PLCs + PACs - Motion Control Tips

HMI simplifies setup of robot-assisted automation for one integrator

November 12, 2018 By Lisa Eitel Leave a Comment

Integrator Inovatech Automation recently decided they were spending too much time programming expensive HMI and PLC platforms, so contacted Pro-Face America for help.

The integrator needed an HMI capable of universal robot and I/O-Link integration, legal for Inovatech Automation branding, and easy to program.

“I was apprehensive at first because we have a lot of projects going … so timing is short,” said Inovatech director of operations Travis Buset. “More specifically, I had concerns about learning something on the fly — and feared the onboarding experience and programming were going double our time investment.”

Pro-Face America supplied its LT4000M HMI plus Control unit. This hardware reduces costs by eliminating the need for an external PLC. In addition, for Inovatech Automation the LT4000M halved engineering time for configuration; offered easy integration to a Universal robot and IO-Link network; and was delivered with a custom overlay for machine-branding purposes.

Inovatech uses Pro-Face America’s LT4000M HMI plus Control unit on its modular automation station.

Trimming the time for setup was the most important benefit, though.

“Another platform needed two different pieces of software. In contrast, Pro-Face uses one software with drag-and-drop functionality. What once took me 32 to 40 hours to program now takes eight hours on the Pro-Face.” In fact, Buset had one programmed in eight hours his first time trying.

“This a powerful unit and well worth its cost for the level of configuration it allows.” Inovatech estimates it’s now operating 75% more efficiently than before.

Application example: Motion components on a typical form-fill-seal machine

November 12, 2018 By Lisa Eitel Leave a Comment

Form-fill-seal machines are used to package edible powders, dry food, and liquids into bags and pouches. It’s a common machine design that comes in versions for both continuous and intermittent operation. No matter the design, top design objectives for form-fill-seal machines are high throughput with minimal downtime and the ability to reconfigure the machine to satisfy changing production requirements.

Mitsubishi Electric Automation Inc. offers an array of solutions in its Pak/iQ suite to improve the builds of such packaging equipment with reliable machine performance and communication of system analytics for IIoT functionality.

Consider the build shown in the illustration.

Bulk food product enter from the top as servo-driven axes pull bag material off roll stock (spools). The funnel hood shapes the plastic sheet into a cylinder. Then a thermal heat sealer melts together bag edges; bags are filled from above as the web travels downward. Vertical film index drives time this function to match the machine’s operation cycles. From there, the bags get their final cutting and sealing — and then go onward to conveyors that carry them away.

On this machine, a PLC (in the form of an iQ-F compact controller) provides necessary functions while helping OEMs keep cost down. Programming of the PLC is through simple parameter setting: iQ-Monozukuri Packaging software gives engineers sample programs, sample GOT HMI screens, and auto-generated function blocks — including those for rotary-cutter, camming, long-dwell, flying-shear, box-motion, and mark-detection tasks.

To command and drive the motion tasks, the machine build uses an FX5 Simple Motion controller, MR-JE Series servo amplifiers, and (on the conveyor) an FR-E700 Series VFD. Two of the MR-JE Series servos are for web-index control; one is for the sealer axis. The three servo-driven motor axes are networked through fiber-optic-based SSCNETIII/H. Servo-network refresh rates to 0.222 msec allow accurate control.

Capabilities of Mitsubishi-outfitted form-fill-seal machines include auto-generated function blocks for camming as well as advanced synchronization that’s easy to configure … for fully synchronous multi-axis performance. The hardware also allows for direct control of the VFD from the HMI.

New Add On Instructions for Allen Bradley software from Applied Motion Products

September 27, 2018 By Miles Budimir Leave a Comment

Applied Motion Products has released new Add On Instructions (AOI) for Rockwell Automation’s RSLogix 5000 software to better control industrial devices and motion control components over EtherNet/IP networks. The new Add On Instructions increase the capabilities of Applied Motion Products’ drives and integrated motors within the RSLogix 5000 environment, supporting a faster and easier integration into PLC projects.

Most of the new AOIs use implicit messaging, known as I/O messaging or polling, that simplify sending commands to the drive while making data received from the drive more PLC-friendly. The AOIs also reduce communications overhead to lighten the work required to integrate Applied Motion Products motors and drives into new and existing PLC programs.

Applied Motion offers twenty new AOIs that feature a range of commands and functionality including absolute, relative, jog, and homing moves; motor enable/disable; reading the drive and alarm status; and much more. The company specifically designed these free AOIs for motor and drive users to take advantage of its latest EtherNet/IP firmware.

Applied Motion Products offers a range of integrated motors and drives compatible with popular Rockwell PLCs such as ControlLogix and CompactLogix. Many of these products also feature dual-port Ethernet connections for easy integration into a variety of network topologies. Products include:

StepSERVO™ Integrated Motors: SSM, TSM and TXM series
Stepper Drives: ST5, ST10 and STAC5 series
Integrated Stepper Motors: STM and SWM series
SV200 Servo Drives

For a full list of integrated motors and drives that incorporate EtherNet/IP network communications, the widely used industrial protocol for manufacturing automation applications, refer to the website at www.applied-motion.com/products/series/ethernetip-products.

www.applied-motion.com

New version of Parker Automation Manager debuts

September 7, 2018 By Miles Budimir Leave a Comment

Parker’s Electromechanical and Drives Division North America has released Automation Manager 1.4, an update that significantly expands Parker Automation Controller (PAC) features and functionality.

While the PAC is Parker’s all-in-one machine controls solution that combines PLC, HMI, and motion control functionality into a single device, Parker Automation Manager (PAM) is the single integrated development environment (IDE) used to program it.

“Among the new features that we are very excited about is that PAM now comes embedded with Parker Servo Drive Servo Manager,” says Marissa Tucker, Parker’s Controls & HMI product marketing manager. “Users are now able to program multiple Parker Servo Drives through a single point of connection through the PAC. Since the connection is made over EtherCAT, there is no addressing or additional cabling required, significantly saving on set-up time.”

Also of note is the OPC Unified Architecture (OPC UA), a machine-to-machine communication protocol that has seen wide adoption across the automation industry. OPC UA is considered an interoperable protocol that allows machines to exchange data easily and effortlessly between machine to SCADA, server, or between each other. Its adoption has been so widespread that many Cloud platforms have adopted it as a standard protocol, including Microsoft Azure. OPC UA is the easiest way to upgrade a factory to IIoT.

“PAM also comes with an updated Simulation Mode,” adds Tucker. “When building a machine, there is always some level of uncertainty about which devices to select and how the machine should operate. Simulation Mode in Automation Manager 1.4 completely eradicates this uncertainty, as users can develop their complete machine, including simulating their PLC Logic, Motion Control, and HMI Visualization, without having to commit to any upfront hardware or software costs.”

Other new features with this PAM 1.4 release include:

Fully integrated Parker Drive Developer (PDD) package for the AC30 drives in PAM
Extended PLCOpen4 support
PAC clock can now be synced to an external clock
Updates to the latest of Parker Libraries (PKR lib), including the ability to configure P-series and temperature control

For a full list of new features and bug fixes, download the release notes on the PAC product page: www.parker.com/emn/PAC.

IoT with Beckhoff at IMTS: Hardware + software + networking for machine tool and metalworking

August 23, 2018 By Lisa Eitel Leave a Comment

Beckhoff Automation will highlight smart-factory hardware, software, EtherCAT, and TSN networking solutions this September at the Integrated Automation, Motion & Drives (IAMD) USA show — Hannover Messe USA 2018 — in booth 134417. Visit them September 10 to 15, 2018 at McCormick Place in the convention center’s Lakeside Center — the east building.

This IAMD show is collocated with IMTS 2018.

Beckhoff Automation will also show an integrated PC and EtherCAT-based CNC platform … and support the EtherCAT Technology Group (ETG) — the largest fieldbus organization in the world — at partner booth 134117.

ETG was founded in 2003 and has more than 4,900 members from 65 countries to support and advance EtherCAT technology.

Beckhoff’s TwinCAT facilitates the implementation of advanced data acquisition and analytics in the field via system-integrated hardware, software and networking tools. Users can implement IoT and data analytics scenarios directly into existing control systems and IT infrastructures. Existing fieldbuses can be used for the communication; data exchange with the cloud also takes place via standard protocols. As a result, system costs, engineering effort and training time are all significantly reduced.

The newest series of ultra-compact Industrial PCs from Beckhoff meets all requirements for advanced machine and smart factory designs. Scalable computing power and flexible mounting make the IPCs work for myriad automation, visualization, and communication installations.

C6015 PCs offers ample computing power for use as an IoT edge device for collecting, processing and transmitting process data … up to the more complex tasks of an IoT gateway.

In contrast, C6017 PCs complement the series by integrating a larger number of communication interfaces and a UPS. The C6030, which combines high-end computing power with an ultra-compact design, is targeted for applications with the highest performance requirements in the industry.

Another Beckhoff Automation option on display will be the EK1000 coupler, which connects EtherCAT I/O with time-sensitive networking (TSN). That broadens application possibilities of EtherCAT in heterogeneous network environments. According to Beckhoff Automation, support of TSN networking means the coupler minimizes delay times caused by TSN switches in Ethernet networks and connects the wide range of EtherCAT devices and EtherCAT I/O Terminals to the TSN world.

Still another item on display will be the EL922x EtherCAT Terminal series for integrated electronic overcurrent protection into EtherCAT I/O system (for safeguarding 24-Vdc components).

Use promo code BECKVIP18 for free admission courtesy of Beckhoff Automation to the IAMD-IMTS-Hannover Messe USA show.

Mitsubishi Electric launches new safety PLC

June 27, 2018 By Miles Budimir Leave a Comment

Mitsubishi Electric’s modular PLC series MELSEC iQ-R is now available as a fully redundant pair of controllers for high performance and extra reliability. To help reduce the total cost of ownership (TCO), the system also integrates various features into the PLC for monitoring and managing safety.

In recent years, compliance with international safety standards has become an essential requirement across global markets. In addition, quick recovery from control-system breakdowns has emerged as a common necessity. Many key production applications require full redundancy conforming to the IEC 61508 SIL 2 standard, so critical systems can still operate in case of a failure or accidental damage to the primary CPU unit.

The MELSEC iQ-R redundant pair of PLCs comply with the functionality requirement of this standard, which is certified by TÜV Rheinland to meet global needs. The guidelines within the redundancy standard necessitate a full duplicate PLC rack with all modules, which the primary set will switch over to instantaneously.

The programming platform, GX Works3 engineering software integrates both process and safety-control programming in one environment. This enables the execution of integrated process-and safety-control programs with a single CPU module, eliminating the time and cost associated with purchasing and installing a separate safety controller.

Process integrity and dependability are the main reasons for plant operators to install redundant automation controllers into their systems, which is why another layer of protection has been added to the basic redundancy architecture of the iQ-R. The safety version includes a SIL2-process CPU module and a separate SIL2-function module as a set, sitting alongside the power supply module, basic base unit and network module. This ensures continuous operation by switching to standby operation if an error occurs in the control system.

For more information, visit www.mitsubishielectric.com.

How an IDE reduces development time in PACs

May 10, 2018 By Danielle Collins Leave a Comment

Applications that require complex process or motion control also require elaborate and complicated programming — often across multiple components, functions, and parameters. But thanks to the integrated develop environment found in programmable automation controllers (PACs), the programming task for these complex applications is faster, less burdensome, and more reliable.

The Parker Automation Manager (PAM) software is an integrated development environment that allows users to program robotics applications in a user-friendly, graphical environment.
Image credit: Parker Hannifin Corporation

When ARC Advisory Group introduced the term “programmable automation controller,” they specified five characteristics that signify a PAC, including that it:

Employs a single development platform using common tagging and a single database for development tasks across a range of disciplines. The same software is used for all development; this IDE (integrated development environment) reduces development time.

Note that ARC’s definition specifically states that the purpose of the integrated development environment (IDE) in a PAC is to reduce development time. One of ways it does this is by managing all the tasks related to programming, including editing, compiling, and debugging. And because all programming is done in one software package — rather than requiring multiple software packages from different vendors — the IDE makes programming less tedious and easier to scale.

Also key to a PAC’s ability to simplify and reduce programming time are the two specific features of the IDE mentioned in ARC’s characteristics — common tagging and a single database. Common tagging means that each variable, or tag, the programmer defines (name and definition) can be used in every software application, whether it’s for control, human-machine interface, vision, or plant-wide ERP systems. And if a tag is changed at a later time, it’s easy to propagate the change throughout the system.

This common tagging is enabled by the use of a single database. In other words, the tag definitions are kept in one database that is available to all the applications in the IDE. This means that programmers don’t have to define and synchronize tags across different applications.

The integrated development environment that underpins PAC software simplifies programming for all the applications related to the control system.
Image credit: Opto 22

Integrated development environments aren’t exclusive to programmable automation controllers. While the idea of an IDE goes back to TurboPascal in the early 1980’s, Microsoft’s Visual Basic, launched in the early 1990’s, is commonly recognized among programmers as the first IDE. (Note that Wikipedia identifies Maestro I, from Softlab Munich, as the first IDE, but does not specify the characteristics that made it recognizable as such.)

Probably the most recognized benefit of IDEs during their initial development and adoption was their ability to write, modify, compile, and debug code within a single program, simplifying the iterative process of writing, testing, debugging, and re-testing that programmers were accustomed to.

When to use a programmable automation controller (PAC)

April 12, 2018 By Danielle Collins Leave a Comment

In a broad sense, a programmable automation controller (PAC) is an industrial controller that combines the functionality of a PLC with the processing capability of a PC. The term “Programmable Automation Controller” is generally accepted as having been coined by the ARC Advisory Group, which specified five characteristics that define a PAC:

Multi-domain functionality
A single, multi-discipline development platform
Flexible software tools that maximize process flow across machines or processes
An open, modular architecture
Compatibility with enterprise networks

PACs can operate in multiple domains simultaneously – such as motion control, process control, sequential control, logic, data management, and communication – using a single platform.
Image credit: Opto 22

But with no industry-standard definition of a PAC, the distinction between PACs and PLCs is blurry. Higher-end PLCs now incorporate some of the characteristics described above and are encroaching on what was once considered PAC territory. In fact, many PLCs now include standard programming languages, the ability to expand functionality through add-on modules, and connectivity to various bus systems.

However, PACs still differentiate themselves from PLCs by employing a more open architecture and modular design. They’re also more capable than PLCs at monitoring and controlling a large number of I/O, such as in a large processing plant or a complex automation system. They do this because data can be exchanged between devices and applications in different domains, such as motion and process control. And, a programmable automation controller can send and receive data to and from other PACs, creating a distributed control system of PACs. With large memory capacity, the ability to handle complex or high-speed analog I/O, and high-speed communication capabilities, PACs are well-suited for vision applications, including vision-guided motion.

PACs are often used in Cartesian, SCARA, and 6-axis robot applications, which require coordinated motion across multiple axes as well as integration with other motion and data systems.
Image credit: NEXCOM International Co., Ltd.

The ability of PACs to gather, store, and track large amounts of data means they can handle predictive maintenance and operations monitoring. Data is often stored and accesses through an Ethernet network or a USB storage device.

PACs use the IEC 61131-3 programming languages (ladder diagram, function block diagram, sequential function chart, instruction list, or structured text), and some include standard PC programming languages such as C/C++, so familiarity is retained and the learning curve for programming is low, regardless of prior experience or expertise.

Programming is done in an integrated development environment (IDE) that uses a single, tag-name database. This means that all the defined variables (tags) are kept in one database, which is used by all the software applications — such as HMIs, ERP systems, and vision applications. This greatly simplifies and reduces programming work and makes it easier to scale to larger systems.

In a nutshell, PACs are best suited for applications that require complex controls — in automation, this often means multi-axis, coordinated motion or circular interpolation — while PLCs work well for simple applications such as single-axis motion control.

IDEC introduces MicroSmart FC6A Plus PLC

March 13, 2018 By Mike Santora Leave a Comment

IDEC Corporation announces the release of its MicroSmart FC6A Plus, a PLC with up to 2,060 local I/O. With its expanded I/O capacity, the FC6A Plus can control and monitor the largest machines or entire small-scale manufacturing facilities, a capability seldom found in a micro PLC.

To ensure high-level performance with this expanded I/O count, basic instructions can be executed in 21 nanoseconds, and program memory is 800 kB (100K steps). These capabilities are combined with data memory, more than double the capacity of a typical micro PLC. These features allow the FC6A Plus to handle large programs with complex control requirements such as PID, flow totalization and recipes.

Two models are available, each with 24 Vdc input power. The 16 I/O model has 8 inputs, and 8 relay or transistor outputs. The 32 I/O model has 16 inputs, and 16 transistor outputs. Each model also includes an integral 0-10 Vdc analog input with 12-bit resolution. Each model can accommodate up to three plug-in discrete, analog, serial communication or Bluetooth cartridges. Each discrete cartridge has 4 discrete I/O points, either 4 inputs or 4 outputs. Each analog cartridge has 2 analog I/O points, either 2 inputs or 2 outputs.

Up to 63 I/O expansion modules can be added. This gives the FC6A Plus the capability to handle up to 2,060 I/O with a maximum of 511 analog I/O, much more than a typical micro PLC.

The FC6A Plus also includes an optional Bluetooth wireless communication adapter, giving users the power to monitor the PLC and download/upload programs from any PC or laptop with Bluetooth capability. This eliminates the need to stock, locate and connect a cable to the PLC for these tasks, and provides access to the PLC from a distance up to 10 meters. In addition, any device with Bluetooth capability, such as a bar code reader, can also be configured to communicate with the PLC.

FTP communication allows users to configure the FC6A Plus as a FTP Client or Server for transfer of programs and logged data between a server and the PLC, providing a convenient and effective way to remotely communicate with the PLC. Up to 16 users can be managed simultaneously, and access folders can also be managed. Files can be stored at the PLC or logged to the PLC’s SD memory card for transfer to an FTP server.

All models have two built-in RJ45 Ethernet ports. Optional Plug-in communication cartridges can be added to create two additional RS232C/RS485 ports. With the addition of serial communication modules, up to 33 RS232C/RS485 serial ports are supported

The PLC’s Ethernet port supports the Modbus TCP protocol, and the serial port supports the Modbus RTU protocol. Support for the BACnet communication protocol will be available in mid-2018 to provide communications with building automation components and systems. An SD memory port and a mini-B USB port can each be used for data logging, program storage/transfer, firmware updating or recipe storage.

An optional HMI module can be added to the CPU to provide operator interface via its display and control buttons. The HMI module can also accommodate an optional plug-in analog cartridge, and it has an integral Ethernet port. Using the operator interface functionality, any PLC parameter can be updated.

App Access
The FC6A Plus is one of world’s first micro PLCs with full-featured app access from any iOS or Android smartphone or tablet. These WindEDIT Lite apps can be downloaded for free on the Apple App Store or Google Play. Although browser-based access is also included, many users will prefer the one-touch access and superior speed of the app.

With the WindEDIT Lite app, users can upload and download user programs; monitor and control any parameters in the PLC; monitor and clear PLC error status; start and stop the PLC; send and retrieve program and logged files to a cloud database; and manage the SD memory card. Access control can be configured with different layers of user privilege and password. Connection from a PLC to the WindEDIT Lite app can established using Wi-Fi (internet) or Bluetooth.

IoT Ready
IoT capability is provided by default web pages or by custom web pages, each of which can be configured for remote monitoring and control. Web pages are created within standard IE, Firefox or Chrome web browsers using pre-built objects and symbol factories via simple drag-and-drop functionality. No HTML programming is required, a major advantage over competing products.

Web pages are stored in the PLC’s user web page 5 MB of memory space, or in the optional SD card’s 32 GB of memory space. Using this storage capacity, users can create professional web pages with high levels of graphical content without worrying about memory limitations.

These web pages allow the PLC to function as a web server when one of its two built-in Ethernet ports or the HMI Ethernet port is connected to the Internet. These web pages can be accessed via any web browser running on any Internet-connected device such as a remote PC, a tablet or a smartphone.

Connecting the Ethernet port on the PLC, or on the optional HMI module, to the Internet also provides email and text notification functionality, which can be used with third-party email servers such as Gmail and Yahoo.

Upward Compatibility
The FC6A Plus is programmed with IDEC’s WindLDR PC-based software, which includes no cost updates for the life of the product, and which can be used to program IDEC’s entire line of controllers in a simple and intuitive manner. Software programs from IDEC FT1A, FC4A, FC5A and FC6A PLCs can be automatically converted by the WindLDR programming software for execution on the FC6A Plus.

PLC programming languages include Ladder, Function Block Diagram and Script, the latter similar to the C programming language. The Script language can be used to create more complex programs, particularly those with multiple sub-programs and custom function blocks.

Industries particularly well suited to the FC6A Plus include oil & gas, chemical, solar, marine, packaging, food & beverage, material handling, utility vehicles, and OEM machinery and process skids. Within these industries, a wide variety of applications are a good fit-especially those requiring control of standalone machines, process skids, vehicles and small-scale systems. With its expanded I/O capabilities, the FC6A Plus is also capable of controlling entire small-scale manufacturing and other industrial facilities.

IDEC
www.IDEC.com/usa

What are IEC 61131-3 and PLCopen?

February 23, 2018 By Miles Budimir Leave a Comment

The IEC (the International Electrotechnical Commission) is an international standards organization that publishes electrical and electronic standards. Hundreds of them, in fact; standardizing everything from letter symbols in electronics to medical equipment and railroad communication and signaling.

Specifically, IEC 61131-3 is the standard for “Industrial-process measurement and control – programmable controllers.” It sets standards for PLC programming languages and the programming interface itself. It specifies the syntax and semantics of PLC programming languages; specifically, the graphical languages of Ladder Logic and Functional Block Diagrams and textual languages of Instruction Lists and Structured Text, and Sequential Function Charts as well.

The IEC 61131-3 standard deals with the basic architecture of these five PLC programming languages.

The latest version (61131-3) was published in 2013. It includes technical changes related to data and programming of PLC languages and specifies new data types as well as object-oriented features of classes and function blocks.

As for PLCopen, this is an independent organization focused on industrial controls. It is vendor and product independent and accepts memberships from PLC and automation manufacturers. Its core activity is centered on making software development for PLCs more efficient. Some of the ways it does so is by working to encourage reusability of code as well as offering libraries of control-specific functions to PLC programmers, all of which is based on standard, existing tools that are readily accessible. With the emphasis on PLC programming, the group’s work is naturally centered on the IEC 61131-3 standard for programmable controller design.