireless test solutions, Rohde & Schwarz has extended its portfolio for generation and analysis of 5G signal waveforms. For 5G base stations, RF test solutions for the 5G frequency ranges FR1 (450 MHz to 7.125 GHz) and FR2 up to 44 GHz will be demonstrated.
Customized solution for FR2 OTA tests For over-the-air (OTA) tests on 5G base stations in the FR2 range, Rohde & Schwarz is launching a unique solution based on the R&S FE44 frontend modules, which support signal generation and analysis in the lower-frequency IF band. This enables low-loss transmission of 5G signals and the use of cost-effective T&M instruments by avoiding the need for equipment designed for the millimeterwave range. The R&S SMW200A vector signal generator generates the 5G signals, and the R&S FSVA3000 provides the right analysis functions. Both are ideal for 5G tests thanks to their excellent RF characteristics. The frontend modules can be mounted near the antennas of the DUT on the OTA test chamber. In the transmit direction, the 5G signals generated in the IF band by the R&S SMW200A are upconverted to the FR2 range up to 44 GHz. This ensures that the high output power is generated exactly where it is needed. On the receive side, the R&S FE44A converts the FR2 signal at the antenna inputs
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down to the IF band and sends it with low attenuation losses to the R&S FSVA3000 for analysis. This solution is suitable for test systems in production. Server based production tests For speed-optimized production tests of 5G base stations, Rohde & Schwarz has developed a scalable, high-performance server based testing analysis platform. The R&S SMBV100B vector signal generator and the R&S FSVA3000 spectrum analyzer are used as RF test solutions. The powerful R&S QuickStep test executive software is used to automatically control the test setup and verify test results. The solution is using a 10 Gigabit Ethernet network, where the combination of the server based approach and parallel processing enables extremely high measurement speeds. The infrastructure consists of commercially available components. The combination of the R&S SMBV100B and the R&S FSVA3000 is also ideal for flexible testing of WLAN, cellular and IoT components and devices in R&D, verification and production.
receiver, and the 5G analysis options of the R&S VSE vector signal explorer software running on a laptop. The R&S SMW200A generates the 3GPP-compliant 5G test signals, which can be transmitted on up to four channels using the two additional vector RF sources. The oscilloscope provides phase coherent acquisition of all four signals, a basic prerequisite for cross-channel measurements. The integrated hardware-accelerated digital downconverter of the R&S RTP164 mixes the signals down to the baseband in real time. The R&S VSE software performs measurements in line with 3GPP specifications. Users can also perform MIMOspecific measurements and flexibly compile the test results. The solution is suitable for tests during the development and verification of 5G base stations. Short demo videos about these and other industry-leading wireless test solutions from Rohde & Schwarz are available at www.rohde-schwarz.com/mwc.
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Cross-channel measurements with up to 4x4 MIMO Rohde & Schwarz also offers a new test solution for base stations and small cells that enables cross-channel measurements up to 4x4 MIMO on 5G transmissions in the FR1 range. The solution consists of the R&S SMW200A signal generator, two R&S SGT100A vector RF sources, the R&S RTP164 high-performance oscilloscope used as a measuring 33 | Industry Asia Pacific | July 2020
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MEASUREMENT
NEW R&S NGP800 POWER SUPPLIES BOOST EFFICIENCY WITH UP TO FOUR INDEPENDENT CHANNELS IN A SINGLE COMPACT INSTRUMENT
The new R&S NGP800 power supply series includes two and four channel models, and further extends the functions and performance available for DC power provided by Rohde & Schwarz.
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ealth has become the dominant topic worldwide. Research and development to protect the physical well-being of each individual as well as the entire population have an unprecedented significance. More than ever, laboratories and pharmaceutical companies are striving to accelerate their processes, for example by increasing the throughput of tests or speeding up the production and distribution of medicines. Airports are making increasing use of access For any test and measurement application requiring up to four independent DC power supplies with full flexibility, full functionality, full safety and full connectivity, the R&S NGP800 power supply series will boost the efficiency in any lab or production line. Users benefit from the large 5” high resolution touch screen, which also displays detailed statistics.
Full flexibility The five R&S NGP800 models meet the needs of users seeking minimum device footprint for two or four independent power supplies, with maximum flexibility for voltages up to 250 V, currents up to 80 A and power up to 800 W. Each channel supplies up to 200 W with a maximum of 20 A or 64 V, also covering 48 V automotive and industrial applications. Full functionality Channels can be operated fully independently or synchronized; the electrically equivalent and galvanically isolated outputs can be wired in series for outputs up to 250 V or in parallel for up to 80 A. The tracking function makes it possible for users to adjust voltage and current simultaneously on selected channels, with programmable output delays used to meet specific power-up sequences. The supplied voltage can be ramped up to the required level in any period from 10 ms to a minute. All outputs operate in either constant voltage mode or constant current mode. To meet the requirement of both developers and quality assurance teams in particular, it is possible to set up changes in voltage and current level over time using the QuickArb
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function. This way, users can simulate unstable power supplies with the R&S NGP800. Using Remote Sensing, users can regulate the voltage directly at the input terminals of the powered device itself, instead of the power supply’s output terminals, so that exactly the required voltage is supplied.
www.rohde-schwarz.com/product/ngp800
Moreover, the R&S NGP800 includes functions for logging voltage, current and power values over time for all outputs. Data logs can easily be exported as .CSV files for in-depth analysis or documentation needs. The settings for all channels and functions can also be stored and recalled at the touch of a button, and even exported as a file to other R&S NGP800 to duplicate the power setup. Full safety To protect devices supplied with power, all R&S NGP800 power supplies include overcurrent protection, overvoltage protection and overpower protection.
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Full connectivity The R&S NGP800 features both advanced remote capabilities and fast command processing times that fully meet the requirements of ATE systems or production lines. Optional digital I/O and analog input interfaces further extend the scope of applications. The new R&S NGP800 power supply series is available now from Rohde & Schwarz and selected distributors. 33 | Industry Asia Pacific | July 2020
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PLANT SAFETY
MANUAL WORK MEETS MODERN AUTOMATION TO EMPOWER WORKERS WITH HANDICAPS
In spite of advancing digitalization, the following still applies: Manual workstations are indispensable, because automation is not always profitable with small batch quantities or complex processes. Such workstations are preferred at the Martinshof Werkstatt Bremen, a sheltered workshop for a mixed workforce including people with handicaps, as they are ideally suited for integrating persons with physical or cognitive handicaps into working life.
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Poka Yoke has empowered our workers,” said Miriam Berger, in charge of Production Planning, Martinshof Werkstatt Bremen. “We use automation to avoid mistakes that previously occurred in the production process. Everyone must be able to work smoothly together.”
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The Japanese Poka Yoke principle, which aims at the systematic elimination of human errors, coupled with Mitsubishi Electric's “Guided Operator Solutions,” ensures high quality for Martinshof’s customers, which include wellknown automakers in the region.
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With some 2200 employees, Werkstatt Bremen is one of city’s largest employers as well as Germany's oldest and largest workshops for people with and without handicaps. Apart from job order and contract production in the fields of metal and woodworking, electrical assembly, filling, and packaging, Werkstatt Bremen employs 500 workers alone in the automotive business sector, and has been supplying local automakers for more than 30 years. Handke Industrie-Technik, a long-standing supplier to Werkstatt Bremen of manual workstations, and a premium solution partner of Mitsubishi Electric, recognised the unique opportunity. Together with Mitsubishi Electric, Handke developed a Poka Yoke solution for adapted working. The prototype of the error-free workstation convinced the customer, and was installed in the production line. Since May of 2018, a total of four identical zero-error workstations are in use for automotive parts production.
“Poka Yoke has empowered our workers,” says Miriam Berger, in charge of Production Planning, Martinshof Werkstatt Bremen.
A further advantage is that we can use pictures to provide instructions. This especially helps workers who have reading or writing disabilities.
Integrating on-site technology and visualization “The main challenge of this project involved the integration of existing technology into the new error-free workstations,” said Nils Knepper, Senior Product Manager Modular PLC/ Software at Mitsubishi Electric Germany. “However, thanks to the interfacing features of our Poka Yoke controller, this was not a problem.” The MELSEC iQ-F series PLC, installed on-site in a small control cabinet, is the intelligent, individually configurable and expandable heart of the solution that controls the picking and assembly sequences. Apart from Mitsubishi Electric's own components, the system can also handle third-party sensors and actuators. In this case this included the digital torque wrench and a system for industrial image processing. The connection of a barcode printer is being implemented, and thanks to existing conventional interfaces, this can be done easily by the PLC.
Wide range of components for individualization “The need to prevent errors exists everywhere during production and assembly,” remarks Andreas Kebbel, Managing Director of Handke Industrie-Technik. “What is most important is the quick and flexible adaptation to the needs of the persons working there, and to the requirements of the process.” That is why Mitsubishi Electric and Handke offer their solution in the form of a modular system with a wide range of components and interfaces for operator guidance. Amongst others, these include mechanisms to ensure the correct picking of parts, e.g. light barriers, pick-to-light push buttons (alternatively: pick-to-voice), barcode scanners, and proprietary pick-to-door devices with stroke switches. Moreover, there are monitoring devices such as electric screwdrivers with torque & angle detection, plus vision systems as well as opportunities for robot integration. HMIs (Human Machine Interfaces) from Mitsubishi Electric's
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“During the design of the user interface, Mitsubishi Electric was highly flexible, and took all our requirements into account. Because many of our employees cannot read very well, we make use of smileys and other symbols,” explains Miriam Berger. “In addition to process reliability, the Poka Yoke workstations have the great advantage for us, unlike the past situation, as practically any employee can now do the job.” The supporting visualization mentioned uses a 10inch touchscreen terminal connected in the background to the Poka Yoke controller.
The hardware and software solution from Handke and Mitsubishi Electric deliver simple scalability, convenient configuration, programming and commissioning as well as comprehensive connection possibilities (including MES and ERP). And as soon as freedom from errors is achieved, and the technical potential is available, Werkstatt Bremen will investigate whether the buffer store can be dispensed with in the future, so that after assembly is completed the parts can be directly shipped “in time” to the automaker.
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Thanks to the Poka Yoke controller, existing technology, like a digital torque wrench in this case, can easily be integrated into the error-free process.
GOT2000 series are used for displaying the individual process steps, offering direct connectivity to the Poka Yoke controller, and meeting every display requirement from text through graphical symbols up to animations and augmented reality. Depending on requirements, the latest generation iQ-R or iQ-F PLCs can be used as controllers for the guided manufacturing solutions. Mitsubishi Electric’s Guided Operator Solutions can be integrated in to production systems, so that workstations can be networked and resources controlled and monitored in realtime.
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www.werkstatt-bremen.de https://au.mitsubishielectric.com/en/index.html
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MY
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PLANT SAFETY
WILL TELEDYNE GAS & FLAME DETECTION BRING DIFFERENTIATION TO THE MARKET?
Following Teledyne Technologies, Inc’s acquisition of 3M’s gas and flame detection business, a new company, Teledyne Gas & Flame Detection, has been established under the Teledyne banner. The business has a long and successful track record spanning more than 100 years, supporting a wide range of industries and customers with their gas and flame detection needs. So, the big question is will Teledyne Gas & Flame Detection bring differentiation to this competitive marketplace?
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ith the formation of Teledyne Gas & Flame Detection, the market can indeed expect a major USP that sets it apart from existing players: the company has become the specialized brand in gas and flame detection, offering wide product knowledge and expertise in this niche area. A proven and extensive range of measurement, detection and wireless technologies, set alongside the unrivalled skills and innovation of employees who have been with the business for many years, can meet the needs of customers in all market segments. Teledyne Gas & Flame Detection is adopting a dedicated, one-stop supplier strategy that delivers the optimum solution for the application, every time.
Teledyne is not unfamiliar with this blueprint, as the Gas and Flame Detection business utilizes similar technology, which compliments its portfolio of environmental instrumentation products and services supplied to related markets and have proven to be highly successful for many years. The high-quality products of Teledyne Gas & Flame Detection comprise both fixed and portable instruments designed for demanding applications in sectors such as oil & gas, food & beverage, marine and public utilities. These rugged yet reliable and precise gas and flame detection solutions offer fast response times, durability and intrinsically safe instrumentation, while satisfying multiple international certification standards. Reliable products from an experienced business Based on a culture of safety, the company has pledged to bring stability to the established brands of Oldham Simtronics, Gas Measurement Instruments (GMI), Detcon
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Despite the company’s comprehensive and proprietary portfolio of innovative solutions, one size does not always fit all. If a standard solution cannot be identified, the Application Engineering group within Teledyne Gas & Flame Detection can provide a bespoke offering based on complete end-to-end consulting that embraces design, equipment specification, installation, maintenance and service. The in-house team, which comprises a global network of professionals with more than 50 years’ combined experience in fixed gas detection and integration consulting, has the capability to assess hazardous environments anywhere in the world. Working alongside client teams in a consultative approach, the expert perspective offered by the Application Engineering group ensures that custom solutions are according to specific requirements such as advanced technology within nuclear research and space exploration. As part of this customer-first strategy, projects are kept on track using proactive analysis that harnesses the benefits of advanced technologies such as 3D simulations, custom wireless solutions and gas-plume modeling. Importantly, Teledyne Gas & Flame Detection can leverage its global network of distributors offering sales and service expertise – alongside its manufacturing excellence and custom engineering – to provide turnkey gas and flame detection solutions for a vast range of hazards. With an industry-leading, comprehensive portfolio of products and services, its commitment to cross-platform integration is purpose-designed to provide protection for today and confidence for tomorrow. First-choice solutions provider Teledyne Gas & Flame Detection is a leading solutions provider for gas and flame detection products due to many unique qualities that include product expertise, gamechanging adaptability in challenging environments, wide reaching international distribution and service, and its Application Engineering group.
and the former Scott Safety gas detection range, which together have amassed over 100 years of experience across a wide range of standard and customized products, solutions and services. Teledyne Gas & Flame Detection unifies these four industry leaders, creating a strategic insight that provides smart, firstin-class solutions with a future focus. Teledyne Detcon, for example, is a leader in fixed gas detection and innovative wireless solutions for use in harsh environments, while the Teledyne Oldham Simtronics brand specializes in highend gas and flame detection solutions using advanced technologies and multi-market, cost-effective fixed gas detection solutions. The former Scott Safety gas and flame portfolio, now under the Teledyne Gas & Flame Detection brand, is rooted in the safety of people and plants in an industrial setting, and completing the picture Teledyne GMI is an expert in portable gas detection and a market leader in the gas distribution/utilities sector.
Product reliability in critical situations, whether it refers to detectors, controllers, monitoring systems or wireless technologies, is a further business attribute. By using a reputable detection expert such as Teledyne Gas & Flame Detection, customers can avoid compromising the health and safety of their teams. The company knows the history of the market, the current landscape, and has a strong handle on innovation and vision for the years ahead. Ultimately a new – yet established – global leader in safetyfocused gas and flame detection solutions is now active in the market; one with detection in its DNA. Based on a relationship-driven business model, the company’s priority is simple: protecting assets, operations, the environment and, most importantly, lives. Every day, hundreds of Teledyne Gas & Flame Detection employees are mobilized to offer effective solutions for their customers assets, supporting and protecting workforces around the world. https://teledynegasandflamedetection.com/en
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Every second of every day, thedependable Gas and Flame Detection systems and portable gas monitors manufactured under these brand names are making workplaces safer around the world. For this reason, Teledyne Gas & Flame Detection has introduced a new global tagline that captures the capabilities of the business: ‘Always sensing safety, everywhereyoulook’™.
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NEW INTESIS GATEWAY MAKES COMMUNICATION BETWEEN PROFINET AND BACNET EASY
HMS Networks announces a new Intesis™ protocol translator for communication between PROFINET PLCs on factory floors and Building Management Systems with BACnet IP/MSTP. With this, full data integration, monitoring, and control is enabled between factory floors and building facilities. Key objectives can be achieved with factory-tobuilding communication In factories, it is essential that environmental dimensions such as temperature, humidity, and air quality are controlled and monitored automatically to ensure optimal conditions for manufacturing and working staff. And, by ensuring efficient control of facilities such as HVAC and lighting systems, factory owners can save a lot of energy and manage emergency situations in a safe way.
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However, when system integrators plan for factory-tobuilding integration, they normally face a heterogeneous and challenging communication situation. BACnet is typically the protocol used in the Building Management System (BMS) to control the facilities inside the building, and PROFINET is one of the most used factory networks for controlling production processes.
Communication enabled with certified Intesis PROFINET - BACnet gateway Focusing on this situation, the new Intesis PROFINET - BACnet IP/MSTP protocol translator from HMS Networks is a costeffective and easy-to-install gateway solution that offers bidirectional communication between PROFINET PLCs and BACnet controllers. Able to connect up to 1200 data points, the gateway is BACnet IP/MSTP server/slave on one side and PROFINET I/O device on the other, featuring independent Ethernet ports. The gateway has been BTL certified for BACnet and carries the UL mark in order to guarantee the highest communication and quality standards. Thanks to its strategic placement between the factory and building systems, the gateway becomes an enabler of very interesting applications such as energy metering of devices and machines in the factory from the BACnet-based BMS system, HVAC monitoring, and control from the PROFINET PLC, as well as easy alarm definition and management. Easy configuration and integration process using Intesis MAPS Intesis MAPS, the common configuration tool for all Intesis protocol translators, offers a very intuitive configuration
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process for system integrators covering both sides of the gateway. MAPS help integrators further in their projects by providing valuable EDE files for the BACnet integration, as well as GSD files and TIA portal TAG files for fast configuration of any connected PROFINET PLC controller. The result of HMS’ combined expertise in factory and building communications Extending the comprehensive range of existing Intesis BACnet protocol translators, the new PROFINET - BACnet version is the first product in a new line of Intesis gateways for factory to building integration that will be released step by step by HMS Networks. In these gateways, HMS combines its proven AnybusŽ and Intesis communication technologies for industrial and building-oriented communication respectively, trusted by customers in millions of installations worldwide. www.intesis.com
MORE INFORMATION 33 | Industry Asia Pacific | July 2020
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S M A R T FA C TO R Y
A LOT OF POWER IN A VERY SMALL SPACE
The BXT motors deliver considerably higher torques than those usual in this drive class. (Copyright: FAULHABER)
Drive Systems evolved. Generally speaking, electric motors are not “lone wolves” but for most applications need to be combined with gearheads for speed reduction as well as encoders. To ensure that the components are perfectly matched to each other and to minimise installation requirements, it is recommended to obtain the individual components as a complete solution from a single source.
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ven in cases where installation space is extremely tight and where high-torque drives are required which, owing to the installation situation, need to be as short as possible, there is a practice-oriented solution that is especially suitable for applications in robotics, prosthetic joints, laboratory automation, pumps, medical technology or aircraft cabin equipment.
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The drive specialist FAULHABER has once again demonstrated its competence as a system provider and has extended its BXT flat motor series by adding corresponding gearheads and integrated encoders as well as speed controllers that are also exceptionally short in the axial direction. All components have been optimised to ensure that they function perfectly together. The three sizes can solve many different drive challenges. In the case of a lower-arm prosthesis, for example, the smallest drive with a diameter of 22 mm would be ideal for the hand and the 16 mm long motor for the elbow. Other possible applications for the small compact drive systems are robot grippers, industrial automation, humanoid robots and even bio-robotics for motorised – i.e. power-assisting – hand exoskeletons. Thanks to their precise speed control properties, they are also suitable for e.g. dialysis machines or medical pumps.
NEWS The powerful and compact drive systems are ideal for applications in robotics, prosthetic joints, laboratory automation, pumps, medical technology or aircraft cabin equipment. (Copyright: Schunk, FAULHABER)
Innovative winding technology for more torque The motors were developed based on the classic external rotor design. Thanks to innovative winding technology and optimised construction, the brushless DC-servomotors produce torques up to 134 mNm within a diameter of 22 mm, 32 mm and 42 mm and deliver a continuous output of up to 100 W with a high level of efficiency. This means the compact motors significantly exceed the standards usual in this drive class. Particularly the ratio of torque to installation space and weight is much better than what is common on the market. Thanks to the high copper filling factor and the design of the pole shoes, the magnetic field is strong and the cogging torque very small. The motors, which operate at speeds up to 10,000 min -1, are available with or without a housing, which again extends the range of potential applications.
Furthermore, the gearheads are extremely robust and tolerate continuous loads as well as rapid load changes. They have been developed for limited axial installation space and are significantly shorter than other models with the same diameter. The single-stage 22 mm version, for example, is only approx. 18 mm long and the four-stage version approx. 37 mm. With the 42 mm gearhead, the lengths are just under 31 mm and approx. 68 mm respectively. Housed encoder with high positioning accuracy All BXT motors are equipped with digital Hall sensors and, thanks to their large number of poles, their speed can be controlled very precisely. The IEF3-4096 magnetic encoder is available for precise positioning tasks. The encoder is fully integrated in the housed motor variant, thereby increasing the length of the overall drive by just 6.2 mm. Despite of the flat design, it offers three channels with index function, a Line Driver and a high resolution of up to 4,096 lines per revolution. The combination of motor and encoder is an ideal system solution in cases where extremely precise positioning must be performed in constrained spaces and, at the same time, high torques are required, e.g. in robotics, medical technology, laboratory automation or industrial automation.
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Metallic planetary gearheads with numerous reduction ratios The GPT metal planetary gearhead family, which also impresses with compact dimensions and high torque, is suitable for speed reduction of the flat motors. The pure metal gearheads achieve performance values that are comparable to those of significantly more expensive technologies available, such as those that use ceramic components. The gearheads are available with motorcompliant diameters and offer reduction ratios from 3:1 to 1,294:1 with extremely fine graduations in up to four stages. Each stage was optimised for high performance with
respect to torque and speed. Depending on the diameter, the gearheads achieve continuous torques of 1, 8 and 18 Nm. Higher torques are also possible for a short period.
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NEWS
Compact drive system from a single source: The high-torque flat motor series has been extended by the addition of matched gearheads as well as integrated encoders and speed controllers, which are also exceptionally short in the axial direction. (Copyright: FAULHABER)
Integrated speed controllers complete the product range Beginning in April 2020, speed controllers will also be available for the BXT motors. They are integrated in the housed versions of the BXT motors and increase the length of these motors by just 6.2 mm. The well though-out design concept enables both the encoder and the speed controller to be installed in the same housing and also permits a large number of common parts to be used. Speed control is performed by the digital Hall sensors integrated in the motors. Thus, a wide speed range from 200 min -1 to 10,000 min -1 is available. The compact combination of motor and speed controller is ideal for space-critical applications and simplifies installation and commissioning.
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www.faulhaber.com/evolved/en
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PUMPS
STRONG AND ESTABLISHED SALES PARTNERS REPRESENT THE GERMAN PUMP MANUFACTURER WANGEN PUMPEN IN AUSTRALIA AND NEW ZEALAND
The companies All Pumps Pty Ltd. and Prime Pump Ltd. expand the portfolio of sales partners of Pumpenfabrik Wangen GmbH.
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lorian Holub, Sales Manager Asia Pacific at WANGEN PUMPEN, is very confident. “WANGEN is pleased to cooperate with excellent distributors to expand our worldwide sales network in new segments and regions. We are convinced that our strong and established partners will represent us excellently and provide our customers with exceptional technical knowhow and outstanding service. We are looking forward to a long lasting and fruitful cooperation�.
Persuasive quality and versatility Progressive cavity pumps, twin screw pumps and modules, developed and produced by WANGEN PUMPEN, enjoy excellent global reputation, thanks to their systematic alignment to market and customer demands. WANGEN PUMPEN focuses on the most efficient conveying solutions for the most various applications, a process that starts with development, and continues through construction, production, advice and sales to service.
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All Pumps Sales & Service for Australia: Since 1972, All Pumps Pty Ltd. has been serving customers in Australia with pumping solutions and service for a wide range of applications, especially in the industrial, mining, oil and gas, chemical, as well as the food and beverage segments. All Pumps has branches around Australia to provide local service across the country.
Prime Pump for New Zealand The number one in the pump business in New Zealand, thanks to high pump competence and an excellent reputation. Prime Pump Ltd. serves the civil and mining, agricultural machinery, industrial, as well as the food and beverage segments. The company is located in Greymouth on the South Island of New Zealand.
WANGEN PUMPEN offers an overview of all distribution partners worldwide on its website. www.wangen.com/en/distribution-partners
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S M A R T FA C TO R Y
LEUZE AND ITRACE ANNOUNCE THE BLOCKCHAIN INTEGRATION OF 2DMI WITH THE DCR 200I CAMERA BASED CODE READER
Leuze DCR 200i Camera Based Code Readers.
iTRACE Technologies, Inc., a leading provider of supply chain security applications for anti grey market and anti counterfeit, and Leuze, a global leader in automation sensors, announced today the integration of iTRACE 2DMI with the Leuze DCR 200i Camera Based Code Reader for Blockchain registration and authentication.
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TRACE helps brands fight the issues of counterfeit, grey market, diversion and production overrun of their products with its blockchain connected 2DMI® supply chain security. With the integration of 2DMI® with the Leuze DCR 200i range of camera-based code readers, customers are now able to capture transaction and authentication information automatically anywhere in the supply chain.
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“The integration of the Leuze DCR 200i camera-based code reader is using our standard mobile application infrastructure which allows these industrial sensors to automatically capture the same information as the iPhone and Android devices anywhere in the supply chain.” said iTRACE Founder and CEO Mark Manning. “This means that any system can now automatically participate in track, trace and authentication of any item or component and push that data to a blockchain or tracking database via the iTRACE Blockchain Gateway.”
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Using iTRACE 2DMI® and the DCR 200i allows the part being scanned to be securely identified and the transaction recorded on digital ledger technologies like blockchain, enabling a secure connection between the physical product and the digital ledger which is necessary to complete any blockchain tracking or authentication application. The key to the security of the application is the ability to create the digital twin of the physical product to ensure that is the original item that is scanned at each location. Leuze has recognized that “iTRACE 2DMI® provides a much higher level of security and damage resistance than QRCode, Data Matrix and 1D Barcodes are able to do” said Joerg Woerner, Business Development Manager at Leuze. “This makes the combination of the DCR 200i and 2DMI® ideal for difficult and harsh environment applications in aerospace, automotive and medical device”. https://itracetech.com www.leuze.com
MORE INFORMATION 33 | Industry Asia Pacific | July 2020
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S M A R T FA C TO R Y
ALWAYS IN FRONT OF THE RIGHT RACK: LESS DOWNTIME FOR COMPARTMENT FINE POSITIONING WITH CAMERABASED POSITIONING SENSORS
IPS 200i: Marker in field of view.
Pallet and container racks consists essentially of vertical columns and horizontal bars. In the past 20 years, the design of these installations has changed considerably. For cost reasons, thinner-walled materials were increasingly used. The loading possibilities and range of applications became significantly larger. Racks are increasingly affected by thermal and dynamic influences and shock loads have increased, e.g., from the integration of shuttle systems. The resulting deformation of rack components under load, for example, from deflection or expansion, must therefore be considered in detail.
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ermissible limiting deviations, deformations and open spaces, such as for corridor supply vehicles or high-bay storage devices that serve adjustable, single-depth pallet racks, were defined early on in European standard DIN EN 15620 “Steel static storage systems.� It ensures that the functional requirements are fulfilled and, at the same time, that a suitable interaction with the high-bay storage devices is maintained.
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The 200 class includes racks in which the high-bay storage devices are automatically controlled and which have a fine positioning system at the storage spaces of the loading units. For the fine positioning, influences that act on the tolerances of the steel structure in the warehouse are to be given special consideration. In addition to mechanical tolerances from material- and mounting-related variances such as uneven hall floors, these also include wall and wind loads, elastic deformations 33 | Industry Asia Pacific | July 2020
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as a function of the load state, static and dynamic loads of the high-bay storage device from different load states (empty runs, removal from storage with load), forces from acceleration and deceleration as well as thermal deformations and material expansion under the influence of temperature changes. If one initially considers only the deformation from different load states, it quickly becomes clear that the horizontal position can change as a result of the deflection of the bar (see figure 1 and 2). Just as the horizontal position can change, so too can the vertical position, as the columns can likewise deform as a result of dynamic, thermal or shock loads. It thereby becomes apparent that adherence to the functional requirements for the precise positioning of a high-bay storage device takes on special significance. For positioning in the X- and Y-direction, rough and fine positioning are
IPS 400i: Fine positioning on bar in double-depth pallet warehouse
IPS 200i: Fine positioning on columns in container warehouse.
generally used. Used for the rough positioning of the highbay storage device are, for example, bar code positioning systems, optical distance sensors with long operating range or incremental transmitters. Once the approximate position is reached, compartment fine positioning performs the targeted approach of the high-bay storage device to its final position. Mounted on the load receptacle of the highbay storage device are at least two optical diffuse reflection sensors per positioning direction – for the X- and Y-direction – i.e., at least four sensors. Without object detection, the outputs of the sensors are OFF. If a sensor detects the edge of a column or of a bar, the output state changes and the sensor output indicates ON. With the help of the new signal state, it is possible, on the one hand, to detect the direction of movement of the high-bay storage device and, on the other, to calculate the desired target position with respect to the edge. Shown in the following is the schematic arrangement of the sensors with the corresponding binary evaluation. The arrows indicate the intended direction of movement of the high-bay storage device. Other states arise in a similar manner.
What alternatives are available for a forward-looking compartment fine positioning solution? A camera-based positioning system with an evaluation algorithm tailored to the specific application offers one possible solution approach here and, thus, a smart alternative to the column and bar positioning with multiple diffuse reflection sensors used up to now. This often results in a faster and more elegant approach than the previously used solution with binary sensors. Solutions where the camera and evaluation unit are integrated in a compact system are particularly popular with users. These offer straightforward commissioning and operation, without the need for special
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The solution with binary sensors, which has proven itself over the years, has a number of disadvantages. For example, the space available on the load receptacle is extremely limited, since additional sensors are often mounted there, e.g., for the compartment occupation check, feed-through monitoring or for projection monitoring. In addition, diffuse reflection sensors can relatively easily produce faulty
switching as a result of glossy profile surfaces, undesired reflection signals from edges located in the background or due to the effects of ambient light (especially HF light from energy-saving lighting installations). This results in downtimes, leading to a smaller number of storage and retrieval operations. The biggest disadvantage, however, is the complex alignment of the binary sensors – both during setup as well as during operation – meaning that all storage positions must be approached with the required accuracy. Trained, qualified personnel are required for this purpose. In addition to this is the fact that a binary sensor provides no further state information, such as information concerning the function reserve or sensor state. Similarly, new possibilities and solution approaches that arise from digitalization within the scope of Industry 4.0 for diagnosis and predictive maintenance cannot be supported.
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Figure 1: Unloaded pallet warehouse.
Figure 2: Loaded pallet warehouse results in a deviation of the horizontal position due to the deflection of the cross member.
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knowledge. With the IPS 200i/400i product family, Leuze electronic offers the smallest camera-based sensor available on the market for the compartment fine positioning of highbay storage devices. By means of an additional quality score, it helps to reduce downtimes of high-bay storage devices, thereby satisfying the call for condition monitoring. Tedious mounting, aligning, and readjusting during operation is no longer required, saving the customer valuable time. Using a novel quality score, the IPS 200i/400i notifies of changes to the sensor or rack and thus assists the user in identifying possible faults early, so that predictive maintenance can be implemented: the quality score helps to identify issues such as contamination or an overhanging film at any given position. The endangered part of the system is found in due time, thus preventing a standstill of the system stemming from inaccurate positioning. The quality score also facilitates identifying particularities that may precede a system failure, so that the endangered system components can be duly removed. Maintenance times can be planned preventatively with this information, downtime can be minimized, and the cost effectiveness increased. This approach is very advantageous when time and costs are important, and it is a significant factor in terms of the total cost of ownership. Thanks to the integrated web server, all relevant data is available worldwide, without having to access the control system.
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Fast commissioning and high reading performance The IPS 200i was developed for single-depth containers and pallet warehouses and the IPS 400i for double-depth pallet warehouses. Both versions facilitate easy and quick commissioning and operation. The web-based, multi-language configuration tool with a user-guided wizard reduces the times it takes for commissioning to a minimum. The IPS 200i/400i can also be configured with XML commands or commissioned using parameterization codes printed via the code generator tool. Innovative feedback LEDs offer instant feedback, which makes aligning the sensors as easy as parking a car. Similar to an acoustic distance sensor in a car, the position of the marker is displayed in relation to the sensor by means of four LEDs mounted on the side. Each side LED corresponds to a single quadrant. If the marker is located in one of the quadrants, the corresponding LED illuminates or flashes. If the marker is in the center (coordinate origin), all four LEDs light up simultaneously. Then the sensor is optimally positioned. In addition, in alignment mode the flashing frequency provides visual indication of the distance from the marker to the origin coordinates. The new sensor, which is optimized for depth of field, features a fixed focus position and, after rough positioning, is used for optical fine positioning of a high-bay storage device in the X or Y direction. It is capable of transmitting the correction coordinates for the precise positioning of a rack to a high-bay storage device. This is how it works: The smart
X-direction = column not yet detected Q1: OFF Q2: OFF Y-direction = bar not yet detected Q3: OFF Q4: OFF Figure 3: Binary switching signals on approach of the load receptacle
sensor detects round holes (marker) or reflectors in a singledepth or double-depth bar or column of a pallet storage and determines the positional deviation of the pallets or containers in the X or Y direction relative to the target position. The sensor uses different programs for singledepth and double-depth positioning. The positioning sensor generates one or more images as the gray value. First, the sensor searches for a defined, round marking (hole/reflector) in this image. The X/Y deviation is output in millimeters to the target position or as quadrants by means of the available switching outputs. The IPS 400i covers a working range of 250 mm to 1,900 mm in a single device model, and with the optional reflector up to 2,400 mm.
ensure reliable positioning as well as a high throughput. The FTP (File Transfer Protocol) image transfer of the IPS 200i/400i enables complete documentation of the (error) images. Easy integration into existing network environment With the integrated Ethernet interface (TCP/IP or UDP) and the optional PROFINET interface, both direct integration into the customer's network environment and quick, locationindependent diagnostics via remote control are possible. “With the quality score, the IPS 200i/400i now makes it possible to detect the cause of standstill of a high-bay storage device early on. A significant step toward predictive maintenance, one of the most frequently mentioned applications of Industry 4.0,” summarizes Sven Abraham, Product Manager Identification + Machine Vision at Leuze electronic. “Compartment fine positioning with a camerabased solution is a future-oriented and smart solution that will also be winning out in terms of cost in the long term.” Author: Sven, Abraham Product manager Ident + Vision
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Can be used in different temperature ranges The small IPS 200i/400i dimensioned 66 x 43 x 44 millimeters with an industrial design in compliance with degree of protection IP65 is suitable both for normal temperature ranges or, with optional integrated heating, for deep-freeze use down to 30 °C. Thanks to its assembly options on three sides, the compact sensor can be flexibly mounted to the high-bay storage device. The powerful, ambient-lightindependent infrared LED illumination (Light-Emitting Diode) ensures flexible use in conveyor and storage systems. It provides for a short exposure time for moving objects, and no additional external illumination is needed. The high object speed in combination with a high depth of field also supports the flexibility of the new positioning sensor of Leuze electronic. Intelligent image processing algorithms
X-direction = column detected Q1: OFF Q2: ON Y-direction = bar detected Q3: ON Q4: OFF Figure 4: Binary switching signals upon detection of columns and bars
www.leuze.com
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S M A R T FA C TO R Y
MUTING REINVENTED - SMART PROCESS GATING
Figure 1: MLC SPG 530 safety light curtains.
The “Smart Process Gating” muting process, which completely forgoes the need for signal-emitting sensors, is based on the MLC safety light curtains from Leuze electronic and is integrated in the MLC 530 SPG model.
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andling and mounting systems often contain danger zones which must be protected against unauthorized access. However, material transport must be able to enter and exit the danger zone at the same time. Examples of systems such as this can be found in intralogistics, the automobile industry and the packaging industry. In practice, these requirements are met using optoelectronic protective devices which are installed at the channeling and diverter stations. These protective devices must be designed so that they detect the approach of the transport material at the protective field, and then temporarily bridge the protective field. Fault-free passage of the transport material is therefore guaranteed. The protective field may only be bridged when transport material is approaching - access by persons must be prevented.
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Until now, additional sensors were required for detecting the transport material – and therefore also for distinguishing between transport material and persons. These are also referred to as ‘muting sensors’. The “Smart Process Gating” (SPG) principle meets the above-mentioned requirements without the need for additional sensors. The operating principle The Smart Process Gating principle (SPG) is based on type 4 safety light curtains of the MLC 500 series from Leuze electronic. It is implemented in the MLC 530 SPG model. In the basic principle, the SPG principle uses two control signals (figure 3): The first signal (CS = Control Signal) is provided by the system control (PLC). The point in time for the generation of the CS switching signal must be set such that the transport material is within 200 mm of the protective field. This is necessary to prevent persons from slipping through. The second signal (PFI = Protective Field Interruption) is generated by the safety light curtain itself upon interruption of the protective field by the transport material. Bridging (gating) of the protective field is thereby started as well. Gating ends either after a fixed time (t), after
Figure 2: Process-controlled access guarding with Smart Process Gating (SPG).
Figure 3: SPG allows for a very compact system arrangement with material locks. MORE INFORMATION 33 | Industry Asia Pacific | July 2020
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Figure 4: Overview of the operating principle.
the transport material has exited the protective field again or by actively resetting the switching signal CS.
implemented in the MLC 530 SPG safety light curtain (table 1).
Signal response in detail Once the system control (PLC) has sent the switching signal (CS) to the safety light curtain, the transport material must enter the protective field within 4 seconds (t1, figure 4). During entry, the safety light curtain generates the second signal (PFI) and, thus, starts the bridging of the protective field (gating). With the basic setting, the transport material must pass through within 10 minutes, otherwise the receiver of the safety light curtain goes into interlock state. Alternatively, a timeout extension of up to 100 hours can be activated, in order to permit stops during a shift change or over a weekend, without blocking the gating sequence.
The “standard” operating mode is used above all in applications in the intralogistics. The integrated filter time of 1 second means that the light beams of the light curtain are allowed to have an unobstructed view for a time window of up to 1 second, i.e., they may not be interrupted by the transport material. This means that gaps are permitted in the transport material, such as those that occur when a pallet is being loaded, without the Gating process being terminated. Once the transport material has left the protective field, the protective function is re-activated after 1 second when using the automatic end of gating. It must also be ensured that the gap between the transport material and protective field is no more than 200 millimeters when the transport material is exiting from the protective field in order to prevent persons from entering. If the transport material moves more than 200 millimeters from the protective field within the reactivation time of 1 second, the gating can be terminated prematurely using the “End by control” function. This is done by resetting the CS signal. Gating is terminated within 0.1 seconds and then the protective function is re-activated (figure 4). Depending on the required performance level, the “standard” operating mode can be operated with a standard PLC or with a safety PLC. The timeout extension to 100 hours is supported.
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When the transport material exits the protective field, the safety light curtain resets the signal that it generated (PFI) as soon as the transport material leaves the protective field. Depending on the selected operating mode, the protective field is then either automatically switched on again after 1 or 2 seconds (t2) by the safety light curtain or gating is ended by the control. Access guarding is now active again. Application-optimized operating modes The SPG principle works in three operating modes in order to adapt to different areas of application. These are 33 | Industry Asia Pacific | July 2020
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Figure 5: Typical signal progress whilst transport material is passing through the protective field.
Table 1: Overview of the operating modes.
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Figure 6: Signal response with “End by control” function.
Figure 7: Signal progress whilst transport material is passing through the protective field.
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The “qualified stop” and “partial gating” operating modes are optimized for low conveyor speeds as are common in, e.g., the automotive sector. At slow speeds, the conveyor process can stop extremely quickly. Since the SPG process requires the protective field to be interrupted no more than 4 seconds after activation by the switching signal (CS), these operating modes have the additional function “Qualified stop/restart”. This allows an initiated SPG sequence to be interrupted within the 4 seconds (qualified stop) and then restarted. The process can therefore continue operating without interference, even in the event of an unplanned stop. In these operating modes, two switching signals with antivalent signal edges are used by the PLC. The PLC switching signal (CS) and the timer hold signal (TH) (figure 33 | Industry Asia Pacific | July 2020
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7), which initiate the gating sequence and also control the qualified stop and restart. The TH signal must change with the CS within 0.5 seconds. This operating modes require a safety PLC. The timeout extension to 100 hours is supported. With respect to sequence, the “partial gating” operating mode corresponds to the “qualified stop” operating mode. However, with partial gating, the top four beams are excluded from gating. Interruption of these beams always results in shutdown of the OSSDs. Thus, the light curtain can, for example, also simultaneously monitor the closing state of pendulum flaps (figure 8) or detect an unauthorized riding along on transport material.
Figure 8: Example for the use of the “qualified stop” and “partial gating” operating modes in the automotive industry.
example, be acquired from known processes or additional signal sources. In exit applications in particular, knowledge about the position can often easily be deduced. Examples include exit stations on cross conveyors, the exiting of processing centers as well as exiting when using active conveyors. Synchronization beams and protective field length The transmitter and receiver of the safety light curtain must remain in sync in order to receive a valid protective field signal. The uppermost and lowermost light beam of the safety light curtain are used for synchronization, meaning that they act as synchronization beams. These beams may not be simultaneously interrupted during active bridging of the protective field (gating) for more than 60 seconds, so that the gating function remains functional in regards to safety. In typical intralogistics applications, the gating function is only active for a couple of seconds, i.e. the time needed by the transport material to pass through the light curtain. As this duration is significantly lower than the allowed 60 seconds, the synchronization beams do not have any specific requirements for the dimensioning of the protective field length.
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Requirements for a safe solution The integration of an SPG application into a system is considered to be a system solution as far as safety technology is concerned. This results from the interaction of the safety light curtain, the system control and, if necessary, mechanical elements. In order to do this, the system manufacturer requires experience in safety design, since the manufacturer programs the gating sequence into the PLC and creates the safety system solution. The manufacturer therefore takes responsibility for implementing the overall system. It is therefore important to take the necessary safety-related requirements into consideration with an SPG installation. These are described in the corresponding operating instructions. An important requirement is for the system control (PLC) to be aware of the current position of the transport material. The PLC requires information on when the protective field has been reached and exited by the transport material in order to transmit the necessary switching signals to the safety light curtain at the correct time. This is necessary because the protective field has to be interrupted within 4 seconds of the arrival of the PLC switching signal. In addition, it is necessary to maintain the maximum distance between the transport material and light curtain of 200 millimeters at the start of the gating sequence (entry) and at the end of gating (exit). For the generation of the switching signals by the control, note that these cannot be directly triggered by persons, i.e., cannot be easily manipulated. There are no special requirements on the type of information acquisition. The information can, for
If the transported material requires more than 60 seconds to pass through the light curtain or if the maximum permissible timeout values of 10 minutes or 100 hours are to be exceeded, it must be ensured that at least one 33 | Industry Asia Pacific | July 2020
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Figure 9: Arrangement of the light curtain for gating times up to 60 seconds.
Figure 10: Arrangement of the light curtain if gating times > 60 s are required.
synchronization beam remains available at all times. This can be achieved in two ways: The uppermost beam acts as the synchronization beam. The height of the light curtain is selected so that the synchronization beam is always above the highest point of the transported material (Figure 10 on the right). The lowest beam acts as the synchronization beam. The protective field is arranged so that the synchronization beam is, for example, below the conveyor line. By doing this, the beams of the safety light curtain are partially interrupted by the conveyor line. This area can be hidden with the “Fixed beam blanking with 1 beam tolerance” function (Figure 10, on the left). Standards and specifications The MLC 530 SPG safety light curtain specification is designed in accordance with the safety-relevant, international standards.
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The data of the sensor is type 4 (IEC/EN 61496), performance level PL e/ category 4 (EN ISO 13849-1) and SIL 3 (IEC 61508). The sensors and the associated documentation concerning the integration of the solution are independently certified. All aspects that need to be noted in order to use the system are described in the operating instructions.
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Advantages of the Smart Process Gating • Extremely compact, space-saving system design, since there is no need to make space for muting sensors in front/ behind the light curtain. • Outstanding reliability and availability of the safety device and low installation and service costs at the same time (no set-up/alignment/realignment of muting sensors). • Reduced risk of tampering by operating personnel. • Even parts with openings and pallets with distances between loads are reliably transported. Author: Jörg Packeiser - Product Marketing Safety www.leuze.com
S M A R T FA C TO R Y
MORE THAN 1500 AUTOCLAVE CYCLES POSSIBLE
New drive from FAULHABER for medical applications. Brushless DC-motors of the 2057…BA series FAULHABER.
FAULHABER developed the new sterilisable 2057…BA family of motors especially for medical applications. In the sensor-free variant, the drives can withstand more than 1500 autoclave cycles. They are optimized for high speeds of up to 65,000 rpm, as are required in, e.g., the handpieces of dental equipment.
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he motors of the 2057…BA series are fitted in a moisture-resistant, stainless steel housing. During the development process, they were thoroughly tested for resistance to the loads experienced during autoclaving. Based on these tests, it is ensured that the standard motor can withstand undamaged at typically 1000 cycles in the autoclave. For the sensor-free variant, this value is 1500 cycles.
Autoclavable motors are frequently used in the handpieces of dental or surgical hand-held instruments. Very high speeds are generally required there. The 2057…BA series achieves a speed of up to 65,000 rpm. Further applications for this motor type are found in other areas of medical care, such as in ventilators. Like all motors from FAULHABER, the models of this series are characterised by high power values in relation to their volume. They are therefore very well suited for tight installation situations. Their low weight makes them predestined for use in the handpieces with which doctors and dentists perform delicate tasks, often over several hours. www.faulhaber.com MORE INFORMATION 33 | Industry Asia Pacific | July 2020
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S M A R T FA C TO R Y
AGV NAVIGATION: WHAT ARE THE POSSIBILITIES?
Navigation and safety monitoring of the transportation path with the RSL 400 safety laser scanner.
Various technologies are available on the market for bringing an automated guided vehicle (AGV) to its destination. Let us first of all say: many roads lead to Rome. There is no right way and no wrong way. Decisive is alway the application itself – that means the question of where and how the given AGV is used.
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here are different processes and technologies for navigating an AGV from point A to point B. The various possibilities range from contour navigation (natural navigation) to laser radar, optical or inductive guidance to grid navigation. Which technology is used depends above all on the specific application.
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The price of the AGV itself can also be used as a rough guideline. The costs for the navigation technology should not exceed 5% of the AGV price. For example: for a EUR 10,000 AGV, contour navigation and laser radar do not come into question as their cost lies above the threshold of 500 euro.
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Another decisive criterion for one or the other variant is whether the given AGV is a drive-under vehicle or a platform vehicle. Drive-under vehicles are those that move under the load to be transported and lift it up. Their design makes them unsuitable for, e.g., laser radar, fundamentally excluding this process for such AGVs. Platform vehicles are those onto which the load is pushed and that transport their cargo on the vehicle. Against this background, the individual navigation possibilities are considered in detail below with regard to their possible fields of application. Contour navigation (natural navigation) Contour navigation is also referred to as “natural navigation.” These are the most technically complex as well as the most expensive types of navigation systems. They are unmatched in terms of flexibility and accuracy. Should it be necessary to change the transportation path on short notice, this can be performed for contour navigation very easily and quickly at the click of a mouse in the higher-level software, the socalled fleet management. Because the sensor on the AGV is usually mounted close to the floor, this navigation variant
Optical guidance with the OGS 600.
is suitable for automatic high-lift trucks and tractors as well as for the drive-under or platform vehicles described above. For this type of navigation, neither further tools – such as reflectors or optical or magnetic traces – nor markings or codes are required. Laser radar Navigation by means of laser radar is similar in flexibility to contour navigation. This navigation variant does, however, always require an additional optical connection of the sensor to the reflectors. Each sensor must therefore be mounted high enough on the AGV that it always has a clear view of the reflectors. If the connection to the reflectors is interrupted, e.g., when entering a shelf aisle, the AGV must switch to another type of navigation. This makes it more difficult to change to another room if necessary, limiting the flexibility.
2D-codes or transponders. With the help of the information ascertained while traveling over the individual grid points – with a 2D-code these are, e.g., the code information and reading angle – the AGV can navigate between the individual grid points and thereby reach any specified point within the grid. This type of navigation is suitable above all for clean surfaces and surfaces not subject to heavy loading. A general evaluation and recommendation for the suitable navigation variant can only be determined in combination with the function of the AGV within the given application. At the present time, however, there is a clear trend towards contour navigation with integrated safety function. www.leuze.com
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Optical and inductive guidance Optical and inductive guidance are usually very simple systems that follow a predefined trace. As a result, they are very limited in terms of flexibility. On the other hand, however, they represent a very cost-optimized solution. Because the sensor on the AGV is mounted only a short distance from the floor, such a form of navigation is independent of the selected vehicle type. Grid navigation With the so-called grid navigation, information is embedded in a specified grid on or in the surface that is traveled, e.g., 33 | Industry Asia Pacific | July 2020
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S M A R T FA C TO R Y
CHAIN CONDITION MONITORING
Developed in-house by iwis, the CCM-S monitoring system continuously measures the wear elongation of chains during operation and gives maintenance staff a timely warning that a chain needs to be replaced.
Maintenance 4.0 - Intelligent chain monitoring avoids downtimes.
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redictive maintenance is a key issue in the context of Industry 4.0 when it comes to getting the most out of machines and systems. A new, intelligent system from chain vendor iwis antriebssysteme prevents production downtimes resulting from unscheduled maintenance and repairs: It permanently monitors chain elongation and provides a timely warning so that appropriate action can be taken.
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If chains stretch and wear as a result of temperature and load or if chains running in parallel have different lengths, even a deviation of one percent from the nominal chain pitch can lead to problems in a machine. To take an example from chocolate production, which places very high demands on chains and chain systems, this could cause the position of the chocolate moulds to change.
This is because where chocolate bars, chocolates or biscuits are being made on a production line, the drive chains used are always subject to very strict length tolerances and tolerances across pairs of chains. The mould conveyor chains have to permanently run in parallel – exact positioning is an absolute must. Systems and machine components must therefore be monitored and checked regularly. However, by the time the system indicates a need for maintenance or adjustment it is often already too late. Preventive maintenance allows mechanical engineers to react more flexibly and more economically. CCM-S provides constant monitoring of the live system This is exactly where the smart solution from the international, Munich-based chain manufacturer comes in: With the chain elongation monitoring system CCM-S (Chain Condition Monitoring - Smart), users can permanently monitor the elongation of chain drives on the basis of sensors without having to compromise production by interruptions. The patented system measures the elongation of chains during live operation. It enables companies to take early
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measures by providing maintenance staff with timely information as to when certain measures need to be taken and whether a chain needs to be re-tensioned or replaced. The system's intelligent data analysis enables service staff to plan service activities and personnel requirements in advance. Improved machine utilization “Continuous chain elongation measurement offers some decisive benefits for our customers,” says Florian Wimmer, Value Engineer at iwis. “These include fewer downtimes and interruptions to production on machines and systems, which can jeopardize a company's ability to meet promised delivery dates. If maintenance can be planned, the maintenance staff can react in good time with the help of our system,” he explains. And the time needed for maintenance is also reduced because the CCM-S tells the engineer which drive chain needs to be replaced before the system is opened up. “These benefits allow our customers to get the most out of their equipment and increase machine utilization and productivity,” Wimmer adds.
Contactless and without intervention in the chain drive Once the monitoring system is in operation, it gets on with its job discreetly in the background: “Because it carries out precise chain length measurements without contact, the CCM system does not actively intervene in the chain drive,” Florian Madlener, Director of R&D at iwis, says of the technology behind the innovation, in the development of which he was instrumental. The system can also take measurements irrespective of the speed. It always records two readings at two different sensor locations, with both readings being taken at the same time. d = defined distance between sensors A and B n = number of chain links between sensors A and B p = pitch v = offset resulting from chain elongation
The CCM-S system measures chain elongation without any contact and does not actively intervene in the chain drive. The module can be easily retrofitted in a variety of chain applications. 1) Customer securing point (2x M6) 2) USB connector 3) Housing 4) Sliding guide 5) IO-Link connector Simple plug and play installation The CCM-S module is plug and play. It is very easy to install and it is no longer necessary to preset any values or perform any calibration in the application. The module is simply installed in the machine and the system is ready for use as soon as the cable is plugged in.
In the CCM-S, iwis has developed a monitoring system that makes use of the physical principle of induction: The chain rollers move past the coils of the sensor and can thus be identified as a metallic unit. MORE INFORMATION
If the module is installed in an existing chain drive, users can immediately start evaluating the data on wear in the chain drive using either iwis software or IO-Link.
The measured chain elongation is the difference between the defined distance between the sensors (d) and the nominal dimension of the chain (n*p). The CCM-S returns the ratio between the measured chain length and the nominal length of a new chain. This value is the chain elongation in percent.
Problem-free retrofitting The developers at iwis wanted to make their smart solution as widely applicable as possible and designed the monitoring system for different chain sizes. “Since the CCM-S detects only one strand of the chain, it can also monitor duplex and triplex chains,” says Florian Madlener. 33 | Industry Asia Pacific | July 2020
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The CCM-S system can also measure the elongation of each individual chain segment and displays the results clearly.
He also goes on to explain that the solution can be quickly and easily retrofitted in a variety of applications without the use of special attachments on the chains. Thanks to an SLE function (Segment Link Elongation), the system does not only record elongation of the entire chain in the system. Using the SLE function, the entire chain can be subdivided into individual segments. These are measured individually and assessed for differences from the average chain elongation. To achieve this, magnets must be attached to both sides of the outer plates of the chain strand in order to define a start/end point. This allows the system to generate a bar chart showing the elongation of individual chain segments. Technical properties • The CCM-S system measures the elongation of the following pitch sizes: - British Standard: Pitch sizes 08B to 32B - ANSI Standard: Pitch sizes 40 to 160 • Ambient temperature: 0°C to 70°C • Minimum permitted speed: << 0.1 m/s • Maximum permitted speed: 5 m/s • Chain material types: Carbon steel and stainless steel • Protection class: IP67 • Interfaces: IO-Link and USB The idea “Increasing digitalization in mechanical engineering and the growing importance of issues such as Industry 4.0, the smart factory, predictive maintenance and condition monitoring are leading to greater expectations on the part of our customers. They want IIoT products, intelligent solutions for condition monitoring and higher plant reliability. Meeting these needs was our motivation and the driving force behind the development of a leading-edge monitoring system for chain drives”.
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Florian Wimmer is a value engineer at iwis, working on the development of the CCM-S system.
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What else can CCM-S do? • Temperature monitoring The system uses a sensor to measure the temperature at the sliding guide on the surface of the chain rollers. A lack of lubrication can be indicated by excessive chain strand temperatures. A further sensor also measures the temperature of the CPU inside the CCM-S. • Jolt sensor If the chain hits the sliding guide of the CCM-S, this is registered by a jolt sensor in the CCM-S. This can, for instance, be caused by stiff links, which in turn result from inadequate lubrication. • Multi-CCM-S Chain pitches larger than 50.8 mm can be handled by combining two CCM-S modules and mounting them one behind the other on one chain strand. Each CCM-S then works as a single sensor. Authors: Florian Madlener, Director Development and Testing at iwis antriebssysteme Florian Wimmer, Value Engineer at iwis antriebssysteme www.iwis.com
S M A R T FA C TO R Y
POWERFUL CAN-FD MULTI-CHANNEL IXXAT PC-INTERFACE FOR AUTOMOTIVE TEST SYSTEMS AND INDUSTRIAL APPLICATIONS
HMS Networks now extends its Ixxat® PC-interface portfolio with the multi-channel interface CAN-IB 640/ PCIe that offers four channels each for CAN-FD/CAN and LIN connectivity.
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odern automotive systems and complex industrial applications often include several parallel CAN and CAN-FD networks which must be connected to test, monitoring, and/or control systems at the same time. With the multi-channel Ixxat® CAN-IB 640/PCIe interface, HMS makes network connectivity and integration straightforward and cost-efficient for users. Featuring four channels for CAN-FD/CAN and LIN connectivity respectively, the CANIB 640/PCIe covers the needs of most applications with only one card. And, if even more connectivity is required, several CAN-IB640/PCIe cards can be operated in parallel – a feature supported by all Ixxat CAN interfaces, enabling smart and scalable networking for users.
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Performance and intelligence in focus The CAN-IB 640/PCIe is an active PC-interface with a powerful onboard microcontroller system, which is able to read, timestamp and filter large amounts of data in realtime. The network connection is done via two D-Sub 9 connectors, which are galvanically isolated to protect the interface card and the connected PC system.
Flexible and versatile connection to the customer PCapplication All Ixxat CAN interfaces come with extensive driver packages for Windows and Linux, including SocketCAN. The drivers allow easy and fast development of customerspecific applications, most notably since all Ixxat PCI-cards can be interfaced from the application in the same way. This enables very flexible and versatile switching between different types of Ixxat PC-interfaces, e.g. USB, PCIe, PCIe Mini, and Ethernet, without needing to adapt the customer application software each time. A simple monitoring tool for Windows is included in the scope of delivery, but HMS also offers numerous additional analysis and configuration tools for different purposes and use cases. In addition to the proprietary driver packages, standardized APIs such as the J2534-Passthru or D-PDU API, are available as options, simplifying connectivity to 3rd party tools which use these standardized APIs. www.ixxat.com/can-interfaces
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S M A R T FA C TO R Y
MAGNETIC ENCODER SYSTEM WITH DRIVE-CLIQ INTERFACE FROM BALLUFF
The BML absolute magnetic encoder in the SGA series stands out in any application where high absolute accuracy of position and end-of-travel is required. Comprehensive diagnostics functions ensure reliable operation and more efficient maintenance. With its Drive-Cliq interface the Balluff measuring system can also be perfectly integrated into Siemens controller environments. Siemens has certified the system accordingly.
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lug and play installation makes incorporating into the drive system easy. The controller automatically detects the sensor and its basic settings. The sensor also offers great flexibility, since leaving and reengaging with the tape is permissible. This opens up simple and economical solutions for demanding applications in the field of automation as well as machine tool building, especially specialty machines.
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Since the system works magnetically, it is also extremely insensitive to temperature change, dirt (such as from dust and oil), or wear. Thanks to its compact form factor the measuring system is also easy to integrate into existing applications, even in tight mounting conditions. The generous read distance of 1.3 mm makes installation easier.
In practical operation continuous plausibility checking ensures high reliability, since the system consistently check the measurement quality. Automatic condition monitoring checks the signal quality and, using the controller, is a convenient way to evaluate the function reserve. Status LEDs and diagnostic functions ensure reliable operation and more efficient maintenance. The linear measuring system is suitable for both long measuring lengths up to 48 meters as well as for applications which require high precision. With an accuracy of up to ± 12µm and a resolution of 1µm the measuring system meets these requirements. The system is also simple to retrofit. www.balluff.com
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S M A R T FA C TO R Y
RED LION PRESENTS LAYER 3 GIGABIT ETHERNET SWITCH
Enhancing Interoperability and Management of Vital Industrial Network Infrastructure.
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ed Lion Controls, global experts in communication, monitoring and control for industrial automation and networking, announced the release of their innovative new NT328G Layer 3 Ethernet switch today. Offering 28 high-speed ports (24-Gigabit, 4-10 Gigabit) and reliable wire-speed switching performance, the NT328G offers exceptional performance and reliability to meet the current and future needs of the Oil & Gas, Water & Wastewater, Energy, Transportation, and video and security sectors, as well as other bandwidth-intensive industrial applications.
“Industrial customers are demanding reliable wire-speed Layer 3 switching performance that is scalable to 10Gigabit speed to meet current and future bandwidth-requirements. Customers now have access to a future-proof and durable switch solution that addresses industrial requirements from the network edge to the core.” said Diane Davis, director of product management at Red Lion Controls. www.redlion.net MORE INFORMATION
Red Lion’s NT328G Layer 3 industrial Ethernet models feature a flexible mix of copper and fiber ports, allowing for a vast variety of connection options, with Layer 3 routing that provides the ability to route across VLANs or subnets— versatility that ensures scalability. The industrial-grade NT328G’s robust feature set includes network redundancy, advanced, integrated security, policy-based traffic control and easy-to-use configuration and management—reducing operating costs while providing continuous monitoring of network activity. Its sleek but rugged IP30 rackmount metal housing is constructed for long-life use in harsh industrial environments, including wide operating temperature conditions and hazardous locations—durability that
ensures reduced downtime. Ideal for large-scale and/ or any industrial network, the NT328G has the flexibility to meet both present and long-term speed and media requirements—delivering investment protection for years to come.
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S M A R T FA C TO R Y
LOGIDRIVE INTRALOGISTICS SOLUTIONS COMBINE ENERGY EFFICIENCY AND THE REDUCTION OF VARIANTS
Large intralogistics projects for airports, parcel centres, high-bay warehouses or other warehouse logistics facilities must reconcile several competing requirements. With the LogiDrive concept for drive technology, NORD DRIVESYSTEMS takes a comprehensive TCO approach that combines energy efficiency and the reduction of variants with optimal system solutions for intralogistics.
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onveyor belts in intralogistics installations for airports, warehouses and parcel centres are often designed for the expected maximum load and with corresponding safety factors. This often results in drives that are oversized for the application. However, in real operation, such systems achieve the maximum load only with a small proportion of the conveyed items. As a result of such design, the drives only operate in the inefficient partial load range for most of the time. With the LogiDrive concept, NORD counteracts this trend with a specific reduction of variants using modern synchronous motors. In comparison with conventional asynchronous technology, these have an improved energy consumption performance in the partial load and partial speed ranges. Therefore, they are more energy efficient in these operating points and also keep efficiencies at a high level, even in case of overdimensioning through a reduction of variants. This results in a low total cost of ownership (TCO).
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Four of five drive variants not required NORD frequency inverters can control the output speed via a frequency range of 25 to 100 Hz. Thanks to their high overload capacity modern synchronous motors have a single motor type that can be used instead of different motor sizes. Dependent on the performance requirement, it is operated by its inverter with different frequencies. As an example, in a NORD project for baggage transport at an airport with 700 drive units, the number of variants could be reduced by about 80%. Eight variants of the 11 used drive configurations related to a standard system solution, the NORD LogiDrive. Proven standard solutions are tested and can be safely used. Cost reduction thanks to standardisation The LogiDrive systems from NORD are highly efficient, extremely easy to maintain and install thanks to plug-andplay technology, and result in a considerable reduction of spare part stocks during operation. The whole concept is designed for easy planning and commissioning. The standardised geared motor variants are specially designed
The LogiDrive intralogistics solution from NORD is designed for intralogistics projects at airports, parcel centres, high-bay warehouses or other warehouse logistics facilities.
for intralogistics, parcel logistics and airport technology, and are particularly suitable for reducing the number of variants. The compact design saves space and the lightweight aluminium housing enables weight savings of up to 25%. LogiDrive drive units comprise an IE4 synchronous motor with rated powers of up to 5.5 kW, a 2-stage helical bevel gear unit and a NORDAC LINK frequency inverter to be installed close to the motor. With class IE4 motor efficiency and system efficiency to class IES2, the drive units achieve excellent overall efficiencies - especially in the partial load and speed range. www.nord.com
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TRACEABILIT Y
TRACEABILITY IN THE MEDICAL SECTOR, A TECHNICAL CHALLENGE
Accuracy, efficiency and safety are the key words of an industry at the cutting edge of technology. Governed by numerous standards ensuring the reliability of its components, the medical sector has implemented numerous traceability processes over the last few years.
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hanks to the markings applied to the various components, it is possible to obtain information about the manufacturer, but also the component reference number or their expiry date. All this data complies with the UDI (Unique Device Identification) and MDR (Medical Device Regulation) standards, which are essential for exporting devices to the USA and Europe. The components to be marked are as diverse as the professions that make up the medical sector. There are, for example, many cases of marking on surgical instruments such as scalpels or bistouries, but also on prosthetics or orthoses, made of steel, cobalt, ceramics or biomaterials, dental implants, often made of titanium, or hearing aids or pacemakers. MORE INFORMATION
In order to ensure optimal identification throughout their distribution and use, these multiple devices must have a marking composed of different elements. In order to comply with the standards mentioned above, it must contain a machine-readable barcode or Datamatrix as well as several alphanumeric codes that can be identified by humans. Quite often a logo is applied, meeting a need that is more aesthetic than practical. 33 | Industry Asia Pacific | July 2020
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In addition, there are many constraints linked to the complexity of the marked components and the sector of activity. For example, the materials with which the various devices are made are complex and varied (steel, titanium, stainless steel, ceramics, various alloys, biomaterials, etc.) and require really technical expertise when marking. Precision objects and medical tools are often small and leave very little space for marking. Despite the small marking windows, the identifiers must be contrasting and visible to allow reading via a vision system and a human. Another challenge is not to weaken the part nor to change its surface state (essential for bone prosthetics which undergo important efforts throughout their life span). It is also important to take into account all the surface treatments and sterilization cycles that medical instruments undergo. This is why it is essential that the marking carried out is resistant and durable over time. Benoit Massel, specialist of laser marking technology at SIC MARKING talks about it: â&#x20AC;&#x153;All the difficulty of permanent marking by laser technology on medical parts lies in the ability to obtain a contrasting
part and doesn’t degrade its hygiene, a crucial factor in the medical sector. The SIC MARKING Laser product range can be adapted to your requirements, regardless of the type of marking, the parts, for serial or single marking. It consists of lasers that can be integrated with various options: - 3D function for marking on complex shaped parts, different heights, curves or angled faces. - Integrated Vision function for fast and reliable reading of barcodes and Datamatrix codes. - Rotary D-axis for marking cylindrical workpieces around the diameter. The range is completed by 3 marking stations, L-Box, XL-Box and the new XXL-Box. SIC MARKING provides a feasibility study before each project after collecting the needs of our customers via our representatives. Nicolas Louison, Technical Sales Representative at SICMARKING talks about it:
result without affecting the surface state of the material, which must resist passivation treatments. The technology must also be able to mark on a variety of materials (polymers, metals, etc.).” Laser marking, the most suitable solution for the medical sector All these constraints make the traceability of medical tools a really technical challenge. This is why SIC MARKING, the world leader in traceability solutions, is committed to providing the most appropriate marking solutions to meet all the challenges faced by the medical sector. With more than 30 years of experience, SIC MARKING has become an expert in laser marking. This latest generation technology consists of emitting radiation from a source, amplifying it and directing it towards the part to be marked. The beam creates a chemical reaction on contact with the workpiece.
Numerous references SIC MARKING has many references in the medical sector. Notably in Italy, with the company MECTRON. Specialist for more than 40 years in the manufacture of inserts for clinical applications, it exports its products to more than 80 countries. SIC MARKING was approached with the exciting challenge of marking titanium instruments for dental surgery. The marking consisted of an alphanumeric code and a logo and should not, under any circumstances, weaken the parts, which were then subjected to ultrasonic treatment. The challenge was also to create an automatic laser marking system capable of working in collaboration with the latest generation of COBOT (Collaborative Robot). This project allowed SIC MARKING to once again prove its expertise thanks to an immediate understanding of the customer’s needs and a technical solution proven and validated by electron microscope verification tests in the laboratory. SIC MARKING is also marking on ceramic prostheses, titanium inserts, steel bone fixators…
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This traceability solution, thanks to its many advantages, is becoming more and more widespread in the medical industry. It offers great flexibility of use and is able to mark barcodes, Datamatrix codes, alphanumeric characters and logos. All this while adapting to any material. The highcontrast and durable result obtained allows perfect reading over time for optimal traceability. Finally, Laser marking ensures faultless security because it doesn’t weaken the
“Today, the medical sector is a sector where traceability has become essential and necessary. SIC MARKING’s experience in this sector enables us to provide our customers with the most interesting marking solutions from a technical and economic point of view. The wide range of laser marking solutions from SIC MARKING enables us to offer our customers a marking system that meets the requirements of the various types of applications: permanent, nondestructive marking, resistant to the sterilization process, etc.”.
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