July 2020 www.mepca-engineering.com
Automation software experts
In a world of big data, our software simpliďŹ es its use. From control systems for mobile machines to parameter setting for RFID read/write heads, we have software solutions that simplify your automation. We even have visualisation software for real time plant monitoring, from anywhere in the world. Our software engineers remove the hassle of integrating automation solutions and ensure that you are getting all the usable data you can, providing actionable efďŹ ciency insights.
So challenge us, how can we help?
ifmnovation 2020
Let’s make automation smart and simple!
www.ifm.com/uk ifm Telephone (020) 8213 1111
CONTENTS
Editor Chris Callander chrisc@cimltd.co.uk Publication Manager Jon McIntosh jon@cimltd.co.uk 01795 509105
Classified Sales Executive James Davies jamesd@cimltd.co.uk 01795 509129
Credit Facilities Manager Natalie Murray creditcontrol@cimltd.co.uk 01795 509103 Sales Director Tom Woollin tom@cimltd.co.uk Chief Executive John Denning jdenning@cimltd.co.uk www.mepca-engineering.com © 2020 CIM Online Limited, The Goods Shed, Jubilee Way, Whitstable Road, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to CIM Online Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher. The publisher cannot accept liability for any loss arising from the late appearance or non-publication of any advertisement.
To subscribe to MEPCA visit our website www.mepca-engineering.com/ subscribe/ or simply scan the QR code.
4
www.mepca-engineering.com
8
I
July 2020
t is heartening to see an ever-increasing number of businesses starting to resume operations. Clearly, for the manufacturing sector this is much needed progress, but also for the myriad businesses that our industry serves and is served by. Of course, everyone is aware that these positive moves are not without their risks, but with care and the adoption of good practice, the UK economy can begin its journey on the road to recovery. Managing the risks we face in the manufacturing sector is addressed by two of our opinion pieces in this issue. On page 10, an article from the Institution of Occupational Safety and Health (IOSH), looks at what is involved in carrying out a COVID-19 risk assessment. While on page 12, UKIVA (the UK Industrial Vision Association) explains how advances in vision technology are being used to help the agri-food sector deal with the resource challenges presented by the coronavirus pandemic. Also, in our opinion section, Gambica looks at the importance of bringing IT (Information Technology) and OT (Operational Technology) together. Something which has been brought into sharper focus by recent events and the importance of Industry 4.0. Elsewhere in this issue, we look at developments in connector technology. One piece looks specifically at the food and beverage sector, while the other addresses the ongoing drive to shrink sensor sizes. We explore the role LED lighting controllers play when developing a machine vision system in our Imaging and Vision section. And we look at the role inverters can play in reducing energy use and associated costs in systems using fans. I hope you enjoy the issue! Chris Callander, Editor @Mepcamagazine
CONTENTS Industry Partners:
6 INDUSTRY NEWS All the latest news and updates
8 OPINION Gambica, IOSH and UKIVA
14 COVER STORY Beckhoff
16 SENSORS & SENSING SYSTEMS SICK
18 ROBOTICS KUKA and Kawasaki
22 CABLES & CONNECTORS HARTING and binder UK
12
26 ADDITIVE MANUFACTURING 3DPRINTUK
28 IMAGING & VISION LMI Technologies and Gardasoft
32 POWER & ENERGY MANAGEMENT Axair Fans
22
16
18
28
32 www.mepca-engineering.com
5
iNduSTry NEWS
Subcon and MACH create huge manufacturing event A total of ten co-located events including the Manufacturing Management Show and Engineer Expo which are run under the Subcon umbrella will take place from 25 - 28 January 2021 at the NEC, Birmingham.
T
he organisers of Subcon and MACH have joined forces to create the UK’s biggest manufacturing trade show in over ten years. The partnership will see the two events co-locate once again following previous successful collaborations. Organised by MTA, MACH will start on 25 January and run for four days. Subcon, which is run by MA Exhibitions, will take place on 26-28 January 2021. Together, the two events will take over eight halls of the NEC in Birmingham and are expected to attract many thousands of visitors. Visitors to Subcon and MACH will have free access to a total of ten events at the NEC that week: The Engineer Expo and Manufacturing Management Show running alongside Subcon; MACH; and Drives & Controls (organised by DFA Media) co-
Simple
◾ Digital configuration ◾ Consistent data quality ◾ Intelligent engineering
located with Smart Industry Expo, Air-Tech Exhibition, Fluid Power & Systems and Plant & Asset Management. “By co-locating Subcon with Mach, we want to create a celebration of UK manufacturing and engineering, where we can showcase all of the amazing work that this industry has done in the battle against Covid-19, not just in the UK, but overseas as well,” said Subcon Portfolio Director Gordon Kirk.
Industry calls for National Recovery Plan
T
he Make UK/BDO Manufacturing Outlook Q2 survey comes on the back of a historic fall in GDP and shows the balance for output reached the lowest level in the thirtyyear history of the survey, surpassing the previous record lows seen during the worst of the financial crisis. Looking forward, the survey shows the prospect for the next quarter and the rest of the year looks little better. Given the outlook for the rest of the year and into 2021 Make UK is calling on the Government to work with business and other key stakeholders from across the UK on a National Recovery Plan. In the short term, this should begin with an immediate stimulus package beginning with a business rates holiday for manufacturers similar to that granted to the retail sector earlier this year. The rates holiday should be accompanied by other measures, including a National Infrastructure Strategy with a commitment to immediate projects to help supply chains, a car scrappage scheme and incentives to invest in digital technology and skills. Make UK has also reiterated its previous call for Government help for recapitalisation to allow companies to access capital to service debt incurred during the lockdown.
NEWS
Data acquisition over GSM ifm electronic has launched an easy-to-use plug-and-play data acquisition solution that allows IO-Link sensors to send process values to the cloud even from locations where no network connection is available.
T
he new IO Key from ifm supports up to two IO-Link sensors and transmits data via the GSM mobile network. It is fully preconfigured and requires no SIM card. Users can visualise and analyse the data acquired by the system with a webbased dashboard that also offers options for setting limit values. If these values are exceeded, warnings can be sent automatically to the plant operator either by email or by text message. Additionally, all data from the sensors can be summarised and reported as required. Ideally suited to monitoring and evaluating the operation of remote sections of a plant, such as tank farms or compressed air storage vessels, ifm’s new IO Key needs only a 24V DC power supply and access to the GSM network.
Nero boosts sales team Stainless pipeline products distributor, Nero, has bolstered its sales team.
Tom Pennells joins Nero’s sales team
i
No connections to a controller, PC or the company network are required. To suit the widest range of user requirements, it is offered in versions that transmit data to the cloud once per day, once per hour, once per minute and once every ten seconds. IO Key modules feature compact construction and use standard M12 connectors for sensor connections. They have an IP65 ingress protection rating which means that they can be used in almost any industrial environment.
n his new role at Nero, Tom Pennells will be responsible for building client relationships across the commercial and industrial sectors. He joins the sales department from Nero’s warehousing team where he spent three years helping to manage the storage and distribution of more than 6,000 products, including screwed fittings, valves, compression fittings, flanges, pipe and tubes. Speaking about his appointment, Tom said: “I joined Nero in 2017 to have a career change and haven’t looked back. Right from the beginning, I was encouraged to develop my knowledge and enhance my skills. “When I was offered the chance to work in sales, I jumped at it. This is a great opportunity to build on everything I’ve learnt.”
The new one: the AX/the KX. Opens up perspectives. The new generation of compact and small enclosures.
www.rittal.co.uk
OpInIOn
We must bring IT and OT together GAMBICA’s Sector Head for Industrial Automation, Nikesh Mistry, explores the need to bring information technology and operational technology together if we are to truly reap the benefits of Industry 4.0.
I
nformation Technology (IT) and out. IT needs to start thinking like OT and Operational Technology (OT) vice versa; to work in parallel, they must have been in industry for many understand one another. The introduction years but have generally operated of the Industrial Internet of Things (IIoT) has independently of each other. From created a mutual concern between the what I’ve learnt, this duality is like two two, and that is ultimately employee and ‘edges’ of the same knife. Both edges have customer safety while maintaining control of different functions, yet, both necessary for their systems and machinery. the knife to be a knife. Similarly, both IT and During a roundtable discussion held OT are essential contributors in ensuring the transition into the fourth industrial revolution is as seamless as possible. Nonetheless, with their functions being so different, there is an emerging gap between the two and it is crucial that this is closed or bridged as soon as possible. Historically, the functions of both IT and OT have been clearly defined. Still, as operational technologies are being brought online, with data analytics and higher connectivity, it is becoming progressively essential that the two converge. Using Spiderman terminology, with great connectivity, comes great control, which is fantastic. However, a supposed cause for nikesh Mistry, Sector Head for Industrial Automation, the gap that still exists between GAMBICA IT and OT is the fact that more connections and more networked devices mean a greater risk of security holes in February, the GAMBICA Industrial and new security breach scenarios are Automation Council were able to discuss being created which could have detrimental ongoing advances in technology from their effects on both. This risk must be dealt with own experiences. They deliberated the by increased levels of cybersecurity which most significant impacts of technology seen in turn also aids the movement into Industry in the past decade, and what they may 4.0. expect to see in the decade ahead. While In the most simplistic of descriptions, the the importance of bridging the gap between IT deals with the digital flow of information IT and OT was a key topic of conversation, and the OT with the operation of physical it was agreed by the members that processes and machines used to carry them ‘technologies like the cloud and industrial
8
www.mepca-engineering.com
edge are closing the gap’ and that the ‘flow of data is helping to break down the barriers between the two’. The gap between the IT and OT most certainly needs to be minimised, and during the discussion, it was agreed that a change towards a smart factory also means a change in mindset within the factory. Skillsets from both technologies need to learn to co-exist and attempt learning how to work together for this convergence to be most successful. Coinciding with this mindset alteration, there is also a bridge between IT and OT being formed by more external factors. The need for controlling machines using mobile phones, for example, meaning machines are more ‘user-friendly’ is also a driver, as is the requirement to achieve environmental targets such as a net-zero plant. At the roundtable it was stated that ‘the past industrial revolutions have all consisted of two changes, one is a technology change but each time there has also been a societal change’, and this is most certainly key for Industry 4.0 to transform the ‘if it’s not broken don’t fix it’ mentality to a ‘we can get a lot more for just a little bit more’ ideology. Undeniably, being a master of IT or OT requires not only two different skillsets, but also a new way of thinking to see two separate worlds join, and at the moment, it’s not common to find a specialist of both. However, the emergence of the IIoT has set a pedestal for the union of these technologies, which is likely to unlock a new realm of competitive advantage in almost every industry.
Tel: +44(0)845 260 3400 | Email: SalesSupport@idealpower.co.uk
www.idealpower.co.uk
OpiniOn
Restarting production after COVID-19 Duncan Spencer, Head of Advice and Practice at the Institution of Occupational Safety and Health (IOSH), explains what’s involved in carrying out a COVID-19 risk assessment as businesses bring their staff back into the workplace.
S
ome facilities which paused activities during the coronavirus pandemic are further ahead in restarting production than others. Right now, it’s important to do the right statutory checks and plan and introduce new hygiene protocols and patterns of behaviour to protect workers and suppliers from the continuing risk of COVID-19. In many businesses, heightened risk awareness, adaptations and measures that prevent infection hazards might be less familiar than safety controls. There may be raised levels of fear and anxiety. Some people may not know where to start. This is where carrying out a COVID-19 risk assessment will come into its own. Some factors to consider in your COVID-19 risk assessment are:
Hazard The risk assessment should begin with the recognition that the virus is passed from one person to another through sneezing, coughing, talking and breathing. It can also be transferred to people by touching contaminated surfaces. When considering who is exposed, it is important to know which employees have vulnerable medical conditions that make them more susceptible or have such people in their households too.
Use the hierarchy of control Providing personal protective equipment is not considered a great solution. More effective control can be achieved by considering barriers and other engineering controls or by amended working practices and procedures. The priority will be to limit the spread of the virus, by social distancing and hygiene controls.
10
www.mepca-engineering.com
Safe workplace Consider redesigning the workplace to maintain social distancing. Spread employees out by repurposing rooms and other space; reduce the number of employees working in an area (with some still working from home); and phase shift and break times. Think about where people may be forced Duncan Spencer, Head of Advice and practice at the together such as security institution of Occupational Safety and Health (iOSH) points, lifts, stairs, lobbies, canteens, toilets, Safe people resource rooms and hot desks. How do you Advice on COVID-19 is constantly keep them apart and the area clean? changing, so you need to keep current and Consider the frequency of cleaning update your employees. They should know needed for commonly touched areas about COVID-19 controls at work and what (e.g. equipment control panels, handles, to do if they or someone in their household handrails, kettles, hot-desk surfaces) and is infected by the disease, with proper the strength of cleaning fluid needed to kill channels for reporting. the virus. More hand washing or sterilisation Consider how you manage people facilities will be needed. with special needs and how you support Work equipment employees with increased levels of anxiety If equipment (e.g. phones, desks, vehicle or who have suffered personal loss as cabs, control panels) must be shared, a result of the disease. Consider the consider how it will be cleaned between protection needed for cleaners, who have a uses. Deep cleaning processes will be higher level of exposure compared to other necessary on equipment used by employees employees. falling ill with COVID-19. These are just some measures to give you an idea of the issues you need to Safe systems of work tackle now. Risk assessments require the Reorganise work sequencing to avoid close right approach and a certain discipline, contact between employees. If not possible, and you should be collaborating with your minimise the time they are in contact. occupational safety and health colleagues Transfer some risk by using suppliers to as well as communicating with and take over some aspects of your work. If involving staff. Later innovations, such as employees and contractors must work improved process engineering, automation together, agree on common COVID-19 and screening, will contribute to healthier control standards to ensure consistency. workplace designs.
M NEW KRUK generic Benchmark.pdf
1
28/07/2019
12:21
Setting the benchmark... C
M
Y
CM
MY
CY
CMY
K
Faster, compact, energy saving and affordable...
Kawasaki’s latest robots increase one of the largest robot ranges available today. They are more compact, provide smooth control and give increased all round performance. For assembly the new collaborative duAro; for palletising the CP Series; the general purpose CX Series and the high-speed spot welding BX Series. Check out the new robots and see just how affordable they can be....
info@kawasakirobotuk.com kawasakirobot.co.uk +44 (0)1925 713000
Kawasaki Robotics (UK) Ltd www.mepca-engineering.com
11
OpiNiON
Harvesting vision technology for the future Allan Anderson, Chairman of UKIVA, explains why now is the time for the agri-food sector to invest in machine vision technology.
N
o-one knows exactly what the ‘new normal’, post COVID-19, is going to look like. However, the virus has brought into sharp focus the continuing huge dependence on human workforces in many industry sectors and the problems arising if they are too ill to work or cannot work in close proximity to each other. This should open up many possibilities to increase levels of automation, utilising both machine vision and robot technology.
Helping the agricultural sector The UK has traditionally relied on workers from East European countries to harvest crops such as strawberries, salads and vegetables, but this year their availability has been significantly restricted due to lockdowns and travel restrictions across Europe. The shortfall seems to have been filled through the ‘Pick for Britain’ campaign (pickforbritain.org.uk) from the ranks of UK workers on furlough although they won’t have the experience and skill set of the usual harvesters. The automation of crop harvesting using machine vision techniques has been the subject of many research projects and holds a lot of promise for the future. Some UKIVA members have been involved in successful projects in areas as diverse as broccoli harvesting and post-harvest trimming of vegetables such as swedes, leeks and sprouts. Other applications have included prototype systems for picking cucumbers, lettuce, apples and sweet The key challenge in crop harvesting is to distinguish the crop from any surrounding material such as leaves, to identify when it is ripe and ready for picking. While this is something the human brain is very good at, the subjectivity from person to person can still lead to picking before individual items
12
www.mepca-engineering.com
are really ready, leading to significant waste. Automating the process not only requires produce recognition, but also interaction with a robot for picking, and usually involves the use of 3D imaging in combination with deep learning since 3D imaging allows the shape and size of the crop to be determined. With significant developments in lighting configurations, 3D processing power, low cost embedded cameras and greatly simplified vision-robot interfaces, 3D systems can readily be mounted on the vehicles used for harvesting. As these are generally mobile systems, the most popular 3D technique for these applications is laser line triangulation where a line is projected onto the surface of the crop. As the line moves across the crop, a series of profiles is built up to give the topology of the crop. Classification of the 3D images produced is generally carried out using deep learning methods, which utilise artificial neural networks to imitate the way the human brain works for recognition and decision making. These work particularly well for organic materials where there are lots of natural variations. The system is provided with several training images from which the classification required is learned, and
then this is applied in real time to the crop in the fields. The vision system can then send picking coordinates to the robot. If the system is linked in with GPS data, the location of crop that is not quite ready yet can be stored for automated harvesting at a later date.
Now is the time to invest Machine vision has an important role to play right across the agri-food industry. Some applications are well-established while others such as harvesting are at the earlier stages. In the aftermath of the coronavirus pandemic the time is right for greater focus and investment in this area. In the budget announced in March even before COVID-19 took hold in the UK, it was announced that investment in R&D would increase to £22 billion per year by 2024-25. Significant sums are already allocated to agri-food programmes led by Innovate UK and BBSRC (Biotechnology and Biological Sciences Research Council). It would be good to see some of this investment help lead to more vision-driven automation systems literally deployed in the field for future support of this key sector of the economy.
LE
N AR
RE
TE O M
LY
WANT A QUALIFICATION THAT ASSURES YOU OF GOOD JOB PROSPECTS? The one year Diploma in Acoustics and Noise Control includes the General Principles of Acoustics, Laboratory and Experimental Methods, a Project and two Specialist Modules chosen from: • Building Acoustics • Regulation and Assessment of Noise • Environmental Noise: Measurement, Prediction and Control • Noise and Vibration Control Engineering
Established for more than 40 years, the Institute provides graduates, and those with a proven interest in acoustics, the chance to become a recognised member of a vibrant and active global network with regular UK meetings and CPD.
The Diploma is taught in centres across the UK or through distance learning with live tutorials – find out more: www.ioa.org.uk/education-and-training
FOR MORE INFORMATION: www.ioa.org.uk E: education@ioa.org.uk T: +44 (0)300 999 9675 Institute of Acoustics, Silbury Court, 406 Silbury Boulevard, Milton Keynes MK9 2AF IOA396_Ad_Dip_180x126.indd 1
19/05/2020 12:15
www.mepca-engineering.com
13
Cover Story
Simplify machine vision integration Beckhoff UK explains how its TwinCAT Vision software brings machine vision control into the control environment, for seamless integration with PLC, motion, robotics and measurement technology.
I
n automation applications, image processing has traditionally been handled separately and was often outsourced to external system integrators. Meanwhile, PLC programmers have branched out into numerous disciplines, including motion control, safety technology, measurement technology and robotics. It is possible today to combine all of those functions in a single control system on one computer. However, image processing has typically remained in a black box on a separate high-performance computer, with specific configuration tools and programming languages, or it is implemented directly in specially configured smart cameras. The downside to using a separate computer is that even the smallest changes require input from a specialist instead of the PLC programmer, resulting in avoidable costs. In cases where a thirdparty system integrator is involved, it also means that the expertise remains external. In addition, the communication between image processing and the control system has to be regulated, which is an error-prone process. As a result, an exact timing in image processing could not be ensured. External processes, such as the operating system, can affect the processing time and the transmission time, so the results may not reach the controller in the required time span. The TwinCAT Vision software combines both worlds into one integrated system. The configuration, especially of the cameras, is carried out in the same tool as the configuration of Fieldbuses and motion axes. For programming, the familiar PLC programming languages can be used. In this way, substantial engineering cost savings can be achieved, since there is no need to learn special programming languages, and no specific configuration tool is required.
14
www.mepca-engineering.com
The challenges of communication between image processing and control are not only eliminated, but image processing and control components can directly communicate with each other, opening up entirely new application possibilities. Everything is integrated into one tool and one runtime environment – this is the core innovation offered by TwinCAT Vision.
Architecture PC-based automation combines all control functions on a PC platform and it therefore inherently benefits from a Gigabit Ethernet interface. Based on Gigabit Ethernet, GigE Vision is a communication standard that enables reliable and fast transmission of image data from cameras. TwinCAT Vision provides a real-time capable driver for the Ethernet interface, which makes image data available directly in the controller memory. With support for GigE Vision, TwinCAT Vision is also an open system that makes it possible to use cameras from a large
number of manufacturers. The first step after a connection is established usually involves the configuration of the camera. Manufacturers of cameras with the GigE Vision interface provide a configuration description in GenApi format. The TwinCAT Vision configuration tool reads the parameters and makes them available to the user in a clearly arranged manner. Configuration changes, such as adjusting the exposure time and setting a region of interest, can be made quickly and easily, and the results can be observed in the live image of the camera. In addition to the camera configuration tool, TwinCAT Vision provides another tool for geometric camera calibration. This determines the parameters for describing the mapping from image coordinates to real-world coordinates and vice versa. It also makes it possible to relate positions in the images to real-world coordinates and to convert measurement results from pixels into the metric system. In addition to perspective
Cover Story distortions, non-linear distortions of the lens are taken into account, which can be observed in the form of visible deformations in the image. As part of the camera calibration, one or more images of a suitable calibration pattern are required initially. These images can be acquired directly in the engineering tool, or existing images can be imported. After specifying the calibration pattern, the parameters are calculated automatically. In addition to the standard 2D patterns, such as the chessboard pattern or the symmetrical or asymmetrical circle patterns, users can also read in their own patterns. These may also be 3D patterns. As an alternative to using the calibration tool, camera calibration can be performed in the PLC.
Image processing in the PLC The raw images are transferred directly from the camera to the router memory of the PLC via GigE Vision. For this purpose, the camera has to be set into image acquisition state and, depending on the camera configuration; individual images must be triggered. The software function block FB_VN_GevCameraControl is available for this procedure. For very precise trigger timing, the timestamp-based EL2262 output terminal is available in the Beckhoff I/O system, which can be used to send a hardware trigger signal with microsecond accuracy to the camera. Since everything takes place in real-time in a highly accurate temporal context, image acquisition and the positions of an axis, for example, can be synchronised with high precision – a frequently occurring task for PLC programmers. Many cameras can also send output signals at previously defined events, such as the start of image capture. These signals can be acquired with a digital input terminal from Beckhoff and then used in the PLC for precise synchronisation of further processes. TwinCAT Vision offers a new image processing library in the PLC that contains numerous image processing algorithms. For example, images can be scaled or converted during preprocessing to the desired colour space, and certain characteristics can be highlighted or suppressed using filter functions. The image can then be binarised by means of thresholding, followed by contour tracing on the resulting image. The contours
found in this way can be filtered based on their characteristics, resulting in a selection of interesting image contours or image regions, which in turn are suitable for object identification and measurement. With a previously calibrated camera, the feature points can also be transformed back into the world coordinate system, so that position and measurement data can be specified accurately in real-world coordinates. By integrating TwinCAT Vision into the TwinCAT real-time environment, the timing of image processing functions can be monitored via watchdogs, which interrupt the functions after a defined period of time or at a certain point in time from the start of a processing cycle. At the same time, the user is provided with any partial results that may be available at the time. In addition, suitable image processing functions can be automatically allocated to multiple CPU cores for parallel processing by means of so-called job tasks, so that TwinCAT Vision makes optimum use of the multi-core capabilities in TwinCAT 3. During analysis and visualisation of the results, all images can be represented in the form of images and not only in the form of binary data. Before this, it is possible to write and draw results, such as position information, into the images. Exemplary use cases include colour-coded marking of the filtered image contours or the good/bad marking of parts. The user is only limited by the image boundaries. The images can be displayed directly in TwinCAT Engineering in the so-called ADS Image Watch or for the end-user in TwinCAT HMI.
PLC and image processing TwinCAT Vision combines classic automation technology with image processing, making it especially user-friendly. On the engineering side, camera configuration and geometric
camera calibration are carried out directly in TwinCAT Engineering. No other tools are required. Image processing is programmed based on the languages used by PLC programmers, i.e. in IEC 61131-3, which means that no special programming language has to be learned. In addition, it is possible to respond directly to the results of image processing in the PLC, right away in the next line of code. By triggering the camera from within the real-time environment, image capture and PLC or motion control can be fully synchronised. The image processing algorithms are computed in real-time in TwinCAT, ensuring task-synchronous execution and monitoring in real-time via watchdogs. TwinCAT Vision leverages the multi-core capabilities of TwinCAT 3 to automatically execute algorithms on multiple cores whenever they are available. No special programming by the user is required for this parallelisation capability. TwinCAT Vision is aimed at users who are faced with the challenges and opportunities of having to handle vision tasks within the control system or wanting to do so. Through seamless integration, TwinCAT Vision is easy to operate and program. Naturally, it is also suitable for users who need a high degree of synchronisation among image processing, PLC and motion control. Since delays in processing are eliminated, and the processing of algorithms is time-monitored, the system can respond directly and deterministically. Classic image processing tasks such as finding and recognising or measuring parts can be performed easily with TwinCAT Vision. In addition to PLC, motion, robotics and measurement technology, TwinCAT users can now add image processing to the list of integrated functions in the TwinCAT system. www.beckhoff.co.uk
www.mepca-engineering.com
15
SenSorS & SenSing SySTemS
Tiny, tough and task-orientated The SICK W4 Inox is the company’s first stainless steel photoelectric Inox sensor with onboard smart tasks that can be used even in the harshest hygienic sterilise-in-place (SIP) and clean-in-place (CIP) environments.
T
he W4 Inox miniature photoelectric sensor combines stainless steel-shielded durability with in-built remote sensor intelligence for the wet area of processing plants, filling lines and packaging machines in the food, beverage and pharmaceuticals industries. The IP69K-rated sensor brings the latest advances in onboard sensor processing power, called ‘smart tasks’, to fully-hygienic environments. Smart tasks are intelligent logic functions with which the sensors can autonomously control process-oriented automation tasks such as counting products, checking sealing caps and pack sizes, and switching actuators. David Hannaby, SICK’s UK Product Manager for Presence Detection, explained: “The W4 offers all the long-life durability you would expect from a high-class SICK Inox sensor. With a housing made from extremely resistant stainless steel, the W4 is designed to be completely impervious to water ingress or aggressive cleaning media, even in the most challenging conditions. “Regardless of whether you are dealing with a CIP or SIP processes, manual exterior cleaning such as in a filling line, or sterilising pharmaceutical sterile boxes with hydrogen peroxide, the W4 can be relied on to keep on performing during a long life, as can the allimportant connectors and accessories. “Part of the trend towards ‘edge computing’ capability, smart tasks remove processing time and load from PLCs or other higherlevel controls. The W4’s ability to operate defined tasks autonomously and remotely will, therefore, be particularly attractive in high-speed food processing plants, filling and packaging lines. It offers a chance to improve production efficiency and enable greater process responsiveness including more frequent product changeovers.”
16
www.mepca-engineering.com
Smart tasks operate logic functions that process the detection and measurement signals from the sensor, linking them with additional binary switching signals from an external sensor, where necessary. The smart task then uses this data to generate and output process signals from the sensor needed for the task in hand. For example, the W4 Inox smart sensor can detect and measure objects and gaps in a flow of bottles on a filling line, or goods to be multi-packed on a secondary packaging line, directly in the sensor using the ‘object and gap monitor’ smart task. Rather than the evaluation being completed in the PLC, W4 Inox alerts the control only if there are deviations from pre-set measurement values, while at the same time directly controlling the process autonomously, e.g. to operate a diverter gate for quality-control rejects. The W4 Inox’s ‘counting and debouncing’ smart task enables a quick and simple completeness check, which can be an extra protection against errors that can result from PLC cycling time, for example, while controlling bottle transport systems and during other high-speed processes. Smart tasks for common processes are available as standard for the W4 Inox, and more will become available during 2020, as well as being available on request from SICK. The W4 Inox smart sensor with red light LED achieves highly reliably best-inclass performance in harsh environments.
Immune to ambient light, and with excellent background suppression, it detects reflective, transparent, and jet-black objects with ease. The W4 Inox’s housing is made from 14435 / AISI 316L stainless steel. It is manufactured using specialist injectionmoulding techniques to ensure a continuous unibody housing structure and integrated plug connectors, together with optimised sealing for a flush, seamless and watertight construction. As a result, the tightness requirements, according to IP67, IP68, and even IP69K are greatly exceeded. www.sick.co.uk
Fluid Carrying
Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders
Swivel Joints Swivel joints allow pipework to pressure 1/4� to 40� and beyond. Vacuum to over 20,000psi. Stock and bespoke production. Unique bearing/seal design for longer life. ISO 9001 CE marked where applicable.
Tel:
Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY | UK
+44(0)1663 735003
E-mail:
www.mepca-engineering.com
17
RobotIcs
The rise of the collaborative robot Recent events have highlighted just how fragile our operations are when the key component within a supply chain is compromised: our workforce. While moving back towards full operations will present further challenges. Robotics specialist, KUKA, explains how collaborative robots can help.
I
t appears that the impact of COVID-19 shall be felt within the manufacturing sector for the foreseeable future, as businesses try to cover lost ground and identify ways in which they can continue to operate, safely and efficiently, while adhering to stringent safeguarding measures that will have to be implemented within our manufacturing environments, primarily social distancing. Manual production lines and complex manual production applications incorporating conveyor systems shall need to be reevaluated. Co-workers stood shoulder to shoulder will soon become a thing of the past. Two-meter social distancing legislation will have to be incorporated into business plans and regulatory agendas established, to safeguard employees while successfully maintaining operational efficiencies. This poses a significant conundrum for many businesses which rely upon manual methods to ensure the supply versus demand balance is maintained. Realigning operating models, especially for SME’s, can be costly. Consider having to make changes to infrastructure and operational footprints, to allow for the increase in space needed for operators to continue to work safely. This can be not only costly, but also disruptive. So how do we approach the dilemma of safe working practices when, for some businesses, it’s almost impossible without detriment to their productivity? The solution is to employ a lightweight, sensitive robot; sometimes referred to as collaborative robots or cobots. These sensitive robots are very different to conventional industrial robots widely used within the manufacturing sector, as they are human robot collaboration (HRC) compatible and can work safely alongside human
18
www.mepca-engineering.com
operators without external safety devices, such as fencing/guarding, sensors or light curtains. In human-robot collaboration, the robot assists the human operator. The machine does not replace the human but complements their capabilities and can relieve them of non-ergonomic tasks; mundane, repetitive, strenuous tasks. Human and robot can work in close cooperation, sharing tasks within any given application. But how does the adoption of collaborative robotics assist in addressing safe, social distancing working practices that shall soon become the norm within many manufacturing environments? Business owners within the manufacturing sector will have to adjust if they are to survive. An increased focus upon reducing the concentrations of workers near to one another is needed, while maintaining continuity of production. Especially so to future proof against another major interruption to their manufacturing and supply chain. When introducing a sensitive robot within an application or process, there exists no significant downtime. Adjustments to the immediate production landscape are not required. Cobot footprints are significantly smaller than larger industrial robot models and can be introduced to an existing application by way of static or mobile means. Various methods of programming also allow for easy integration, with some sensitive cobot models possessing teach and learn software, that enables an operator to move
the robot arm, while in compliance mode, through a series of movements or tasks that are then repeated. If paired with a mobile platform, controlled by software that utilises sensors to identify its immediate surroundings and move about an environment, a cobot affords a whole host of benefits, not only being able to move between work stations but supporting multiple applications/programmes aligned with several individual tasks within a supply chain. The key advantage of the cobot, whether static or mobile, is that it does not need to adhere to the stringent health and safety measures that are applicable to social distancing currently being adopted across the manufacturing sector – business owners can retain their established production footprint, but re-position key, skilled personnel and supplement production with sensitive robots. Social distancing is a workplace reality, and cobots will offer a flexible, efficient and multi-purpose operational value-add to manufacturers that want to achieve operational continuity throughout these testing times. www.kuka.com
Speak the same language as robots • VISOR® Vision Sensor for vision guided robotic applications • 2D or 3D localisation in robot coordinates • Different hardware versions up to 5 megapixels • Less robot programming thanks to 3D gripper point transformation
www.sensopart.com mecpa_uk_visor_robotic_halfpage_180x126_05_2020.indd 1
30.04.2020 20:36:14
Providing flexibility. Simplifying integration. Opening communication channels.
RFID Read/Write Heads with IO-Link
Standardized IO-Link interface unlocks the potential of Industry 4.0 Easy mode reduces complexity without compromising performance System standardization with multi-protocol support to most common bus systems Flexible and efficient solution enables IO-Link read/write heads to be combined with other
devices on Ethernet IO-Link master www.pepperl-fuchs.com/pr-rfid-io
www.mepca-engineering.com
19
Robotics
Robot helps horses sleep soundly Kawasaki Robotics is helping a business to ensure its wood shavings for the equine sector are safely and securely prepared for dispatch, as MEPCA found out.
M
etsä Wood UK’s head office in Boston, Lincolnshire is just one of many sites across the globe which specialise in providing sustainable, premium-quality wood products for many industries including the construction and industrial sectors. Metsä Wood employs around 1500 people, and 2019 sales reached EUR 0.4 billion: its primary products are Kerto LVL (laminated veneer lumber) together with birch and spruce plywood. The four UK sites at Boston, Kings Lynn, Widnes and Grangemouth also supply machined softwood and panel material to the Merchant and DIY markets. Another key strength of the business is an associated revenue stream which makes good use of the wood shavings generated during the various manufacturing processes at the Boston site. The shavings produced go into a sector which has proven both buoyant and resilient over the years: the equestrian market. Every year, thousands of tonnes of Metsä Wood ‘Hunter’ Woodshavings are used for bedding in stables across the country. Once the loose shavings have been collated into bales using bespoke machinery at the Boston plant, the bales are removed from the line by a recently installed Kawasaki robot and placed directly onto a 1200mm x 1200mm pallet ready for dispatch. To ensure that the load is stable, the robot must also rotate the bales through 90° as it stacks, a task easily performed while transiting from pick-up to deposit. The new robot, which was installed in August 2019, is a Kawasaki CP180L with associated HMI, which replaced an older robot, also a Kawasaki unit (a ZD130) that was originally installed at the plant in 2002. This machine had provided sterling service, and according to Metsä Wood Project Manager Andrew Burns: “Our
20
www.mepca-engineering.com
records revealed that the Kawasaki robot installed in 2002 had completed 10,794,000 cycles, and it had performed superbly. We valued its reliability coupled with Kawasaki Robotics’ responsiveness and professional engineering approach. When we wanted a replacement for it in August 2019 there was only one place to go – Kawasaki – for another robot to last us the next 20 years or so”. In a typical working day, around 1000 25kg bales are picked off the line and stacked safely using the necessary orientation changes programmed into the new Kawasaki CP180L robot. Removing the old robot and placing the new one onto its plinth was straightforward according to Mick Middleditch of Higham Ferrers based RJC Projects, who were tasked with accessing the cell and swapping them over. “It was a trouble-free, like-for-like exchange that presented us with no problems or challenges”. The installation, integration and programming of the newly installed CP180L was undertaken by industry experts KTM Systems of Liverpool. KTM Director Peter
Mason has over 25 years in the business of robot installations and commissioning: “This job was identified as a critical one from the start. It was made clear that if this part of the manufacturing process were closed down for more than a few hours, production at the entire factory would come to a standstill. Our team set to work the moment RJC had placed the new machine in position, and we had the new robot installed, programmed and commissioned well inside the stipulated window. It has been performing flawlessly since.” Kawasaki Robotics’ Ian Hensman observed: “When our original ZD130 robot was installed at the Boston Metsä Wood plant almost 20 years ago, it represented the state-of-the-art at the time and it served our customer extremely well. The Kawasaki CP180L that has replaced it is faster and more accurate but uses less energy than its predecessor. The reach is longer (at 3.255m) offering greater flexibility for users, and it is easier to programme. Further, this latest model requires less maintenance too.” robotics.kawasaki.com/en1
Cables & ConneCtors
A clean connection The newest addition to the HARTING Han portfolio is the Han F+B range of connectors which have been specially designed for the requirements of the food processing, bottling and packaging industries. MEPCA found out more.
W
ithin the food processing, bottling and packaging sectors, hygiene and safety are key considerations, meaning machines and equipment must be both easy to clean and designed so dirt pockets and bacteria cannot accumulate. Before creating the range, it was important to recognise how a production site within the food industry is divided up. The EN 1672-2 standard defines three distinct zones for food production, which differ in terms of contamination risks and the number of cleaning cycles required. Zone 1 is the food zone, where components come into direct contact with foodstuffs. Zone 2 is the splash zone, where components must be cleaned regularly using high-pressure washing and chemicals to avoid contamination. Anything outside of these two zones is classed as a non-food zone, where the contamination risk is minimal. The Han F+B has been specifically developed as a suitable product for the food zone and splash zone, and there are several innovations which make it the ideal solution. Firstly, all hoods, housings and seals are IP69K rated, so the connections are fully protected and resistant to the water jets used to clean equipment. They also have large nooks and surfaces in accordance with the guidelines of the European Hygienic Engineering & Design Group (EHEDG), which allows cleaning and disinfecting agents to flow unhindered. For secure identification and easy traceability, the connectors are blue, although a black version is available. The range is Ecolab approved, so it is resistant to the highly aggressive cleaning agents used in the food and splash zones. As the housings are constructed from polypropylene, they conform to the directives of FDA 21. All surfaces also have a smooth finish, which prevents impurities and bacteria from accumulating, while the portfolio can function in a wide temperature range from -40 to +125°C.
22
www.mepca-engineering.com
Cable glands available include variants made of PA plastic in combination with blue silicone sealing rings, which achieve the highest degree of protection against the penetration of dust and water. As well as hygiene and safety concerns, HARTING has also considered the impact of machine downtimes, designing in features which keep disruptions on the production line down to a minimum. Businesses are increasingly looking for solutions which allow them to embrace flexible schedules and smaller batch productions, meaning they must become adaptable to meet these demands. As a result, the ability to quickly attach and detach connectors is vital if costly production downtimes are to be avoided. With the Han F+B, operators do not need to open any cable glands on the control cabinet to decouple field devices, eliminating the complex disconnecting and reconfiguring of fixed wiring. This solution also allows for fast replacement of defective components and a
more efficient configuration when changing components, allowing businesses in the food industry to shorten set-up times and reduce production stoppages. In addition, the Han F+B series has been designed so it can be plugged and unplugged easily, safely and quickly. Special fluting in the housing walls ensures that the installer’s hands do not slip off the connector, even in damp or humid conditions. The housings can be used with hybrid contact inserts for all types of industrial transmission, including data, signal and power, a versatile connector concept which makes it possible to configure future-proof machine design for processing units, including Ethernet. With the use of an adapter, the user can integrate a selection of Han 3A inserts, including RJ45 interfaces, signal inserts with up to 21 poles as well as power contacts for currents up to 40A. bit.ly/hanfplusb
well placed M5/M8/M12
Signal/Power/Data
IP67/IP68/IP69K
For assembly & moulded
www.binder-connector.co.uk
Cables & ConneCTors
Connecting sensors when size matters
Circular connector specialist, binder, talks to MEPCA about how connectors are keeping up with the miniaturisation of sensors and the ever-smaller spaces they are being used in.
T
hanks to the continued development of the smart, automated factory, the need for connected sensors has never been greater. And, since the sensors themselves are getting smaller and the space provided for them is constantly shrinking, the M5 circular connector has become the first choice for installers looking for a tiny, high-performance connector that can operate in demanding environments. Although miniaturisation is the key driver for many of today’s sensor applications, low weight, environmental protection and shielding are also key aspects across the lifetime of a connection when used for data and signal transmission. The latest M5 connectors from binder weigh around 30g, and that includes 2m of cable and, although tiny, the connectors feature easy-to-use screw locking. They are also waterproof to IP67, even for applications in overvoltage category II up to 125 V and for pollution degree 3. The connector range is also versatile, which allows it to meet a wider spread of applications. As well as straight and angled moulded connectors, binder’s M5 connector family includes panel mount connectors which can be offered with three or four dipsolder contacts for PCB assembly or single wires for front mounting. Male receptacles are also available. The M5 family also includes shielded connectors. Shielding is needed when the cable needs to be protected against electric or magnetic fields, or vice versa when the environment needs to be protected against these fields. To guarantee transmission without interference, binder’s shielded M5 connector provides screening attenuation values of 60dB in the 1GHz frequency range. An inward-facing coding nut provides a high degree of safety. M5 connectors are widely used in many
24
www.mepca-engineering.com
applications and can be configured according to customers’ individual needs, e.g. in terms of material for cables (PUR or PVC) and their length. Where miniature sensors are deployed, the M5 connector offers the perfect interconnection solution. As well as applications throughout automated factories, M5 connectors are widely used where size, weight and connection integrity are vital factors. These
include robotics, test-stand pressure sensors in the automotive sector and aerospace applications, including drones. binder operates in many industrial sectors and is a specialist manufacturer of circular connectors for applications that range from automation and food and beverage to medical and outdoor applications including agriculture. www.binder-connector.co.uk
SLS 3D PRINTING SERVICE LOW VOLUME MANUFACTURE PROTOTYPES
PLASTIC PART MANUFACTURE ORDER PARTS ON DEMAND 1 -10,000 UNITS, EXPRESS TURNAROUND Upload your .stl file now for an instant quote!
3DPRINTUK
A D D I T IV E F O R MA N U FACT U R E
£40 Minimum Order
T. 0208 692 5208 hello@3dprint-uk.co.uk www.3dprint-uk.co.uk
AddiTive MAnufAcTuring
Smart design speeds up 3D production of PPE One of the key advantages offered by SLS-based additive manufacturing is the ability to nest items. This offers the ability to maximise the available build space and makes the technology viable in an increasing number of small-to-medium batch size manufacturing situations. However, for SLS specialists, 3DPRINTUK, it enabled the company to step in and support the nationwide effort to produce PPE for front-line workers, as MEPCA found out.
T
here has been a large scale response by the 3D printing community to the COVID-19 pandemic, with a giant effort to close the gap between supply and demand for PPE for front-line NHS workers. Some clever and innovative designs have been released for people to produce, but all have been designed and optimised for fused deposition modelling or FDM printers, the kind many people are used to seeing, which use a plastic filament. Nick Allen, MD at 3DPRINTUK said: “From the very beginning of the COVID-19 crisis, in common with numerous other 3D printing companies, we analysed ways in which we could make useful interventions and help the efforts of the NHS. “One thing we noticed was that many of the face shield related designs were perfectly suited for FDM machines, but didn’t work well with the Selective Laser Sintering (SLS) process. As a company, we are specialists in SLS and have printed over two million SLS prints, so we began to look at how we could optimise designs for the 3D printing technology that we use every day.”
The advantages of nesting What the team at 3DPRINTUK noticed when they looked, for example, at the amazingly well-designed and groundbreaking Prusa face shield design was that only 14 individual headbands could be printed on the company’s EOS FORMIGA P110 SLS machines at a time. So, the team focussed on a design that the P110 could accommodate in much larger numbers. By nesting the main peak component inside one another, they were able to create one that allowed for 260 to be printed in a single print with a 27-hour build time.
26
www.mepca-engineering.com
Nick continued: “That is six minutes per shield, which is a game changer. The design that we created clips together in ten seconds, uses silicone straps for adjustment, can take an acetate sheet with three holes, is lightweight at only 42g, and is sterilisable with IPA, autoclave, or ethylene oxide (Et0). All in all, we believe that this is the most efficient visor design to produce via 3D printing available today.” Additional design benefits included a closed peak design for extra protection, the material used (PA2200/Nylon 12) is biologically safe, and the shape has been designed so that it can be flat packed into an A4 envelope for cheap postage and storage. Once the design was proved and validated, 3DPRINTUK had to look for partners to scale up production. At the time, the company was directly involved with the UK Cabinet and manufacturers working on several large ventilator projects, which had taken up their own printing capacity. Information relating to the design was released free-of-charge, and the first facility to take on the manufacturing role was the Arts University Bournemouth (AUB) which had access to a P110 machine and also had laser cutting capabilities. The arts university had been spearheading an effort by educational institutions to manufacture and create vital protective equipment for the healthcare sector. Since its campus closure in March, the University’s
facilities had become a production line for visors, facemasks, scrubs and gowns, which were being distributed across a range of public healthcare settings, including doctors’ surgeries, care homes, and volunteers providing door-to-door services for the elderly. AUB Vice Chancellor Professor Paul Gough said: “We were delighted to be involved with this vital project. Many AUB staff members have been involved; from our cutting-edge technical teams to our Innovation and Campus Services teams. AUB was honoured to play a part in the national drive to create and distribute lifesaving apparatus; it’s so important that we’re all able to play our part during this global pandemic. Nick concluded: “We would invite anyone else with the SLS capacity to make the face shield to contact us and we will share the design data with them. This has been a monumental effort, and I would personally like to thank all involved, both at the University and at 3DPRINTUK.” 3dprint-uk.com
Your additive manufacturing production partner
Our dedicated team of additive manufacturing experts will guide you through from prototype and development to serial production. With two decades of experience in AM technologies we’ve watched it develop into a robust solution for part production. This experience is what positions 3T to be your next additive manufacturing production partner. • • • • •
20 years’ additive manufacturing experience ISO9001, ISO13485 and AS9100 accredited Specialist Application Engineers to optimise designs Complete process capability Rigorous New Product Implementation (NPI) process ensuring repeatability and reproducibility www.3t-am.com enquiries@3t-am.com 01635 580 284
IMAgIng & VISIon
Multi-view 3D scanning and processing In applications where the scan target is larger than a single sensor’s field of view or has a complex shape, multi-view scanning and processing is required to capture the complete geometry of the part. LMI Technologies explains.
M
ulti-view processing is used to cover larger fields of view while maintaining high resolution; to see more of a part (360º ring layout or opposing layout to measure thickness); to see past occlusions (undercuts, gaps, steep edges); and to perform absolute measurement between two or more features separated by a large distance (both sensors must be calibrated to a world coordinate system) LMI’s Gocator 3D sensor features built-in multi-view processing capability, which can be executed in several different ways. It can use multiple networked sensors to scan all the different views of a part to build a fully digitised 3D model, and it can use an XY stage and a single sensor to scan and stitch several views into a single surface.
Overlapping sensor data is intelligently merged, and the final 3D cross-section is resampled to the desired resolution. 360° crosssectional profiles from laser profilers are synchronised to an encoder and collected to build 3D point clouds. Point clouds are aligned and projected to height maps for fast 3D feature or profile measurement.
Multi-sensor networking
Data synchronisation
The Gocator’s multi-sensor operation is supported by built-in connection and streaming logic. Users connect to the ‘main’ sensor using any browser, then connect additional sensors. Each sensor is assigned a location in a layout, and its physical to logical mapping is assigned. All sensors in a network are usually aligned to a common coordinate system to stitch sensor data into a single 3D model or perform absolute measurement. The Gocator offers built-in alignment that scans a known shape (such as a 4-sided polygon), where each sensor ‘sees’ one of the vertices of the polygon and creates a transformation from the sensor to real-world coordinates (figure 1). Data merging and resampling are built-in to the Gocator. The smart sensor applies 6 DOF transformations from the alignment process to convert sensor coordinates to a common coordinate system.
Data acquisition from multiple sensors requires accurate synchronisation, so each sensor exposes at precisely the same time (based on time, discrete triggering, or an encoder). This can be achieved using LMI Master hubs. Master hubs transmit submicrosecond synchronisation (more reliable than PTP/IEEE 1588 and much lower cost - with no need for 1588 Gigabit Ethernet switch) to each sensor. Masters also support time or encoder-based offsets as required.
28
www.mepca-engineering.com
Surface stitching with a single sensor In this approach to multi-view processing, multiple scans from a single sensor are combined to build a 3D surface to which the engineer can apply measurements. This is a cost-efficient alternative to multi-sensor inspection systems, as it achieves the same results with just a single sensor and an XY
Figure 1
motion system or robot. Stitching a scan is carried out with the built-in Surface Stitch tool in Gocator, which combines multiple scans from one snapshot sensor into a single 3D height map. The stitched 3D scan is ready to use as input by any other native tool requiring a surface to carry out advanced measurement.
Accelerated inline inspection When you need to process large data sets (i.e., generated from multiple-views) at production speed, you can choose to accelerate your inspection cycle times using a smart vision accelerator. LMI’s solution, GoMax, instantly adds 1.5 Teraflops of GPU-driven data processing power to your sensor or sensor network for faster inspection cycle times and improved overall inspection performance in applications where multi-view processing is required. lmi3d.com
THE FUTURE DEPENDS ON OPTICS ™
FOR SHOCK & VIBRATION Our range of ruggedized machine vision lenses are specifically designed to perform in environments with high amounts of movement, shock and vibration. Minimize pixel shift and maintain the stability and accuracy of your machine vision system. Stay On Target With Ruggedized Imaging From Edmund Optics Find out more at
www.edmundoptics.co.uk/ruggedized
UK: +44 (0) 1904 788600 I GERMANY: +49 (0) 6131 5700-0 I FRANCE: +33 (0) 820 207 555 I sales@edmundoptics.eu
ImagINg & VISIoN
Powering machine vision lighting Getting great results from a machine vision system requires great images. Jools Hudson, Head of Marketing at Gardasoft Vision, looks at the role LED lighting controllers play when developing a machine vision system.
N
o amount of software processing can recreate data that hasn’t been captured on your camera sensor, and reproducible perfect images need accurate and consistent lighting control. Most machine vision systems use an LED illumination source with one of three drivers: a simple voltage drive, voltagedrive with pulse width modulation (PWM) or a constant current drive. Simple voltage drive can be the cheapest option, but it has significant practical disadvantages. Although LED lights are often specified by voltage, it is actually the current flowing through them that dictates the brightness obtained, not the supply voltage. Figure 1 shows that a tiny change in voltage creates a much bigger change in the current flowing, which in turn creates a large change of brightness. This means that simple voltage drive cannot be used to adjust the lighting intensity accurately. In addition, any fluctuations in the system supply voltage may cause fluctuations in lighting levels. PWM voltage controllers provide limited intensity control by pulsing the light on and off so that the average intensity is approximately what’s needed. Pulsing the light on for longer increases brightness, but there are practical disadvantages. The PWM cycle speed dictates how many intensity steps are available for adjustment. This is often limited to about 100 coarse levels. The PWM pulses are usually independent of camera exposure timing which can cause intensity variations between exposures, particularly for fast systems. Faster PWM pulsing can reduce this effect, but these high-speed voltage pulses can cause EMC interference in neighbouring systems. Constant-current controllers are a better choice because they directly adjust illumination levels through accurate control of the current flowing
30
www.mepca-engineering.com
Figure1: The relationship between voltage, current and intensity of LED lighting
through the light with no fundamental limitation on the number of adjustment steps. A typical Gardasoft controller will provide 3,600 steps of brightness with no risk of EMC interference.
Strobing and overdriving Continuous illumination using either voltage-drive or constant-current controllers is sufficient for some applications, with a light set up to operate below 100 per cent brightness so it can be increased later if needed. However, illumination intensity falls as an LED heats up. This effect can be minimised by pulsing the LED briefly so that the light is only on while the image is captured. Pulsing both prolongs the LED lifetime (which degrades with on-time), and can also prevent image blur on fast production lines. Effective strobing relies on consistent and repeatable square light pulses with rapid rising and falling edges. This can be achieved easily with a constant current controller but is more difficult for a PWM controller, particularly if there is a long cable between the controller and the light. If the pulse edges have a poor profile, the intensity of the illumination is likely to vary between exposures. A powerful extension of strobing is overdriving, where short pulses of current higher than the maximum rating are driven through the LED. This can produce
much brighter illumination than the maximum specified by the device manufacturer and will not damage the light if a good strobe controller is used to carefully manage the frequency, pulse duration and current to prevent heat build-up. Voltage-based lighting controllers including PWM versions that supply a standard 24V cannot overdrive lights, and those that offer the option of an additional, higher voltage for overdrive suffer from an unpredictable discontinuity in brightness between the two voltage levels. Constant-current controllers, however, can achieve a safe and accurate overdrive and most can operate with complete flexibility in either continuous, strobe or overdrive modes.
High-speed lighting control High-speed inspection lines, systems using a single imaging station to capture multiple images and line scan applications all require short camera exposures and precision lighting control. Some more advanced PWM systems can synchronise the PWM cycle with the camera shutter, but this can be difficult to implement in practice. Constant current lighting controllers offer much more flexibility at high speed because they allow the intensity and duration of lighting to be precisely adjusted and are not tied to a PWM cycle. www.gardasoft.com
2530 3D Smart Sensor | Blue Laser
HIGH SPEED 3D SCANNING AND INSPECTION FOR SHINY AND CHALLENGING SURFACES
GocatorÂŽ 2530 provides 3D blue laser profiling, measurement, and inspection at speeds up to 10 kHz. Easily integrate this all-in-one smart sensor for robust inline inspection of shiny materials (e.g., batteries, consumer electronics), low contrast targets (e.g., tire sidewall), and for general factory automation applications.
Discover Gocator 2530
visit www.lmi3D.com/2530
Power & energy MAnAgeMent
Save energy by controlling your fan speed Andrew Ward, Technical Support at Axair Fans UK, explains how better control of fan speed equates to better control of energy consumption and energy costs.
A
n inverter is used to vary the speed of a motor to match the required load. In most cases, fans are specified to match the maximum ventilation requirements of the setting. Installing an inverter allows users to control the speed of their fan motor to match the actual ventilation needs, rather than run the fan at full power continuously. An inverter can vary the motor speed with no loss of efficiency. Inverters can be used for simple speed control permanently or linked to controls which can change between pre-set speeds, dictating the amount of time that the fan runs at full speed. When linked with a sensor system, inverters can prove to be even more effective by controlling the motor’s performance based on any number of predefined settings. These settings usually relate to factors like temperature, airflow or humidity and remove the need for manual adjustment. Reducing the speed of a motor will reduce the amount of energy needed to power it.
32
www.mepca-engineering.com
The reduction in energy can be by as much as eight times the reduction in speed. The resulting energy savings usually pay for the inverter in a relatively short time. Due to recent ErP (Energy related Products) regulation changes, some motor sizes and efficiencies can now only comply if used with an inverter. While inverters play a key role in energysaving initiatives, there are further benefits to speed control. Reducing the amount of time that the motor runs at full speed will reduce the strain on a motor and any related components. A motor only works as hard as it needs to helping to prolong the service life of the motor and the whole system. This results in lower maintenance requirements and, again, lowers costs. The improved control provided by an inverter also makes it easier to stop a ventilation system; another factor which can impact on the wear and tear of the mechanical components. Other forms of fan control, such as
dampers, change the resistance of the system with the fan on full speed and so do not save energy. Inverters also make it easier to commission the fan with the equipment it is extracting from as the system can be controlled in one place, and there is no need to make alterations to ducting. Axair’s inverter models can run off a 230/1/50 electrical supply and convert it to a 230/3/50 supply into the fan motor. Other models run off a 400/3/50 supply with a 400/3/50 to the fan motor. The inverter is simple to set up and easy to use. It has an on/off switch and a potentiometer to control the speed on the front of the unit. There are two levels of ingress protection available; IP20 or IP66. The IP66 version is suitable for hose down but if installed outdoors may need additional protection. The inverter also has the option of being connected into the Building Management System. www.axair-fans.co.uk
UK made Industrial Laminates Our product development and manufacturing expertise aren’t the only reasons our customers choose us. They want our products precisely machined exactly to their requirements, without fuss and on budget. All at our UK based plant. ▲ PAPER BASED LAMINATES (SRBP) ▲ FABRIC BASED LAMINATES (SRBF) ▲ GLASS BASED LAMINATES (SRBG) ▲ COMPOSITE / SPECIALIST ▲ GLASS FIBRE TUBES ▲ COMPOSITE, SRBP & SRBF TUBES
▲ +44 (0)1772 258245 ▲ sales@attwater.com ▲ www.attwater.com AttwaterGroup
Attwater Group
CONNECTIONS Anti Vibration Products, Mounts & Bushes
Industrial Fasteners & Components SD Products Ltd Unit 1, Fulwood Road South, Fulwood Industrial Estate, Sutton-In-Ashfield, Nottinghamshire, NG17 2JZ T: +44 (0)1623 655 265 E: sales@sdproducts. co.uk W: www.sdproducts. co.uk
Fibet Rubber Bonding (UK) Ltd Unit 9 Dale Mill, Hallam Road, Nelson, Lancashire, BB9 8AN T: 01282 878200 E: sales@fibet.co.uk W: www.fibet.co.uk
Control Systems Beckhoff Automation Ltd. The Boathouse Station Road Henley-on-Thames, Oxon RG9 1AZ T:+ 44 (0)1491 410539 E: info@beckhoff.co.uk W: www.beckhoff.co.uk
Machine Tools, Factory Automation & Laser Processing Yamazaki Mazak UK Ltd Badgeworth Drive, Worcester, WR4 9NF T: 01905 755755 E: sales@mazak. co.uk W: www.mazakeu. com
Displays & Sensors MMS Electronics Ltd Unit 3, Whiteley Court Pool Road, Pool in Wharfedale, Leeds LS21 1FR T: +44 (0)1943 877668 E: sales@ mmselectronics.co.uk W: www. mmselectronics.co.uk
Power Conversion Products Powersolve Electronics Ltd Unit 8A Arnhem Road, Newbury RG14 5RU, Berkshire T: 44-(0)1635-521858 E: sales@powersolve. co.uk W: www.powersolve. co.uk
Dust & Fume Solutions Impact Technical Services 3 Kingsley Street, Leicester, LE2 6DY T: 0116 244 8855 E: enquiries@ impactts.co.uk W: www. impacttechnica lservices.co.uk
Electronic Filters Kemo Limited Unit 1, Dene Yard Green Street Green Road,Dartford, Kent, DA2 8DH T: +44 (0)1474 705168 F: +44 (0)1474 705366 E: uk@kemo.com
Flow Meters iCenta Controls Ltd Unit 3 The Woodford Centre, Lysander Way, Salisbury, SP4 6BU T: +44 (0) 1722 442 307 F: +44 (0) 8445 430 845 E: sales@icenta.co.uk W: www.icenta.co.uk
34
www.mepca-engineering.com
Sensors
Stainless Steel Fittings Nero T: 0121 665 3900 F: 0121 665 3903 W: www.nero.co.uk
Standard Machine Elements Elesa 26 The Moorlands, Metheringham, Lincoln LN4 3HX T: 01526 322670 E: sales@elesa.co.uk W: www.elesa.co.uk
Temperature and Humidity Measurement & Calibration Rotronic Crompton Fields Crompton Way Crawley, RH10 9EE T: 01293 571000 E: instruments@ rotronic.co.uk W: www.rotronic.co.uk
Test & Measurement HBM United Kingdom Limited Millbrook Proving Ground, Station Lane, Millbrook, Bedfordshire MK45 2RA T: +44 (0)1525 304980 W: www.hbm.com W: www.hbm.com/ hbmshop-uk
Valves - Actuated & Manual Carlo Gavazzi UK Ltd 4.4 Frimley Business Park Frimley GU16 7SG T: 01276 854110 F: 01276 682140 W: www.carlogavazzi. co.uk IFM Electronic Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD T: 020 8213-0000 E: enquiry.gb@ifm.com W: www.ifm.com Monitran Monitor House, 33 Hazlemere Road, Penn, HP10 8AD T: 01494 816569 E: info@monitran.com W: www.monitran.com
Albion Valves (UK) Ltd T: 01226 729900 E: sales@ albionvalvesuk.com Dixon T: +44 (0)1772 323529 E: sales@ dixoneurope.co.uk W: www.dixoneurope. co.uk
Water & Chemical Storage Drayton Tank & Accessories Ltd T: 0871 288 4213 E: enquiries@ draytontank.co.uk W: www.draytontank. co.uk
29 SEPT - 1 OCT 2020 NEC, BIRMINGHAM SCAN TO REGISTER
WHERE PRODUCTIVITY MATTERS See the latest processing and packaging machinery, robotics and machine vision in action Network with industry peers and gain valuable insight at our must attend seminars
ppmashow.co.uk OWNED AND ORGANISED BY
PPMA Group of Associations is a trading brand of PPMA Limited.
The New KR IONTEC _ the robot for every task in the medium-payload range An all-in-one solution. With the KR IONTEC, you are opting for pure performance and the largest work envelope in the medium payload category. Maximum dynamics and minimum cycle times. Perfection in every installation position. In the future, you will master all tasks with just one robot.
Utmost flexibility during the life cycle Sustainably cost-efficient For nearly all applications Largest work envelope in its class Performance redefined • 30% smaller footprint • 10% more streamlined disruptive contour • 20% less weight • Top dynamic performance • A1 hollow shaft with Ø 119 mm for optimized energy supply Adaptable to processes at the push of a button!
For more information, contact KUKA at sales@kuka-robotics.co.uk or call 0121 505 9970 www.kuka.com