Annual Review 2014
Annual Review 2014
Murrelektronik - see more on page 5
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Introducing “EPLAN Experience” Engineers and designers are under increasing pressure to enhance in production whilst reducing costs and time to market. Ken Christie, Director of EPLAN UK, introduces
challenges in controls engineering they are facing in today’s fast evolving data, and new types of connectivity. All
the new concept aims to optimise the
reduced to one common denominator:
who want to do more with fewer resources, accelerate product development and free product development resources for other value-added activities.
P8), is highly modular and consists of eight “Fields of Action” which are
The Challenge for Engineering
company wishes to optimise and make
The “internet of things” - in which connectivity and can send and receive
easily and smoothly with each other. The consequence is that the world
require and include: IT Infrastructure – integrating a customer’s EPLAN software into their IT infrastructure to ensure it is high-performing.
working environment. This helps settings in the most optimal way.
world of automation engineering of plant and machine design. New technologies and new products are driving down the time to market – and companies need to respond agilely to stay ahead of the competition.
Codes & Standards companies to comply with all the
Optimal And Flexible Working Processes
Product Structure – provides a clear method for structuring machines and systems.
A key factor to meet the challenges of engineering is to make sure you
Design Methods – analyse,
processes for your automation and EPLAN
driven international programme that aims to optimise engineering with the necessary tools, know-how, standardisation and structure. 4 - Automation Update December 2014
Project Management – EPLAN
Platform set up – allows a customer
parts of the world now connected challenging ways.
Process Integration – integrates
documentation for production. This includes the new IEC 81346 standard.
selected design methods with the aim of reducing engineering efforts – evaluates and automates design processes stepThis will reduce errors, integrate data technology in processes and ensure consistency within engineering.
hosting an Industry 4.0 event at the National Space Centre, Leicester with and Igus. The educational event will include a variety of workshops where what it means to your company and
You can register for tickets here industry-40-tickets-14192105971 For further information on EPLAN co.uk or contact us on 01709 704100.
Single wire connection? Passive distribution boxes? question sparks intense discussions in the electrical Fieldbus? This departments of many companies. 360° yellow ring markings. This makes it easy for machine operators and maintenance personnel to clearly recognise the safety ports.
conductors, terminals and multi-pole connections. Herbert Assner valves, we use a two-channel switch off for safety reasons”.
Here Murrelektronik presents its approach to this question using This approach has saved space, installation time and has proved to Germany company Schuster Maschinenbau GmbH to illustrate it’s be error free. system consultancy service – CONNECTIVITY. Schuster has four main pillars: it produces vertical turning machines, impact cutting systems, automation solutions and custom machines. They deliver 35 machines and systems a year. The majority - about 30 machines - are vertical turning machines. sped up installation, as it's no longer necessary to terminate 23 wires, The company distinguishes three different types of turning cells with integrated fast handling systems.
error source is eliminated, when the machine is commissioned”.
Across the globe, Murrelektronik System Consultants create the best installation concepts by looking individually at each machine. Working together with customers, Murrelektronik analyse the entire process according to the TCO perspective, identifying the most suitable connectivity technology from more than 42,000 products. Products that have international approvals, have been pre-engineered and work perfectly together. And the best part is: our System Consultancy advice is completely free!
A service adapter offers an additional option to visually check all I/O signals. If all connections are error-free, the test LED on the control
Schuster is a mid-sized company with strong customer orientation: many machines are designed according to customer requirements. Murrelektronik worked closely with Herbert Assner, Manager of the electrical department at Schuster. One of his responsibilities is installing and connecting the I/O points on the machines into the control cabinet and connecting them to the controller. Three different installation concepts are established in the market: conventional parallel wiring, passive distribution technology and installation concept is the relationship between the I/O points and their distance to the machine.
installation concept creates a clear separation between the control we have a simple separation for transport that speeds up on-site commissioning. Additional connectors to separate the machine from
Free System Consultation! Book an on- site visit and receive a bespoke technical report Outlines practical and cost saving solutions Compares range of different concepts Includes visualizations and technical data Call 0161 728 3133 Email: firstname.lastname@example.org In the case of installations with a high I/O density that require
points is a typical number for a Schuster machine and they are
system Cube67. This system is used on their impact cutting machines, either a pre-made and pre-tested pluggable or over moulded and has proven to be the most cost-effective solution. homerun cables. These can be quickly installed and prevent wiring each I/O point. The time required for installation, commissioning and support of our System Consultants who will design tailor-made play resulting in lower total costs. Passive distributors gather the and Customer Service Team, Murrelektronik combines the best technologies in automation with optimum service. controller within the control cabinet.
Automation Update - 5 December 2014
TEXTILE COMPANY CUTS YARN PRODUCTION ENERGY COSTS WITH ABB DRIVE A specialist manufacturer of yarn for sports equipment is saving £18,000 a year on energy costs with the installation of variable-speed drives (VSDs) from ABB.
Textiles replaced a mechanical speed control system (Variator) on its spinning motor and VSD, cutting out failures and stoppages completely and saving energy costs. The company, based in Gloucestershire, manufactures cloth for billiard and snooker tables, as well as cloth for many well-known tennis ball brands such as Slazenger and Dunlop. A critical part of the process is the spinning machines, which take wool slubbing and form it into a continuous yarn ready for processing. The problem with these machines is their speed control system. The motor runs at full power constantly, with the speed of the spinning machine controlled via a system of variable diameter pulleys the system suffers a high number of mechanical failures and spare parts are Alan Harnden, Technical Manager for WSP, says: “We wanted to get rid of the variator system, as we were suffering breakdowns once a fortnight. This entailed a major strip down to get these pulleys out, taking two men up to one day. We were also losing a lot of production time. The spinning machines feed other machines downstream, which affected production volumes. As we are a 24/7 operation, these breakdowns were very disruptive.” The company also had to have certain parts specially made, adding to the cost.
6 - Automation Update December 2014
Textile company cuts yarn production energy costs with ABB drive WSP researched VSDs as an alternative method of speed control: “Essentially we had two options - get VSDs or get a new spinning machine. These machines are very expensive, so buying a new one was not really viable.”
VSD itself, with commissioning support
solution. “The ABB general purpose
for us is that there is no down time since the VSD was installed. We have had no need to think about them and no spare parts are needed.”
control panel and we could pick up the original signals. The VSD just slotted in, making it very easy and quick to connect up –other vendors’ solution This would have required extra expense and time as new panels would take a
WSP asked ABB authorised value provider, APDS, to provide a solution. “We chose APDS because they are a local supplier, are very competitive and could supply a product that customer service excellent. They are very customer focused and know what engineers need.” Alan Jones of APDS says: “We selected
project, three more machines have been converted to VSD operation, with WSP carrying out all commissioning.” Says Harnden: “There have been some
The company is achieving better production quality as the ability to vary the speed allows then to adjust the tension of the yarn, giving a more controllable stop. This is gentler to yarn and avoids the tangling of the yarn that occurred on the previous method. come into their own and we would now every time.” ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs
â€“ THE PLUS FOR ADDED FLEXIBILITY The next generation The innovative multi-protocol fieldbus system from Murrelektronik, which has radically simplified and modernized decentralized installation has taken a step further with a plus. The single bus node can support up to 20 I/O modules in a 30m circumference and with a reduced number of cables. The range of I/O modules continues to grow and includes digital and analogue ports, safe outputs, logic, counter, valve island, temperature, I/O link etc. Both IP67 or IP20 are available. Cube67+ : a truly flexible system. t.PSFPQUJPOT t.PSFGMFYJCJMJUZ t.PSFEJTUBODF t.PSFQFSGPSNBODF
Cube67 â€“ the modular bus system
Murrelektronik Ltd 5 Albion St, Pendlebury Ind.Estate, Swinton, Manchester, GB M27 4FG
Phone 0161 728 3133 www.murrelektronik.co.uk email@example.com
PUTTING SAFETY FIRST WHEN WORKING WITH ROBOTS An introduction to DCS safety
Ensuring worker safety should be the prime consideration in all robot applications, especially when humans and robots may need to share the same workspace. “Robot safety is an issue that transcends sectors or applications,” says Darren Whittall, technical manager at FANUC UK. “In addition to regulatory requirements, there is also a moral obligation to ensure that the workforce is properly protected. If overlooked, robot-related accidents can have implications too,” he warns. Unlike more predictable automated operations, robots can produce powerful and rapid movements through a large operational space, and the path a human to accurately predict. Most robot-related accidents occur during non-routine operating conditions. For example, when an operator temporarily enters the robot’s working envelope to complete programming, maintenance, testing, setup, or adjustment tasks. Until recently, the only acceptable way to make a robot safe was to banish humans from the robot working area using physical guarding solutions. However, the development of softwareenabled safety technology has changed this. Software-enabled safety is now becoming accepted practice. Dual Check Safety (DCS) Position & Speed Check software, for example, is a package of software-based safety options integrated into FANUC’s R30iA and R30iB robot controllers, ensuring safe monitoring of robot position and speed. It allows safety zones to be quickly and easily designed, and removes the need for hardware such as limit switches and zone switches. FANUC’s safety technology is well-proven, being based 8 - Automation Update December 2014
on a design that has been employed for many years in its CNC products. The BS EN ISO 13849-1. software-based safety solution when compared to hardware-based solutions: “Having less hardware means that safety can be integrated more cost-effectively. Traditionally, it has been necessary to bolt a number of sensors onto a robot to determine where the robot and its arm are positioned within the cell at any time. This can cost several thousand pounds, depending on the application and the number of sensors needed. With a software-based solution these sensors are not required, reducing hardware costs, not to mention the physical time it takes to install the sensors.” Darren estimates that it is possible to achieve a 50% cost reduction for a small single robot system with multiple safety devices, just in terms of the hardware savings versus a software-based safety solution. DCS Position Check features ensure that the robot stays inside designated safe areas, and the robot can be locked out of areas where it might cause a hazard. Position Check can identify multiple areas of the robot, including any attached end effectors. The safe zones can be modelled within the software using geometric shapes of up to eight vertical lines each. These areas can be adapted – enabled and disabled to change the areas that the robot is not allowed to enter – depending on the task it is undertaking and the changing these adaptive zones allows for a more compact cell layout and allows humans
and robots to safely share a common space in a controlled way. The DCS Speed Check functionality robot speed. Speed can also be changed to ensuring that the robot holds a position when necessary. “Often, there must not move while the operator is undertaking a loading procedure,” Darren explains. Safe IO Connect. This allows the robot controller to manage the enabling/ disabling of position and speed functions of other equipment in the designated area due to an external event – such as an operator stepping into a set zone. including DeviceNet Safety, EtherNet/ IP Safety and PROFInet Safety. FANUC’s DCS offering also includes the optional Safety PMC (programmable machine control). An addition to the standard PMC, it allows the robot to control the entire cell, including the safety functionality, negating the need for additional dedicated safety hardware, such as a safety PLC. There are many features available within FANUC’s DCS Position & Speed Check to ensure worker safety in robot applications. In addition to achieving this in the most cost-effective way, it also has the potential to enhance productivity by allowing humans and robots to inhabit the same space in a controlled and safe manner. www.fanuc.eu
High Precision MEMS Inertial Sensors and Systems
Recent developments mean that Silicon Sensing can now provide high precision MEMS gyroscopes and accelerometers with low output noise and bias instability able to meet the accuracy requirements for all applications. High accuracy
Excellent bias stability
Low output noise
Robust and reliable
2014 INDUSTRY AWARD FOR COMPANY GROWTH
Fortress Technology (Europe), walked away with the prestigious “2014 Exceptional Sales /Company Growth Award” at this year’s Process and Packaging Machinery Association (PPMA) Group Industry Awards held at the end of which was taking place at the NEC. This event brings together industry suppliers and customers to recognise the contribution and achievements of the PPMA member companies. There were a record number nominations within this particularly hard fought category which is judged by an independent panel of industry based experts. The award was presented by Mr John Kehoe, Managing Director of TekPak, along with co-hosts for the evening Rory Bremner and Helen Fospero. Fortress, who started manufacturing at their Banbury site at the end of 2010, manufacture and supply metal detection equipment for industrial use. The largest sector being that of the food industry where the use of metal detectors within the production process is an essential part of providing conformance and peace of mind when it comes to satisfying food safety audits. The judges concluded “Fortress Technology far exceeded their budgeted and forecast sales increase in 2013 which in itself is an exceptional achievement. The fact that this is being done from a UK based manufacturing base is also very heartening”.
The results were not luck either, but the result of a focused approach across all levels of the business which included establishing KPI’s and targets. The cornerstones of which included: UK Manufacture, Export Growth, Employee Fortress Technology (Europe) Ltd is a wholly owned subsidiary of the privately owned Toronto based company Fortress Technology Inc. Over 1000 Phantom and Stealth metal detectors have now been manufactured and Fortress Technology is the only Metal Detection Manufacturer that, since its inception in 1996, custom manufactures for their customers and offers a Never Obsolete Commitment. In addition to product manufacture the company offers a range of after sales service and support services including training, preventative maintenance plans, spare parts and validation visits. For further product information please contact:
Tel: 01295 256266 Email: firstname.lastname@example.org or visit www.fortresstechnology.co.uk
10 - Automation Update December 2014
Innovate UK 2014: BIGGER and better than ever
It was a record-breaking 2 days with over 2,000 attendees from 30 countries and a stellar line-up of speakers. Some of the brightest and best innovators on the planet brought the wow factor to London last week at Innovate UK 2014. More than 2,000 attendees streamed through the doors on both days to network with speakers, exhibitors and each other. 4 ministers, a smoothie and a fashion show Highlights of a diverse programme of speeches and seminars included: Ringing endorsements of the importance of innovation to UK plc - from no less than four government ministers Richard Reed’s story of how Innocent Smoothies went from start-up to one of the UK’s most recognisable brands The ‘high-tech meets high fashion’ show which brought two exciting days to a stylish close
from fellow delegates about other applications for Loopwheels. Lots of good links made with people. Our Twitter account has gone crazy! Steve Lindsay, CEO of Lontra added:
“ We were far busier than we ever expected. Lots of interest from potential investors, partners and customers - not just from the UK but from around the world. We haven’t had a moment’s peace, but that’s good.
Iain Gray, CEO of Innovate UK said: Bigger than Christmas The buzz was evident even outside the room. Live streaming It’s been a triumph. More attendees helped bring the event to people who couldn’t be there and exhibitors than ever and a long list themselves. At one point #InnovateUK2014 was the top trending of inspiring speakers. The energy and Twitter hashtag in the UK - ahead of Christmas and Benedict enthusiasm I’ve seen for making innovation Cumberbatch’s engagement. happen is truly inspiring. Connect, connect, connect For some people Innovate UK 2014 was a chance to renew friendships, for others it was an opportunity to build new relationships with potential customers, partners and investors.
The common message from attendees was that the event surpassed their expectations. Exhibitors in particular praised the diversity and quality of the attendee mix - which led to many interesting dialogues about new markets and applications for their technologies. Gemma Pearce, co-founder of Loopwheels speaks for many: An incredible level of interest in our products. Some great ideas 12 - Automation Update December 2014
Breakthrough Motor Cures Reliability Challenges For Synseal A company producing extruded
Synseal Extrusions Ltd, based in Nottinghamshire, is one of the UK’s largest PVC-U extrusion companies, producing system solutions for windows, doors, conservatory roofs and orangeries. Its Line 20 and Line 21 used servo motors that were becoming increasingly unproductive. Steve Scurrell, Works Manager for Synseal, says: “The existing extruder motors were 20 years old and largely obsolete. Although we kept refurbishing them, they were lasting for shorter and shorter times between refurbishments. We knew that if we did not replace them, either could fail at any time and we would lose the use of an extruder line completely. Although we may not lose a huge number of hours, even a minor loss of production time could have a negative effect on our business productivity and this is something we would want to avoid wherever possible.” At this time, ABB was looking for a suitable constant torque application to test its new SynRM motor. Phil Nightingale, of ABB authorised value provider Inverter Drive Systems (IDS), says: “This was a standard constant torque extruder application, which was ideal to test the capabilities of the SynRM. The servo motors were long and thin. Although they could have been replaced by normal squirrel cage installation as they offer more power for their size than conventional motors.”
frame sizes smaller than a conventional induction motor, work with stringent space restrictions or for refurbishing existing machines. It offers the high power density of an equivalent permanent magnet motor with the robustness of an asynchronous squirrel-cage motor. Because the rotor runs cooler than other technologies, the bearings also run much cooler, making the motor much more reliable. The two 25 kW motor, together with matched ABB ACS880 drive, was installed on the extruder. IDS installed the drive, while Synseal installed the SynRM motor itself. This installation included a force vent kit, foot mount and HTL encoder. As well as curing the reliability and obsolescence problems, the SynRM motor also cut 20 percent off the running costs of the extruder, saving £754 a year on electricity. permanent installation and we have another machine to spare motors off the shelf and know that we can keep our extruders running.”
solution, then we were happy to go ahead.”
ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 150,000 people.
Offering up to 40 percent more power density than conventional induction motors, a SynRM can be up to two
For more information please visit www.abb.co.uk
Says Scurrell: “We have done a lot of work with IDS over
Automation Update - 13 December 2014
The Ppma Show 2014 Makes Its Triumphant Return To The Nec
Showcasing A Hotbed Of Innovation
The 2014 One to Watch
14 - Automation Update December 2014
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HBMâ€™s Genesis Highspeed GEN3t data acquisition device is intended for high-speed data acquisition primarily with test bench applications..
16 - Automation Update December 2014
The Silicon Sensing road to precision MEMS IMUs for demanding engineering applications Silicon Sensing is an Anglo-Japanese joint venture company established in 1999 Coriolis VSG (Vibrating Structure Gyroscope) technology with the emergence of MEMS as a mass production process. Aerospace way back in the 1980s and the sensor inside resembled a miniature ‘wine glass’ of piezo-ceramic machined from a solid bar billet. In the ‘90s the
resonating ring gyro sensor – VSG3. Since its formation Silicon Sensing has shipped 30 million MEMS inertial sensors. It now has three different MEMS gyro sensor technologies;
Silicon Sensing; SSS controls all the wafer level MEMS processing in its assemble electronic modules and assemblies before being calibrated by
relentless striving to improve the sensors which will help keep Silicon Sensing at the forefront of this burgeoning industry.
Automation Update - 17 December 2014
CAD solutions for the UK automotive industry Automotive original equipment manufacturers (OEMs) and their suppliers are under unrelenting pressure to design automotive product that exudes quality, is pleasing to the eye, and appeals to buyers, hundreds of conceptual design details must be vetted. Automotive designers must then shepherd the winning concept through design review, evaluate it for manufacturability, and plan for production— all to ensure a beautiful, quality vehicle. Manufacturers, meanwhile, are in an endless race to introduce the newest design trends to market as quickly as possible, while avoiding costly design changes. This creates both time and quality pressures in the automotive product development cycle. What if automotive design software had the tools needed to visualise a vehicle from conceptual design through to engineering and production? High-end photorealistic visualisations and virtual prototyping enable better design decisions up front and help speed the best concepts through the product development process. In the automotive design and development process, communication gaps often arise between product development and management, and between design and engineering teams. Even in the earliest stages, designers must communicate and present design intentions to management for approval. But management needs visual aids to understand what the actual vehicle will look like, and to help inform their decision making. An innovative and powerful software solution for high-end 3D visualisation, Autodesk® VRED™ solutions evolved from VRED enables the automotive industry to create high-quality visualizations for use from conceptual design to design review to engineering. You can make better decisions based on realistic parameters and share one virtual prototype helps you take advantage of today’s global trends and prepare for tomorrow’s demands. Man and Machine offer a range of services and consultancy for the automotive industry including VRED software, training and support. For more information call 01844 263700, email firstname.lastname@example.org or visit www.manandmachine.co.uk/industries/manufacturing/automotive-transportation/automotive
18 - Automation Update December 2014
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