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Vol. III Issue 12 DECEMBER 2012 Rs.50/- Annual Subscription Rs.500/-

Connectors in Industrial Automation:


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EDITOR’s NOTE

Published by : A.K. Industrial Automation Media Pvt Ltd 11,Krishnan Koil Street, 3rd Floor, Rotary Lane, Chennai 600 001 Tel: +91-44-32500513 Fax: +91-44-25243290 Email: sales@iamedia.in info@iamedia.in Web: www.ia-community.in Editor : S. Y. Ahmed Khan Asst. Editor : M. Arul Raj Copy Desk : J. Babitha Yazeer J. Veloo Business Development : Nawaz Ahamed Khan Marketing : Arun Prabu - Southem Region Saradha - Western Region Sanjay Singh - Northern Region

A

s this issue of Industrial Automation Pages reaches you we continue our connection with our readers by focusing our cover story on Connectors.

The Cambridge Advanced Learner’s Dictionary defines a connector as “a device at the end of a wire in a piece of electrical equipment, which holds the wire in position.” This is the literal definition of the word connector. However the beauty of the English language is that many words can be interpreted to have different meanings. Our team believes that Industrial Automation Pages is also a connector which connects technical information, product updates, cover story, industrial news, new products, trade events etc which it puts forth in each issue to with you, its dear readers. Hence in this issue our cover story focuses on Connectors. We hope this issue further strengthens the bonds between us and our readers and that this connection between the magazine and its readers becomes stronger and grows in leaps and bounds each month, each year and each decade. Please contact us with your suggestions, feedback or any other information you consider relevant, at info@iamedia.in .

Pagination : Geetha

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Editor

Subscription : Geetha Chennai:09789907275 Mumbai:09320283997 Delhi: 09350470074 Bangalore: 09381053490

Industrial Automation Pages is targeting and promoting latest industrial technologies to the end-user in the process and manufacturing sectors. Views expressed are not necessarily those of publisher of this magazine and / or its agents/representatives. Although efforts has been made to ensure the accuracy of information given in this publication, the authors, publisher, agents, representatives and/or servants shall not beheld responsible or in any way liable for any errors, omissions or inaccuracies in this publication whether arising from negligence or otherwise whatsoever, or for any consequences arising there from. The inclusion of any product does not mean that publisher advocates or rejects its use either generally or in any particular field or fields. The information contained within should not be relied upon solely for final treatment decision. All rights reserved. No part of this publication may be reproduced in any form, stored in or introduced into a retrieved system, or transmitted, in any form or by any means (electronically, mechanically, photocopying, recording orotherwise), without prior written consent of the copyright owner. Permission to reprint must be obtained from the publisher. Advertisements are subject to editorial acceptance and have no influence on editorial content or presentation. IndustrialAutomation Pages does not guarantee, directly or indirectly, the quality of efficacy, of any product or service described in the contents, advertisements and/or other material published in this publication. Published by S.Y. Ahamed Khan on behalf of A.K. Industrial Automation Media. Pvt Ltd from 11, Krishnan Koil Street, 3rd Floor, Rotary Lane, Chennai 600001 and Printed by M.Poongodi at Sree Mugambikai Hi-Tech Prints, No. 90/51, Surappan Street, Triplicane, Chennai 600005 Editor: S.Y. Ahamed Khan

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CONTENTS

Connectors in Industrial Automation:

Bringing Together Simple and Complex Devices Worldwide NEWS

08 Products

22 Technology

• Red Lion Wins Multiple Awards at the 2012 Industrial Automation Show in China

• Red Lion Supports 4G LTE on Sixnet IndustrialPro 6000 Cellular Routers

• Danfoss Opens New Cold Chain Centre in India

• New Solutions for Integrated Motion on EtherNet/IP from Rockwell Automation Use Less Energy and Shrink Application Footprint

• UCB Chooses Emerson Automation and Operations Management Technologies for One of Europe’s Largest Biotech Plant • Advantech wins the First Ever iF Product Design Award 2013 • Schneider Electric secures over 100MW in India with the new Conext Core XC Inverter

• Lenze FAST: More time for what really matters • Banner Engineering Releases Online Tower Light Configurator • Communication the direct way

• ABB develops world’s most powerful highvoltage direct current converter transformer

• OMRON : E5AC Digital Temperature Controller

• Emerson to Deliver Control Technologies for Nevada Solar Project to Power 75,000 Homes

• Banner Engineering Introduces Two Sensors for Hygienic and Washdown Environments

• Ten years of the configurable control systems PNOZmulti – and the success story continues.

• Hybrid paper type recorder, combines functions of paper recorder and paperless recorder

• Rockwell Automation Bundles Keys to Machine Control Design in One-Stop Solution • Emerson Wins $33 Million Contract to Upgrade Automation on Statoil Platform in Norwegian North Sea • Atlas Copco (India) Ltd. continues its run in Top 500 of manufacturing industry in India

6 INDUSTRIAL AUTOMATION PAGES > December 2012

34

• Red Lion Adds N-Tron 716M12 & Sixnet SLX Switches to New Industrial Networking Portfolio • Advantech Supports Fieldbus Couplers — APAX-507x Series • New Danfoss Industrial Refrigeration App for your Smartphone • Rockwell Automation Expands MCC Portfolio With Embedded EtherNet/IP Capabilities • Flexible operating concept: electromechanical buttons supplement multi-touch functionality • Easily Manage Your PROFIBUS Devices via Modbus TCP

Case study

38

Haas Makes Light Work

33 A truly total solution for Factory Automation

Event news EVENT CALANDAR

42 43


NEWS Red Lion Wins Multiple Awards at the 2012 Industrial Automation Show in China Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, today announced that its ready-to-deploy visual management solution, the ProducTVity Station™, has been recognized by CA168, a group of leading Asian technology and automation publications, as the Most Competitive Product at the 2012 Industrial Automation Show (IAS) in Shanghai. Additionally, Control Engineering China, a leading Asian technology publication, has named Red Lion’s ProducTVity Station and Crimson 3.0 software as Editor’s Choice Award winners for 2012. The awards were presented during ceremonies in Shanghai last week. “Many great features set Red Lion’s ProducTVity Station and Crimson software apart from other solutions on the market today,” said Mr. Youlong Lou, techni-

cal director at Bosch Power Tools China co., Ltd. “For instance, the solution gives us the flexibility required to quickly make changes in real time – even when controlled remotely.” Editor’s Choice Award winners are selected by a panel of Control Engineering China’s senior editors and local automation industry experts. Winners are decided based on overall excellence in the two key areas: technical innovation and the market influence of the product.

“Winning these awards speaks to Red Lion’s integrity and commitment to delivering industrial solutions that help increase productivity,” said Michael Wang, general manager of Greater China for Red Lion. “We are honored to provide innovative technology and responsive service to our customers worldwide.” The ProducTVity Station is a ready-to-deploy visual management system that displays real-time KPI data and Andon messages on large televisions to drive

productivity. Crimson software, with over 250 communication drivers and a builtin graphics library, provides a powerful programming environment for Red Lion devices. To learn more about Red Lion’s solutions, please visit www.redlion.net or email info@redlion.net. About Red Lion Controls As the global experts in communication, monitoring and control for industrial automation and networking, Red Lion has been delivering innovative solutions for forty years. Our award-winning technology enables companies worldwide to gain real-time data visibility that drives productivity. Product brands include Red Lion, N-Tron and Sixnet. With headquarters in York, Pennsylvania, the company has offices across the Americas, Asia-Pacific and Europe. For more information, please visit www. redlion.net. Red Lion is a Spectris company.

Danfoss Opens New Cold Chain Centre in India Danfoss India inaugurated a new Cold Chain Centre in Chennai, India, in association with Shravan Engineering Enterprises Ltd. “We believe this center will help encourage an indepth understanding of the Cold Chain industry for the various stakeholders and customers involved. Moreover, this move reiterates our objective of not just offering complete cold chain solutions but also changing the way cold chain solutions are offered in India,” Noel Ryan, President, Danfoss India, said.

In addition to providing customers with rel-

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evant updates on new software and product catalogues, the centre will display the complete range of key products like Controls for Ammonia/Freon cold store systems, Condensing Units for Dairy & Cold Chain applications, ADAPKOOL® solutions for supermarkets; Variable Speed Drives suitable for the Re-

frigeration Industry and much more. The centre will be a one-stop-destination for all Cold Chain Solutions. It will also serve as an engagement center to key consultants, contractors and end users to select and design Danfoss products as per the their cold chain application requirements. The centre plays an important role in Danfoss’ initiative to improve and instigate swift growth of the Cold Chain Industry.


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NEWS UCB Chooses Emerson Automation and Operations Management Technologies for One of Europe’s Largest Biotech Plant Belgium-based UCB has awarded Emerson Process Management, a global business of Emerson (NYSE: EMR), a $6.1 million contract to provide integrated process automation and operations management systems for a new biopharmaceutical production center in Bulle, Switzerland. Emerson’s technologies and engineering services will be crucial in meeting the very high standards expected by the UCB project team. UCB is investing $228 million to construct the first phase of a new plant, its first biopharmaceutical project in Switzerland. The 20,000-square-meter facility, which will be one of the largest in Europe, will be the main production center for Cimzia® (certolizumab pegol), which is used to treat rheumatoid arthritis and Crohn’s disease. “The state-of-the-art and largely automated facility at Bulle will be a model for the industry when it opens in 2015,” said Michele Antonel-

li, UCB executive vice president. “To ensure the project meets its tight build-out schedule, we selected Emerson Process Management for its demonstrated ability to engineer and coordinate fast-track automation projects of this type.” Emerson’s integrated solution includes its Syncade™ Smart Operations Management Suite, DeltaV™ digital automation system, and AMS Suite predictive maintenance software. Emerson will also provide related engineering services, including design, installation, testing, and commissioning. The Syncade Suite software integrates real-time plant floor data with business processes, decisions, and asset management – a key advantage in managing complex operations and extensive documentation required in pharmaceutical production. Syncade Suite manages workflow processes, including electronic work instructions, equipment status and material tracking,

recipe-driven operations, automated weigh and dispense operations, and exception reporting. “Typical biotech manufacturing can involve thousands of pieces of paper that can affect the ability to produce ‘right-first-time’ batches,” said Lorenzo Zampini, automation project manager. “With Emerson’s integrated operations management and control systems, we can automate the reporting process as well as gain tighter process control for increased productivity and smoother regulatory compliance.” The Syncade software integrates with Emerson’s DeltaV automation system to facilitate operational activities and information flow from the plant floor up to UCB’s SAP system. In the UCB plant, the DeltaV system will control 163 process units including fermentation, purification, filtration, and bottling. Emerson’s new electronic marshalling technology with CHARMs

(characterization modules) will help minimize installation time by eliminating up to two-thirds of the wiring and connections needed with traditional control systems. Emerson’s AMS Suite predictive maintenance software that will be supporting HART instrumentation will make it easy for technicians to calibrate critical instruments, check their status, and even detects potential problems before they affect operations. “Emerson is delighted that UCB has chosen us to automate this groundbreaking facility,” said Steve Sonnenberg, president of Emerson Process Management. “Our proven ability to provide a single source for both plant automation and operations management systems will help UCB seamlessly manage operations from the plant floor to the head office. We look forward to working with them as they bring the Bulle facility to life.”

Advantech wins the First Ever iF Product Design Award 2013 Advantech (2395.TW), a global leader in the industrial platform computing and automation device market, won its first ever product design award—the iF Product Design Award 2013. Out of over 3000 entries, Advantech’s Human Machine Interfaces (HMI) products, SPC and TPC series has won an iF product design award 2013 and will be recognized with the renowned iF label in the industry / skilled trades category. From 2010, Advantech put “Enabling an Intelligent Planet” as its corporate vi-

sion and set in motion an organizational evolution, marketing transformation, and steady expansion, to realize its mission to empower the development of smarter working and living. Advantech’s next generation of HMI -SPC and TPC series come with the user-oriented design including capacitive multi-touch displays with 16:9 ratio wide screens, intelligent keys, and customized user interface which change existing HMI user behavior into being more intuitive and ergonomic.

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For 60 years, the iF Product Design Award has been an internationally recognized label for award-winning design and the iF brand has become a prestigious

symbol for outstanding achievements in product design. It is Advantech’s great honor to be recognized by the iF product design awards.


NEWS Schneider Electric secures over 100MW in India with the new Conext Core XC Inverter Schneider Electric, the global specialist in energy management,has secured over 100MW projects in India with the new Conext Core XC Inverter within 3 months after the launch at Intersolar Europe 2012 in June. The Conext Core XC Series is a new line of central inverters designed for groundmounted solar farms & large commercial buildings. The Conext Core XC Series has best-in-class peak efficiencies up to 98.9% and a field proven industrial design based on Schneider Electric industrial power drives. The Conext Core XC Series includes an innovative fast sweep MPPT algorithm (Maximum Power Point Tracking) and has been qualified for use in the harshest environmental conditions through intensive Reliability Testing. Schneider Electric is providing integrated solutions

to its customers including the PV Box, array boxes, monitoring & control, and the grid connection substations. The PV Box is a factory integrated, tested & validated plug & play power conversion system that contains two Conext Core XC inverters, a DC combiner box, a step-up transformer, medium voltage switch and other accessories and is adapted to the meet the local installation conditions. This enables customers to reduce construction lead time, lower the costs of commissioning and enhance uptime thanks to qualified & reliable design. Schneider Electric is also providing its customer the newly launched Conext Control, an innovative monitoring & control solution that allows customers to monitor the installation from the module to the Grid Box and minimize the site intervention costs thanks to remote

diagnostic and repairs. ‘’Schneider Electric is committed to provide bankable solar solutions to help meet India’s growing demand for power. We are extremely proud to have been able to gain confidence of Solar Project Developers and EPCs in this fast growing market. The reliability & the competitiveness of our integrated solution coupled with our ability to meet local conditions and provide local support were determining criteria,‘’ declared Laurent Bataille, Senior Vice President, Schneider Electric’s Solar Business. Schneider Electric provides bankable photovoltaic solutions for any size installation, together with a long-term support from a global company with over 175 years of experience. Schneider Electric products are present at every link in the energy chain, helping

customers get the most efficient solar harvest from their installations thanks to qualified and reliable integrated solutions. About Schneider Electric As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in Utilities & Infrastructures, Industries & Machine manufacturers, Nonresidential buildings, Data centers & Networks, and in Residential. Focused on making energy safe, reliable, efficient, productive and green, the Group’s 130,000 plus employees achieved sales of 22.4 billion euros in 2011, through an active commitment to help individuals and organizations make the most of their energy. www.schneider-electric. com/company

ABB develops world’s most powerful high-voltage direct current converter transformer ABB, the leading power and automation technology group has successfully developed and tested an 1,100 kilovolt (kV) ultrahigh-voltage direct current (UHVDC) converter transformer breaking the record for the highest DC voltage levels ever, and facilitating more power to be transmitted efficiently over longer distances. The Xiangjiaba-Shanghai link, commissioned by ABB was the world`s first commercial 800 kV UHVDC connection. It has a capacity of 6,400 MW and covers a distance of just over 2000 kilometers (km), making it the longest of its kind in operation. The new 1,100 kilovolt (kV) converter transformer technology will make it possible to transmit

more than 10,000 megawatts (MW) of power across distances as long as 3,000 km. Higher voltage levels allow larger amounts of electricity to be transported across very long distances with minimal losses using HVDC technology. Converter transformers play a critical role in HVDC transmission serving as the vital interface between the DC link and the AC network. Development of the 1,100 kV transformer addressed several technology challenges such as the sheer size and scale, electrical insulation including bushings and thermal performance parameters. “This new 1,100 kV transformer technology will make it possible to transmit even

12 INDUSTRIAL AUTOMATION PAGES > December 2012

more electricity efficiently and reliably, at higher voltage levels, across greater distances with minimum losses,” said Bernhard Jucker, head of ABB’s Power Products division. “Technology and innovation are at the core of ABB’s culture and this is yet another example of our pioneering spirit.” UHVDC transmission is a development of HVDC, a technology pioneered by ABB more than 50 years ago, and represents the biggest capacity and efficiency leap in over two decades. ABB is a world leader in HVDC transmission technology, with many pioneering achievements and over 70 such projects around the world with a combined transmission ca-

pacity of around 60,000 MW. Transformers are integral components of an electrical grid, and essential for the efficient and safe conversion of electricity between diverse voltage systems. ABB’s transformer portfolio includes power transformers, dry and liquid distribution transformers, special application transformers and related services and components. ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 145,000 people.


NEWS Emerson to Deliver Control Technologies for Nevada Solar Project to Power 75,000 Homes

Emerson Process Management, a global business of Emerson (NYSE: EMR), has been awarded a contract to apply its Ovation™ expert control system at the Crescent Dunes Solar Energy Project near Tonopah, Nev. When it comes online at the end of 2013, this 110-megawatt concentrated solar power (CSP) project will be the first commercial-scale solar facility in the United States to generate power from solar energy that is captured and stored in liquid molten salt. The project, which is being developed by Tonopah Solar Energy LLC, an affiliate of SolarReserve LLC, is expected to produce enough clean, renewable electricity to power more than 75,000 homes during peak electricity demand, and will be exe-

cuted by Cobra Thermosolar Plants, Inc. as engineering, procurement and construction contractor. The Crescent Dunes facility will use SolarReserve’s CSP technology, which enables energy from the sun to be captured and stored to generate electricity on demand – not only when the sun is shining – thereby contributing to overall grid stability. The facility’s 10,500 mirror assemblies focus the sun’s energy to heat molten salt that flows through a central receiver, which sits atop a 540-foot-tall solar power tower. The molten salt will flow from the “cold” storage tank, up the tower where it circulates through the receiver and is heated by the sun’s energy from 500 degrees Fahrenheit to 1050 degrees. The molten

salt then flows down to the “hot” storage tank, where the thermal energy will be used to produce steam to power a standard steam turbine, which then generates electricity. Excess thermal energy will be stored in the molten salt. Emerson’s Ovation technology will directly control the circuit and heating process of the molten salt system, the water/steam cycle and auxiliary processes. The control system will also provide supervisory control of the mirrors and interface with the turbine control system. An important consideration in the selection of Emerson was the robust diagnostic capabilities offered by its AMS Suite predictive maintenance software. AMS Suite will provide online ac-

cess to instrument and valve diagnostics and automatic documentation of field device maintenance information – all contributing to ongoing efficiency at the solar plant. It will also be used to streamline device configuration and commissioning. “This is a truly innovative project that will be an important source of clean, reliable electricity,” said Bob Yeager, president of Emerson Process Management’s Power & Water Solutions. “By providing integrated control of major equipment and processes, our Ovation system and the predictive intelligence of AMS Suite will play a key role in the smooth, efficient operation of this noteworthy solar project.” The contract was awarded by Cobra Thermosolar Plants Inc.

Grace Lieblein, GM Brazil President And Managing Director, Joins Honeywell’s Board Of Directors Honeywell (NYSE: HON) announced today that Grace Lieblein, 52, GM Brazil President and Managing Director has been elected to its Board of Directors. She will serve on the Corporate Governance and Responsibility Committee and the Management Development and Compensation Committee. “Grace’s proven business acumen, combined with extensive experience in global manufacturing and a deep understanding of lean production tools, make her a terrific fit with Honeywell’s culture and values,” said Honeywell Chairman and Chief Executive Officer Dave Cote. “She spearheaded GM’s Global Manufacturing System, which utilized lean production tools and concepts to improve engineering systems and processes,

to drive significant improvements in productivity and lead time. She also has successfully led GM’s businesses in Brazil and Mexico to profitability in a complex business environment. We look forward to the contributions she’ll make as we continue to drive both productivity and global growth at Honeywell.” Appointed to the role of GM Brazil President and Managing Director in 2011, Lieblein, the highest ranking Latina employee in GM, is responsible for approximately $12 billion in annual revenues and 25,000 employees that produce and sell more than 600,000 vehicles a year under the Chevrolet brand. Prior to this role, she served as GM Mexico President and Managing Director, responsible for approximately

14 INDUSTRIAL AUTOMATION PAGES > December 2012

$2 billion in revenues and 11,000 employees. Lieblein began her career in 1978 as a co-op student at General Motors Assembly Division in Los Angeles and has since served in a number of positions within the company. As Vehicle Chief Engineer, she led the design, development, testing and launch of the company’s new line of mid-size crossover vehicles, one of GM’s most profitable platforms to date. Lieblein has been widely recognized for her achievements. In 2012, she was featured on CNN as part of their “Leading Women” series and was added to Hispanic Business magazine’s Corporate Elite 25 list. In 2011, she was named on Fortune magazine’s list of the 50 Most Powerful Women in

Business. She also appeared second on the list of 2010’s Most Power Women CEOS in Latin America by America Economy magazine and was recognized by Financial Times as one of the Top 100 Women in World Business. Lieblein was appointed to the Board of Directors of the American Chamber of Commerce of Mexico and she served as Vice President of the Board of Directors from May 2012 to May 2011. Lieblein received a bachelor’s degree in industrial engineering from General Motors Institute (now Kettering University) in 1983 and a master’s degree in management - materials/logistics from Michigan State University in 1987. She also holds a certificate from Thunderbird’s Global Leadership program from 1998.


NEWS Ten years of the configurable control systems PNOZmulti – and the success story continues. In November 2002, PNOZmulti was introduced to the public for the first time at sps ipc drives, the leading automation exhibition. With the newly created device category “configurable control systems”, at that time Pilz was bridging the gap between classic safety relays and programmable control systems. Today, the configurable control system is the world’s most widely used safety system. At sps ipc drives 2012 in Nuremberg, Pilz will continue the success story - with the new PNOZmulti 2. Used to monitor several safety functions PNOZmulti is used in particular when several functions on a machine

need to be monitored. It is multifunctional, freely configurable and tailor-made for use in many areas of mechanical engineering. The control system can be used to monitor safety functions such as E-STOP, safety gates, light beam devices, twohand and many more. The PNOZmulti can also perform standard control functions. Presentation of PNOZ-

multi 2 at sps ipc drives With the new base unit PNOZ m B0, Pilz will be introducing the next generation of configurable control systems at sps ipc drives 2012. Just like ten years ago, user friendliness is still a key product feature on the new PNOZ m B0: the new base unit is only 45 mm wide. 20 safe inputs, up to eight of which can be configured as standard outputs, plus an illuminated display all help to save time during configuration and diagnostics and reduce engineering costs. PNOZ m B0 achieves PL e and SIL CL 3 and is cost-effective from three safety functions. New input/output module PNOZ At Nuremberg we will

also be showing the new input/output module PNOZ m EF 8DI4DO, which for the first time provides 8 safe inputs as well as 4 safe semiconductor outputs (PL e, SIL CL 3) in one module - at a width of just 22.5 mm. The expansion module can be configured using the PNOZmulti Configurator from Version 9. New PNOZmulti Configurator version From Version 9 of the PNOZmulti Configurator the software tool can also be used to configure the PNOZmulti 2. The new software version will be available on DVD at sps ipc drives. You can also download it free of charge (after registering).

Siemens technology sets world’s largest giant wheel in motion At the beginning of January, the world’s largest transportable giant wheel was erected in Munich and is shortly due to be shipped by sea to its destination in Mexico. The R80XL, a giant rising 80 meters in height, is completely equipped with automation technology from Siemens. The scope of delivery includes Simatic-S7 control technology, drive technology including motors and low-voltage power distribution. The steel giant weighs in at 750 tons and will accommodate a total of 432 passengers rotating in 8-seater

or 16-seater cabins. As the rigging and derigging process takes several weeks, its future use will not focus on deployment in permanent fairgrounds. Its main application will be as an observation wheel in large metropolises around the world, where it will be set up for a number of months at a timeas a tourist attraction. The giant wheel was developed and designed by the company Bussink Design. Responsible for production of the giant wheel, which is available in two different versions, is Munich-based Maurer German Wheels GmbH.

16 INDUSTRIAL AUTOMATION PAGES > December 2012

Siemens supplies drive and control technology solutions designed specifically to be used in these types of rides for traveling carnivals or “Fliegende Bauten” as they are known in German. A company steeped in tradition, Maurer Söhne GmbH & Co. KG and its subsidiaries have been based in Munich since 1876 and are specialized in the interaction between forces and

movement in constructions. The company’s product portfolio also includes special products foramusement parks, in particular rollercoasters.


NEWS Rockwell Automation Bundles Keys to Machine Control Design in One-Stop Solution Rockwell Automation introduces the Connected Components Accelerator Toolkit (CCAT), a bundled, one-stop solution that simplifies and expedites complete, cost-effective, smallmachine control design and implementation. The CCAT combines a simple, yet powerful controller with a full suite of compatible components and class-leading application development tools that enable OEMs to focus engineering and development resources on creating compelling and differentiating machine features. The CCAT speeds the basic, common design functions that every machine design requires. By providing this functionality, the CCAT allows the OEMs to invest

their design work in developing better, more competitive machines. The CCAT’s pre-configured Building Blocks include automation engineering design tools for comprehensive control application development from layout and component selection to troubleshooting. For example: Quick Starts provide information to use the CCAT and set up individual components. Selection tools and example bills of material streamline component and

18 INDUSTRIAL AUTOMATION PAGES > December 2012

accessory selection. Wiring diagrams and panel layout drawings, in native AutoCAD Electrical and EPLAN formats, save weeks of design effort. Controller programming handles all communications, commands and status updates. Common application starting system examples jump-start control design. Sample human-machine interface (HMI) screens provide a superior operator interface, plus diagnostics, alarming and start-up assistance.

Connected Components Workbench software from Rockwell Automation supports the CCAT. Based on proven Rockwell Automation and Microsoft Visual Studio technology, the single, easy-to-acquire-and-install package simplifies controller programming, device configuration, and data sharing with the HMI editor for Allen-Bradley PanelView component products. The software makes it convenient and cost-effective for machine builders and end users to leverage a single platform that also supports other Allen-Bradley component-class devices, including drives, motion control and operator interface products.


NEWS Emerson Wins $33 Million Contract to Upgrade Automation on Statoil Platform in Norwegian North Sea Statoil has awarded Emerson Process Management, a business of Emerson (NYSE: EMR), a $33 million contract to upgrade safety and automation systems on the Visund oil platform in the Norwegian North Sea. Previously selected by Statoil as one of its preferred automation and safety suppliers, Emerson will provide integrated safety and automation systems to help the international energy company boost oil recovery and extend the life of the field while also reducing operating costs and minimizing safety and environmental risks. The Visund project includes a complex but seamless changeover from existing to new automation and safety systems (known as a hot cutover) to allow uninterrupted operation of the floating production,

drilling, and living-quarters platform. Emerson will design, configure, and install the new safety and automation systems, as well as provide ongoing support services to help ensure continued smooth operations. Aker Solutions of Bergen, Norway, will provide project-execution support to Emerson. To help with space and weight limitations on the platform and to offer more design flexibility during the upgrade, Statoil will take advantage of Emerson’s electronic marshalling with CHARMs technology. This technology reduces the complexity of connecting such systems to the hundreds or thousands of measurement and control instruments in typical process operations – a significant advantage because last-

minute wiring changes with traditional marshalling can result in high costs and expensive delays. Statoil will also benefit from Emerson’s operator and maintenance interfaces that were designed with humancentered design principles to make it easier for workers to correctly and efficiently assess operational conditions and take appropriate action to ensure production uptime. Based on Emerson’s PlantWeb™ digital architecture, the integrated solution will include a DeltaV™ digital automation system to monitor and control platform operations, as well as a DeltaV SIS system to perform emergency shutdown functions and to control fire and gas detection systems. Emerson’s AMS Suite predictive maintenance software

will be used for instrument commissioning and configuration and to monitor field devices for potential problems that could affect operations. “Emerson continues to develop its safety and automation business in the North Sea by providing the best technologies and by investing in support services and skilled personnel to help our customers make the most of their operations,” said Steve Sonnenberg, president of Emerson Process Management. “We are delighted that Statoil has recognized the value our technologies and experience can bring to the Visund project.” The Visund oil and gas field, which came onstream in 1999, is located 22 kilometers northeast of the Gullfaks field in the Tampen area of the Norwegian North Sea.

Atlas Copco (India) Ltd. continues its run in Top 500 of manufacturing industry in India Atlas Copco (India) Ltd. was ranked at number 26 in Industry 2.0 magazine’s tenth annual listing of Top 500 manufacturing companies in India in 2012. The ranking is based on composite scores on nine parameters comprising sales turnover, absolute increase in sales, percentage change in the sales turnover, net profit, increase in net profit, PAT/sales ratio, return on capital employed, and increase across two financial years. The process involved identifying the sectors that comprise the manufacturing industry in India. The CMIE Prowess database was used to obtain data on

key performance financial indicators for all companies in the identified industrial sectors. Companies with net revenues equal to or more than INR 300 crore

20 INDUSTRIAL AUTOMATION PAGES > December 2012

for the financial year 201211 were classified as ‘Top Manufacturing Companies’, while companies with net revenues less than INR 300 crore and more than INR 10

crore were grouped into ‘Top SMB Manufacturing Companies’. Industry 2.0 describes the listed companies as, “Top performers of India who have scored big through innovative thinking, cost-optimisation strategies, intelligent marketing and quality products and services, and, of course, sheer hard work.” Filip Vandenberghe, Managing Director, Atlas Copco (India) Ltd. comments, “We are honored to be on this list yet again and in fact, to have improved our ranking. Our position on this list validates our commitment to finding innovative solutions that help meet our customers’ growing needs.”


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PRODUCTS Red Lion Supports 4G LTE on Sixnet IndustrialPro 6000 Cellular Routers

Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, today announced the availability of 4G Long Term Evolution (LTE) support for its Sixnet IndustrialPro® 6000 series of industrial cellular routers in North America. Effective immediately, the IndustrialPro 6000 routers are the first M2M rugged devices certified by and compatible with the Bell Mobility 4G LTE network. Providing customers with faster 4G wireless connectivity, LTE is ideal for organizations of all sizes that require

increased data speeds when using cellular technology for primary or backup WAN connectivity. With data rates up to 100 times faster than 2G and 3G technology, LTE is well suited for remote offices, video surveillance and remote automation environments. “With more organizations using wireless technologies to monitor and control critical operations in remote locations, LTE support gives customers the advantage of speeds that rival wired broadband connections,” said Mahesh Patel, director of wireless product management at

Red Lion Controls. “While our products still offer flexible backwards compatibility to 3G networks, the addition of LTE not only delivers significant performance improvements, but also offers 10 times lower latency than earlier technologies. Increased speeds are essential for streaming video and remote applications where

high latency or jitter is simply not acceptable.” Sixnet IndustrialPro 6000 cellular M2M routers provide secure, cost-effective wireless connectivity to remote locations and assets while offering technology assurance from 3G to 4G in a single solution. As a reliable primary WAN connection or a backup to existing network links, IndustrialPro routers are suited for harsh industrial environments such as oil & gas, power & energy and water & wastewater applications where space may be limited and wired connectivity not feasible.

New Solutions for Integrated Motion on EtherNet/IP from Rockwell Automation Use Less Energy and Shrink Application Footprint Rockwell Automation has introduced the AllenBradley Kinetix 5500 servo drive, Kinetix VP low-inertia (VPL) servo motor, and single-cable technology as an integrated motion solution on EtherNet/IP that is more compact, easier to use and simplifies system wiring. “Machine and equipment builders are challenged with making smaller, more complex equipment in a shorter design cycle and at a lower price point,” said Mike Schweiner, Kinetix product manager, Rockwell Automation. “Our new single-cable Kinetix motion solution gives machine builders a proven solution for both servo and induction motor control on a single development platform that will result in less design time and cabinet space with improved power density and efficiency.” The Kinetix 5500 servo drive joins the Kinetix 350

and Kinetix 6500 drives to provide users with more options to match motion control needs. Integrated motion control on EtherNet/ IP eliminates the need for a dedicated motion network, reducing cabling by up to 60 percent and removing the need to create gateways to get information to or from secluded networks. Additionally, the Kinetix VPL motors new winding technology and DSL encoder, connected with the smartcable technology, allows power transmission and feedback communication to and from the Kinetix 5500 drive to take place on a single cable. This further simplifies application design and limits points-of-failure for improved reliability and uncomplicated maintenance. Ideal for packaging, material handling or converting systems with more than six axes, the Kinetix 5500

22 INDUSTRIAL AUTOMATION PAGES > December 2012

and Kinetix VP drive-motor system does not require discrete power rail or additional accessories, so machines can be scaled up as needed. Optimally matched motor and drive ratings uses half the energy of comparable solutions, while still providing 125 μsec loop closure for maximum performance. The Kinetix 5500 drive is the first Kinetix drive designed with an external common AC/DC bus connection system. It reduces hardware requirements and allows for seamless scalability, using a single platform for either single-axis or multiaxis systems. The Kinetix 5500 drive also has the ability to control both servo and induction motors, provide best–in-class power density that reduces the size of the drive and cabinet space required by up to 50 percent, and simplify machine maintenance by minimizing the

need to fuse or use contactors. Additionally, the system can be optimized to balance power use and lower energy needs because of its unique ability to share power across multiple drives. The Kinetix VPL servo motor uses the same proven magnetic core as the Allen-Bradley MP-Series servo motors. The Kinetix 5500 drive is supported by the recently released Rockwell Software Studio 5000 integrated engineering environment and can be used with the Integrated Motion Encoder on EtherNet/IP to provide a feedback-only axis solution for Allen-Bradley ControlLogix 5570 and CompactLogix 5370 programmable automation controllers. A feedback-only axis allows the motion application to synchronize efforts with other portions of a machine or line for more efficient production.


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PRODUCTS Lenze FAST: More time for what really matters With its Application Template and ready-made standard software modules - called Lenze FAST - the specialist in Motion Centric Automation is supporting machine builders in efficiently creating modular control software. Indeed, programmers can use Lenze FAST to cover up to 80% of all their software engineering requirements for standardised machine modules both quickly and reliably. The programming is particularly efficient with the function and technology modules provided and tested by Lenze. The bottom line is that the use of standardised and re-useable modules offers greater freedom for devising and testing special features of a machine - which then impress the end user and provide the decisive purchase incentives. Lenze’s “ApplicationTemplate”, provides the necessary structures for standardising soft-

ware and therefore allows users to create their own machine modules. The significant reduction in software development time and costs that more and more companies are now demanding can be achieved in the field of engineering by using standard software. Experience has shown that 80% of the software for a new machine can be generated using code which was developed for previous generations or which can

be provided in the form of ready-made technology modules from system partners like Lenze. However, for this to work, it must be possible to provide the software with the necessary structure. To simplify this step, Lenze has developed an Application Template that already provides important structures - such as error handling, statemachine for switching over machine states and communication interfaces - and thereby

guarantees standardisation. The software modules created on the basis of the Application Template can then be put together like bricks with minimum effort, creating systems that are easier to understand and can be re-used with no issues. This speeds up the entire process, as Lenze provides a whole range of standard software modules for depicting the basic functions of a machine. These include for example modules used for feeding, unwinding, sealing, cross-sealing and discharging. The standard software modules from Lenze are tested and subject to continuous further development. The (re-)use of tested modules reduces costs and also allows errors to be reduced and important time to be freed up for implementation of machine features with which machine builders can offer their customers important benefits.

Banner Engineering Releases Online Tower Light Configurator Banner Engineering recently released a new tower light configurator, an online tool that allows users to customize tower light selections and view related information. The new tool was designed for a variety of operating systems including iPad and Android tablets. Over the past several years, Banner’s Lighting and Indication (L&I) product offerings have grown at an increasingly fast pace. New color options, light functions and alarm-styles give customers more choices than ever before. The tower light configurator has been released to help customers conceptualize potential tower light

solutions. Users can design their own tower lights, by choosing from the following

24 INDUSTRIAL AUTOMATION PAGES > December 2012

features: * Standard, high-intensity, and daylight visible bea-

con models * Up to 10 light color choices for standard and five for high-intensity or daylight visible models * Steady-on, rotating or flashing light functions * Three optional audible functions: continuous, pulsed or staccato * Housing color and connection types The end result is an interactive experience that helps users visualize—and hear— the flashing, rotating, alarmsounding tower light of their choice. It also provides a corresponding model number, wiring diagrams, CAD files, accessories, and data sheets to help streamline the purchasing decision.


PRODUCTS Communication the direct way Lenze has now established direct connection of the Inverter Drives 8400 frequency inverter range to Ethernet/IP-capable control systems with a new communication module. The 8400 StateLine, HighLine and TopLine control cabinet devices, as well as the 8400 motec and 8400 protec decentralised frequency inverters can be equipped with this fieldbus interface. With their dual-port technology and external 24V supply to back up the communication at mains failure, the Ethernet/ IP modules ensure a simple commissioning process and a fast service. The new sequence control for positioning procedures represents yet another highlight of the device range. With the sequence control (sequencer) included in the 8400 TopLine, up

to 100 actions for automatic execution of positioning can be parameterised directly in the inverter. This integration lightens the load on the PLC, as the frequency inverters are capable of executing approaches to consecutive positions independently, quickly and precisely. The 8400 TopLine can also perform the same kind of flexible positioning control that typically needs to be programmed in a PLC. This for

example includes actions such as waiting times, counters or branches, which can be influenced using external sensor technology or the inverter’s internal signals. Another new feature is the integrated oscilloscope function, which simplifies commissioning, maintenance and troubleshooting. The signal scanning and recording within the drive can be performed in as little as

just 1 ms. The convenient display and further processing of the measured data is performed using the “L-force Engineer” PC software tool. The oscilloscope presents the recorded signals with an adjustable time base from 5 ms to 1s simultaneously for up to eight channels. Pretriggers and post-triggers allow users to hone in on the desired measured data.

OMRON : E5AC Digital Temperature Controller Large White PV Display That’s Easier to Read. Easy to Use, from Model Selection to Setup and Operation. A Complete Range of I/O Capacities, Functions, and Performance. Handles More Applications. A white LCD PV display with a height of approx. 25 mm improves visibility. Tool ports are provided both on the top panel and the front panel. Set up the Controller without wiring the power supply by connecting to the computer with a Communications Conversion Cable (sold separately). Setup is easy with the CX-Thermo (sold separately). High-speed sampling at 50 ms. Models are available with up to 4 auxiliary outputs, up to 6 event inputs, a transfer

output, and a remote SP input to cover a wide range of applications. Short body with depth of only 60 mm. Easy connections to a PLC with programless communications. Use component communications to link Temperature Controllers to each other. The new position-proportional control models allow you to control valves as well. The new standard in temperature control... Omron has been an active innovator in temperature control since introducing its first temperature controller in 1967. Now temperature control has taken a giant leap forward with Omron’s next generation of controllers - the E5AC/CC/EC, which set new global standards in the crucial areas of precision,

26 INDUSTRIAL AUTOMATION PAGES > December 2012

user friendliness and control performance. The E5AC/CC/EC series will save you time and effort in set-up and operation, while enabling faster and more accurate monitoring/ control of your process. The high-visibility display of the new series is also extremely easy to read and virtually eliminates any possibility for human error.

Key features High-contrast, white LCD display visible from large distances and from any angle Easy to set up without power supply and operate intuitively via CX-Thermo software 50 ms sampling period for fast and precise regulation Functions for diagnosis for secure operations* *Alarm for loop break or PV change rate, heater burnout or sensor burnout detection Clearer LCD display The large, high-contrast, white LCD display contributes to the exceptional clarity and therefore readability of the E5AC/CC/EC series. The display can be read unambiguously from greater distances and from much wider viewing angles than normal.


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PRODUCTS Banner Engineering Introduces Two Sensors for Hygienic and Washdown Environments

Banner Engineering announces the QM26 and the QMH26 photoelectric sensors, designed specifically for food and beverage and pharmaceutical industries. Influenced by the 2011 Food Safety Modernization Act (FSMA), the European Hygienic Engineering and Design Group (EHEDG) and food safety initiatives among private businesses, Banner wanted to ensure the sensors provided reliable performance in manufacturing and packaging zones, including contact zones, splash zones and non-contact zones. “The sensors’ design considers Hazard Analysis and Critical Control Point (HACCP) principles for hygienic manufacturing processes,” said Mark Schmid, Banner Engineering Food and Beverage Industry Manager. “Our goal was to deliver Banner’s prov-

en sensing capabilities to areas where the sensors may come in contact with food or materials, and make them suitable for harsh washdown environments with high pressure, extreme temperatures and chemicals.” The QM26 is housed in

a non-toxic 316L stainless steel housing, and can survive high pressure washdowns and temperature cycling, ranging from -30° C to 60° C. The sensor is ECOLAB® certified for inexhaustible sensor life in chemically cleaned environments and

is intended for splash zone areas. The QM26 also features easy side-mounting for quick set-up and installation. The QMH26 has all the advantages of the QM26, however, it is designed with minimal grooves and crevices, leaving no room for bacteria to hide and multiply. It is self-draining for clean-inplace (CIP) applications. The sensor’s hygienic mounting shape reduces contamination risk, making it a suitable sensor to place in contact zones. “As US food and drug manufacturing companies engage more with hygienic food safety controls, they’ll be able to rely on Banner— and our extensive system of distributors and local support—to quickly and efficiently supply them with hygienic, washdown sensors,” said Steve Wong, Pharmaceutical Industry Manager.

Hybrid paper type recorder, combines functions of paper recorder and paperless recorder Autonics unveiled KRN100 well. In addition, it supports * Enables to print the saved series, its brand 100mm data of inner memory Thenew Iconic Brands of Coimbatore CODISSIAparameter setting on the PC The Iconic Brands of Coimbatore CODISSIA hybrid recorder following the through USB communicawhen run out of recording launching of the KRN50 series tion, Max 12 channel support paper (Date logger funcin 2009, 50mm compact padue to its slot type input/ tion) per type hybrid recorder. KRN output cards and a wide va- * Inner data backup with USB 100 series can both display riety of optional cards. memory a wide variety of industrial * Supports several communivalues on the LCD and print Major features cation (RS485,Etherner) to them on the paper. It can Features transfer real time data save data at an external USB * Combines functions of paand setting The Iconic memory and also can print function (data logger funcper recorder and paper- * High legibility Brands of Industry convenient by graph LCD it through its data backup tion) of internal memory as less recorder INDUSTRIAL TRADE FAIR COIMBATORE

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December 2012 > INDUSTRIAL AUTOMATION PAGES 29


FOCUS

Connectors in Industrial Automation:

Bringing Together Simple and Complex Devices Worldwide

A

connector is indeed a prized possession, whether in electronics, computer science, mathematics, transport or even society. An electrical connector is a device used to join together electrical circuits. In computer science a connector is used to link together two data structures. In mathematics, a connector is a mathematical mapping whereas in transport systems a connector is a road or a high way which connects to another road or highway. In society, a connector is a person or in this technocratic world a magazine , a website or a social network that brings together human beings socially and connects the whole world

together as a global village. Though the scope of exploring each connector in detail is enormous, we hope to elucidate some information on connectors. Connectors bring together elements, wires, cables etc. There are various types of connectors. Electric connectors join electric circuits together. Both permanent and temporary connections (for portable devices) may be made. Connectors may be classified as male M, female F, genderless and gender changer. Though their basic function of “connecting� remains, connectors have evolved through the decades. Beginning as simple plugs which are still used, connectors evolved leading

30 INDUSTRIAL AUTOMATION PAGES > December 2012

to the invention of more specific connectors which became obsolete and have been replaced by more modern and sometimes cheaper ones. As the digital world replaces the analog world HDMI, DVI and Digital Ports are important connectors. In each industry there are various types of general and specific connectors. In Industrial Automation Industrial automation globally contributes to the economy. It cuts costs, improves productivity and maintains constant quality. Machines do not get tired; do not take vacations nor do they have any emotional baggage to handle. However they require maintenance, monitoring and

need to have state of the art parts and accessories to work at full capacity. In industrial Automation connectors are becoming more complex and are evolving rapidly. The M12 Standard has been adopted. This standard has been chosen for its reliability, for its ease of operation and is now a major aspect of the industry. Initially used by automobile manufacturers, the Automation Industry has embraced the M12 Standard. For a process to have a long run with consistent success it is essential that uniform standards are set. The M12 Standard has been adopted for ensuring proper connections of industrial components. This standard


also helps to protect components from natural contaminants including dust, water, hazardous chemicals and other industrial undesirable pollutants. The M12 connector is considered to be the workhorse of the industry and most large manufacturers keep modernizing their products by using smart click, water proof technology as well as the ability to let the connectors to work at ambient temperatures, as these are the needs of Automation. It is a common standard adopted by various process industries. It is also compatible with existing structures and is a uniform worldwide standard that is being adopted by many more industries as they progress towards semi automation or total automation. The standard defines certain parameters including per-

formance requirements, specific sizes and mating interfaces for connecting systems. The major technologies used in connectors for Industrial Automation are as follows: • Bayonet Lock technology • Single Keyway technology • Screw Lock Push Pull Technology Bayonet Lock technology Using this technology, connectors may be made compatible with automated assembly systems. They shorten assembly times and lower costs. These connectors are rugged have the advantages of high vibration performance. They can properly be mated for both general duty connector applications as well as for high performance connector applications. They provide a tough and high density

interface as connectors in challenging industrial environments. Bayonet lock connectors are used for critical applications as they have a high safety factor. Compared to traditional screw style connectors one touch bayonet locking systems offer reduced connection times and optimum seal performances. Single keyway technology This technology is used when connectors are used with sensors. They are generally compact in size and give reliable performance. They also save time and money. Screw Lock Push Pull Technology Push Pull connectors have various advantages over traditional systems that use twist or screw lock systems. They reduce setting up and dismantling time. They prevent stress and are ergonomically de-

signed. They are rugged, safe and compact. They are easy to maintain. Different manufacturers use different names and similar technologies and some of the major companies that manufacture connectors for Industrial Automation are as follows: Omron This manufacturer uses Bayonet Lock technology and its product is called SmartClick. Molex This manufacturer uses Single Keyway technology and its product is called Micro- Change. Phoenix Conctact This manufacturer uses Bayonet Lock technology and its product is called SPEEDCON. Hirschmann This manufacturer uses Screw Lock /Push-Pull Lock technology and its product is called Circular Connectors Erni This manufacturer uses Screw Lock technology and its product is called M12 Circular Connectors. Harting This manufacturer uses Screw Lock technology and

December 2012 > INDUSTRIAL AUTOMATION PAGES 31


FCOCUS ASE STUDY its product is called Harax. Amphenol This manufacturer uses Screw Lock technology and its product is called Circular Connectors This manufacturer is a leading provider of connectors for Industrial Automation, catering to specific needs. It manufactures high density PCB connectors, field bus and ethernet solutions and optical connectors for hash environments. Lumberg This manufacturer uses Screw Lock technology and its product is called FIXCON. Automation Systems Interconnect This manufacturer has recently released a 7/8” T shaped Splitter. This connector has one male and two female connectors and offers three, four or five

poles as per client requirement. Tyco Electronics This manufacturer also provides various connectors like circular connectors, CPC connectors, pin connectors of different specifications for the Automation Industry. Binder USA This company mainly manufactures cylindrical connectors for sensors and for factory automation. Staubli This company manufactures quick connector systems which may be used in factory automation as well as in the field of robotics. Turck This company also manufacturers various connectors that may be used for factory automation systems.

32 INDUSTRIAL AUTOMATION PAGES > December 2012

The vast filed of Industrial Automation has been growing by leaps and bounds and new technology is the need of the hour. Industrial Automation is replying to these needs by constantly upgrading existing technology as well as looking at new and enhanced versions of connectors. The major challenges and future trends in the industry are: • To improve lock designs • To lower application costs • To increase reliability • To develop backwards compatability • To reduce downtime The industry has risen to face these challenges and many of the leaders are engaged in cutting edge research to meet these requirements. The number of

options available to meet these demands is increasing as the playing field is becoming larger. More industries are joining the automation bandwagon and this in turn leads to the synergistic approach where research and technology is also growing to meet the current and future demands of practical applications in industry. Whatever the use of the connector whether in a simple operation as a phone jack, a more complex device in a digital interface or a fairly sophisticated, high tech link in Industrial automation, the humble and simple connector has grown in leaps and bounds as is an integral aspect in many industrial operations.


A truly total solution for Factory Automation Project Introduction: In order to optimize manufacturing management, manufacturers need visibility to accurately control workflow information. As a result, there are more companies willing to implement Manufacturing Execution Systems (MES). According to the definition of Manufacturing Execution System Association (MESA), “MES delivers information that enables the optimization of production activities from order launch to finished goods.” However, the lack of bottom layer information, which is responsible for the physical control of machinery and equipment, makes MES unable to maximize the effectiveness of factory automation. In addition, industrial grade devices to precisely acquire signals and immediately deliver data are also important for such automation applications due to the harsh environments in factories. System Requirements: A well-known manufacturer of various electric oven products, water heaters, cooker hoods, etc in China. was planning to improve its factory management efficiency and has implemented MES, but the critical data of the manufacturing equipment cannot connect to its system because of the

outdated machinery, meaning that the company has to manually upload data that increases the chance of human errors but also substantially increases the workload. Meanwhile, the work place is filled with multiple punching machines and related equipment, and is therefore unable to do the network wiring. The oven manufacturing plant is a high temperature and dusty environment without air conditioning so the devices have to operate under quite stringent conditions. System Description: For this case, three types of ADAM modules were deployed in the factory to collect information because some of machines are too old and don’t even have data acquisition devices. This important data will affect the manufacturing quality, so Advantech addressed these issues with the robust ADAM-4100 series which are compact, versatile sensor-to-computer interface units and designed for reliable operation in harsh environments. The first is an ADAM-4117, analog input module in charge of the pressure values of the oil cylinder, and the second is an ADAM-4118, thermocouple input module to collect the machines’ temperature. The last, an ADAM-4051, is an

isolated digital input module with special features making it suitable for critical applications, mainly counts the number of operating times of the punching machine. Advantech also provided a UNO-2174A Embedded Automation Computer, as a gateway next to the manufacturing equipment to acquire the on-site signals of the PLC and ADAM devices as well as delivering data to Advantech WebAccess that Product Advantech WebAccess UNO-2174A ADAM-4117 ADAM-4118 ADAM-4051

is installed in IT control room and is responsible for sending data to the MES. With Gigabit Ethernet ports, multiple I/O, and PCIe sockets, this embedded computer offers excellent functions for MES applications. Additionally, it features IP40 certified anti-dust ingress protection and wide operating temperature range (-10~70°C) to enable a reliable operation in severe environments. Project Implementation:

Description Browser-based HMI / SCADA Software Intel Atom N450 Automation Computers with 6 x USB, 8 x COM, 2 x Mini PCIe Robust 8-ch Analog Input Module with Modbus Robust 8-ch Thermocouple Input Module with Modbus 16-ch Isolated Digital Input Module with Modbus System Diagram:

Conclusions: A d v a n t e c h ’s total solution includes hardware, software, and professional services to truly achieve the efficient Factory Automation goal and it overshadows other competitors’ incomplete HW/SW programs. At first, all of Advantech’s products passed customer’s 24hour burn-in test to prove their stability, and then perfectly combining with a variety of PLCs, sensors, and other devices from different vendors to collect on-site information enables customer to correctly control the production conditions in real time via our open architecture software to connect MES. Consequently, our customer can not only increase its production capacity and product yield rate but also reduce management cost and solve the problem of human errors


TECHNOLOGY Red Lion Adds N-Tron 716M12 & Sixnet SLX Switches to New Industrial Networking Portfolio Red Lion Controls, the global experts in communication, monitoring and control for industrial automation, today announced that the company has expanded its portfolio of industrial Ethernet switching solutions with the new N-Tron 716M12 and Sixnet SLX-5EG, SLX-3EG and SLX-3ES switches and media converters. Available now, these Ethernet switches and converters provide high performance in a rugged package to meet networking requirements for industrial applications such as transportation and video surveillance. The Red Lion N-Tron 716M12 managed switches deliver 16 Ethernet ports with M12 connectors in a rugged IP67 enclosure, which is ideal for wash down, temporary water immersion, offshore, dust proof, military, power substation, transportation and

other outdoor applications that experience exposure to liquids and excessive dirt and dust. The 716M12 has UL approval for use in Class 1, Div. 2 hazardous locations and the EN50155 certification for railway applications. The Red Lion Sixnet SLX5EG switches provide 5 Gigabit Ethernet ports for real-time operation and high performance in industrial networking environments. With rugged packaging that offers superior reliability in extreme environments, these easy-to-use switches require no user setup and

work right out of the box. Available in two models, the SLX-5E-1 offers 5 Gigabit copper ports with 802.3af Power over Ethernet (PoE) available on 4 ports while the SLX-5E-2SFP delivers 3 Gigabit 10/100/1000 PoE and 2 Gigabit SFP ports. The Red Lion Sixnet SLX3EG is a rugged 3 port Gigabit industrial Ethernet media converter that provides flexibility and fast performance in industrial settings. For additional connectivity options, Red Lion also offers SLX-3ES Ethernet copper-to-

fiber media converters. “Many transportation, video surveillance and security applications run outdoors in harsh conditions around the clock so they require reliable Ethernet connections,” said Diane Davis, director of product management, Ethernet networking at Red Lion Controls. “Our new switches provide flexible connectivity options that deliver the reliability and performance expected of industrial Ethernet to support bandwidth-intensive applications such as video traffic.” The 716M12 and all SLX switches and media converters are available now through authorized Red Lion N-Tron and Sixnet resellers and distributors. To learn more about Red Lion’s industrial Ethernet solutions, please visit www.redlion. net/networking or email info@redlion.net.

Advantech Supports Fieldbus Couplers — APAX-507x Series The Industrial Automation Group of Advantech now provide a complete range of APAX products, the new APAX-5071 PROFINET Coupler, APAX-5070 Modbus Coupler and APAX-5072 Ethernet/IP Coupler. Depending on their application, APAX I/O modules can act as remote stations which can be used in different locations for data acquisition and control tasks. The APAX-507x series feature an integrated 2-port Ethernet Switch, which sup-

ports a flexible topology connection. For example, the I/O nodes can be connected in a line (bus) topology, instead of a traditional

34 INDUSTRIAL AUTOMATION PAGES > December 2012

star topology, therefore reducing the effort required for wiring and saving installation costs. For more information or

to purchase, contact Advantech directly or your regional Advantech authorized dealer.


New Danfoss Industrial Refrigeration App for your Smartphone Danfoss Industrial Refrigeration strives to design and manufacture technology leading valves and controls with one main objective - to make your work in industrial refrigeration as safe and trouble-free as possible. To complement our products, our newest tool, the Danfoss IR app, is designed to do just that. Download it today to stay up to date with the latest products and developments from Danfoss. Danfoss IR app is tailored to collect apps/tools that will make your work with industrial refrigeration products from Danfoss easier. Just one download and you will be connected. 1st release: The first app within the Danfoss IR app is SVL Flexline™. SVL Flexline™ is our newly introduced line com-

ponents for industrial refrigeration. The app will explain the product features and benefits and will give you easy access to technical data and other relevant product information. But that is not all. Included is a bit of fun in the form of a challenging game. The game is built around the “One Platform, Multiple Options” concept, which is the main principle of the SVL Flexline™ line design. Test your product knowledge and have some friendly

competition with your colleagues. See who can answer the questions the quickest! 2nd release: The next tool scheduled for release within the Danfoss IR app platform is a Spare Parts app. This app will make it easy to find relevant spare parts for a given Danfoss industrial refrigeration valve.

All you have to do is download the Danfoss IR app once, and you will always be updated on the apps developed for Danfoss Industrial Refrigeration. The app is developed for iPhone, iPad, and Android and can be downloaded via your normal app store or via our Industrial Refrigeration website.

Rockwell Automation Expands MCC Portfolio With Embedded EtherNet/IP Capabilities Rockwell Automation has announced the addition of EtherNet/IP to its mediumvoltage Allen-Bradley CENTERLINE motor control centers (MCCs). With the features of an integrated EtherNet/IP network, manufacturers now have access to production information throughout the enterprise and can take advantage of simplified device programming with Premier Integration. “We are excited to extend our portfolio of EtherNet/ IP-enabled MCCs to include medium voltage,” said Jeff Nolan, product manager, Medium Voltage MCCs, Rockwell Automation. “As with our low-voltage MCCs, EtherNet/ IP integration allows customers the ability to access more detailed production data, allowing plant engineers to predict potential problems

and help prevent equipment failures. This ultimately results in higher asset availability and reduced maintenance costs.” Leveraging a single, standard network simplifies communication for the entire enterprise and provides users with the flexibility to control, configure and collect data from any point in the system. In addition, by taking advantage of Premier Inte-

gration, users can configure and commission their MCC faster with Rockwell Software Studio 5000 engineering and design environment, helping to eliminate errors associated with redundant programming. Furthermore, the Ethernet connection allows CENTERLINE MCC users to access information remotely. This lets personnel safely monitor, troubleshoot and diagnose

the MCC without exposing them to potentially dangerous conditions and power equipment. Knowing how an MCC is performing from anywhere also saves time by minimizing the need for maintenance personnel to enter the MCC. This involves suiting up with personal protective equipment to help protect personnel from exposure to hazardous conditions. With embedded AllenBradley IntelliCENTER technology, Centerline MCCs use a pre-configured and pretested network with integrated hardware and software. This level of integration helps reduce installation time with its plug-and-play setup, and can help minimize facility downtime by quickly providing intelligent diagnostic and predictive failure information.

December 2012 > INDUSTRIAL AUTOMATION PAGES 35


TECHNOLOGY Flexible operating concept: electromechanical buttons supplement The new generation of Beckhoff panels from the CP2xxx and CP3xxx series includes multi-touch displays as a major new feature with which operating options and comfort can be significantly increased. However using electromechanical buttons for key functions is still necessary or desired in many industrial applications, despite the many benefits provided by modern multi-touch technology. As with previous Panel series, Beckhoff supports this with numerous standard and custom designs: from integrated short-stroke or emergency stop buttons to RFID or USB interfaces. These hardware options are connected by direct wiring, USB or any common bus system such as EtherCAT, PROFIBUS or PROFINET. Safety-relevant functions can be integrated easily via the TwinSAFE or PROFIsafe protocol.

Beckhoff Control Panels and Panel PCs with optional push-button extensions enable the applicationspecific arrangement of electromechanical buttons, switches, indicator lamps, additional membrane keys and hand wheels directly on the operating unit. As a result, the efficient Control Panel can be adapted pre-

cisely to the needs of the machine controller with all necessary functions, so that more complex machine control panels can be rendered obsolete. The standard buttons, switches and indicator lamps are connected to the controller via USB or, for increased functionality, via EtherCAT or other bus sys-

tems. Additionally, all buttons can be directly wired via a terminal strip using a second NO contact. Beckhoff offers pushbutton extensions as standard options (C9900-G0xx) or alternatively also as customer-specific versions. The design is almost arbitrary here: from different button versions in terms of colour, membrane keys, switches, capacitive buttons, electromechanical buttons, shortstroke buttons, toggle or key switches to RFID or USB interfaces. The multi-touch Panel series from Beckhoff offers maximum flexibility: different display sizes from 7 to 24 inch, horizontal or vertical orientation, 4:3 or widescreen format, built-in or mounting arm Panels as well as the DVI/USB Panel variants or complete Panel PCs with powerful integrated processors.

Easily Manage Your PROFIBUS Devices via Modbus TCP Moxa is pleased to release its MGate 5101-PBM-MN PROFIBUS-to-Modbus TCP gateways series with PI certification. The MGate 5101-PBMMN gateway features enable bridging PROFIBUS devices (PROFIBUS drives or meters) to Modbus TCP master (SCADA or PLCs) with ease. In addition, its rugged design with optional built-in optical isolation, and -40 to 75°C wide-temperature operation, ensures reliable performance for use in industrial applications such as oil/gas, power, process automation and factory automation. According to Jun Chuang, product manager for Industrial Ethernet Gateways, “As a networking expert, we always try our best to keep

providing an effortless and cost-efficient solution in assisting our customers to remote monitoring field devices with different protocol. Through Moxa’s gateway solutions, customers can easily perform configuration via an innovative AutoScan function in one easy click and online

36 INDUSTRIAL AUTOMATION PAGES > December 2012

MGate monitoring tool. This simplifies maintenance and eliminates the need to buy an extra monitoring tool.” One-Click AutoScan Enables Easy Configuration To complete gateway configuration in one easy click, Moxa’s MGate 5101-PBM-MN provides an innovative Au-

toScan function to detect all connected PROFIBUS slave devices and their available I/O modules. After configuration is done, an easy-to-read data mapping table is created to assist in the configuration of Modbus TCP master (e.g. SCADA, PLC) settings. Web-based I/O Monitoring Offers Easy Maintenance The MGate 5101-PBM-MN provides an online web-based I/O data monitoring tool with import/export functions for easy configuration, and records logs for troubleshooting purposes. This monitoring tool also supports encryption functions such as HTTPS and SSH to prevent unauthorized access. With this tool, customers won’t need to spend an extra cost to get a PROFIBUS monitoring tool.


December 2012 > INDUSTRIAL AUTOMATION PAGES 37


CASE STUDY

H

aas customer, Thorlabs Inc., has evolved to become a leading global player in the supply of photonics products to customers conducting light-based experiments – viz., the people who are creating the light-based technology of tomorrow. The company has writtenthe-book (a shelf-busting 12lb catalog in fact) on how to run a successful mail order, high-tech component business. Needless to say, while Thorlabs innovates, it’s Haas CNC machine tools that are doing the metal cutting, at the company’s US headquarters in Newton, New Jersey.

Haas Makes Light Work So much modern technology is light-based, from supermarket checkout scanners to life-saving medical imaging equipment. For engineers and scientists developing the next generation of such technology, Thorlabs offers a staggering 20,000 different photonics products, including optomechanical components, motion control equipment, optics, fiber, light analysis equipment, and imaging devices: in other words, all the building blocks needed for laser and fiber optic systems are available through its online store. In all, Thorlabs has 15

38 INDUSTRIAL AUTOMATION PAGES > December 2012

design and production facilities located in eight countries around the world. In Newton, New Jersey, there are four buildings, one of which is a few miles from the other three that form a campus. The company’s imposing new headquarters is in the center of town and houses, amongst other things, engineering staff, assembly and administration. The former headquarters on Route 206 is now dedicated to the company’s machine shop and contains six Haas VF3SS high speed machining centers with automatic pallet changers, three EC400 horizontal machining cen-

ters (two with six station Pallet Pools) and a DT-1 drill-tap center. At present, Thorlabs manufactures a portion of its products in-house, but there are plans to bring this figure up considerably in the coming 3-5 years. Now that most of the non-manufacturing operations have been moved from the Route 206 building, there’s ample space for new equipment and the organisation has plans to double its machine shoap capabilities. Patrick Mulvoy, of the company’s Mechanics Business Unit oversees the machine shop and explains his vision for a


bigger, expanded manufacturing operation. “As you can see,” he says, “we’re not short of space now that the rest of the business is relocated in the new building. I can see us having 100+ machines in here in the future, which is probably what we’ll need if we’re going to meet our business goals.” That’s particularly good news for Haas, since Thorlabs has committed to a predominantly one-make shop. “Five years ago we were using machine tools supplied by a number of different manufacturers,” Patrick Mulvoy explains. “We decided to standardize and Haas stepped up to the plate – they’ve been a great partner for us ever since. The machines are relatively low-cost and are very productive. We

have Haas 4th axis rotary tables on all the VF machines, as well as pallet loading systems.” The use of pallet change technology allows Thorlabs to perform its component loading and unloading offline while the spindle is still cutting. Using tombstone fixtures on the EC400 Pallet Pool horizontals, Thorlabs says it can complete even highly complex parts in a maximum of two set-ups, while the four-axis verticals are also able to replicate some of the processes performed on the EC400s. Through the use of pallet pools, Thorlabs has taken advantage of “unmanned or lights out machining” in order to stay competitive in its respected industry. Workpiece materials range from aluminium to

stainless steel, and volumes vary widely. A typical part, such as a mirror mount is produced in numbers of around 40,000 units a year. However, some components are made in annual volumes of up to 110,000 units and more. The company has different Haas machines set aside for one off prototypes, families of parts, and high volume components. Pointing at one particular EC400 Pallet Pool, Patrick says: “This one will only make two components for the rest of its life. We bought it for a specific high volume purpose. We foresee a life expectancy of up to 15 years, which is a very impressive ROI.” Having machines set-up for certain tasks and volumes also aids personnel deployment. “Operators can switch from one job to an-

other without problems or assistance from senior staff,” explains Patrick. “One particular Haas machining center produces a family of 12 different parts. Here, several components are loaded on to a 36 inch work-holding bar – we can flip the whole row and cut the back-side off. In fact, this particular setup yields about 70 parts per load, which allows the operator to walk away and do something else for an hour.” All of the Haas machines at Thorlabs are fitted with Renishaw probes, which are particularly useful when machining some of its stainless steel parts, as the company can use broken tool detection capabilities between spot drilling, drilling and tapping. “If a tool breaks, the others don’t follow,” says Patrick.

December 2012 > INDUSTRIAL AUTOMATION PAGES 39


CASE STUDY

Company President, Alex Cable, founded Thorlabs in his basement, back in 1989 and named it for his dog, a black Labrador. Today, the firm has 850 employees worldwide, half of which work in New Jersey. Most of its sales come via the website, and when orders are placed, customers can count on the part being in stock and available for immediate shipment. The responsibility for making sure this happens for the Mechanics Business Unit falls on the shoulders of Rick Chiong, Mechanics Business Unit Leader, who claims to be a “recovering accountant” and is based at the new Thorlabs

headquarters. With an eye for figures and accuracy, he’s also an expert in lean enterprise and Six Sigma: knowhow he applies rigorously to get the very most from the Haas machine tools. “Haas machines have proved to be extremely worthwhile assets,” he says. “They hold tight tolerances, are user friendly and can accommodate a lot of tools, which helps minimize setups. They are also fast, which is important because everything we do has a bottomline impact. “We need the Haas machines to be extremely agile,” he adds, “which also match-

40 INDUSTRIAL AUTOMATION PAGES > December 2012

es the Thorlabs business model. We offer our customers a wish list of every conceivable part and product for light-based experiments. However, if someone doesn’t find what they need on our site, it is very easy for them to web-search for similar products elsewhere, so we have to have the product on the shelf all of the time and be able to deliver without delay.” This is what Rick refers to often as the company’s ‘customer centric’ approach and it is, he says, “a large part of why we are successful.”

“I must say, the Haas machines have really fulfilled the potential we saw when we bought the first, back in 2007. I remember being very impressed when the machines and their various productivity enhancing features were demonstrated. Also, they are made in the US, which is particularly good for us: a company with a large part of its manufacturing based here. It’s also very refreshing to see that Haas invests in its own in-sourcing, which is what we plan to do even more of as we get bigger and carry more product lines.” It’s difficult to imagine just how many more products the company could offer. But, given that the plan is to have a total of 100+ CNC machine tools, the online catalog could be an order of magnitude bigger than it is currently. What the already tome-like printed catalog would look like is anyone’s guess!


INNOVATIVE AUTOMATION... l Grippers

l Linear Motion

l Rotary modules

l Robot Tool Changers

l Robotic Deburring tools

l Sensors

l Valves

l 6 AXIS Force Torque Sensor

l Robot Accessories

Call Us Now: SCHUNK India Branch Office, No. 80-B, Yeshwanthpur Industrial Suburbs, Bangalore-560022, December 2012 > INDUSTRIAL AUTOMATION PAGES 41 Phone +91 80 40538999, Fax +91 80 40538998, info@in.schunk.com, http://www.in.schunk.com


EVENT NEWS Invitation to Biggest Logistics Event of Western India The stage is set for the leading logistics event, India Warehousing and Logistics Show 2012, scheduled to be held from 7th to 9th December at Auto Cluster Exhibition Centre in Pune. The exhibition focuses on warehousing infrastructure, materials hanlding, automation, industrial solutions, storage and supply chain. One stop shop for all your logistic needs, IWLS 2012 is featuring all major brands and latest technology in materials handling to help you in reducing cost and human efforts within your manufacturing facility or warehouse. The event gives you a platform to meet leading supply chain companies and ware-

house facilities suiting your distribution requirements and guides you to source IT products and solutions to streamline your warehouse and logistic operations. “Pune has proved to be the ideal location for IWLS this year. The show is an absolute sold out with 200 + brands from all over the country. There is already a big buzz in the region and the response is overwhelming with pre-registrations going up every day. I am sure that IWLS would trun out to be the best show ever organized in Pune” said Anuj Mathur, Managing Director, Reed Manch Exhibitions. Visiting the event is

particularly beneficial for end-user industries such as Automotive, Automobile, Pharma, Chemicals, Electronics and Electricals, FMCG, Food & Beverages, Glass, Paper, Retail, Textile, Steel and many more in addition to the logistics and supply chain segments. Industrial and logistics parks giant, Indospace Industrial Parks has continued its partnership with the warehousing show series as ‘Foundation Partner’. The leading entrance automation company, Gandhi Automations is the Gold Partner of the event. Gathering huge support from trade associations, the event is supported by Deccan Chamber

of Commerce Industries & Agriculture (DCCIA), AIDC Technologies Association of India, Indian Private Ports & Terminals Association (IPPTA) and Consolidators Association of India. “This edition of IWLS is a notch above its launch edition in Ahmedabad with all major brands in logistics business exhibiting with us in Pune. There are several equipments on display from Godrej, Maini Materials Handling, Motorola, Nilkamal, Schaffer and many more including new market entrants Kelley Material Handling. I look forward to welcome you all in Pune in December.” concluded Mathur.

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EVENT Calandar Event’s Name / Venue

Date

Event’s Name / Venue

Robotic Conclave 2012 november AZISINDIA2012_Industrial Automation_208x275:Layout 1 26.03.12 12:13 Hotel Le Royal Meridien, 02 - 02 Chennai 2012

Date

Elektrotec 2013 January Trade Fair Complex, 23 - 26 Coimbatore 2013

SeiteCODISSIA 1

UMEX 2012 (USED MACHINERY EXPO) november Nehru Centre, 02 - 04 Mumbai 2012

India Automation Technology Fair february Bombay Exhibition Centre 01 - 03 Mumbai 2013

Engineering Expo november Pune 02 - 05 2012

Ieema Metering India february Hotel Le Meridien 21 - 22 New Delhi 2013

InterSOLAR India november Electronics For You Expo 2013 february Bombay Exhibition Centre Pragati Maiden, 06 - 08 21 - 23 Mumbai 2012 New Delhi 2013 AZISINDIA2012_Industrial Automation_208x275:Layout 1 26.03.12 12:13 Seite 1 MDA INDIA 2012 november India Expo Center and Mart, 21 - 24 Greater Noida Expressway 2012

Techno 4 march CODISSIA Trade Fair Complex, 01 - 03 Coimbatore, India. 2013

Industrial Automation India 2012 november India Expo Center and Mart, 21 - 24 Greater Noida Expressway 2012

Acrex India march Bombay Exhibition Centre 07 - 09 Mumbai. 2013

CeMAT INDIA 2012 november India Expo Center and Mart, 21 - 24 Greater Noida Expressway 2012

India Engineering Sourcing Show 2013 Mumbai

Surface INDIA 2012 november India Expo Center and Mart, 21 - 24 Greater Noida Expressway 2012

Intec 2013 JUNE CODISSIA Trade Fair Complex, 06 - 10 Coimbatore, India. 2013

Laser INDIA 2012 november India Expo Center and Mart, 21 - 24 Greater Noida Expressway 2012

Modern Machine Shop 2013 New Delhi

Rajkot Machine Tools Show 2012 nov - Dec Race Course Ground, 28 - 02 Rajkot 2012

Modern Machine Shop 2013 Mumbai

ImHLS 2012 December Auto Cluster Exhibition Centre 07 - 09 Pune 2012 AZISINDIA2012_Industrial Automation_208x275:Layout 1 26.03.12 12:13

March

14 - 16

2013

august

22 - 25

2013

September

25 - 28

2013

Modern Machine Shop 2013 November 6–8, 2012 Chennai

october

25 - 28

2013

Seite 1

India's Largest Exhibition and Conference for the Solar Industry Bombay Exhibition Centre, Mumbai

November 6–8, 2012 India's Largest Exhibition and Conference for the Solar Industry Bombay Exhibition Centre, Mumbai

350 Exhibitors 20,000 sqm Exhibition Space 10,000+ Visitors 350 Exhibitors 20,000 sqm Exhibition Space

www.intersolar.in

10,000+ Visitors

December 2012 > INDUSTRIAL AUTOMATION PAGES 43 www.intersolar.in


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