University of Arkansas – Fort Smith
University of Arkansas – Fort Smith
ABB’s new control panel portfolio expands upon the current CP600 platform to provide premium HMI for high-end applications and challenging installations. The new CP600-Pro ensures reliable operation within a wide environmental temperature range of -4 through 140 °F, and features a true glass touch-screen for clear information display and easy operation. Strong aluminum front frames ensure IP66 protection, and the all black front design is a good match for multiple applications either in landscape or portrait format.
Available in 5, 7, 10.1, 15.6 and 21.5 in. screen sizes, the panels provide comprehensive HMI functions with multi-touch operation. Three Ethernet interfaces, one with 10/100/1000 Mbit, support up to three networks. With an OPC UA server and client protocol, the CP600-Pro is well prepared for TSN connectivity. A serial port simplifies integration of products without network interfaces, and USB ports and SD cards facilitate backups and system updates.
Like the other control panels in the CP600 platform, the CP600-Pro is fully compatible with ABB’s AC500 and AC500-eCo PLCs, and includes all standard HMI functions such as alarm management, schedulers, recipes, trends, data acquisition, gateway function and user management.
The programming tool features an HMI simulator ensuring efficient set up either offline or online. HTML5 pages enable easy remote access to HMI applications via smartphone or other mobile devices.
For more information, visit https://new.abb.com/.
ABB’s new series of dc variable speed drives (VSDs) allow users with a large installed base to get better performance from their existing systems. With the new DCS880 VSDs, customers who are heavily invested in a dc system have the option to continue using dc technology while better aligning with modern ac advancements.
The dc VSDs are built on ABB’s all-compatible, common drive platform, sharing the same control panel, features and tools as recent- and future-generation ABB drives. Once users have learned one ABB all-compatible drive, they can easily use other all-compatible drives — both dc and ac.
They are also easily integrated with ABB Ability monitoring services – ABB’s unified, cross-industry, digital offering, which provides real-time data about drive status and performance from any location. Monitoring parameters include drive availability, environmental conditions and fault events.
Optimized for safety, simplicity, and user-friendliness, the drives feature built-in functions, such as safe torque off (STO), which prevents unexpected startup of machinery. This protects people and equipment by reducing risk during operation.
DCS880 drives have the flexibility to meet the precise needs of a broad range of industrial environments and applications with superior speed and torque control in a compact, space-saving design that easily fits into electrical control rooms. They can handle advanced programming with standard IEC languages and include many ready-made, dedicated application programs, including those for a variety of cranes, such as industrial, harbor, tower and marine deck cranes.
Other suitable applications include extruders, winches, winders, conveyors, mixers, mill stands, centrifuges, test benches, elevators, electrolysis and kilns. The DCS880 is also a great solution for non-motor applications like magnets and battery charging.
ABB’s smartphone service applications, Drivebase and Drivetune, connect wirelessly to the drive. Optional Bluetooth connectivity between the drive and mobile devices makes it easier and safer to access the drive in hazardous or difficult-to-access locations. It helps customers to maintain their drive performance and, in many cases, can save a visit from a service technician.
For more information please visit: https://new.abb.com/drives/dc/dcs880-s
The ACS580 all-compatible general-purpose, low-voltage drive for the North American market is the newest entry in ABB’s low-voltage AC drive portfolio. The ACS580 drive provides user-friendly, energy-efficient motor and process control, keeping user systems running smoothly while saving time and money over the product lifecycle. It’s designed to control pumps, fans, conveyors, mixers and many other variable and basic constant-torque applications. All units for the North American market will be made at the ABB facility in New Berlin, Wisconsin.
The ACS580, which supports a variety of motor types, including high-efficiency permanent magnet motors, is part of ABB’s all-compatible drives portfolio, offering scalability without adding complexity. With all essential features built-in, the robust ACS580 is designed for reliability and ease of-use, and greatly simplifies drive selection, commissioning, operation and maintenance.
The wall-mounted drive is available in power ranges from 1 to 350 hp at 460 V, in both UL Type 1 and 12 enclosures. The UL Type 12 drive has a reduced footprint providing more mounting flexibility in harsh environments.
The Drive Composer PC tool simplifies the use of the drive, and the control panel’s primary settings menu and built-in assistants speed up commissioning, allowing basic set-up to be completed in minutes. The assistant control panel can be upgraded to an optional Bluetooth control panel to enable wireless commissioning and monitoring. The I/O menu displays how the electrical terminals are configured, and provides quick access to related terminal settings like filtering, scaling, delay or function selections.
The drive also provides reduced harmonics with built-in, second-generation swinging choke technology in a smaller and lighter design. Other features include EMC filter, brake chopper up to frame R3, Modbus RTU fieldbus interface and Safe Torque Off (STO).
ABB all-compatible drives share the same architecture. Once users have learned one all-compatible drive, they will be able to quickly integrate others, including larger drives, saving effort, training costs, energy and money with each installation.
The capability of the ACS580 can be extended with optional plug-in modules. A wide range of fieldbus adapters can easily be mounted inside the drive allowing connectivity to all the major industrial fieldbus protocols. The standard I/O can be extended by using optional analog and digital extension modules.
For more information, visit www.abb.com.
The answer is… it depends.
For starters, it depends on one’s level of programming experience. Either past PLC programming or computer programming in general, as well as the types of programming environments (visual or textual, for instance) one is used to. Someone with a good bit of programming experience will probably find the process easier than someone with little to no experience.
On average, the expectation is that usually within a week or so one should be able to grasp the basics of PLC programming no matter what language is used. These basics have less to do with the specific programming language than with the underlying concepts involved. Different languages will have differing ways of representing these basic concepts and functions. For instance, opening and closing switches, starting/stopping motors, turning devices such as actuators and indicators on and off, etc. Also, higher-level functions like PID control will probably take more time to master.
Of course, a lot also depends on individual aptitude. So, how good of a programmer are you? Older engineers may have some experience with ladder logic, the industry standard for many years, and so may be more comfortable with visual programming environments. Younger, fresh-out-of-college engineers may be more versatile and used to C programming, for instance, so higher-level programming languages may be easier to learn.
Most PLC manufacturers also offer courses for learning to program and work with their PLCs. For instance, Rockwell Automation offers a variety of training methods from virtual classrooms to on-site training, as do Siemens and ABB.
You can find more information on PLC training here:
The bottom line is that ultimately the most successful PLC programmer will probably be the one that has a solid understanding not only of the programming language but how machine processes work.
ABB’s new customer drives test laboratory has been established to enable customers to evaluate the capability of their own motors when operating in combination with the new generation of ABB drives. The facility incorporates independent equipment for high-precision measurements of drive/motor dynamic performance, load capability and efficiency that enables customers to find the optimal drive system for their application, helping reduce costs, equipment size and energy consumption.
The test laboratory is an entirely new concept that is aimed primarily at high-volume drives customers and ABB partners such as technology companies in the machine building industries and system integrators. It now offers an easy and reliable way for customers to test various motor/drive combinations before introducing a new ABB product into volume production.
“This investment really supports the process of establishing the ideal drive/motor combination and demonstrates how we can help customers test their equipment up to 400 kilowatts (kW) with a minimum amount of effort to verify that ABB’s solution is the best choice for their application,“ explains Morten Wierod, Managing Director of ABB’s Drives and Controls business unit.
ABB’s global drives business also has customer laboratories in the United States, China and India that provide local support. Morten Wierod continued, “This new laboratory in Helsinki is the center of excellence for our business unit from where we support global customers with the most demanding requirements. The main advantage of these laboratories is how we connect them together in a global chain so that all customers always receive the best support available from the most appropriate ABB unit.”
The decision to make the investment to create the new facility was based on ABB’s successful experience with the customer application laboratory for crane and winch applications that opened in 2011. This facility, also located at the drives factory in Helsinki, provides facilities for OEMs to test ABB’s drive compatibility in cranes and winches in a simulated environment corresponding to actual application conditions. The laboratory has played a significant role in helping ABB to grow its business in this sector and it has recently been upgraded to increase its test capacity to cover a wider range of application areas.
Morten Wierod acknowledges that customers are increasingly demanding and ABB wants to offer even better service and application know-how by bringing customers into its own facilities. “We are dedicated to our customers and want to help them achieve the right features and performance in their applications by investing in these facilities. Being able to test the customer’s own equipment together with our drives gives them the confidence that ABB really can support our partners and customers in their day to day operations,” Wierod said.
Several announcements from ABB at this week’s Hannover Messe industrial trade fair in Hannover, Germany showcase the future of IoT, connectivity and remote monitoring. Two announcements in particular illustrate how these trends are shaping the development of Industry 4.0.
The first is that ABB has extended its discrete automation offering to deliver more connectivity and application solutions for discrete manufacturing, general machinery and food and beverage machine builders.
The ABB zenon software, developed by the Austrian automation company COPA-DATA, extends communications, machine-to-machine connectivity and application control possibilities for machine builders. (Note: The ABB zenon software is still in the pilot phase in the United States.) This supervisory control and data acquisition (SCADA) software extends ABB’s discrete automation portfolio which includes variable speed drives, motion control solutions, motors, programmable logic controllers and human machine interface panels. Together, these products enable the development of solutions for the Internet of Things, Services and People, (IoTSP) which present new business models for improving factory and process performance, product quality, production flexibility and energy efficiency.
ABB also showcased its new, customizable drives Remote Condition Monitoring service. (Note: Remote Conditioning Monitoring service for drives is still in the pilot phase in the United States.) This service helps in predictive maintenance planning by using remote data. It includes an expert analysis report on the drive’s condition and proactive e-mail alerts regarding potential faults or limited availability, ensuring that equipment is available, reliable and maintainable.
In industries where equipment downtime is extremely costly, new solutions are needed to assess future risks. Since drive performance data is readily available, making use of this information to find out how equipment operates and why it could fail can let users maximize drive performance and extend its lifetime. ABB’s Remote Condition Monitoring goes a step further by using remote data to identify early signs of possible system failures or production problems.
After the monitoring need has been assessed, an ABB expert will discuss the set up that is most relevant to the user’s objectives. Services can be tailored to meet specific needs.
Once a personal account has been created on the myABB Customer Portal, users can monitor live data such as availability, condition, operating parameters and fault events on their laptops, desktops and mobile devices. Customized performance reports with clear charts and graphs can also be generated.
For more information, visit www.abb.com.
Until now, the monitoring and preventive maintenance of low-voltage motors has been time-consuming and expensive. New technology from ABB transforms simple motors into IoT motors — intelligent machines that tell you when they need servicing. Smart sensors attached directly to the motor supply information regarding operating and condition parameters via wireless transmission.
The innovative sensor technology offers plant operators not only huge potential savings on maintenance and repair, but will henceforth also make it easy to utilize the Internet of Things, Services and People (IoTSP) … for millions of motors. The IoTSP is ABB’s concept for enabling its customers to take advantage of the opportunities of digitalization. With the new solution, small and mid-sized companies can also benefit from the advantages offered by the IoTSP.
The smart sensor provides information on operating and condition parameters such as vibration, temperature or overload and calculates power consumption. The data are analyzed by a specially developed software program and provided to the plant operator in the form of graphics for maintenance planning, thereby enabling downtime reductions of up to 70 percent. At the same time, the lifetime of the motors can extended by up to 30 percent and energy consumption reduced by as much as 10 percent, so that the investment in this innovative form of condition monitoring pays for itself in less than a year. More after the jump.
“This innovative solution makes condition monitoring the new standard for low-voltage motors,” says Pekka Tiitinen, President of the ABB’s Discrete Automation and Motion division. “Optimized maintenance schedules help reduce maintenance costs greatly. Unscheduled outages are reduced considerably or even eliminated completely. Increased availability significantly boosts our customers’ productivity.”
This innovative solution is not restricted to new motors made by ABB. The sensors can be installed at the factory or retrofitted on already operating low-voltage motors within minutes.
Cyber security is guaranteed at all times with the new sensor technology from ABB. The sensor is not electrically connected to the motor, so unauthorized parties cannot access the motor via this route. The smart sensors wirelessly transmit the data via encryption protocols to a secure server where they are analyzed using special algorithms. The cloud-based server implementation fulfills all of ABB’s strict specifications for cyber security. The data are stored in the cloud in encrypted form. The Internet-based customer portal also uses a role-based access protocol to make the data securely accessible.
For over a decade, ABB has been enhancing its control systems, communication solutions, sensors and software to make them compatible with the Internet of Things, Services and People. These technologies enable customers in the industrial, utility and infrastructure sectors to analyze their data more intelligently and thus to optimize operational management while increasing productivity and flexibility. The product introduced in this press release once again expands the range offered by ABB in this field.
Last week, many of us with motioncontroltips.com and Design World headed to MD&M West 2016 colocated with the ATX West show in Anaheim, Calif. The Internet of Things (IoT) still leads much industry buzz, as does the idea of increasingly smart and connected components and the unabated rise of automation — in the medical industry and elsewhere.
Just check out this item from Paul — Live from MD&M West: Festo talks automation safety … or this from Danielle — Things are moving at ATX West 2016: Rollon in Cartesian robots.
I also visited some industry leaders in linear motion. Check it out: Recap of top linear-motion technologies at MD&M West
Following are some other new things I saw at MD&M West 2016 — motion-control technologies from AllMotion, Altech, Applied Motion, Beckhoff, Changzhou Motors, Herrmann Ultrasonics, KHK Gears, maxon motor, MICROMO, Neugart Precision, Opto-22, Suhner, and Wittenstein.
The biggest developments at MD&M West — multi-axis driving and controlling off of increasingly tiny boards; motors that communicate and get power over Power over Ethernet (PoE); and one major manufacturer putting all of its chips on IoT for all future automation. Enjoy!
In an early booth visit with AllMotion accompanied by our own Scott McCafferty, I got the chance to visit engineer and president David Goodin (in the picture to the left below). He explained how more engineers than ever are using his company’s four-axis drive-controller board in super-compact designs. In the center picture below (click to enlarge) the daisy-chained setup with multiple single-axis boards. In the image to the right, there’s an equivalent design that uses just one board for multiple axes … for a setup with a lower cost per axis.
Here’s tiny fluid-sample-processing machine AllMotion showed at MD&M. In this case, one of the company’s four-axis drive-controller boards (flat and tightly integrated) drives all the axes.
Back in 1982, General Motors demanded that all automation control suppliers develop a communication standard that would let the automaker gather data easily from all its machines. This attempt was known as the Manufacturing Automation Protocol (MAP) and it was a huge failure. The controls vendors did not cooperate, resulting in a seven-layer monster that actually slowed the transmission of data. GM was not pleased. So the vendors shrank it down to three layers, which was not much of an improvement. At about the same time, another communication protocol of seven layers, the Open Systems Interconnect (OSI) model was under development. It was more organized than MAP, and became the foundation for the controls vendors’ proprietary “field and device level buses” as they used OSI’s first two layers. Today, Ethernet is the most well known version of these first two layers.
Soon after, nearly every drive manufacturer found it had to be compatible with all the major field buses, which numbered at least ten. Now, 33 years later, we have the Internet of Things (IoT) driving the desire for data and all the perceived benefits and efficiencies it may deliver.
Those field- and device-level communication protocols that survived are preparing for the IoT. And drives and motor developers are working to connect all things to the Internet as well.
Yet, motion control systems will need communication protocols for other reasons too:
• Thanks to efficiencies in machine tool design and motion control components, more machines handle more axes. “But more axes requires networks with higher speed and performance to suit the tasks,” said Joey Stubbs, PE, North American Representative, EtherCAT Technology Group.
• Many applications require tight coordination between axes to maximize both quality and throughput. The manufacture of flat-panel displays and batteries, for example, is becoming increasingly sophisticated as the products get more complex. But the demand for lower prices requires increased efficiency at every step, including testing. In many industries where the main process was automated, loading and unloading were still manual. Now these ancillary processes are automated and highly integrated, noted Curt Wilson,VP of engineering, Delta Tau.
• Accommodating safety regulations is another trend. More drives manufacturers are directly integrating safety functionality for efficient implementation of safe motion functions.
• Increasingly, robots are converging with
machine controls, which requires faster
• Many drive developers are moving to Gigabit Ethernet to take advantage of the fast speeds, noted Steven A. Zuponcic, chair of ODVA’s Distributed Motion Special Interest Group.
• Several networks are working on more efficient messaging. For example, the use of standard prioritization services for different message types, such as motion, I/O, safety and so on. Motion traffic can be prioritized over standard I/O traffic.
• The trend of using more servos to control more axes is increasing the demand for more coordinated axes. This development is driving the need for more capabilities from industrial networks that help synchronize all of these motion control devices, added Zuponcic.
• In addition to increased flexibility, the market is also demanding networks converge into a single approach. Versions of Ethernet networks are already being used for many motion, control and information applications. The emergence of Ethernet as a standard has been driven by the market’s need to obtain data from all sections of the production and enterprise domains and to be able to configure and control down to the end device in the system. Ethernet/IP, for example, enables data to be transmitted from motion, control and sensors, but it may not be enough for some applications, especially as the IoT increases data demand.
• Today’s data collection involves alarming, diagnostics and general metrics of a device. Soon, it will involve smart decision making if the IoT develops as proponents hope.
• One of the most interesting recent advances involving networks has been in the area of hydraulic-based motion control. The industry has found that it is simpler and more precise to synchronize multiple hydraulic actuators using a communication protocol like Sercos than by conventional means, noted Friedrich Scheurer of Bosch Rexroth. Applications such as injection molding or metal forming presses use Sercos as the nervous system for centralized multiple input/multiple output (MIMO) control systems. Even large structures used in water engineering, ships and large buildings are run with centralized hydraulic controls through the Rexroth IndraMotion MLC for Hydraulics function toolkit.
• Many motion specific networks already include the features needed to work with IoT applications. All that is required is to activate them.
“The Industrial Internet (or IoT) makes it possible to collect and integrate much more information than we ever have before,” said Claes Rytoft, ABB Chief Technology Officer.
As companies shift to Gigabyte networks, the choice of what data are sent from a device to a controller becomes important. Measurement devices, such as encoders, or other motion control devices, such as power transistors, can have small imperfections in their signals, noted Wilson. While there are devices to correct those signals, you still may not want a network to send every bit of data.