Featuring a very compact design, the new controller has also been fitted with a microSD card that offers a large storage capacity. Its Embedded PC features a CPU, a number of IT connectivity solutions and optional interfaces, a direct I/O interface and power supply for Beckhoff I/O systems. It also automatically detects the connected EtherCAT Terminals (E-bus) or Bus Terminals (K-bus) as well as switches to the corresponding mode for convenient system management.

Its CPU has access to 1 GB internal DDR3 RAM and a 256 MB microSD card for its operating system. For additional operator data, the controller also offers a free microSD card slot.

The CX9020’s basic version offers two 10/100 Mbit/s Ethernet ports, a DVI-D interface and four USB 2.0 connections. Its multi-optional interface allows integration of added interface that includes PROFINET, PROFIBUS, Ethernet/IP, DeviceNet, CANopen, audio or serial interface (RS232/RS422/RS485).

Unlike the current ARM9 architecture, the controller’s ARM Cortex A8 processor features a hardware-based floating point unit, which makes floating point operations (LREAL, REAL) faster. When combined with Beckhoff’s TwinCAT automation software platform, the CX9020 system turns into a high-performance PLC and Motion Controller that can be utilized with or without visualization. The operating system of the CX9020 is Microsoft Windows Embedded Compact 7.

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The module supports circular interpolation of two axes, linear interpolation of up to four axes, continuous orbit control and fixed feed control. Users only have to set the speeds as well as the positioning addresses from within a sequence program.

The auxiliary functions of the Melsec L series positioning module feature step operation, M codes, skip and target position change. Featuring a built-in mark detection interface, the series’ cam control and synchronous control can also be combined.

The module has been specifically designed to match a library of function blocks that are based on PLCopen motion control specifications. Offering single- and multi-axis functions, the library delivers a standard command set that effectively enhances the set-up, despite the complexity of motion tasks, leading to reduced maintenance, development and support costs.

Instead of using motion programming, the motion module employs parameter settings to simplify the system set-ups. A data table is used to execute the positioning control, while the positioning data is set with the help of functions such as offline simulation, automatic calculation of auxiliary arcs and speed simulation. Synchronous control can be implemented using parameter settings, while cams can be easily set without worrying of electronic cam controls.

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Compliant with PLCopen and IEC 61131-3, the MotionPAC can be used in conjunction with AeroBasic programs or independently for full machine control. It also allows users to program in Function Block Diagrams (FBD), Ladder Diagrams (LD) or Structured Text (ST). Its integrated automation reduces commissioning and programming time by 30 percent to 50 percent, making it ideal for use in machine control program development.

Since it is integrated with the company’s A3200 motion controller, users can directly command coordinated, asynchronous, geared, blended or cammed motion from FBD, LD and ST. MotionPAC also allows users to specify moves as absolute or relative either in English or metric units.

Meanwhile, programmers can create shared Tags and variables that are referenced by Name in the A3200 tools, AeroBasic, Operator Interface, C or .NET programs. MotionPAC automatically handles memory management for all variables and Tags.

Its tools, which include user definable libraries (FBD, LD, ST or .NET), global Tag database, integrated axis manager for manual control and readout, virtual execution of the PLC and automatic memory management effectively increases programming quality and efficiency. Through MotionPAC, PLC and .NET programmers can collaborate seamlessly to deploy machine control applications. MotionPAC comes with standard fieldbuses, high-end data acquisition and drive I/O, which can also be shared with applications by Name.

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The new series does not only increase the amount of information exchanged between the supervisory layers and the control, but it also boost system performance and improve productivity by enhancing access to real-time information.

Ideally suited for synchronizing complex motion applications, the ControlLogix 5570 Series offers high-speed axis and trajectory planning. With two to three times quicker scan times, the new controllers feature memory options ranging from 2 MB to 32 MB.

The new series includes the ControlLogix 5571, 5572S, 5572, 5573S, 5573, 5574 and 5575 controllers. In December, it will be expanded to include the GuardLogix 5573S and 5572S controllers, which are designed to provide similar automation capabilities as the ControlLogix platform and safety-rated control for safety-related functions.

The controllers are fitted with on-board display features that offer improved diagnostics as well as run-time information to increase uptime and help ease troubleshooting. Its improved security features includes optimized data integrity and quicker data transference with its 1-GB secure digital card.

It will again be expanded in January with the addition of the ControlLogix 5573XT PAC. Suitable for extreme environments and rated for extended temperatures ranging from -25°C to 70°C, this soon-to-be addition is coated for use in corrosive and high-humidity environments.

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A part of the Allen-Bradley Micro800 range, the component-class micro programmable controllers provides machine manufactures a cost-effective control solution, making them suitable for standalone machine applications with less than 48 I/O.

“With this new line, Rockwell Automation is delivering the functionality and flexibility of a micro programmable logic controller for the price of a smart relay. Yet, the greatest value of the new Micro800 range is the simplicity and convenience it provides, with the right amount of control, so customers only pay for what they need,” said Adrian van Wyk, Business Manager at Rockwell Automation.

The Micro800 controllers feature a vast array of plug-in modules for communications, analogue/digital I/O and expanded memory. The range’s plug-in modules allow machine manufacturers to customize the controllers to optimize functionality without increasing the product footprint. Aside form providing removable terminal blocks, the new range also simplifies communication through point-to-point data exchange.

The smallest of the Allen-Bradley Micro800 family, the Micro810 programmable logic controller comes with embedded smart relay function blocks, which can be configured from the keypad and LCD. These function blocks include time of day, delay OFF/ON timer, time of week as well as time of year for applications demanding a programmable lighting and timer control.

Offering flexible communications, the Allen-Bradley Micro830 programmable logic controllers offers up to six high-speed counter inputs. These off-the-shelf controllers have been specifically designed to allow easy integration of up to five plug-in modules on the 48pt variants. They are fully customizable and carry global certifications and support.

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The earliest PLCs came along to replace large cabinets of electromechanical relays which were used to control machine processes. Cabinet-based control systems were big and bulky and required an enormous amount of wiring. And when a change in the control system was desired, the only way to do so was to go into the cabinet and rewire connections, which was costly and took up a lot of time.

The introduction of PLCs meant that the same control functions could be accomplished in a fraction of the space of a traditional control cabinet with far less wiring and complexity. Also, if a change in control was desired, the change could be handled via simple ladder-logic programming, eliminating the need to rewire large portions of a control cabinet.

The basic parts of any PLC system include the processor, I/O modules to handle inputs to the controller and outputs to the controlled devices, and some type of user interface which could be as simple as a keypad or a touchscreen interface or a programming link via a PC. The PLC’s processor is programmed via the user interface. The I/O modules are used to bring input signals into the PLC’s CPU and output control signals to controlled devices such as motors, valves, sensors and actuators, among others.

Individual PLC manufacturers may have different programming languages, but most are still based on the fundamental ladder logic programming structure. Although now, they can be programmed in higher-level languages such as C and BASIC. Communication options may include simple RS-232 serial communications to more advanced Ethernet protocols.

One of the most important considerations for any PLC is the scan time. Basically, this is the time in which the PLC runs through the program taking in data and updating outputs. This is typically a few milliseconds but can be much longer depending on the program length and the speed of the processor. Higher scan times can accommodate processes with more real-time demands than traditional slower applications where scan speed is not as critical.

Other points to consider include the I/O count and the ability to expand I/O if needed. This can range from a handful of I/O for simple applications to hundreds in more complex machinery. The type of I/O, whether analog or digital, is also important. It’s common for manufacturers to supply modules designed for unique input types, such as counting encoder inputs.

Another point to consider is the level of customization needed. For instance, PLCs can be set up with individual web pages where operators can go to view system parameters and machine conditions. They can also be programmed to send alerts and condition status updates to mobile devices such as cell phones to keep operators and engineers abreast of machinery and processes.

More recently, some manufacturers have introduced so-called PACs (programmable automation controllers). A PAC is similar to a PLC but denotes a controller that accommodates better real-time control needed in some automation applications. Also, special PLCs can include dedicated safety PLCs which monitor machine inputs such as photoelectric sensors, light curtains, magnetically operated sensors, emergency stop buttons, and safety mats.

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The machine controller’s primary operations include scanning I/O, updating output and process control. After an initialization phase, the controller will continuously read inputs, calculate control parameters for the machine process using application-specific logic based on the input data, and then update outputs to the machine. If the controller is turned off, some shutdown process may be completed.

The central part of a machine controller is the controller itself, which can take on several forms. For single machine control, a programmable logic controller (PLC) or a programmable automation controller (PAC) is usually sufficient to handle the job. PLCs are usually programmed using ladder logic or sequential function charts. The controller receives various sensor data, processes this information and executes controls via some combination of digital and/or analog I/O signals to turn on or off processes, actuate or stop movement, and take user or environmental input and make decisions based on these inputs. Machine controllers will generally work together with some type of human-machine interface (HMI). These can be either integrated with the controller as one piece or can be stand-alone units that communicate with the controller.

More recently, machine control has seen a move to PACs because they can offer better performance and a wider range of functions than traditional PLCs. For instance, PACs can support high-speed data acquisition and processing, as well as motion control and vision functions.

In order to take advantage of all the features and capabilities of a PAC, the application code must be well designed, balancing and coordinating various controller processes such as I/O, process control logic, communication to an HMI unit and other tasks.

There are a number of considerations to keep in mind when selecting a machine controller. One of the most important is the number and type (i.e. analog or digital) of I/O the controller will have to handle. Also, do the speed requirements of the machine match up with the controller’s capabilities? For instance, some machine controllers may be tasked with closing servo loops and thus must be capable of handling such a task.

Another consideration is the type of communication link needed. The machine may have special demands or may be wired to accommodate a specific networking protocol, so ensure that the controller can communicate with the machine. Related to the communication link is the programming environment. Is the controller simple to program? Can programs be edited quickly and easily? Lastly, consider any environmental factors in which the machine will have to operate such as shock and vibration, extreme temperatures, and moisture or humidity.

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The new PLC offers extremely fast I/O update, user defined web pages, various field-bus options (Profibus / Modbus), redundancy features, hot swappable I/O modules, enhanced diagnosis, flexible architecture, easy installation and maintenance design, special modules and wide I/O. Aside from having a life span of approximately 10 to 15 years, the PLC is also IEC 61131-3 compliant and can support up to 32 expansion racks.

The new PLC also offers other latest user friendly features in mechanical structure such as special diagnostic push button for field diagnostics, diagnostic LCD on each module, huge memory for data storage, dynamically updated diagnostic Web pages, remote monitoring, application event logging, road map towards hot-standby redundancy and hot plugging of all modules.

Its unique design allows it to be utilized in various applications including machinery automation, infrastructure, utility sectors and water management. With the product design focused on controller for process automation, much attention has been placed on its ability to handle numerous analog I/Os and other related processing.

“NX7 PLC series is another step by Messung to provide path breaking automation technology to the industrial segment in India. The engineers involved in the development of this product have ensured that the product is not only best in terms of quality but also fulfills all the automation needs of its users,” said Mr. Farook Merchant, Chairman and MD of Messung Group.

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Featuring color touch screen control panels, this Siemens-based PLC can support polymer-conveying systems with up to 120 stations and 20 pumps. Its base panel can control up to 25 purge valves, 32 material receivers with proportioning capability and five vacuum pumps, while its icon-driven graphic display offers an easy-to-learn user interface.

With Ethernet connection capability, the PLC can be controlled from any remote personal computer. It is also designed with Profinet communications to allow the PLC to remotely add more components. Expansion is achieved through FlexXpand FXMS modules that automatically connect to the main control through Profinet communications network. The modules, which control additional pumps, receivers, material-selection stations and purge valves, can be arranged in such a way to minimize wiring to system components.

Every FXS control features a three-port Ethernet connection for added FXS modules or remote or local human-machine interface (HMI) modules. Expansion requires no additional programming, since all modules are automatically recognized by the FXS control.

Moreover, both visual and audible parameters are integrated on the control face. With assignable levels of security, various changes to operating parameters can be easily made. Likewise, the Ethernet capability of FlexXpand allows the advanced, intuitive interface to monitor as well as control other Novatec ColorNet-compatible HMI’s integrated on the local network.

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“Utility and industrial companies around the world depend on SEL automation and integration solutions,” noted David Whitehead, Vice President of Research and Development at SEL.

“The Axion is a key new product to help our customers solve tough control system and substation automation problems.”

An Axion system can be developed with up to six nodes or units connected to a network utilizing the EtherCAT protocol. Every node can accommodate ten modules, which includes one or two power supplies, a processor module, and a user-determined mix of I/O modules ideally suited for the application.

Featuring a complete IEC 61131 logic processor, the Axion also comes with an advanced data concentration, secure communications, protocol conversion capabilities between multiple integrated client/server protocols as well as local and remote I/O. The IEC 61131 logic processor allows engineers to operate their custom control logic at two varying rates. The solution also offers integrators the necessary tools to easily concentrate and integrate information from various microprocessor-based devices.

Each Axion provides an ACSELERATOR RTAC SEL-5033 configuration software for no extra cost. The software provides everything the users need to set up I/O, security, communications and programmable logic in a single easy-to-use package.

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The new PLC controllers provide standardized functions for planning, programming, configuration and diagnostic in one single engineering environment. It also features flexible motion control functions. Using SERCOS III and other communication interfaces, IndraLogic XLC can be connected into various communication networks.

Rexroth’s new range of PLC enables controller-based, scalable and embedded PC solutions in relation with the company’s newest IndraControl device platform.

Using state-of-the-art PLC kernel, IndraLogic 2G, the company has enhanced the PLC programming of the latest IndraLogic XLC PLC and integrated it into the multitasking runtime system and the company’s IndraWorks software tool. This enables users to take advantage of the various functions of the IndraLogic XLC PLC for developing modular software projects in an end-to-end overall system quickly.

The new range of PLC features functions such as comprehensive function libraries, object orientation as an extension to IEC 61131-3, convenient editor tools and fast compilers for efficient production of machine codes. Simplifying the process of designing new machines with improved software quality, the modular GATcompact (Generic Application Template) project template also reduces effort considerably.

Ethernet SERCOS III provides end-to-end communication between the decentralized system peripherals, such as drives or I/O, and the controller. The controller’s fast PLC cycles of up to 250 µs offer excellent response times in handling time-critical process signals. To enhance the company’s previous IndraLogic system, the new controllers have integrated into its run system versatile motion control functions.

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With the enhancements on its programmable automation controllers (PACs) portfolio, the company now offers Integrated Motion over EtherNet/IP technology. This new technology helps companies optimize their machine design flexibility, reduce overall system costs and improve their systems performance.

“This really is an important evolution in machine control; what we have done is close the loop,” said Haïthem Mansouri, European Product Manager, Motion Control, Rockwell Automation.

“By introducing motion over EtherNet/IP we have given engineers the ability to side step their reliance on specialist motion protocols, such as SERCOS. This has removed the final remaining barrier that was preventing the adoption of a complete, single, integrated network that is already capable of undertaking safety, process and discrete control.”

“EtherNet/IP is, to all intents and purposes, identical to standard Ethernet; the only change being in the Application Layer,” explained Mansouri. “It uses standard, unmodified Ethernet, and allows users to effectively manage real-time control and information flow for improved plant-wide optimization; ultimately resulting in more informed decision-making and better business performance.”

He added that although other vendors use Ethernet “but they just use the first physical layer – the actual protocol is proprietary and specialist. This means that although they can claim ‘Ethernet compatibility’, it is, in fact, just as closed as any other proprietary protocol.”

With this latest innovation, machine builders can now program, commission, configure and maintain PowerFlex 755 AC drives and Kinetix 6500 servo drives with the outstanding processing capabilities of Allen-Bradley ControlLogix 557X PACs – all over EtherNet/IP.

Motion Control Tips

IndraLogic XLC (eXtended Logic Control) PLC controllers feature capabilities go beyond standard PLC functions. Users can leverage a wide range of new functions that achieve modular software projects quicker than before. All planning, configuration, programming and diagnostic functions are standardized in one single engineering environment, with flexible motion control functions fully integrated. IndraLogic XLC can be connected into different communication networks thanks to real-time communication via SERCOS III and other common communication interfaces.

A state-of-the-art PLC kernel, IndraLogic 2G, is integrated into the company’s IndraWorks software tool and the multitasking runtime system. This lets users take advantage of many new functions for creating modular software projects in an end-to-end overall system in less time than before. Functions include convenient editor tools, object orientation as an extension to IEC 61131-3, and comprehensive function libraries as well as fast compilers for efficient generation of machine codes. The modular GATcompact (Generic Application Template) project template simplifies the process of designing new machines with enhanced software quality while reducing effort considerably.

End-to-end communication between the controller and decentralized system peripherals, such as inputs and outputs or drives, takes place via real-time Ethernet SERCOS III. Fast PLC cycles to 250µs enable optimum response times for handling time-critical process signals. IndraLogic XLC controllers come with versatile motion control functions, integrated into the run-time systems, to enhance the previous IndraLogic systems.

With its motion control functionality, the XLC handles machine applications ranging from simple point-to-point motion to the synchronization of multiple axes that use Rexroth’s FlexProfile to integrate complex motion sequences. The graphical profile editor in the Rexroth IndraWorks software tool offers numerous offline and online functions for this purpose. Master and slave interfaces for PROFINET RT, PROFIBUS and EtherNet/IP are also available, in addition to SERCOS III, for integrating into a wide range of communication networks.

For more information, visit www.boschrexroth-us.com

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These new FMD PLCs complete Triangle Research’s lineup of highly integrated “Super PLCs”, which starts from the small Nano-10 to the F-series. The super PLC series blends the easy-to-use and powerful i-TRILOGI Ladder+BASIC software with a vast array of features, such as PWM, PID, built-in analog and digital I/Os, stepper controls, encoders, and on-board communication ports which enables connection to other devices.

The FMD models allow Nano-10 PLC users easy creation of graphic web page without the need of writing any Internet program. For remote interaction with the controlled device, users simply have to define a background image and modify significant variables that define the location and I/O labels over the image on a browser screen.

Aside from making the FMD model PLCs remotely accessible for OEM troubleshooting and machine monitoring, the company’s iTRILOGI client/server software also allows easy integration into mixed-brand PLC networks and environments.

As implied by the model name, the FMD88-10 comes with eight digital inputs and outputs, and 10 analog I/Os while the FMD1616-10 features 16 digital inputs and outputs, and 10 analog I/Os. Specially designed with an I/O expansion port, both models also offers RS485 and RS232 serial ports, LCD display interface and an Ethernet port which has become quite indispensable.

The FMD1616-10 and FMD88-10 are available at $295 and $229 respectively.

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Cognex Connect enables users to easily monitor and configure a network of vision systems and Cognex ID readers through its open standard industrial Ethernet communications protocols. Since In-Sight and DataMan are network devices, the protocols enable the devices to be easily accessed from any terminal connected to the network. Thus, they eliminate the need for a host PC that will translate USB or RS 232 communication to a central or PLC network. Images and data files can be archived using the Cognex Connect’s FTP support. This capability allows later analysis and review of files. DataMan ID readers also allow users to customize terminal interfaces and GUI through a NET based command library. Its simple command line interface provides users control over the ID readers.

“By adding industrial protocols, the DataMan 8000 series is the first and only hand held ID reader to allow a direct connection to a PLC-acting as a node on the factory network,” Senior Vice President, International Sales and Marketing Didier Lacroix said. “DataMan readers with Cognex Connect completely eliminate the need for a PC and simplify the integration into the factory network, reducing costs and downtime.”

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“Combining this feature-rich industrial fieldbus adapter with the ACS355 and ACS850 drives will make available a great drive solution for OEM’s or system integrators who are focused on the packaging, material handling, printing, rubber & plastics, and machine tool industries,” said ABB LVD Senior Platform Solutions engineer Chris Stamas.

The adapter’s flexibility offers easy and fast connectivity to major programmable automation interfaces/controllers that support Ethercat protocol including ABB AC500 programmable logic controller (PLC). Some of the applications for coupling with this advanced drive adapter are high-speed presses, packaging machines, injection molding machines, machine tooling (CNC), robotics, test beds, woodworking machines, high speed bottling lines (food and beverage) and materials handling / logistics.

EtherCAT is an Ethernet technology aimed at maximizing the capability of full duplex Ethernet bandwidth. It exceeds the overhead usually associated with Ethernet by using “on the fly” processing hardware. An EtherCAT bus comprises up to 65535 slave devices and a master system, linked together with standard Ethernet cabling. The incoming data are processed by the slave devices, which insert or extract them and shift the message to the next slave device, creating a loop.

Various protocols can be utilized as the application layer. ABB’s drive adapter uses the CANopen over EtherCAT (CoE) technology. Customers can create a robust solution out of the combination of this data infused protocol with the company’s ACS850 and ACS355 drives. It does not only provide real time control but also the capability to extract data in order to optimize applications.

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“Our HVAC/R OEM and end user customers face a unique set of challenges when it comes to designing machines that are efficient, productive and reliable while also being cost effective,” said General Manager – OEM Business, Industry Business, Schneider Electric Ian Hitchins. “Automation solutions are a driving force behind controlling costs, reducing design time, and continuing to deliver innovative products, so we’re proud to deliver an HVAC/R-tailored solution that will also enable a value-add through decreased energy costs.”

The Modicon M168 PLC is part of the company’s automation solution that uses new equipment platforms and a single software suite to help OEMs design machines that are optimized for energy efficiency, performance and cost.

The Modicon M168 PLC features web-enabled capabilities, which allow end users and machine OEMs to monitor machine shutdowns, energy consumption and other problems remotely. Communications protocol such as BACnet allows the controller to easily integrate into Building Management System platforms, savings up to 30 percent of energy. These unique products are powerful enough to control various building functions: electrical and mechanical equipment for heating, air conditioning, ventilation, shutters/blinds, lighting and power distribution, including security functions as CCTV and access control.

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Lenze’s I/O System 1000 is integrated with a 136mm-wide DIN-rail-mounting controller to create a single station with a 1µs time stamp and a 48MHz backplane bus. Up to 64 I/O modules can be combined to offer analog and digital I/O, counters and encoder evaluation, and temperature measurement.

To avoid moving parts, the 3200C makes use of Intel Atom processors, which operate without fans, and flash memory storage. It also features a built-in UPS to save variables in case of power interruptions. The controller has two USB ports and a SD memory card slot.

The controller also has two 100Mbit Ethernet interfaces. A third Ethernet interface is also provided to allow real-time communication with drives. Users can also add further communication buses, while the controller’s two synchronized CAN buses can support CANopen. The 3200C controller can also serve as a gateway between supervisory-level computers and field devices.

The Windows CE 6.0 based controller is complete with Lenze’s PLC Designer software, which allows programming compliant with IEC61131-3. The PLC Designer software is based on the CoDeSys3 programming system, which has been upgraded for the controller. The controller also features an integrated Web server, which provides access to all control parameters and to any Web browser’s logbook.

Individual System 1000 I/O modules can also be added as elements in the PLC Designer’s project tree. The I/O systems are integrated in the controllers mechanically and in the programming software.

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This embedded, low-power tool removes the need for an external ASIC, FPGA or PROFIBUS, which saves development cost and time while enhancing system performance. The AM1810 Sitara ARM MPU offers ample performance to support industrial applications implementation, whether or not these applications require a PROFIBUS. Industrial applications best suited for the AM1810 Sitara ARM MPU include a human machine interface (HMI) or programmable logic controller (PLC).

Texas Instruments also announced that it joined the PROFIBUS International, affirming its commitment to the industrial market by delivering an integrated and certified solution to improve costs and help make development easier for industrial designers.

Compared to other multi-chip solutions on the market, the AM1810 Sitara ARM MPU directly connects the PROFIBUS interface to the RS-485 transceiver, doing away with the need for a FPGA or ASIC.

“In the industrial space, the PROFIBUS standard is synonymous with reliable networking, and with this certification, TI is giving a higher assurance that our product is a quality alternative to existing solutions,” said Ram Sathappan, industrial end equipments manager of Texas Instruments Inc. “We are very excited to be a member of PI and introduce our certified AM1810 Sitara ARM MPU PROFIBUS solution to the industrial market. Our aim is to help our customers reduce BOM costs, PCB space and design time. We are confident that TI’s one chip solution, the AM1810 Sitara ARM MPU with PROFIBUS, will do just that.”

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This allows the instruments to communicate with other kinds of industrial control systems and their components like I/O systems or programmable automation and logic controllers.

G4 instruments from VPG provide high performance and high speed for industrial applications, including force measurement, process weighing and control, Web tension control and measurement, high dynamic force measurement, force vector calculations, automation and high-speed batching/blending systems. These units are certified to connect to a variety of communication interfaces, such as Profibus, Modbus/RTU, DeviceNet, RS232, RS485, USB, Modbus/TCP and EtherNet/IP.

The G4 family is available with four base mounting options: panel (PM), desktop (DT), harsh environment (HE) and DIN rail (RM). The IP65-rated G4-PM, HE and DT are integrated with 5.7” color graphic display and touchscreen for simple parameter changes and easy operation. The screen simultaneously displays up to four weight/force channels to allow user full control of multiple process vessels. Rated IP20, the G4-RM is designed for blind applications and needs a PLC/DCS interface.

The units can be configured for 24 VDC or 115/230 VAC operation. Software upgrades are downloadable from the company’s website and transferable to the instruments through a standard USB port connection. Custom software designed according to customer requirements for special applications can be made available when requested and is easily accommodated by the Microsoft Windows CE software platform. Remote access through a standard Web browser permits for monitoring, simple set-up and diagnostic tests.

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“These solutions scale capacity and integrate special functionality more easily than platforms based on dedicated hardware,” said Gilvarry, who is the marketing manager at Embedded and Communications Group for Intel Corp.

Rather than installing a number of system boards for HMI and control functions, multi-core processors allow consolidation of applications onto one board, he said. This boosts processing flexibility and power and further improves control performance.

Intel’s Atom processor and integration with certain input and output interfaces are important to control usage, he added.

“Without a doubt, we will see more multi-core CPUs (central processing units) being used in the industrial and embedded spaces as multi-core technology trickles down into smaller and lower-power designs,” said Casey Weltzin, product manager of LabView Real-Time, with Texas-based test and automation supplier National Instruments Corp. (www.ni.com). “The Intel Atom processor is a very good example of this trend.”

Beckhoff Automation LLC (www.beckhoffautomation.com) is now working with Intel on the next-generation Atom. “It has a low-heat, low-power footprint,” said Corey McAtee, technical marketing manager at Beckhoff. He envisions a paperback-novel-size controller that features low power and heat doing complete machine control, from HMI to PLC control between motion and robotics.

Mr. Weltzin shares the same vision, adding: “Multi-core CPUs and the work being done by Intel are clearing the way for more complex algorithms to be used (e.g., machine control) that can improve the capabilities and efficiency of machines. Designers will be able to reduce power consumption and size of current applications that require a lot of computation.”

Intel’s goal is to attain a single architecture converged on an embedded PC. “In the next several years, we may see many-core CPUs with 16, 32 or more cores,” Weltzin said, adding that it will force programmers to be much more adept at parallel application development. “It will also push researchers and companies like Intel to invest in interconnect technology for networking the CPU cores on a chip,” said Gilvarry.

As the number of cores increases, real-time response is, however, getting shorter. McAtee said: “In an EtherCat network with distributed controllers, the ‘slave’ device becomes more like a microcomputer, capturing data at 10-20 microseconds, with 10-20 nanosecond jitter. With [our] TwinCat 3.0, which has two cores, I can say I want one core to handle one high-speed task, such as registration, at 50 microseconds. The next core would do the basic programmable logic state, which you could set at 10 seconds.”

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The stepper motors offer a resolution of 819,200 steps/rev for smooth and quiet operation. The motors integrate everything needed for stand-alone control or operation from a PC or PLC. A total of eight I/O points can be configured as digital inputs/outputs, or analogue inputs. Aside from the 95 mm-long version, there is also a 126 mm version that can deliver 6.1 Nm, as well as a 156 mm version that delivers 9 Nm.

The stepper motors are said to deliver an acceleration precision of 1rpm/s and a velocity precision of 0.01rpm. The motors operate from 12V DC to 80V DC supplies and can deliver high torque at high speeds.

An ActiveX/OCX driver is also supplied to simplify interfacing with Excel, VB, LabView or other PC-based programs. Use of MAC protocol from JVL allows SMC85 controllers and QuickStep and MAC motors to be integrated on the RS-485 bus, supporting multiaxis or point-to-point operation of up to 254 axes.

Options include planetary gears, RS-485 and RS-422 interfaces for encoder I/O and connection to external PLCs or HMIs, double-shaft and single- or multi-turn encoders, and a pulse/direction mode for electronic gearing. The stepper motor can be available with wireless WLAN, Bluetooth or ZigBee functions, and is ready for next-generation options such as industrial Ethernet, Profibus and multi-turn encoders without external batteries.

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“Industrial-strength ozone solutions have traditionally been designed for facilities with rooms that are a few hundred thousand cubic feet in size—which makes those solutions impractical for facilities with banks of smaller rooms. This reality limited the ability for countless produce storage facilities around the world to leverage the natural purification powers of ozone,” said Mr. Andy Smith Purfresh’s vice president. “In response to increased demand from this industry segment, we developed the MRCB—a cost effective solution optimized for the unique needs of agricultural environments that monitors and delivers ozone to many rooms without compromising worker safety or reliability.”

Each MRCB can monitor and deliver ozone from four to eight rooms, and two MRCBs are capable of configuring a single Purfresh’s generator to deliver ozone to up to 16 rooms. Every MRCB is equipped with a PLC (Programmable Logic Controller) that accurately distributes and controls low doses of ozone through ozone resistant valves. The controller directly communicates with the main generator in order to execute 15 unique alarms to keep workers and produce safe.

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Based on the patented PLC-on-a-Chip technology, the HEC-HMI series controller allows programmable intelligence under lesser ideal conditions thanks to a water-tight enclosure with gland connectors. This standard enclosure is screw and sub-plate mountable, as well as sealed against the environment. The HEC-HMI series is programmed with Divelbiss EZ Ladder software that supports ladder diagram with function block programming.

The HEC-HMI series is offered as a HMI only or a HMI with Programmable Logic Controller (PLC) in the same enclosure. The entire series is available with an extended operating temperature range from -40°C to 80°C and 8VDC to 32VDC input power. A backlit LCD display is also offered in either 4 line by 20 character or 2 line by 16 character configurations. Character heights for the 2×16 and 4×20 options are 0.38” and 0.187”, respectively. Moreover, a total of four programmable indicators and nine pushbutton inputs are also provided. Four of the pushbuttons – in a horizontal row – are labeled as function keys, while the remaining five buttons are arranged in a compass pattern to be used as a joystick input. Network communication is achieved through a CAN port or a second serial communication port that is field configurable for RS323/422/485.

The HEC-HMI model series with integral PLCs integrate these additional features to the HMI only version. I/O includes six 8VDC to32VDC inputs (two are 200kHz high-speed counters) and six digital outputs with four rated to four amps with programmable status monitoring and automatic over-current safety. In addition, there are two analog inputs that can be individually configured to 0-5VDC or 0-20ma as required. Analog is offered in either 10- or 15-bit resolution.

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Nowadays, if the manufacturing system of the customer has a Rockwell PLC, then the vision system must talk to it, said Rick Roszkowski, the company’s senior director of vision systems marketing, adding that this ability to communicate is becoming a customer expectation.

“To meet it, we’re building tools within the smart camera, as well as including the ActiveX control software component for integration into third-party HMI systems,” said Roszkowski. “The demand for extending software features and tools to help quickly integrate vision into the industrial environment is becoming as important as the demand for new vision tools to solve a particular application. Most companies don’t have the time, and often not the expertise, to create a program that makes all those devices exchange data easily and quickly.”

Samantha Frost, product marketing specialist at Cognex, said OEMs look first for the ease of development and then integrate vision into other factory systems. “This means connecting to major factory communication protocols such as PROFINET, EtherNet/IP, and Modbus TCP, as well as interfacing with HMI programs,” said Frost.

Looking ahead, the company plans to give more pixels and more horsepower to its vision system products so they can handle data more accurately. “We want to make smart cameras and vision systems smarter, and make them play well with the rest of the factory,” she said. “So, we expect to provide more powerful application-building tools that require little or no operator input to set up the machine to accomplish the vision task.”

Kamalina Srikant, vision product manager at National Instruments, said embedded vision systems are utilized in scientific contexts including failure analysis labs and R&D, and industrial applications. The application’s complexity in industrial environments does not come from image-processing requirements but from the synchronization and the need to integrate vision system with other industrial systems such as control systems, robots, and PLCs, to handle the inspection results. Customers want a wider range of industrial communications options. “For example, you might need to ensure that your vision system uses a certain protocol to talk to one of the more expensive industrial robots on your line,” said Srikant. New Embedded Vision System models from NI are the first vision systems to support Ethernet for Control Automation Technology or Ethernet-based fieldbus system EtherCAT, also called deterministic Ethernet.

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Kors Engineering uses a PleXML system to integrate several plants to SaaS (software as a service) ERP solution Plex Online. Its architecture centralizes the IT infrastructure and does away with the need for an infrastructure, server and licensing at every plant. The solution streamlines management and outcomes in substantial cost savings for Marwood.

Marwood Metal Fabrication, an Ontario-based company, is a multi-facility, modular assembly and stamping supplier dedicated to delivery, quality and price competitiveness. The company produces a wide range of components for use in the car manufacturing industry.

“Integrating PLCs with Plex Online allows the machines to communicate with each other and ensure a consistently high-quality part output,” said Steve Spanjers, engineering director of Marwood Metal Fabrication. “Our customers are delighted with the results as they can review the number of quality checks and be assured that any part that does not meet quality specifications will not be shipped. This implementation also significantly reduces downtime for the machines, which is a huge benefit for us.”

Tony Kaczmarek, President of Kors Engineering, said: “Our mission at Kors Engineering is to help manufacturers ensure its products meet or surpass quality specifications in an efficient and safe manner. PLC implementations help operators monitor and control the rigorous quality standards and ensure customers receive a high-quality product. PleXML automatically manages large volumes of machine data to achieve the highest levels of quality, while helping management increase equipment and process uptime.”

Motion Control Tips

All motorized linear actuators produced by Oriental Motor feature the Alpha-Step stepping motor equipped with built-in closed loop performance, which is best for high response moves with no gain hunting or tuning problems common to servo solutions. They also feature a common controller allowing users easily run in driver mode or set all functions needed, accepting direction and step from a PLC or master controller.

Each of the new packages has unique features. With an aluminum frame structure as well as a pulley and belt mechanism, the SPV Series is best for applications requiring high speeds and long strokes, whilst the EZC II Series is a space saving ball screw system best for high speed applications or positioning where the load is pushed or pulled.

The EZA Series, with a built-in guide, offers greater ease of use and improved performance while maintaining a compact size. Just install a load directly in to the rod, and the EZA will do the push-motion and transfer operations. Lastly, the PWA II Series is ideal for high thrust force, through the use of a ball screw, and gears, together with the folded motor configuration. This package achieves a compact size ideal for applications with pressurized positioning and push motion.

Commonly, linear actuators are used in X-Y applications, pick and place applications, parts assembly or parts inspection applications, pressurized positioning operations and push-motion applications.

Motion Control Tips

INGEAR NET.LOGIX version 3.0 software can be used by those who write automation and control applications in Visual Studio C# or Visual Basic.NET to communicate with Allen-Bradley controllers, design data acquisition applications and custom communications, and deploy them on several machines, without the need to pay additional license fees.

“The better the information plant personnel have regarding operations, the greater their ability to manage costs, output, quality and ultimately — profitability. Some of the most valuable data lies within the programmable logic controllers (PLCs) that automate assembly lines. Manufacturers typically deploy PLCs machine-by-machine, so accessing that data can be a real challenge. This new set of class libraries provides anyone who knows Visual Basic.NET or Visual Studio C# everything they need to communicate with some of the world’s most popular Allen-Bradley controllers,” said Chuck Karwoski, head of CimQuest INGEAR.

NET.LOGIX 3.0 has several advanced features, including a new PeerMessage class for Unsolicited Messages, which waits idle in a passive state to allow the Allen-Bradley controller to send data through MSG instructions. Upon receiving communication, the PeerMessage class sends a notification event with information for the user application to process it immediately. The PeerMessage class is designed to receive MSG instructions from CompactLogix, ControlLogix, ControlLogix Gateway, MicroLogix, as well as PLC-5E and SLC 5/05 family of controllers.

NET.LOGIX 3.0 also features the DTEncoding class, which helps read and write Pre-Defined Types (PDT’s) and User Defined Types (UDT’s) as objects with or without the need to read or write every atomic member individually.

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The easy-to-use PM Designer features high-end vector graphics, solution-oriented screen objects, Microsoft Windows(TM) fonts for multi-language applications, operation logging, data loggers, alarms and recipes. The integrated development tool also includes online/offline simulation and other utility programs like Data Transfer Helper (DTH); text editors and recipes editors. The series’ runtime, which is part of PM Designer, guarantees performance and reliability because of high communication data rates, sub-second screen switching, minimum system overhead and 24/7 operation.

The new series consists of up to 200MHz ARM9-based processors and 4 to 16MB flash memory. It can support several LCD sizes from 3.5 inches to 12.1 inches and is best suited for applications that involve the use of motion/thermal controllers, PLCs, inverters and sensors.

With a variety of communication interfaces such as RS-232/422/485 Ethernet and USB ports, the series can be easily connected to several equipments. Its monitors boast SVGA TFT LCDs with 800×600 resolution and 64K colors for clear displays in any factory setting. Moreover, the product includes 0 to 50° C operating temperatures and NEMA 4/IP65 protection to guarantee performance in hash environments.

The series is compatible with more than 250 of the most popular PLCs, such as Modicon Quantum™ series, Allen Bradley Micrologix series, Siemens AG Simatic S7 series, GE series 90™, Omron Corporation Sysmac C/CV/CS/CJ series, Yaskawa Corp. MP series and Mitsubishi Electric Corp. FX/Q series.

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Hydro Engineering Inc. (www.hydro-eng.com), which has been making water filtration systems for equipment wash rack applications over the past 20 years, introduces its enhanced Hydrokleen product line. The product has simplified every aspect of the recycling and filtration requirement and eliminated the guess work of selecting the suited equipment to recycle or filter wash water.

“Water filtration is a little like crushing rock. We start by filtering the largest item (rock), and then filter down to the smallest item as required for your operation. We make sure that each contaminate from beginning to end is identified and removed so that the end product is water that can be reused in the washing process or discharged to sewer,” said James McCormick, president of Hydro Engineering.

Each Hydrokleen component provides results for a single task. It identifies contaminates in the waste water stream and then selects the component required to eliminate or reduce contaminates.

Water filtration is added to continuously filter the water of emulsified oils and dissolved solids. These modules contain programmable logic controller (PLC) control, which monitor the system activity, backwash automatically and ensure that the system is operating well. Touch-panel remote monitoring is added to provide required service notifications through email to anyone, anywhere around the globe.

“One or all of these steps may be required in a filtration or recycling system within a wash rack environment,” McCormick said. Modifying an equipment wash rack to meet Storm Water Pollution Prevention Plan and conforming to water discharge requirements are getting easier.

Motion Control Tips

The benefits of using the Rota-Rack include greatly reduced risk of part damage, systematic storage of parts for quality control purposes and the ability to operate a second or third shift with no additional employees and existing equipment. With the device, first-shift employees can be freed up to do more productive tasks.

The new Rota-Rack is comprised of a solid-state programmable logic controller (PLC) control, optional integrated conveyor and a heavy-duty welded steel turntable. All of the contact surfaces have a high-lubricity UHMW plastic covering for workpiece protection. Its one-meter diameter turntable gives over 850 sq in. of usable surface area and has a 700-pound payload capacity.

The Royal Rota-Rack’s universal design enables it to be utilized with any CNC lathe, which is equipped with a parts catcher. The devise is mounted either to the right or left of the machine tool, and its height can be adjusted from 11 to 50 inches. Programming takes about 20 seconds with the intuitive touchscreen PLC control and eliminates the need for machine tool interface. The device works on standard 110 V electrical power.

By providing a means for safely collecting large volumes of completed parts, the Royal Rota-Rack helps machine operators achieve significant improvements in both profitability and part quality.

Motion Control Tips

Currently, PROFIBUS has over 30 million installed nodes around the world and is a leader in industrial networks for connecting programmable logic controllers (“PLCs”), drives, sensors and I/O in automation and industrial systems. The new C Series modules can make it possible to connect NI Single-Board RIO and CompactRIO PACs embedded systems to PROFIBUS industrial network and add custom field-programmable gate array (“FPGA”) logic, high-performance measurements and advanced analysis to existing systems. Engineers now can easily retrofit and upgrade existing systems and machines by using the new PROFIBUS modules to quickly add LabVIEW graphical software and flexible, high-performance NI hardware to accomplish custom and high-speed tasks that traditional PLCs cannot solve.

Foundation Fieldbus is a two-way digital communication protocol normally used in process automation. The latest NI USB-8486 is a one-port FOUNDATION Fieldbus H1 interface that gives data control, logging and configuration in distributed control system and HMI applications.

Motion Control Tips

The new compact connector from Tyco Electronics also features two points of contact interface, polarized, small, compact size and latching feature. It is best suited for programmable logic controllers (“PLCs”), industrial controls, motion controls and robotics.

“Our new product meets the stringent demands of industrial devices. The rigid latching system and multiple contact points significantly reduce the risk of information loss in a high vibration environment,” said James Gula, product manager of Tyco Electronics. “The connector system is an excellent replacement for existing RJ-45 technology. It occupies significantly less space while offering increased functionality.”

The polarized, wire-to-board interface feature in the new compact connector has two keying options to prevent mismating and it is consist of individual circuits to accommodate I/O signals. Its electrical specifications include a current rating of 0.5Amps and a 30V rating on 0.635-millimeter centerline spacing. The connector’s operating temperature is ranging from -40° to +70° Celsius with a durability of 1500 cycles.

The product is ideal for robotics, motion control, PLCs and industrial controllers in the industrial automation market. It meets the Cat5e requirements when utilized in Ethernet applications.

Motion Control Tips

This Power Panel 65 combines compact and high performance dimensions in a single central operating and control unit. Through the integration of control (“drive technology and visualization”), the operator profits from intelligent complete solutions, which are easily connected to a variety of automation infrastructures.

The Power Panel 65 with a powerful 500MHz Geode LX800 processor can handle a performance range which is important for multi-axis applications. Moreover, the unique combination of a compact design and high performance for calculations ensures optimal utilization of the space at the switching cabinet. Intuitive operator panel can be expanded as desired by the operator.

The new unit is available with a 3.5 inch touchscreen or 5.7 inch touchscreen and function keys. It also provides an optimal design for any system or machine type.

A Fast Ethernet port and two USB interfaces guarantee that the data can be exchanged quickly with higher level systems. Remote drives and I/O can be easily connected using modular fieldbus interfaces if expansions are required. The new PP65 is available with POWERLINK interface or integrated X2X. Also, the devices can be extended with CAN, Profibus DP slave and RS232/RS485 interfaces depending on the requirements. Through this, machine operators can profit from the highest level of freedom for the control topology.

Motion Control Tips

When the screenings are received from the bar screen at the SPIRALIFT SC hopper, they are grounded finely by a heavy-duty TASKMASTER spray washed and grinder. The solids are then drop into the second washing zone for intensive washing even under high pressure. They are then transported to a screw press where the solids are compacted and the contaminants and liquids are drained. The cleaned solids are discharged out of the unit’s elephant trunk to a container or bin.

The new SPIRALIFT SC is freestanding and compact and it can be placed in any tight plant locations. It can also be installed as a convenient retrofit to an existing installation or behind a new mechanical bar screen. The unit can be configured and fixed mounted for portable operation to handle the output from several sources. The SPIRALIFT’s tank enclosure and hopper are made of durable stainless steel. A programmable logic controller (“PLC”) based control system which integrates and monitors the entire system is supplied.

Motion Control Tips

The machine is comprised of a STATISCAN II unit for induction tempering and STATISCAN IV unit for induction hardening. The part goes through eight station cycle using these material handling features: a continuous feed conveyor, two pneumatic accept/reject arms and four pneumatic linear transfer 180º grippers.

Each of the eight stations adhere to these responsibilities: parts are automatically loaded (Station 1), pneumatic part locator and check (Station 2), induction hardening O.D. of hub shaft (Station 3), I.D. auxiliary quench cooling (Station 4), acceptable parts and pneumatic exist are transferred onto the tempering system conveyor (Station 5), parts travel through a channel coil for tempering (Station 6), conveyor quench cooling (Station 7) and automatic part unload for exit conveyor or accepted parts for rejected parts (Station 8).

In this compact system, there are two induction power supplies. The hardening inverter is a STATIPOWER SP16 power supply giving 50kW @ 10kHz for the tempering portion and UNIPOWER UP12 power supply, which gives 200kW @ 10kHz.

Allen-Bradley programmable logic controller (“PLC”) control with touchscreen HMI interface and process monitoring provides superior process control and monitoring capabilities to assure the repeatability and highest quality. An integrated closed-loop water recirculation system is also included for system cooling and part quenching.

The new machine also features an auto reject after both harden and temper cycles, and process monitoring with data archiving. With hardening module, the machine can use the auto lubrication system. For process monitoring, pyrometer is included on the machine’s tempering system.

Motion Control Tips

R-LITE can be utilized as standalone unit with direct inputs, or connected to a programmable logic controller (“PLC”) for controlling I/O lines and registers in the PLC. The R-LITE is a very versatile communication application for PLCs, to support Hostlink, Unitronics, Modbus and other serial communication protocols. This new tool can serve as a mobile phone gateway for a PLC, to enable complete, mobile phone communication and control, interactive, or for downloading saved data files.

Moreover, using R-LITE Web, direct measurement of remote sensors and devices can be done through GSM/GPRS, by sending logged data straight into a secure Web browser. SMS can simultaneously send crucial data to a mobile phone, giving urgent information instantly. The Data locally logged to R-LITE Web’s internal 32K NVRAM with a rate of almost once a minute and sending it to the online Web server through the cellular network (“GPRS”). Its supplied HMI software is made to support several application areas and can be specifically tailored to the project needs.

The new R-LITE family gives 24/7 global communication coverage for SMS alert messages, SMS I/O settings and SMS I/O inquiries.

Motion Control Tips

The new Model 500 Peak and Hold PWM Driver features a stand-alone, low-cost PWM Driver using reliable, repeatable and accurate APM’s digitally generated PWM technology. It features a rotary switch adjustable peak time (“full-on, pull-in”) from five msec to five sec; rotary switch adjustable high frequency PWM with hold duty cycle from 90 percent to 15 percent; contact closure trigger input, or opto-isolated trigger input; output and input LED indicators; and power MOSFET output with a low side load control, fuse protected.

The Model 500 also feature PWM output sinks up to 4 A at 12 V, up to 10 A peak and a controller, which operates from 9 V DC to 28 V DC. Its load can be operated with up to 50 V DC, and I/O connection using terminal strips.

Motion Control Tips

Designed to detect cycle completes, unfinished rundowns and cross-threading, this new scout ensures users that the cross-threading is done properly and correctly for the first time. It operates jointly with STC40 or STC30 power supply and electric screwdrivers from Mountz. With four additional ports on the Scout’s side, a total of four screwdrivers can share one program with the unit. It has the ability to learn the characteristics of the power tool and the application that is being used. This permits the Scout to distinguish between a fastener that was either cross-threaded or stripped and one that was properly seated.

The screw counting process’ intent is to ensure all fasteners are accounted for in the assembly process. The later an error is found on the assembly process, the more it costs in expenses and rework time. If a fastening error is detected and committed in the assembly process, the user can fix it by completing the process properly or prevent the faulty product being moved down the line.

The Scout can be programmed either manually through the keypad or by the PC software. The unit gives the user visual and audible indications, which the assembly has been rejected or it has been rejected. The Scout alerts the user with a buzzer sound if fastening error is found and it immediately displays a red light to show a screw fastening error.

The Scout has the ability to save multiple fastener settings for applications, which utilize various fasteners. With a programmable logic controller (“PLC”) system, the screw counter can be easily integrated to activate other functions for line control. The scout features a password protection to avoid operator tampering of settings and prevent incidental.

Motion Control Tips

The new unit is packed with a broad range of features and functions and it can handle a multitude of operational modes (“Current Mode, Velocity, Position and others”), thus allowing flexible employment of drive systems in mechatronics and automation. Among the functions is the Master Encoder Mode for the drive’s utilization in electronic gearing applications or Step/Direction Mode for step-by-step movement of the motor (“as a replacement for a stepper motor”). Commanding through an analog set value voltage can replace conventional servo amplifier applications.

The EPOS2 70/10 has high-precision motion control functionality. For instance, the controller offers a dual loop position and speed controller. It means that the load is controlled directly, extremely and precisely with an additional sensor, thus elasticity and mechanical play can be compensated for. Because of the Interpolated Position Mode (“PVT”), the EPOS2 positioning drive has the capability to synchronously run a path specified by interpolating points with high accuracy and great dynamics.

When commissioning, Regulation Tuning allows an extremely efficient adjustment of position regulation, current or velocity. Its integration into the EPOS Studio, a graphic user interface, allows fast parameterization.

The unit is controlled by means of a CAN Master (“for example EPOS2 P, programmable logic controller, Soft PLC”) or with PC through RS232 or USB. Its standardized CANopen interface allows coordination and integration of several drives. Moreover, integrated gateway functions (“RS232-to-CAN, USB-to-CAN”) facilitate access-to-CAN frameworks.

Motion Control Tips

The EtherNet/IP Tag Wizard tool can give immediate benefits to all EtherNet/IP applications, which uses Beckhoff I/O to cut down equipment costs. The company makes comprehensive Beckhoff Bus Terminal I/O system of more than 400 different signal types available to EtherNet/IP users. The IP 67-rated IL2301-B905 Fieldbus Box and IP 20-rated BK9105 Bus Coupler from Beckhoff are ODVA-certified and follow the consumer and producer model for I/O data. It is developed with the use of advanced Industrial Ethernet technology, the IL2301-B905 and BK9105 provide EtherNet/IP operators dramatic price-to-performance ratio.

After saving the RSLogix™ 5000 programmable logic controller (“PLC”) program, the EtherNet/IP Tag Wizard opens up – just like other small applications such as Microsoft Word or Excel. When it is open, the operator can map multiple I/O nodes by choosing an IL2301-B905 EtherNet/IP Fieldbus Box or a Beckhoff BK9105 EtherNet/IP Bus Coupler. After the box or coupler is addressed and selected, I/O terminals are simply added to the system by double clicking the I/O to the correct category. When a node been mapped, it can be imported by the operator into the program using a previously saved RSLogix™ 5000 program.

Motion Control Tips

The EtherNet/IP’s integrated motion within the Kinetix 6500 servo drive utilizes Common Industrial Protocol (“CIP”) Motion, an extension of CIP from the Open Device Vendors Association (“ODVA”). EtherNet/IP is the leading industrial Ethernet topology in the world, with more than 850 product lines in 250 companies and more than two million nodes sold.

Torque, speed and position loops can be adjusted within the Kinetix 6500 servo drive, giving an open, bandwidth solution for motion control. Adding the power of CIP Sync technology from ODVA (“IEEE-1588 compliant Precision Clock Synchronization”) and a variety of axes can be organized for synchronized motion control.

To leverage the tested performance of the Kinetix 6000 family, Kinetix 6500 drive also gives advance safety features, including safe maximum acceleration monitoring, safe direction monitoring, zero speed monitoring and safe stop. These amazing features will improve user safety and enhance machine efficiency by permitting access to guarded areas when a process or machine is still operating, to reduce downtime.

The Kinetix 6500 servo drives have an innovative modular structure to give an adaptable platform for machine enhancements, including increased power range. With interchangeable control modules, one axis can easily transit to another safety functionality or network, to help operators adapt new technologies or market trends, reducing upgrade costs by 50%.

The Kinetix 6500 servo drive is best suited for motion control applications where safety, efficiency and performance are crucial, such as printing and web, packaging, food processing, and other machine types that require position control.

Motion Control Tips

The MR266/MR267 series has additional features for analog input/output control. Three operator-adjustable trimpots determine the SPEED (“10-120 seconds”), MAX (“20mA/10V input”) and MIN (“4mA/0V input”) set points. Its OVERRIDE mode option permits the system engineer for defining how the unit will respond when an operator tries to override the unit manually through the front panel knob. Setting up the OVERRIDE DIP switch to “ON” disables analog input control until Reset is performed.

For example, a systems engineer wanted to automate the motor drive system’s speed control, which is manually controlled through a 2-W potentiometer adjusted in a range of 10-85 Ohms. The engineer has a PLC interface with 4-20mA programmable output.

The new MR266 Remote Control Rheostat offers a way of moving high-power rheostats near the controlling equipment for better thermal control and shorter electrical connections. Simply mount the MR266 in the instrument cabinet and remotely control it from the user’s console through optional HPFF front panel-mount control accessory.

The new MR266/MR267 remote control rheostats/potentiometers operate from 24 V DC with -15°C/+65°C operating temperature and -20°C/+75°C storage temperature. If used near their power limits, high-wattage rheostats will require temperature derating.

Motion Control Tips

The new LAF welding power sources have excellent welding features throughout the entire voltage and current range, with particularly good re-ignition and starting properties. The power sources show good arc stability at both low and high arc voltages.

Its welding power source can be monitored and adjusted from the process controller’s front panel to easily adjust all welding parameters. For the most demanding applications, its welding current range is extendable by connecting the two power sources in parallel.

The power sources are made to be utilized using the fully digital PEK controller to maximize functionality or using the PEI controller with its basic functionality for less demanding applications. In automation applications, communication is very vital. Therefore, the power sources are prepared for communication with most standard protocols including CAN, Profibus, Anybus, TCP/IP (“LAN”) or even a straight communication with a programmable logic controller (“PLC”). Also, optional communications modules are available.

The new LAF power sources are ideal for boilers, heavy pipe, nuclear power vessels and wind power components and are very popular in automotive applications and shipbuilding.

Motion Control Tips

According to case studies, the compact footprint Ethernet Control Module can usually save operators 15 to 40 percent on their control and automation costs against other solutions. Additional to lowering cost, the flexibility of the expandable design allows operators to add I/O following installation by using the additional expansion slots.

The new ECM has a compact, high-density design, which reduces the number of controllers required to save cost and tool real estate. It is designed with interlock, digital and analog I/O connectivity in one controller. The ECM features reuse and adjust interlocking schemes on the fly to save costs and engineering time.

It features a cLogicTM that distributed real time logic engine allowing operators to control faster and more tightly than the original control scheme. It also features a data monitoring and control interfaces using Web browser, EtherCAT, DeviceNet, or Modbus/TCP for flexibility and migration. It has an expanded front panel LCD display that shows basic diagnostics and IP address, as well as status. With TOOLwebTM Interface, the new ECM can collect and analyze data. Through the standard Web browser, configuration and remote setup can be easily made.

Motion Control Tips

The compact X-gateway is a device for 24 V industrial power supply and standard DIN rail mounting. It operates as a master on the Profibus network and as a server (“slave”) on the Modbus-TCP side. The Profibus master functionality is configured using HMS Anybus NetTool for Profibus, a powerful, easy to use Windows-based configuration tool which comes free with the X-gateway. When the initial configuration is downloaded into the X-gateway, it transfers up to 512 byte of output and 512 byte of input data transparently between Profibus and Modbus-TCP. Up to 124 Profibus slaves can also be connected to the gateway. The X-gateway incorporates a powerful integrated web server on the Modbus-TCP network that supports web-based visualization and remote diagnostics. An OPC server is also included in X-gateway’s scope of delivery. The X-gateway’s Modbus-TCP and Profibus communication interfaces have a certification for full compliance to respective protocol standards.

The new Anybus X-gateway family consists of more than 200 proven, ready-to-use and robust gateways targeted to connect almost all of the possible combinations of two industrial networks. The product family can support 17 different industrial Ethernet and fieldbus networks, including Profinet, EtherNet/IP, CC-Link, CANopen, DeviceNet, Profibus and many more. All versions operate the same way and they give a flexible standard solution to connect two industrial networks.

Motion Control Tips

The new TOUGH GARD™ Spatter Cleaner greatly fits for the user’s welding cell with its low-cost features. It quickly removes all spatter build-up from the MIG welding consumables, and features factory-installed wire sprayer and cutter.

The Tregaskiss TOUGH GARD Spatter Cleaner has a factory-installed wire cutter and sprayer, which minimizes cost and the need for separate peripherals, as well as maximizing its space within the robotic weld cell (“footprint: L = 9.75 x W = 9.75 x H = 17.5 in.”). The wire cutter redresses the welding wire to a consistent and clean length ensuring accurate arc starting, while the wire sprayer applies a layer of  TOUGH GARD Anti-Spatter Liquid for front-end consumables protection. When it is exposed to heat, its anti-spatter liquid produces a protective barrier, which resists spatter accumulation, extending their life and keeping the consumables clean.

“We designed the TOUGH GARD Spatter Cleaner to be an all-in-one cleaning solution-one that minimizes the need and cost for purchasing a separate wire cutter and/or anti-spatter sprayer,” said Rob Ryan, product manager of automation group, Tregaskiss. “It’s a great fit for customers’ welding cells and their budgets.”

Motion Control Tips

Using Opto 22’s award-winning SNAP PAC System(tm) family, SNAP Ethernet I/O, and the latest PAC Project Professional 9.0 software suite, with the SNAP PAC Redundancy Option Kit, users can configure automation systems with dual PACs that essentially run and synchronize in parallel. When a controller fails or knocked offline, the other controller will take command and continue to perform the control program and applications it runs with no restart necessary or interruption. This feature, commonly called as “redundancy” in the automation industry, provides many advantages. Among these is an important reduction in mean time between failures (“MTBF”) of the control system, and thus greater levels of reliability for process-oriented applications in the manufacturing of thin film LCD, semiconductors and high-value product batches. Also, redundant control systems prove advantageous (“and are frequently mandated”) for handling, processing, and transport of byproducts, and oil and gas products, pharmaceuticals and chemicals.

For both established and new installations, redundant control systems from Opto 22 created with the SNAP PAC Redundancy Option Kit give several unique features. It offers unique flexibility and other benefits in system commissioning and start-up. Users can keep their control system operating and online even they make changes to or replace their control program. A controller becomes active and the other controller is updated once the new program is downloaded using the new instruction set.

Other features that the SNAP PAC Redundancy Option Kit (“and the redundant systems it establishes”) differ from other automation suppliers: It uses the Opto 22′s standard controllers with no required special redundant controllers. It communicates over Ethernet by standard Cat 5 cabling with no proprietary communication interfaces, protocols, or custom cables.

The new SNAP PAC Redundancy Option Kit has a SNAP PAC Redundancy Arbiter, a standalone processor which connects serially to both monitors and controllers. The SNAP PAC Redundancy Arbiter maintains organization of the control program during startup.

It also has a SNAP Redundant Power Switch that allows power re-starts to controllers during firmware upgrades.

Motion Control Tips

“Many of our customers migrating to the performance advantages of 64-bit Windows computing have had concerns about being able to continue to run their 32-bit programs. With this new version of our Allen-Bradley ActiveX Studio, we enable them to update existing or newly created 32-bit programs and run them on Windows 7 and on 64-bit Windows operating systems,” said Chuck Karwoski, president of CimQuest INGEAR.

The latest Allen-Bradley ActiveX Studio version 6.0 from CimQuest provides component Microsoft Visual Basic 6.0 programmers a communication channel to Allen-Bradley PLCs without the complexity or overhead of OPC and it does not rely on third party drivers like RSLinx. Also, it enables two-way communications with Allen-Bradley SLC, PLC-5, MicroLogix, CompactLogix, and ControlLogix controllers, supporting ActiveX/OCX-based communications applications development written in .NET programming, C++ and Visual Basic languages.

Machine users who have built applications using the Allen-Bradley ActiveX Studio 5.2 can now upgrade their applications for them to run on Windows 64-Bit and Windows 7 operating systems with minor changes to their code. New machine users can deploy and develop application for Windows 64-Bit and Windows 7 operating systems.

Among the usability and performance enhancements in the latest version are updated example files and projects, improved error reporting, and improved CIP (“Common Industrial Protocol”) communications. Also, the Allen-Bradley ActiveX Studio version 6.0 supports an optional USB License Key which enables machine users to move developmental licenses from machine to machine without activation or registration.

Motion Control Tips

The new controllers use the same visualization, networking and configuration environment as Rockwell’s larger systems. It helps end-users and machine builders to integrate safety or machine applications cost-effectively to plantwide control systems.

Ken Deken, vice president for portfolio management of Rockwell, predicts that the two controllers will “open a new door for many manufacturers with mid-range applications who previously did not have the means to implement an integrated architecture. The scalability of the Integrated Architecture system means that manufacturers and machine builders can design their applications using a single control engine and a single development environment, regardless of the application size.”

By using Sercos communications, PACs can control approximately eight axes. When utilized with Allen-Bradley Kinetix 6200 servo drives, the controllers give machine builders advanced safety options such as safe direction and safe speed.

Also, the controllers support the use of Point Guard I/O modules and CompactBlock Guard I/O modules from Allen-Bradley on EtherNet/IP, enabling improved sharing and fast system configuration of information. The controllers have highest level of machine safety rating, up to SIL 3 and PL e.

When utilized with new RSLogix 5000 programming software from Rockwell, the latest PACs can utilize high-integrity add-on instructions (“AOIs”) for faster commissioning. The AOIs encapsulate code for usual routines to pre-validated modules, which can be easily reused to help lower risk of coding errors and save time. Manufacturers in regulated sectors, including food and beverage manufacturing and pharmaceuticals, can utilize the software to help protect intellectual property, fulfill regulatory requirements, and manage revision control.

Motion Control Tips