PLCs + PACs - Motion Control Tips

What are some common PAC chassis, module, controller, and I/O options?

May 15, 2019 By Miles Budimir Leave a Comment

ControlLogix PACs from Rockwell Automation feature tight integration between the programming software, controller, and I/O modules which helps reduce development time and cost.

In the field of programmable controllers, there are a number of different types of product offerings, depending on the application requirements. Traditional programmable logic controllers (PLCs) have been the industry standard for decades. They are well known and understood in terms of operation and programming and there are many PLC manufacturers to choose from.

As control demands became more complex, programmable automation controllers (PACs) came onto the scene to handle these more demanding cases requiring more complex control and coordination, involving many more axes and I/O than a typical PLC could handle. According to an industry standard definition, PACs operate on a single platform and handle multiple tasks including logic, motion, drives, and process control.

PACs stand between PLCs and PC-based controllers, combining the best elements of both. PACs are characterized by multiple processors, more memory and communication options, and more functionality beyond just the logic-based operations of traditional PLCs. They also can be programmed using ladder logic familiar to PLC programmers and other higher-level languages consistent with IEC 61131-3 standards.

Because PACs are similar to PLCs both in function and form, many of the options ordinarily available for PLCs are the same for PACs. So for instance, common component options include the controller, chassis, modules, and I/O.

Analog I/O modules from AutomationDirect are available in current, voltage, and temperature models with LCD displays. They can handle many standard analog I/O signal types including 0-20 mA, 4-20 mA and 0-10 Vdc.

Controller – the controller contains the central processing unit (CPU), memory, and the main networking and communication ports such as Ethernet and USB.

Chassis – the physical enclosure housing all the PAC components such as the controller/CPU unit, power supply, and modules and I/O. Options include rack-based systems (mountable to backplanes inside equipment racks via DIN rails) or mounted directly to machines.

Module – modules exist for all manner of applications and uses, designed to perform some specific function. So for instance, there are modules designed specifically to accept either analog or digital signal inputs and designed for specific uses. Examples include relay modules, counter modules, serial modules, servo or stepper controller modules, timer modules, and data acquisition modules, among others, including I/O modules (see below).

I/O – Just as with PLCs, I/O type can include voltage or current analog, digital, or mixed analog/digital. Common physical variable inputs to I/O modules can be pressure, force, or temperature data from thermocouples, among others.

Controller trends: edge, fog computing and more

March 30, 2019 By Miles Budimir Leave a Comment

Edge computing and greater connectivity are some of the key trends controller manufacturers are seeing in their industry. Here’s what else they told us they’re seeing in the way of tech trends.

With respect to the IoT and IIoT, what kinds of capabilities do your components or engineered designs incorporate to support functions related to fog computing on local networks?

Lee Cheung
Product Marketing Engineer II (Controller/Visualization)
Mitsubishi Electric Automation, Inc.

Our iQ-F and iQ-R controllers feature a built-in web server that allows users to access status information, diagnostics, error and operation history from any connected device with a web browser. Advanced GOT2000 HMIs with GOT Mobile functionality offer even more capabilities with web pages that can be beautifully designed with simple drag and drop operation. GOT Mobile is easily configured even without any IT or web technologies knowledge, and can also serve up work instructions, manuals, and troubleshooting videos. Additionally, iQ-R controllers and advanced GOT2000 HMIs can deliver factory floor data directly to upper level IT systems databases.

Mike Chen
Director of Automation Center Americas
Omron Automation Americas

We’ve debuted our latest Sysmac AI Controller as an Edge based controller with machine learning engine embedded. To Omron, Edge is literally inside a machine, with direct access to data values being collected within the machine controller processing time. Data is analyzed within the machine and utilized within the user program without any data needing to go up into the local Fog or remote Cloud based IT infrastructure. We give our customers the option to connect their machine to Fog level SCADA software, in-house custom software solutions or long-term historian databases, but those systems are not required for high-speed high-accuracy anomaly detection on process data to be used for equipment maintenance or productivity optimization. Omron sells a robust line of Industrial PCs that reside on local Fog level networks that can run Omron InduSoft SCADA software, or other Windows/Linux based applications for visualization or batch data analysis.

The Gold Twitter servo drive from Elmo Motion Control delivers over 5,500 W of power and supports EtherCAT or CANopen networking. They weigh just 18 g and are less than 13 cubic cm in volume.

Rodney Rusk
i4.0 Business Leader
Bosch Rexroth Corporation

Fog or Edge computing is common both in our Bosch manufacturing methodology as well as an integral part of many of the connected solutions that we adopt. Like many companies, we jealously guard our data and our knowledge know-how. Thus Fog computing is one methodology that helps us to optimize.

Looking at this from three viewpoints, we find ways to merge technology into a holistic plant ecosystem that feeds the necessary data into our Edge devices and our cloud-based resources.

At the top level, Fog (or Edge) computing to drive localized data analysis, condition monitoring and helping to drive machine learning. Within this sphere we work with such Bosch products as our Nexeed Production Performance Manager, Nexeed Production Quality Manager and Improvidus OEE analysis tools.

In the middle level, we network these tools to smart devices on our manufacturing floor to not only empower our associates with up to date real-time information, but allow for localized data comparisons. One example here would be the utilization of the Active Cockpit in our production rally/meeting areas. Using this tool, we can look at performance from individual machines, compare data sets, set priorities, capture decisions and respond to the needs of our production environment quicker.

Moving down to the lowest level, the actual machine level, by using smart devices such as our MTX CNC controls; our PRC7000 Adaptive Welding Controller or our IoT Gateway devices, we can pull data up through the new or older system to drive continuous improvement. In the case of the PRC7000 Adaptive Welding Controller, we can make-real time decisions to adjust the current voltage being applied to the welding operation and optimize consistent weld spots while reducing material losses.

What edge devices do you supply or support to allow for use of feedback signals or distributed motion control?

Mike Chen
Omron Automation Americas

Our latest Sysmac AI Controller is an Edge based controller with a machine learning engine embedded as well as motion control. We give our customers the option to connect their machine to Fog level SCADA software, in-house custom software solutions or long-term historian databases, but those systems are not required for high-speed high-accuracy anomaly detection on process data to be used for equipment maintenance or productivity optimization.

Rodney Rusk
Bosch Rexroth Corporation

The Bosch Rexroth and Bosch portfolio of products is quite expansive in the amount of manufacturing technology solutions that have feedback capabilities or motion controls resident on the devices. These pieces of equipment represent one example of i4.0 ready products that we produce for the external market and use extensively in our own manufacturing operations.

For example, the IndraDrive XLC combines the performance of Bosch Rexroth drives with embedded logic capability on-board. The product allows for advanced PLC programming using state-of-the-art PLC kernel, IndraLogic 2G, integrated homogeneously into the IndraWorks software tool and the multitasking runtime system. 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.

Another example would be the Bosch Connected Industrial Sensor Solution (CISS). The CISS is a multi-sensor device detecting acceleration and vibration as well as environmental conditions. The robust housing and the small outline makes it perfectly suitable for industrial retrofit applications such as condition monitoring and predictive maintenance. Configuring the device lets customers address a broad variety of use cases by interpreting the sensor data by smart algorithms from eight possible inputs such as acceleration, temperature, vibration and humidity.

Describe what you’re seeing in time-sensitive networking (TSN) and its application in motion applications.

Mike Chen
Omron Automation Americas

All Omron motion control capabilities have been standardized on the EtherCAT open network standard, as well as MACRO for specialized OEM applications. Using these high-performance deterministic network architectures, multiple motion devices can be synchronized to create complex electronically coordinated motion profiles, completely re-programmable and simulatable with direct control over torque, acceleration, deceleration, and jerk.

Rodney Rusk
Bosch Rexroth Corporation

Given the strong position of Bosch in the on-board vehicle product segment and the need for time-sensitive networking, the company has a long history as an industry leader. This includes all three areas of time synchronization, scheduling and fault tolerances. Looking back, we can see the development and implementation of early CAN-BUS solutions within these on-board vehicles by Bosch, for example in airbag deployment systems.

One of those areas was the early adoption of CAN-BUS within the Bosch Rexroth DC Tightening Systems, Platform 200 and 220, to provide rapid transmission of torque control data from the DC Tools installed on the line, back to the control panel and line management system. Today, when we look at the current generation of DC Tightening Tools from Bosch Rexroth, we find a high sensitivity to TSN and the improved transmission speeds that have resulted in the Platform 350 and now the NEXO Cordless DC Tool. The ability to provide time-sensitive feedback in an on-going assembly process is critical when dealing with minimal variation windows on safety critical applications like seat secure or restraint installations.

Other examples of our experience in the TNS area can be seen in the full complement of our Controls Product Lines, whether we look at the MTX CNC, the IndraDrive Mi or the MLC PLC products. In each case the use of synchronization modes such as velocity and phase synchronization or standardized motion profile functionality that is built in to the systems have all become second nature to our development teams.

In other areas, when fast absolute position of linear technology applications are required (+/- 4µm/m), such as when small rail deviation needs to be combined with multi-axis interpolation we look at our IMS-A line (Integrated Measuring System). These types of products allow us world-class accuracy of position and allows us to communicate over interfaces, such as Hiperface, SSI and DRIVE-CLiQ.

Shown here is a new RIO-47162 Pocket PLC from Galil Motion Control. It has 64 digital I/Os (40 optically isolate digital inputs and 24 digital outputs) and 16 analog I/O as well as two Ethernet ports. Analog I/O includes an available 16-bit ADC/DAC option or 12-bit standard. The analog I/O is user-configurable for +/- 10 V, +/- 5 V, 0 to 10 V, or 0 to 5 V. DSUBs make for ease of assembly. the RIO-47162 measures 3.88 x 4.65 x 1.3 in.

How does your company ensure interoperability between its offerings and product families?

Lee Cheung
Mitsubishi Electric Automation, Inc.

Mitsubishi Electric uses a rigorous design and quality review process that includes testing to ensure seamless integration between product offerings. We are uniquely able to maintain this strict level of control because we design and manufacture our own products. This also guarantees that the latest software versions are always compatible even with older hardware regardless of the firmware version, which saves end users and technical support staff a lot of headache.

Mike Chen
Omron Automation Americas

Omron has standardized on open networks such as EtherNet/IP and EtherCAT to ensure the broadest interoperability with different automation devices, while still maintaining the high-performance that our customers expect. Between our own product families, Omron has created a single Integrated Development Environment (IDE) which provides a single interface for configuration, programming, commissioning, and troubleshooting across our core automation technologies: logic, motion, vision, safety, robotics, visualization, and enterprise connectivity.

Jonas Proeger
Trinamic Motion Control

All of our products use the same protocols and interfaces, especially Trinamic’s own TMCL protocol. One of the results is that you can get any evaluation board you want and connect them together using Trinamic’s modular evaluation system. In addition, our components always follow the same partitioning between hardware and software. We equip them with industry-standard interfaces such as SPI, Step/Direction and standard encoder interfaces. A typical setup consists of:

Microcontroller (not Trinamic product)
Motion control IC, that generates ramps and commands current or target position via SPI
Current control part, typically integrated in the motor driver, that generates a PWM-scheme
The actual motor driver

Tomer Goldenberg
Elmo Motion Control

Interoperability of Elmo Motion Control’s servodrives and multi-axis controllers is guaranteed through adequate networking communication. EtherCAT implementation ‘by the book’ is mandatory not only to assure interoperability between Elmo products, but also in order to interoperate with third-party devices. Ensuring high confidence levels of interoperability in terms of fieldbus communication is a result of ongoing efforts to follow strict industry regulations set forth by the EtherCAT Technology Group (ETG). Elmo has built an in-house lab with hundreds of I/Os and third-party devices with which it continuously tests every version of its products.

Further, regular delegations from Elmo’s R&D team visit ETG for their European Plug-Fest events, of which the goal is to assure interoperability with other EtherCAT communication devices in the market.

Rodney Rusk
Bosch Rexroth Corporation

Interoperability is one of the great challenges for both the provider and user of manufacturing technology. From our viewpoint, this is best served by not focusing on the individual product, but focusing on the ability of any products to be as scalable, flexible and open to as many “systems” as possible. Thus we try hard not to rely on one type of industrial protocol, for example, and we work diligently to make our products as compatible with non-Bosch solutions.

On a more practical day-to-day level, especially on the manufacturing floor, we have developed solutions that empower the users to bridge technology differences and try to meet the user where they are. For example, the use of our IoT Gateway device, allows us to help bridge the gap between older equipment and pull data into useful analysis tools; and our Open Core Engineering (OCE) software lets the machine programmer program in the scientific language that they are most comfortable with.

Finally at the higher software level, we have taken many of our stand-alone software solutions and have been unifying them under the Nexeed Suite of Software, creating a stackable solution set where we are actively pulling in various software modules (such as our Track & Trace and Intra-Logistics packages). Of course, this is an on-going development that has no real end date; we simply apply our philosophy and drive toward increase interoperability to meet the needs of our clients.

Stepper cDriver Modules from Trinamic Motion Control can control and drive up to six axes standalone, or from a host over UART or CAN interfaces. The manufacturer simplifies programming with CANopen as well as its TMCL motion-control language.

What value-add services (or in-house engineering support) have you provided to an OEM or other customer during the last 12 months?

Todd Mason-Darnell, Ph.D.
Marketing Manager – Services & Safety
Omron Automation Americas

Omron provides automation and safety systems engineering and integration services to OEMs and end users. Combining our in-house engineering resources with a network of certified partners, we support automation and safety engineering at all stages of the machine life cycle.

Jonas Proeger
Trinamic Motion Control

Our business model is selling standard products. Nevertheless, we offer engineering support for key accounts and also design customized board level solutions, if this helps the customer to achieve their goal faster. A typical application is for the development we did for a customer specialized on motorized prosthetics, where we developed a servo drive for the knee joint in an artificial limb. The customer provided the AI algorithms for the kinematics and interpreting the patients’ movements, while we provide the electronics and the software for the motion control.

What are your thoughts on new trends in wireless connectivity and technologies related to wireless power transfer for industrial applications and machine designs?

Lee Cheung
Mitsubishi Electric Automation, Inc.

We see wireless connectivity being adopted in particular with the use of GOT Mobile functionality on advanced GOT2000 HMIs. This lets maintenance engineers remotely monitor machine status and gives them the flexibility to move around a machine while checking documentation when troubleshooting. Production managers also benefit from being able to monitor production status to ensure that production targets are being met.

Mike Chen
Omron Automation Americas

Omron puts 7% of its annual revenue back into R&D across many technology sectors that is then applied into industrial automation, healthcare, mobility, energy management, and other business units. At this point, the Omron Industrial Automation business has not yet productized any wireless power transfer devices, but has released battery-less wireless push-buttons and wireless Ethernet communication adapters that are available according to regional regulatory compliance.

Tell us about any selector, sizing, or sales software you use or offer to customers and how these tools are changing how design engineering is done.

Lee Cheung
Mitsubishi Electric Automation, Inc.

Selection tools that we provide for controller products help streamline the process for creating a bill of materials. These tools check to make sure that the system configuration is valid and even take out the tedious work of calculating power requirements.

Mike Chen
Omron Automation Americas

Omron has recently opened up its internal cloud-based Bill Of Material (BOM) generation tool to our customers, abbreviated ONSeT – Omron Navigated Selection Tool. This tool lets design engineers peruse and select Omron products by feature and application needs, identify optional or required accessories, and then add-in their non-Omron line items for a single point proposal generator.

VFDs with integrated PLCs for motion and machine controls: Programming and setup considerations

March 24, 2019 By Lisa Eitel Leave a Comment

Today’s ac drives can be controlled by either an external or internal PLC. Those with built-in controls move machine intelligence to the edge.

By Jeff Payne • AutomationDirect

Though ac drives can operate in standalone, they often integrate into automation systems to control speed of three-phase ac motors that commonly run conveyors, fans, and pumps. For such speed control, ac drives most often pair with PLCs. But ac drives are becoming more intelligent … and some now include built-in PLCs to work as smart drives. These smart ac drives are compact; add intelligence at the edge of machinery; include inverters capable of more than just typical speed control; and accept the setting of myriad parameters.

In this feature, we’ll detail how to integrate smart ac drives and the applications for which they make the most sense.

Many VFDs, such as this AutomationDirect DURApulse GS4 series AC drive, can be controlled and monitored by an external PLC.

Review of how ac drives work

An ac drive is often called a variable frequency drive (VFD), adjustable frequency drive (AFD), or frequency inverter. We use the term VFD for its main function of varying the speed of a three-phase ac induction motor. VFDs also provide motor overload protection, non-emergency starting and stopping, and control of acceleration and deceleration.

VFD benefits significantly boost the efficiency of many applications. In addition, they gradually accelerate the motor — which in turn reduces inrush current during motor startup. This minimizes both electrical and mechanical stress on the system.

VFDs operate by rectifying incoming ac power to dc and then inverting it back into three-phase ac output power. The voltage and frequency of this inverted output is controlled by the drive to vary the speed of a three-phase ac induction motor.

Control modes include volts per Hz (V/f), V/f with encoder, open-loop vector, and closed-loop vector control. These methods all use a pulse-width modulation (PWM) voltage waveforms; they’re well-developed motor control methods needing some level of automation to control the drive.

VFD control methods

A VFD is controlled by discrete inputs (two or three-wire control), analog inputs and/or digital communications. In its simplest form, a VFD can be manually controlled using the built-in digital keypad’s run/stop buttons. This keypad also allows setting of the drive speed and other parameters, as well as monitoring of drive status variables. Manual pushbuttons can also be wired to the drive in a two or three-wire configuration to control basic functions.

A two-wire control setup provides a run command input and a direction input to the drive. The run command must remain high (on) for the drive to run the motor. The direction command controls forward and reverse motor rotation. Deactivating the run command stops the motor.

With three-wire control of a drive, a stop command is added to the drive control inputs. To activate the drive, the stop command must be high, often through use of a normally closed (NC) pushbutton or an NC relay contact. A momentary run command is all that is needed to activate the drive.

Both two or three-wire drive control methods can be via manual pushbuttons, PLC-activated relay outputs, or PLC discrete signal outputs. Some drives also have programmable functions such as jog, speed change, and acceleration and deceleration control.

Analog signals can also help control drives to deliver speed-control or tension-control functions. Signals take the form of analog 0 to 10 Vdc voltages, analog 0-to-20-mA or 4-to-20-mA current, or potentiometer signals. A two or three-wire discrete control method is still needed to start and stop the drive.

Digital communications between PLCs and VFDs

In addition to discrete and analog inputs, PLCs often control VFDs using digital communications such as Modbus ASCII and Modbus RTU, or via industrial Ethernet protocols specifically created for real-time control. These digital communications can control all drive functions or work in concert with discrete and analog signals. This two-way digital communication often enables all drive commands to be controlled by a PLC, as well as monitoring all drive parameter and reading drive variable, status and fault codes. This can include more than 100 commands, parameters, and status and fault codes.

Serial or Ethernet communication from the PLC can issue speed references, run, direction and jog commands. It can also adjust motor parameters such as voltage and amps and run parameters associated with set acceleration and deceleration times, S curves, and skip frequencies. Other digital parameters include the issuing multi-function input commands and triggering functions just as a discrete input would. Target frequency and current (and many other analog and preset parameters) are also available for control and monitoring using digital communication. Where the PLC communicates with the drive to monitor status and fault codes, it might compare the frequency command to output frequency or the output current to rated current or motor rpm.

The monitoring of drive faults is also enhanced by digital communication. Instead of just a ‘fault present’ discrete signal, the system can register dozens of error codes — including overcurrent, overvoltage, overtemperature, overload, low voltage, and more.

Upfront programming of the drive’s monitoring and control functions (through discrete communication) makes for a more intelligent system. A serial or Ethernet link between the PLC and drive(s) is required; with Ethernet, a hub or a switch is also needed. The ability to configure, control, and monitor the drive from the PLC via digital communications helps futureproof automated systems.

These WEG-CFW300 ac drives from AutomationDirect offer high performance in a compact size, along with a built-in operator interface and a SoftPLC. They eliminate the need to purchase, install, and integrate an external PLC with the drive.

Programming ac drives with built-in PLCs

As mentioned, PLC control of VFDs is well-developed with many configuration and monitoring options. But devices at the machine edges are becoming smarter … and VFDs with built-in PLCs are no exception. These VFDs provide all the precise variable speed-control functions of separate PLC-controlled drives, but in one compact package. Such Smart drives typically have a built-in operator interface panel and a SoftPLC. Via the interface panel, it is possible to control the VFD and view (and adjust) its parameters. A typical keypad toggles between parameter numbers to show position or value. Up and down buttons let operators change the parameter number or its value. Anotehr button lets operators run and stop the drive and reset drive faults. A variety of plug-in option modules are typically available for additional I/O … and to add additional communication protocols.

In an array of applications, smart drives can often control entire machines or systems … helping negate the need to purchase, install, and integrate separate PLCs and operator interfaces.

Some vendors provide free PC-based programming software for the SoftPLC portion of the drive — to let design engineers create custom-tailored control schemes. These then download from the PC to the drive (often via a USB connection). Such software typically includes ladder diagram programming for the creation of function blocks to monitor inputs, operate the drive, and control outputs. Besides controlling the VFD housed in the same package, the SoftPLC can also work to monitor additional components on the plant floor — including other VFDs.

A VFD with a built-in Soft PLC can monitor sensors and run programmed logic to properly convey products.

Driving conveyor, mixer, and other applications

Common applications for smart drives include packaging machines, mixers, kneaders, and dosing pumps. Other applications include the control of fans, exhausts, centrifugal pumps, granulators, palletizers, stirrers, and conveyor belts. Many conveyor or gate applications need to monitor inputs from a few sensors to properly control a VFD as well as an output to trigger a solenoid. Here a carefully selected smart drive having a built-in PLC (meeting full-load amperage, overload, and temperature requirements) can monitor sensors; make programmed decisions; and control field devices.

Jeff Payne is a product manager for the Drives & Motors Group at AutomationDirect. Before joining the company 20 years ago, he managed, designed, programmed, installed, maintained, and repaired a wide variety of automated equipment. He’s worked in the field of industrial automation for nearly 28 years and earned a degree in Industrial Systems Technology and Industrial Automation from Lanier Technical College.

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.