Automation Mag | 02 - October 2020

Page 1


automation mag










International capability

Outstanding results

Optimized process

More than 100 employees in 35 different countries, ensuring a strong relationship with main local media. Mepax distinguishes itself through its extensive media knowledge and ability to select the best international online/print advertising options. PR can be translated into 35 languages.

35,000 published articles in 2019: EMEA: 48% - Asia: 31% - Americas: 21%. Most of the articles are published in the top 1000 media worldwide.

With a proven process set for more than 120 active customers, we can adapt to all specific client needs with the highest reliability. We have developed in house the most advanced PR dedicated ERP, enabling transparency and real-time full online reporting. International media management is then made easy, fast, and efficient for optimal results.



IN THIS ISSUE... 4  The Smart Factory: An Overview 10  New "Intelligent Guided Vehicle" (IGV): Autonomous counterbalanced forklift is guided by swarm intelligence

12  AGILOX Autonomous Mobile Robots are substantially saving costs by applying Artificial Swarm Intelligence

14  The Energy Saving App, Coval's software that measures energy savings 15  Cognex Introduces Next Generation of High-Performance Handheld Barcode Readers

16  Cognex image-based barcode readers in Flensburger brewery's logistics center 18  Ease of use lowers entry barrier for users without prior knowledge 20  2200 Series Modular Belt Conveyor Now Being Built at Dorner Europe’s Jülich, Germany, Location; Faster Delivery Throughout Region

21  ElectroCraft Introduces MPW Series Wheel Drive 22  Hyperturn 45 G3: 22  Dynamic. Intelligent. Fully automated 24  Volkswagen integrates newest Eplan and Rittal solutions 26  FLIR thermal sensors help hamburg to enhance city traffic flow 28  FLIR Systems Announces Modified Thermal Cameras Specified for Elevated Skin Temperature Screening

30  Electronic assemblies without PCBs 33  Cognex launches new Item Detection System 3D-A1000 34  New Intesis gateway makes communication between PROFINET and BACnet easy 36  Softing enhances edgeConnector Siemens 37  Ewon DataMailbox – remote access to machine data just got a lot easier! 38  “In this industry, reputation is everything. The components that you supply must be perfect”

39  Sharp images even with varying object distances 40  Automate image-based inspection with artificial intelligence 44  IDS to offer 20.35 MP IMX541 sensor from the Pregius S series from September 45  Innodisk and DFI Combine Expertise for the Best in IoT Device Management 46  Rutronik develops first development kit for AI based applications to implement EDGE intelligence

48  Technology Report 50  How Standard Components Minimise Downtime and Provide Business Continuity 53  Innodisk’s Industry-leading Solutions Enable Next-generation Networking and Telecom

54  Stepping Towards Automation with norelem’s expanded Stepper Motors Range 56  Short lead times for UK-made NSK NH/NS linear guides 57  Red Lion’s FlexEdge™ Intelligent Edge Automation Platform Integrates IT and OT 58  New DC Platform: Interroll brings innovative drive solution to the Americas 60  Intelligent image processing supports production workers in industrial 4.0 applications

63  Wireless Safety

Advertisers: LEUZE 21 • MEPAX 25

automation mag

Send your press releases to: AUTOMATION Mag is the ultimate source for automation engineers: industry 4.0, IA, motors, sensors, controls, software… Our international team covers product developments, application stories, and technical articles, as well as offering comprehensive analysis of the latest engineering trends. AUTOMATION Mag edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used. To receive the AUTOMATION Mag newsletter, subscribe online:





THE SMART FACTORY: AN OVERVIEW The smart factory is still a work in progress, but the building blocks are already in place. A report.

5G plays a central role in the Bosch vision for the factory of the future. Picture: Bosch


couple of years ago, a technocrat from a leading automation vendor, chatting on the side-lines of an industry event made an interesting observation. “A factory manufactures products, but that is not the purpose of the factory,” he said. “The purpose of a factory is to make profits.” Implicit in this assertion is the role technology plays in making those profits. It started with the very first Industrial Revolution in the mid-18th century powered by steam,



and continues with the Industry 4.0, the fourth version – unleashed by the Internet and facilitated by cyber physical systems in the new millennium. Each of these revolutions brought in tremendous advantages in terms of transportation, telecommunications, access to raw materials, exploration of resources, etc., and led to large scale manufacturing of industrial and consumer goods, gadgets and appliances

for everyday use. However, by now, most of these advantages have been exploited to the hilt, and production efficiency in some sectors has reached in the higher 90s in terms of percentage. Yet today, more than at any other time in human history, manufacturers are under constant pressure to produce higher quality products in lesser time at lower prices, and to suit individual requirements as well. With margins shrinking, the only way to squeeze profits is to further increase efficiencies, reduce errors, anticipate failure of equipment and eliminate breakdown altogether. Welcome to the Smart Factory era, made possible by the bouquet of emerging technologies now available to the industry in quest of still higher efficiencies. What exactly is a Smart Factory? In simple terms it is a place for smart manufacturing where machines, already automated to a great extent – and increasingly intelligent robots – are linked together by smart devices through the Industrial Internet of Things (IIoT). This in turn facilitates self-learning and adaption, improving the processes through advanced automation and self-optimisation, with seamless endto-end connectivity and data analytics. The resultant benefits are not just in terms of efficient production, but also the streamlining of all related functions like supply chain logistics and pre- and post-production processes, to make it sustainable. The secret to unlocking this potential is hidden in the data generated by these processes. According to an IBM report, an average factory generates 1TB of production data each day, of which over 99% is not analysed. The information hidden in this data, the analysis of which is beyond human capabilities and needs technologies like artificial intelligence and machine learning, holds the key to greater operational efficiencies. The smart factory does not necessarily have to be built from scratch. Existing facilities can be transformed into smart factories, provided there are investments made to put a few things in place. These include a proper network infrastructure, smart controllers, analytics software with integrated information systems including

ABB’s smart factory module demonstrated at Hannover Messe 2019. Picture: Hannover Messe

IoT, cloud computing, Big Data and technology using artificial intelligence. Above all, this needs skilled manpower and the preparedness to adapt to new technologies.

one umbrella. The ABB Ability platform today offers more than 220 digital solutions, which enable enterprises to increase productivity and improve safety at lower costs.

The smart factory is still a work in progress, but the building blocks are already in place. However, there are gaps to be filled – while Artificial Intelligence plays a key role in data analytics, 5G is the go to technology for connectivity – and a lot remains to be done in both these areas.

The ABB factory at Heidelberg in Germany is a classic example of a smart factory, a showcase of ABB’s cutting edge technology as well as manufacturing prowess. One of the oldest plants of the ABB group, it manufactures miniature circuit breakers (MCBs), a common but critical safety device used in electrical installations, available in many different variants. The MCB effectively breaks the circuit in case of overload and other faults, protecting the installation from fire and damage. The Heidelberg plant is a demonstrator for smart manufacturing – of how the factory of tomorrow looks like. It is equipped with seven types of ABB robots, all interconnected on the ABB Ability platform, the digitalisation increasing their productivity. The transformation has increased the plant efficiency to handle 3 times as many product variants as before, adding to a whopping 6000 variants now, also improving quality of the products. Predictive maintenance practices have led to accurate delivery schedules and better in-plant material handling.

So what is the status of the smart factory and its implementation from the perspective of the leading vendors of technologies for the smart factory? Presented here is a snapshot of 5 leading vendors and their technologies. ABB and its Ability A custom-made wristwatch assembled within three minutes. That is what ABB demonstrated at Hannover Messe 2019 at the smart factory module on display at its booth, using three of its key technologies – the YuMi collaborative robot performing precision assembly operations; the SuperTrak flexible transport system ensuring timely movement of parts; and the ABB Ability Connected Services monitoring health and performance. ABB launched the Ability™ technology platform in 2017, bringing together a number of its digital products, solutions and services under

The Ability platform leverages intelligence gathered from ABB’s vast global installed base of over 70 million connected devices and 70,000 control systems. This not only helps customers optimise operations, but 02 - AUTOMATION Mag - OCTOBER 2020



Bosch smart factory working on the Nexeed platform. Picture: Bosch

ABB also uses the insights to develop network and plants at multiple locations. new business models. But Bosch also offers solutions to SMEs in smaller packages, introducing to them the benefits of Industry 4.0, especially Bosch goes beyond Mobility when they do not have in-house digital Bosch, the renowned provider of vehicle expertise. technologies and mobility solutions, now offers Industry 4.0 technologies for smart Bosch’s Blaichach plant in Germany, factories. With the focus on automation, specialised in manufacturing ABS and digitalisation, AI and IoT, the idea is to ESP systems for automobiles, is a boost productivity, quality and safety. As smart factory working on the Nexeed a leading user and provider of Industry platform. This brings all the benefits of 4.0 solutions, Bosch follows the ‘3S’ the connected plant for both new and strategy – using sensors, software and existing machinery, as Nexeed is an open services. These are channelised through system, where it is easy to retrofit IoT its software platform Nexeed, on which devices on legacy production lines. The reside a variety of ‘Source-Make-Deliver’ Blaichach plant employs 3000 associates solutions for continuous optimisation as Bosch calls them, and produce 6.7 – from procurement (source) through million ABS/ESP safety systems. The production (make) to the end customer transformation has made it possible for (deliver). Nexeed includes tools like Bosch to increase productivity at its ABS/ predictive maintenance, cockpit charts, ESP manufacturing facilities worldwide traceability and tracking solutions, by almost 24 per cent. manufacturing execution, maintenance support, autonomous transport systems, For Bosch, these initiatives of integrating intralogistics – all connected. Nexeed Industry 4.0 technologies in the smart is ideal for larger enterprises that factory is paying off with the company have deployed Industry 4.0 solutions, having earned more than Euro 1.5 billion companies that have global production with Industry 4.0 applications in the last 02 - AUTOMATION Mag - OCTOBER 2020


5 years. By 2022, Bosch has ambitious plans to generate annual sales of over a billion euros with Industry 4.0. Rockwell Automation and The Connected Enterprise Rockwell Automation believes the world needs to become a smarter place and offers solutions to that end through The Connected Enterprise, where products become smarter, people become smarter, and their decisions become smarter. The 117-year old company is a major provider of industrial automation and information technology products with global sales of USD 6.69 bn for 2019. The company conducts signature events like the annual Automation Fair in the US and the region specific TechED events at other global locations to connect with and educate customers about the latest developments in the field. The hardware offering of Rockwell Automation comprises thousands of Allen-Bradley products, the software comprises numerous software suites

under the FactoryTalk banner. The Connected Enterprise is a platform that brings these smart solutions together for the benefit of discrete manufacturing as well as process industries, bringing them tangible benefits like faster time to market for manufactured products, improved asset utilisation, lower total cost of ownership, and more effective enterprise risk management. That these are all tried and tested solutions is borne out by the fact that Rockwell Automation uses them in its own manufacturing facilities as part of its digitalisation transformation journey. The Connected Enterprise, according to the company, is a five-step journey: identify a desired business outcome; get an outside perspective; assemble the team; implement a pilot program; and scale for expansion. For companies who adopt the platform for their digital transformation, the outcome, based on use cases, leads to: productivity increases of 4-5% per year; waste reductions that result in hundreds of thousands of dollars in savings; faster time to market, which

includes plants that become operational in weeks instead of months; quality improvements that result in defects being cut in half; and up to 98% on-time delivery. In 2017, Rockwell Automation opened its EMEA Customer Center for The Connected Enterprise in Karlsruhe, Germany, offering customers and visitors the opportunity to receive tailored advice on smart factory subjects combined with a 360-degree view of The Connected Enterprise. Schneider Electric builds the EcoStruxure Schneider Electric, the leader in the digital transformation of energy management and automation, traces its origins to 1836. It is a European multinational company with operations in over 100 countries and 2019 revenue of Euro 27 billion. Since 1980, the company has grown phenomenally through a series of acquisitions, shedding its traditional steel business in favour of electricity and related technologies. Having reinvented itself for the digital era in the new millennium, the company launched its IoT enabled EcoStruxure platform for digital transformation, with sector specific suites covering not just industries, but also homes, buildings, data centres, energy and infrastructure. EcoStruxure for Industry is the Schneider Electric IIoT platform that is open, interoperable, and ready for smart manufacturing, at every level from Connected Products to Edge Control and Apps, Analytics and Services. It is the digital backbone connecting bestin-class operational technology (OT) solutions with the latest in IT technology to unlock trapped value in operations and leverage the true potential of the Internet of Things. With integrated software, it improves productivity, efficiency, sustainability, and cybersecurity for plants and machine builders. Benefits include up to 80% reduction in engineering costs and time; up to 75% savings in maintenance cost; and up to 50% reduction in carbon footprint.

The Rockwell Automation EMEA Customer Center at Karlsruhe, Germany. Picture: Rockwell Automation

Schneider Electric executives often say ‘we eat our own food’, which means 02 - AUTOMATION Mag - OCTOBER 2020


MARKET OVERVIEW the smart technologies the company offers to the industry are implemented in its own plants first. The company has launched several Smart Factories around the globe in countries like France, USA, Mexico, China, India, Indonesia, and the Philippines. These are central to its Tailored Sustainable Connected 4.0 supply chain digital transformation where it leverages digitisation across its supply chain operations to deliver end-to-end integration and visibility to enhance its performance. The World Economic Forum has designated the Schneider Electric facilities in Le Vaudreuil in France, and Batam in Indonesia, as Advanced 4th Industrial Revolution (4IR) Lighthouses. The company has set for itself a target of 100 smart factories for 2020, and the same technologies are available for any company looking for similar transformation. Siemens and its MindSphere Established in 1847, Siemens is the German multinational corporation and the largest industrial manufacturing company in Europe with a global footprint, with 2019 revenue of around Euro 87 billion. With its main business verticals of Industry, Energy, Healthcare and Infrastructure, Siemens today has the domain expertise and digital knowhow to generate performance improvements across the entire value chain through digital transformation. This is achieved with its two main solutions: MindSphere – a cloud-based, open IoT operating system; and Digital Twin – the virtual representation of products and production. Launched in 2016, MindSphere today connects an estimated 1.3 million devices and more than 1,000 customers. Global automobile giant Volkswagen uses MindSphere in its cloud network, connecting machinery and equipment at more than 120 of its plants. This data is used to improve productivity and efficiency across plants and production lines. What MindSphere does essentially are 4 things: connect assets and upload data to the cloud; collect, monitor, and analyse data in real-time; gain insights that improve efficiency and profitability; and take advantage of apps and solutions that solve real problems.



The Schneider Electric smart factory at Le Vaudreuil in France. Picture: Schneider Electric

The Siemens Smart Factory at Amberg, Bavaria. Picture: Siemens

Like other major vendors, Siemens too has an excellent example of the Smart Factory in its Amberg plant in Bavaria, which has deployed the MindSphere system as well as executed the digital twin. Spread over 100,000 sq.ft, the Amberg plant manufactures a mix of 1200 products, which means on an average there are 350 production changeovers per day! The plant produces 17 million Simatic components per year, and about 50 million items of process and product data is evaluated and used for optimisation! In the process of the smooth running of the plant, Siemens uses other ground breaking technologies like artificial intelligence, machine learning and Industrial Edge computing. The results of the transformation are evident in the figures – a 13-fold rise in production since the plant started operations in 1989, without any additional manpower or expansion. Summing up According to a market research report on global smart factory industry posted by Reportlinker recently, the global market for Smart Factory is estimated at US$136.4 billion in the year 2020. This is projected to reach a revised size of US$218.4 billion by 2027. The expected additional value for manufacturing industry due to productivity gains in smart factories by 2023 is expected to be between US$1.5 to 2.2 trillion, according to the Capgemini Research Institute’s estimates, published in its report ‘Smart factories @ scale’. This indicates the potential gains of smart factory for the manufacturing world. An important question that rises from these developments is the human role in the factory of the future with the spectre of massive unemployment caused by digitalisation. But Prof Martin Ruskowski, Chairman of the Executive Board at SmartFactory-KL, the manufacturerindependent demonstrator and research platform based in Germany, does not agree. According to him, “Humans will and must be able to change every decision made by a machine. We will retain responsibility for what happens in the production processes. Machines and artificial intelligence cannot and should not take this away!” 02 - AUTOMATION Mag - OCTOBER 2020



NEW "INTELLIGENT GUIDED VEHICLE" (IGV): AUTONOMOUS COUNTERBALANCED FORKLIFT IS GUIDED BY SWARM INTELLIGENCE After the “ONE” comes the “OCF”: AGILOX expands their line of intelligent guided vehicles by introducing a new autonomous omnidirectional counterbalanced forklift, operating with swarm intelligence. In doing so, AGILOX has entered a new area of ​​application: classic intralogistics in inbound/outbound warehousing and storage.


ith the ONE, AGILOX's ultralight, high-efficiency forklift product line, the company has reshaped the concept of AGVs. The fleets operate without a central control system, meaning the vehicles navigate the production facility or warehouse in a truly autonomous fashion. The exceptionally compact AGILOX IGVs organize their routes according to the decentralized principles of swarm intelligence, making them much more flexible than traditional AGVs.



Additionally, programming or “teaching” the vehicles becomes significantly easier, while central software programs including maintenance, updates, etc. are rendered obsolete—an innovation that lowers operating costs. AGILOX is now expanding its range of IGVs to include the OCF—an abbreviation for “Omnidirectional Counterbalanced Forklift”. While the ONE is equipped with a scissor lift to function as a load handling device (and thus transports the load

AGILOX’s intelligent and cost-saving IGV concept opens up new application areas.

within the vehicle contour), the OCF is designed according to the principles of the counterbalanced forklift. Hence, it can pick up pallets, lattice boxes, and other load carriers with a maximum weight of 1500 kg (3300 lbs), transport them to the destination, and set them down at a height of up to 1600 mm (63 in). AGILOX’s intelligent and cost-saving IGV concept opens up new application areas. While the ONE vehicles are mainly used for material supply in production, the OCF enables classic intralogistics tasks in incoming and outgoing goods, order picking and storage, as well as in production—provided that the transport is pallet-bound. Just like the ONE, the OCF uses an omnidirectional drive concept. It can therefore also drive sideways through narrow aisles, turn on the spot, and maneuver in the tightest of spaces. The same lithium-ion (LiFePO4) battery technology ensures short charging and long operating times - just three minutes of charging allows for up to one hour of operating time.

analytics module provides the user with all relevant operating data and KPIs. Dipl.-Ing. (FH) Franz Humer, M.A. CoFounder and CEO of AGILOX, notes “The OCF is a logical addition to round out our product portfolio. With it, we open up opportunities in storage and order picking technology, and thus, a large market in which the IGVs can showcase their advantages over both AGVs and manoperated forklifts.” The combined operation of the ONE and OCF in a “swarm” also provides a great advantage. For instance, while the smaller vehicles carry out delivery services to assembly workstations or tend to e-Kanban shelves, the OCF can, using the same control system and WiFi infrastructure, take over pallet transport. The OCF pilot series has already been successfully tested in Vorchdorf, Austria. Series production will begin shortly, with the first OCFs set to be delivered to customers in the first quarter of 2021.

The IGV fleets can be connected to customer software systems (LVR, ERP, WMS, MES, etc.) via an open API interface. An optional IO box enables the integration of external infrastructure, such as rolling gates and stationary conveyor systems, in the intelligent control system. An




AGILOX AUTONOMOUS MOBILE ROBOTS ARE SUBSTANTIALLY SAVING COSTS BY APPLYING ARTIFICIAL SWARM INTELLIGENCE Swarm Intelligence (SI) and bio-inspired computing have attracted great interest in almost every area of science and engineering, including robotics, over the last two decades.


eing an innovative manufacturer of autonomous mobile robots (AMRs), AGILOX directs most of its effort into developing one of the most unique robotic material handling features on the market - completely decentralized autonomy. AGILOX Intelligent Guided Vehicles (IGVs) are completely independent, self-controlled, and intelligently designed to handle failover, recovery, and deadlock prevention perfectly. Our SI system can provide real-



time solutions to impossibly complex optimization problems in the most efficient way possible, often in ways that a human designer could never anticipate. The swarm can also handle unexpected changes in dynamic environments without any human intervention. AGILOX vehicles automatically exchange information about the environment and the current work order situation with each other via WiFi several times per second.

Based on virtual transport costs, which each participant constantly recalculates for all pending orders, it is automatically decided which vehicle fulfills an order and which path that vehicle can take to fulfill this order in the shortest amount of time. All of this is possible with almost no overhead cost to the end-customer. There are no expensive server systems, no wires added under the floor, no reflector or beacon installations - no hardware of any kind, other than your regular 2.4 or 5 GHz WiFi network and the charger. There is no software to install or maintain, no version numbers to keep up with, and no licenses with ongoing subscription fees. The nature of our Swarm Intelligence also provides another massive advantage in terms of setup cost. Once the first AGILOX unit learns its environment and workflow details, the system becomes immediately infinitely scalable. Adding additional vehicles to the swarm to increase throughput is as simple as turning on the power and assigning an

IP address. Within minutes, the new vehicle will automatically download all of its configuration information from the swarm and begin working, no additional commissioning or programming required. AGILOX represents a total departure from the traditional approach to material handling processes. We apply the principles of our decentralized IGV system to our entire business model from top to bottom as well, by providing our customers with the training and tools to perform their own maintenance and expand or modify the system as they see fit. With open interfaces, infinite flexibility, and unrivaled collective intelligence, the possibilities for your AGILOX implementation are limited only by your imagination. Welcome to the future of logistics automation.




THE ENERGY SAVING APP, COVAL'S SOFTWARE THAT MEASURES ENERGY SAVINGS COVAL has been committed, for several years now, to improving the energy efficiency of their vacuum pumps. The French manufacturer of components and solutions for vacuum handling offers the Energy Saving App software, accessible online, which allows easy evaluation of energy savings made by an installation equipped with a vacuum pump using the ASC energy saving system.


SC (AIR SAVING CONTROL) is an intelligent system which is used to stop consumption of compressed air as soon as the necessary vacuum level has been reached, avoiding any unnecessary consumption and ensuring energy saving during facility operations.

The Energy Saving App software measures the cost savings when using COVAL’s LEMAX, LEMCOM or GVMAX vacuum pumps, both equipped with the new ASC technology, compared to a conventional vacuum pump. Use of this software, unique in the vacuum world, is very intuitive. After entering the main characteristics of the installation (the duration of operating cycles, number of cycles, time of use, volume to be evacuated) the gain is displayed simultaneously in euros, in air volume and in percentage gain. In most cases it is very significant since it culminates with 97% of energy gain, in particular with the LEMAX. Therefore, it is easy to see that investment in a COVAL pump equipped with ASC pays for itself on average after less than one year of use.



This software can be downloaded from the COVAL website: company/our-technologies/energysaving-app/ This COVAL exclusivity strengthens the vocation of the Vacuum Manager company and their desire to contribute to improving the energy and productive performance of each installation. Note Covid-19: COVAL maintained its activity during the imposed confinement caused by the recent pandemic and ensured its customers always received the same level of great service. Today, life goes back to the normal and our teams are mobilized to support and respond to their customers' requests. They offer face-to-face meetings, videoconferences to discuss projects, face-to-face or distance training, and on-site or on-site testing.




ognex Corporation announces the launch of its DataMan® 8700 Series of handheld barcode readers. Built on a completely redesigned platform, this next generation of handheld readers delivers cutting-edge performance and ease of use with no tuning or operator training required. “Cognex specializes in reading the most difficult barcodes at the highest speed and accuracy,” said Carl Gerst, Cognex Senior Vice President and Business Unit Manager of Identification Products. “With the 8700 series, we’ve developed the world’s fastest line of industrial handheld readers, offering unprecedented response times and durability right out of the box.” Featuring advanced image formation and quick processing, the 8700 Series can instantly read challenging direct part mark (DPM) and label-based codes, even when vital elements of the code are missing or damaged. Designed with oil-resistant and waterproof plastics, the readers are built to last in the harshest manufacturing environments. The new readers include built-in OLED display screens to enable quick setup and operator feedback, such as wireless signal strength, read string data, and remaining battery life. They also support a broad range of industrial protocols and wireless communication options to connect seamlessly and operate efficiently in any facility. The 8700 Series is ideal for improving factory efficiency, productivity, and component traceability across a range of industries, including automotive, medical devices, electronics, and aerospace.





Each Linde forklift truck mast has two DataMan 360 Series barcode readers installed on it and the readers reliably read the 1D barcodes on the pallets to be loaded.


ging handheld laser scanners are considered outdated technology: When the forklift drivers load trucks at the Flensburger brewery with filled kegs or beer crates, a Cognex barcode reader mounted on the mast recognizes the pallet label and scans the barcode. This not only saves time, but enhances safety in congested forklift and truck traffic, and has proven its worth since the technology was installed.

Piotr Kaczmarek and Christian Ludwig, Business Solutions specialists at Jetschke, used their great knowledge and skills to meet the challenge. 02 - AUTOMATION Mag - OCTOBER 2020


In beverage logistics, operations centers require large amounts of goods to be handled at high speed. This is particularly true for the Flensburger brewery, as the company has achieved growth in a virtually stagnant market and sold a record of 628,000 hectoliters of beer in 2018. In other words: 172,000 liters of beverages were brewed and bottled per day, and divided into 17 kinds. The bulk of the beer brewed continues to be the legendary Flensburger Pilsener with the distinctive swing top. The non-alcoholic beverage segment is also seeing strong

The readers can read all codes without a problem, even in poor ambient light, as they are equipped with highperformance lighting accessories.

growth, which has facilitated a business decision to build a new, larger logistics center. A new code-reading solution for pallet identification For the present, the logistics managers are working closely with Jetschke GmbH & Co. KG to optimize the flow of goods and information in the existing building. Jetschke is the licensed dealer for Linde forklift trucks in the far north. The company with over 270 employees provides and services the fleet of robust and high-performance multi-pallet forklift trucks that convey the “Flens” to the trucks. In addition, Jetschke is responsible for incorporating mobile scanning solutions into the information flow, i.e. into Flensburger brewery’s merchandise management system. Historically, the forklift drivers were equipped with a handheld scanner, with which they recorded the pallets to be loaded. A terminal in the forklift truck

In beverage logistics, the technical equipment must withstand a lot. Thanks to their robust design, the DataMan readers from Cognex consistently achieve extremely high read rates over time.

Even creased, torn or reflective codes can be read with the image processing-based devices’ robust decoding algorithms.

The splash guard protects the readers from everyday damage.

cabin displayed which lorry was to be loaded with the respective pallet and once the pallet was scanned and put on the lorry, the system registered the item as “loaded.” This is a common practice in many companies. However, Jetschke's experts aimed for an even faster solution that was comfortable for the operators. The idea: An image processing system is mounted on the forklift truck's mast, which automatically recognizes the palette's EAN code. The driver simply activates the scan at the touch of a button, and is otherwise able to fully concentrate on driving and lifting the pallets; eliminating the need to handle the scanner. This saves time and enhances safety with the high volume of forklift trucks and trucks in the goods issue area. Wanted: Robust identification technology While the idea of installing fixed mount barcode readers to the forklift truck masts seems good in concept: It can only be carried out if the barcode reader

is robust enough to be able to withstand the constant vibrations and impact loads that act on the mast during the journey. The tough environmental requirements disqualified some common types of devices, such as laser scanners. They contain moving parts that would not survive long under the arduous conditions of beverage logistics. Fortunately, the logistics operations team evaluated Cognex DataMan 360 Series image-based barcode readers. They are ideally suited for robust industrial barcode reading applications — as they have no moving parts and are designed from the ground up to withstand tough environments. Image-based barcode readers prove themselves Christian Ludwig, a Business Solutions specialist at Jetschke, chose to use the DataMan 360: “Because the software is already integrated into the reader, the devices are robust, easy to install,

and are easy to adapt to the individual requirements of the application. The large depth of focus of the optics and the very high read rates, even under unfavorable conditions, are also advantageous.” The labels with the codes on them are often creased or partially torn due to the harsh environmental conditions. Nonetheless, the barcode readers at Flensburger brewery achieve continuously high read rates thanks to Cognex’s robust decoding algorithms. Flensburger brewery uses additional numeric coding on their pallet markings next to the barcode, so minor adjustments were required and were quickly completed. Christian Ludwig: “We also equipped the readers with a splash guard as they are used outdoors.” The forklift drivers no longer need to read the codes with handheld scanners, but only need to push a button to trigger the scanning process. This new solution brought huge time and cost savings, both through the modified scanning process, as well as eliminating the additional expenses associated with fixing damaged, unread codes. The masts of six Linde forklift trucks in the logistics center have been fitted with Cognex's DataMan readers and the solution is proving a success.




EASE OF USE LOWERS ENTRY BARRIER FOR USERS WITHOUT PRIOR KNOWLEDGE IDS NXT lighthouse: intuitive AI training software without the need for programming.

Camera hardware and training software are available via IDS NXT ocean Design-In Kit.




n order to implement AI vision solutions, specialist knowledge, development effort and investment in computer hardware and storage technology are usually required. With cloud computing and specialised training services such as IDS NXT lighthouse, the process becomes much easier: neural networks can be trained individually and at the push of a button, without the need to set 978YIDS NXT ocean, the training software helps to make deep

IDS NXT lighthouse is an easy to use training software for creating neural networks

cameras that can solve completely new image processing tasks thanks to artificial intelligence. They have learned which image features are important and are able to apply this knowledge to new image data. This is an enormous advantage compared to classical programming, especially in applications with highly varying objects.

learning accessible to everyone. With the release of IDS NXT lighthouse version 1.1, additional functions are now available. The training of neural networks in the web application requires three basic steps: to upload individual sample images, to label the images (e.g. "good" / "bad") and then to start the fully automatic training. The generated network can be executed directly on IDS NXT industrial cameras. This turns them into powerful inference

All components – camera hardware with AI core and different sensors and protection classes, software, infrastructure, knowledge and support – are developed and provided by a single supplier. This holistic approach makes IDS NXT ocean a unique solution in the vision market. The IDS NXT lighthouse training software for neural networks is now available as version 1.1. The company has further improved both usability and the range of functions, for example by redesigning the detail view or extending filter functions. The next version is already in the works – then, in addition to classification tasks, object detection will also be feasible, for example. 02 - AUTOMATION Mag - OCTOBER 2020




Dorner GmbH continues product expansion by adding the 2200 Series Modular Belt Conveyor to its portfolio of conveyor platforms being manufactured in Jülich, Germany. Dorner is an industry leader in the design, application, manufacturing and integration of precision industrial and sanitary conveyor systems.


he 2200 Series Modular Belt is ideal for small to medium part handling within the automation, packaging, assembling, metalworking and general manufacturing industries. The conveyor comes with features and benefits that make it ideal for a variety of conveying applications, including: • Ladder-style, open-frame design that allows better airflow through the frame for cooling, water and chemical drainage applications • Sleek, narrow profile for positioning under machinery and in other tight spaces where other conveyors wouldn’t fit • Universal T-slot compatible with industry standard hardware for attaching accessories and guiding fast and simple



The 2200 Series Modular Belt joins the 2200 Series LPZ as the second major conveyor platform this year being manufactured from Dorner’s Jülich, Germany, location. Now building three versions of the 2200 Series in Germany enables customers throughout Europe and the Middle East to take delivery of their equipment faster than ever before. Features and specifications of the 2200 Series Modular Belt conveyor include: • Loads up to 68 kg • Belt speeds up to 76 m/min • Belt widths: 76 mm to 610 mm • Conveyor lengths: 457 mm to 9,144 mm • Micro pitch (general purpose) belt option • Metalworking belt option • 12 mm diameter integral drive shaft • Fully encapsulated in frame belt return

For more information on Dorner’s 2200 Series Modular Belt conveyors being manufactured in Germany, visit Connect with Dorner on Facebook at h t t p s : // w w w . f a c e b o o k . c o m / Dornereurope/ Subscribe to Dorner on YouTube at UCJbrRugp-agWittxmW1lq5A Follow Dorner on LinkedIn at dornergmbh/


ELECTROCRAFT INTRODUCES MPW SERIES WHEEL DRIVE ElectroCraft, Inc., the global fractional horsepower motor and motion solutions provider, has expanded its MobilePower™ product family with the MPW Wheel Drive.


he MPW Wheel Drive features a high torque-density brushless DC motor with a heavy duty integrated planetary gearbox mounted inside the hub of a lightweight aluminum wheel with custom tread. Designed for mobile robot applications, the MPW combines optimum performance with highefficiency, quiet operation and long life. ElectroCraft MobilePower MPW series wheel drives feature an integrated design that provides increased performance and reliability compared to traditional motor/ gearbox/wheel combinations.

• The MPW52 (150 mm Wheel), provides a best in class peak torque of 12.4 Nm (110 at 2.4 meters/second, while carrying up to 68 Kg load (150 lbs.) per wheel. • The MPW86 (200 mm Wheel), provides a robust peak torque of 35 Nm (310 at 1.9 meters/second, while carrying up to 227 Kg (500 lbs.) per wheel. Most impressive is the form factor and weight of the wheel drive assembly; it is small and lightweight while producing industry leading performance. ‘The result of the integrated design of the MPW featuring ElectroCraft’s high torque density motor technology is in the overall efficiency and performance of the robotic application’, notes Scott Rohlfs Director of Product Marketing. ‘Robotic OEMs can save space and reduce weight, without sacrificing load capacity and speed.’

The MPW provides a complete motorized wheel-drive solution for mobile platform OEMs, eliminating the need for the OEM to design a solution using disparate components from several different suppliers. The ElectroCraft MPW is engineered for integrated efficiency; the motor, gearing, hub, wheel assembly and optional accessories provide a single-source solution for efficient battery-powered AGV and mobile robot applications. Video Links: Onsite: h t t p s : // w w w . e l e c t r o c r a f t . c o m / re s o u rce s /v i d e o / ? v i d e o = W h e e l Drive#MobilePower YouTube: watch?v=RMiSsYF3LYo




HYPERTURN 45 G3: DYNAMIC. INTELLIGENT. FULLY AUTOMATED The machine base and the slide geometry of the HYPERTURN 45 G3 have been redesigned to enlarge the working space and accommodate a wider turret clearance to allow the integration of a 16-station tool turret and a larger Y-axis stroke of +/- 40mm. The machine remains compact, and the 72° slant bed perfectly supports the ergonomic requirements and optimal chip flow. What is more, EMCO offers holistic solutions for the automation of machine tools, e.g. “Turn/Mill Assist”, a standardised automation solution and currently the most compact solution for loading and unloading EMCO turning and milling machines.


s the entry-level to the Hyperturn series, the new HYPERTURN 45 G3 is impressive with its increased spindle distance of 760 mm for collisionfree processing with two turrets. The expanded working space offers sufficient room for the integration of BMT turrets in 12x or 16x versions. With its precision interface for fast tool changeover and direct drive for high power milling of complex workpieces, it is an excellent choice. The water-cooled direct drive has



8 kW of power; it drills and mills at up to 12,000 rpm and offers 20 Nm of torque. The stable BMT interface ensures that tools have a long service life. Overall, it gives the user more possibilities in terms of workpiece processing or increasing productivity. EMCONNECT, the new assistant for control and production processes, is included in the machine's standard equipment. EMCONNECT is a digital

process assistant for the comprehensive integration of customer- and systemspecific applications for controlling the machine and the production flow. As the operating sequences focus on the user and their requirements, it is possible to create more efficient work processes without losing sight of the machines' outstanding reliability in all operating modes.

This model is equipped with two servo-controlled stacking tables which are capable of stacking larger quantities of both blanks and machined parts.

Thanks to the very beginner-friendly control unit, the operator can quickly move into the implementation phase, thus increasing the processes‘ efficiency, profitability and flexibility to a significant extent.

Hyperturn 45 G3 with automation When selecting an automated complete solution by EMCO, the operator benefits, above all, from sophisticated technology and quality, whereas the programmer profits from the automation philosophy “everything from a single source” and its concrete technical implementation. Thus, they can capitalise on the ideal solution for their company. Turn/Mill-Assist EMCO's Turn/Mill-Assist is the most compact complete solution when it comes to loading and unloading EMCO turning and milling machines. Turn/MillAssist is characterised especially by its user-friendliness. Thanks to the beginnerfriendly control, users can get down to work without delay, which results in significantly higher efficiency, profitability and flexibility. The work will get effectively easier; customers will benefit from longer machine service lives and have an extremely flexible solution with a wide range of applications regarding weight and workpiece type at their disposal. With the Turn/Mill-Assist series, EMCO offers different standard automation solutions, each of which comes with specific features. Each model – Turn/ Mill-Assist Essential and Turn/Mill-Assist 200/270 – offers a wide range of robot payloads as well as options and modular expansions. All advantages at a glance When opting for Turn/Mill-Assist, the customer acquires one of the most user-friendly and most reliable systems currently available on the market.

Highlights: Flexible • Unique gripper design • Different gripper types • Built-in air nozzle • Workpiece recognition Straightforward and intelligent • Intuitive graphical user interface • Very short set-up and changeover times • Touch screen Capacity • Maximum capacity with minimum space requirements • No grid plates required • Workpiece stacking Extraordinarily compact • The most compact automation solution available on the market • Visible and open installation Options and modular expansions EMCO's Turn/Mill series includes a wide range of standard products, standard options and modular expansions. With these components, every operator can compile their very own, tailor-made automation solution: additional features such as turning units, devices for placing the finished parts onto Euro-pallets or an axis extension for the handling of shafttype components are available. It is even possible to operate the solution together with a bar loader.

also being implemented in the machine design. As central brand ambassadors, the machines now feature a new look, a look that constitutes a functional and visual upgrade. This upgrade is reflected in a variety of design changes: In order to ensure efficient processes, userfriendliness and a clear arrangement, the machines' main interaction areas (such as the work area) have been highlighted in both colour and shape. The operating panel comes with homogeneous aluminium surfaces, ergonomically adjustable controls and an intuitive user interface. The housing features a reduced and precise design. Clean contours and precise joint patterns convey superior product quality. In order to keep track of the different product classes, price levels and equipment options are also reflected in the design features. The recognition value of the technically sophisticated and ergonomic machines is fully guaranteed by the new design of the EMCO product family. The machine design, too, is meant to convey the company's conscious decision to go beyond what is standard and thus fulfil its commitment to quality, maximum precision and efficiency in turning and milling operations. In doing so, EMCO starts implementing its objective where others stop: beyond standard, that is.

A new machine design reinforces the EMCO brand The repositioning of the brand – which is also reflected in the claim and commitment “beyond standard” – is now 02 - AUTOMATION Mag - OCTOBER 2020



VOLKSWAGEN INTEGRATES NEWEST EPLAN AND RITTAL SOLUTIONS VASS Standard: now expanded with 3D functionality and state-of-the-art control cabinet technology.

Markus Hülsmann: Global Key Account Manager Automotive Markus Hülsmann at Rittal says: “The current release of the VASS V6 library delivers fully integrated reference control cabinets in 3D based on the new Rittal VX25 control cabinet system.”

Daniel Gräser: “This expansion of the VASS Standard with the newest aspects of Eplan’s engineering software and Rittal’s state-of-the-art system technology means we’re ideally supporting our suppliers in realising digital and automated manufacturing processes,” says Daniel Gräser in the Division for Manufacturing Automation and Digital Production at Volkswagen.

Andreas Bamberg: “The additional 3D functionality from Eplan Pro Panel makes it possible to directly derive manufacturing information for automated control cabinet and switchgear system engineering,” says Eplan Strategic Account Manager Andreas Bamberg.


olkswagen has recently released the sixth generation of its VASS (Volkswagen Audi Seat Skoda) Standard, which includes an update to Eplan Version 2.9. The standard – used in production plants for models on the MEB platform – has also been expanded with 3D functionality in switchgear system engineering and with data for bi-directional exchange with PLC project planning tools. The new VX25 control cabinet system from Rittal has additionally been integrated into the standard.



Volkswagen’s decision to start providing its suppliers with 3D data based on Eplan Pro Panel in the VASS standard libraries means that the complete digital twins of control cabinets and the installed components can be depicted. Previously, only 2D representations from Eplan Electric P8 were included in the standard. For suppliers, this creates the foundation for entering into and expanding automated manufacturing steps in control cabinet and switchgear system engineering: from mechanical NC machining to automated terminal assembly to wire processing and

wiring support. Companies benefit from the fully developed design templates provided by Volkswagen that can be used as a basis for faster and higher-quality system engineering, manufacturing and commissioning. Uniform plant system documentation Eplan Strategic Account Manager Andreas Bamberg explains: “The additional 3D functionality from Eplan Pro Panel makes it possible to directly derive manufacturing information for automated control cabinet and switchgear system engineering. Engineering offices further benefit from the integrated collision check and thermal power dissipation considerations for components, enabling optimised component placement in the cabinet and a more energy-efficient design for Rittal climate control systems.” An extra benefit: the addition of key control technology information to the device and project data enables completely bi-directional data exchange between Eplan (hardware engineering) and the Siemens TIA Portal (software project planning) using the AML interface. “This considerably reduces the efforts required in engineering and for system planning since the PLC hardware structures, pre-defined inputs and outputs and bus topologies can be imported directly from Eplan, not to mention the exact port wiring,” Bamberg says. During plant system operations and for later modifications or expansions, the information from TIA Portal can be fed back into the Eplan Project. This ensures uniform, error-free plant system documentation “as built” and shorter entry processes for integration into digital production management. State-of-the-art control cabinet technology Rittal, with its large control cabinets and small enclosures, has been a part of Volkswagen’s corporate standard for years, just like Eplan. As Global Key Account Manager Automotive Markus Hülsmann at Rittal says: “The current release of the VASS V6 library delivers fully integrated reference control cabinets in 3D based on the new Rittal VX25 control cabinet system.” It also includes fully integrated enclosure accessories and

ten variants of the AirSTREAM mounting frame from the company Friedrich Lütze, which can be selected directly from a list of accessories and placed as a complete macro. Hülsmann continues, “This considerably reduces the work required in engineering since the components can start being placed directly in the cabinet after just a few clicks.” Future VASS releases will include libraries expansions with the Rittal AX and KS enclosures and the respective sample assemblies. Associated enclosure macros in 3D are already available in Eplan Data Portal and can be used when designing with Pro Panel. The goal: digital manufacturing Automobile production is becoming increasingly challenging, including ever shorter start-up times, individualised design efforts, new control technologies and high demands on maintenance and repair to name just a few. Volkswagen is diligently working on further developing automation standards, which are then passed down to the company’s suppliers. Daniel Gräser in the Division for Manufacturing Automation and Digital Production at Volkswagen says, “This expansion of the VASS Standard with the newest aspects of Eplan’s engineering software and Rittal’s state-of-the-art system technology means we’re ideally supporting our suppliers in realising digital and automated manufacturing processes. At the same time, we are also adding an important component along the path we’ve started towards the digital factory.” After all, the digital twin of the control cabinet as part of the production process is an essential foundation for fully digital operating and maintenance processes of the future. International service support Since 2018, Eplan has been offering a three-day VASS V6 Training for suppliers in English and German. It lays the international foundation for successful project planning according to this standard. Along with regular dates in Germany, initial trainings have also been conducted in the US and in China. 02 - AUTOMATION Mag - OCTOBER 2020





amburg is Germany’s second largest city and a major port city in the North of the country. It is The BXT motors deliver considerably higher torques than those usual in this drive class. connected to the North Sea by the Elbe River. Hamburg is quickly building a reputation as Germany’s most innovative As one of the most ambitious smart city. The city has launched no less than 60 smart city initiatives that address smart city projects in Europe, the city’s mobility and sustainability Hamburg, Germany is challenges.

determined to tackle its urban mobility and sustainability challenges head-on. To have better insights into its city dynamics, Hamburg strongly believes in digitizing traffic. Data collection and data analysis will allow the city’s traffic authorities to make smarter decisions. A new set of data will come from a vast network of FLIR thermal imaging cameras.



Hamburg feels a high sense of urgency to tackle its mobility problems. According to a 2018 survey of German cities by navigation technology company TomTom®, Hamburg has more congestion than any other city in Germany, even Berlin. The study revealed that in 2018, Hamburg commuters encountered jams on 33% of road journeys, which means motorists lost on average 113 hours a year to traffic jams. Collecting traffic data Hamburg city authorities are convinced that congestion can be mitigated by having a better picture of the traffic dynamics. Where in the city does traffic flow smoothly and where do traffic jams occur regularly? What traffic diversions make sense? And how are roadworks affecting traffic fluidity? Based on this type of traffic data, Hamburg traffic authorities

want to make better traffic forecasts and smarter real-time decisions. To meet its high need for traffic data, Hamburg Verkehrsanlagen GmbH (HHVA), the city’s public service provider for traffic control and infrastructure, ordered more than 2,000 FLIR thermal imaging sensors for vehicle and bike detection, to be installed on traffic lights and street lighting by 2021. The cameras are helping traffic controllers to adjust signals in (near) real-time depending on how busy the roads are. Furthermore, the huge volume of traffic data helps traffic managers to improve their long-term planning and reduce blockages. Data collected by the FLIR sensors is fed to the city’s Urban Data Platform, a cloudbased platform that enables its users to evaluate the data in real time. One of the users of the platform is the Hamburg traffic police, who is using the data to optimize traffic light control and solve traffic issues, like unusual congestion or roadworks, much faster. Vehicle data on intersections FLIR’s thermal imaging cameras will be used for two separate data collection projects, both of which will be managed on the Urban Data Platform. Most of the

More insight into the city’s traffic dynamics will help Hamburg to reduce congestion. 2,000 FLIR sensors for vehicle and bike detection will be installed on traffic lights and street lighting by 2021. FLIR thermal sensors can distinguish between passenger cars, trucks and cyclists. Hamburg can monitor intersections closely 24 hours a day in all weather conditions.

thermal cameras will collect data about the motorized traffic at approximately 420 intersections all over Hamburg. The plan is to install multiple thermal cameras per intersection to monitor traffic in every possible direction. The FLIR sensors are capable of collecting traffic data, including volume, speed, occupancy, headway, gap time and vehicle classification (including passenger car, truck and bicycles). The integrated traffic data can be provided for each lane and each vehicle class separately. All this information will enable traffic managers to forecast traffic more accurately, simulate developments, plan for more or fewer lanes, make smarter decisions about parking management, and much more. Bike counting FLIR cameras attached to 45 street lights will be used to collect data about bicycle traffic for the Hamburg-wide Bicycle Traffic Counting Network project. The cameras are installed on important bicycle routes in the inner city, on major entry routes, and on the Elbe river crossing, which has heavy traffic due to the few crossing points.

The location of the counting points in the city road network should enable the city to investigate influences such as weather, public holidays, major events, construction sites, as well as the effects of traffic diversions on the volume of bicycle traffic. According to city officials, counting bicycle traffic with FLIR thermal cameras is much more efficient and cost-effective. Whereas in the past, bicycles were counted via in-ground magnetic loops, optical sensors, or even manually, the FLIR sensors can be mounted on the existing lighting infrastructure and can monitor bicycle traffic 24/7. 24/7 thermal detection The city of Hamburg opted for FLIR’s ThermiCam 2, an integrated thermal sensor and detector for vehicle and bike detection. The FLIR ThermiCam 2 does not need light to operate. It uses the thermal energy (heat) emitted from vehicles and cyclists. This enables the sensor to detect vehicles and bikes over a long range, even in poor lighting conditions, in bad weather and at night. The thermal sensor also has no problem with shadows and intense sunlight; phenomena which are hard to deal with when using regular visiblelight cameras. Being able to rely on the

cameras in all conditions means Hamburg can monitor intersections closely 24 hours a day in all conditions. Another important benefit is that thermal cameras present no privacy issues, which are a major hurdle for visible-light cameras. Although thermal cameras provide enough detail to know the type of vehicle (FLIR ThermiCam 2 collects data about five different vehicle classes), they cannot see faces or license plates. Reducing traffic pollution The 2,000 thermal cameras installed across Hamburg will help traffic authorities to forecast traffic, reduce congestion, and make smarter decisions on roadworks or traffic diversions. But smoothening the traffic flows also has another benefit. Reducing congestion in the city will undoubtedly lead to less idling traffic, which in turn will improve the city’s air quality. The national German government has adopted the EU’s Clean Air initiative, which lays out stringent guidelines for improving air quality in German cities over the next decade. FLIR sensors will help Hamburg and Germany to reach that goal. 02 - AUTOMATION Mag - OCTOBER 2020



FLIR SYSTEMS ANNOUNCES MODIFIED THERMAL CAMERAS SPECIFIED FOR ELEVATED SKIN TEMPERATURE SCREENING The Line of FLIR EST Thermal Solutions Include Enhanced Screening Mode to Offer Fast, Safe, and Simplified Frontline Screening.


LIR Systems announced modified thermal cameras for fast and safe non-contact elevated skin temperature* screening. The FLIR EST thermal screening solutions provide frontline screening at building entries and in high traffic areas to improve safety and help curb the spread of COVID-19. The FLIR Axxx-EST, FLIR T5xx-EST, and FLIR Exx-EST series cameras are designed to simplify the screening process, reducing the burden on screening operators and adhering to recommended social distancing guidelines. “The new FLIR EST thermal solutions represent nearly two decades of experience designing and manufacturing thermal measurement solutions for skin temperature screening,” said Jim Cannon, President and CEO at FLIR. “These cameras are our easiest cameras to set up and operate to date for skin temperature screening, requiring limited training to begin screening people more quickly and accurately.” FLIR Screen-EST Mode The new EST cameras also introduce an enhanced, on-camera FLIR Screen-EST mode, which increases throughput by 25 percent compared to the previous version. To further improve accuracy, the updated Screen-EST mode automatically generates a sample baseline temperature average and compares individuals’ skin temperature against that baseline, reducing measurement uncertainty from natural body temperature fluctuations and environmental effects. This mode can sound or display an alarm when the camera detects an elevated temperature above a set threshold. If the screening mode detects an individual with elevated skin temperature, they should then be evaluated using a medical device such as a thermometer. In addition, the new EST cameras are compatible with the new FLIR Screen-EST desktop software announced earlier in June.



FLIR Axxx-EST Series The A500-EST and A700-EST cameras are designed for permanent, fixedmounted installations and can be deployed as a single, standalone screening station or in a network. The cameras can be connected to most video management systems while the camera housing features multiple mounting points to support tripod or permanent installations. FLIR T5xx-EST Series The T540-EST and T560-EST are designed to operate in either a mobile or more permanent setting. The flexible form factor enables a cable-free mobile operation with up to four hours of battery life or hands-free use with an integrated tripod mount. FLIR Exx-EST Series Light, ergonomically designed for handheld use, and battery-powered, the E54-EST and E86-EST offer the capability for mobile screening settings with a bright, easy-to-use integrated touchscreen display. Tripod mounts are also available for the Exx-EST models. The FLIR Axxx-EST series, T5xx-EST series, and Exx-EST series will be available for purchase worldwide in the Third Quarter 2020 on and through FLIR authorized distributors.




ELECTRONIC ASSEMBLIES WITHOUT PCBS Laser direct structuring (LDS) is a special success story. For almost 20 years, it has been possible to apply electronic conductor paths directly onto plastic parts during series production.

L The BXT motors deliver considerably higher torques than those usual in this drive class.

DS enables the production of electronic assemblies with flexible geometric shapes. This process enables electronic products (such as smart phones, sensors or medical devices) to become even smaller and more powerful. Automated manufacturing processes also make this process more economically attractive. There is less and less space available for electronic assemblies, so solutions are needed which replace conventional printed circuit boards. LDS enables further miniaturisation and makes increasingly complex geometric designs possible. This is a stable and reliable process that has established itself in quality-critical sectors such as medical technology or safety-relevant components for the automotive industry.

Laser Direct Structuring (LDS) - The structure of the conductor path is applied using the LDS process. LDS enables electronic assemblies to be made in flexible geometric shapes. Smart phones, hearing aids and smart watches are becoming smaller and more powerful thanks to this process. 02 - AUTOMATION Mag - OCTOBER 2020


The LDS process enables threedimensional assemblies Direct laser structuring enables 3D-MID (Mechatronic Integrated Devices) assemblies to be produced. When using 3D-MID, electronic components can be fitted directly onto a three-dimensional base body, without circuit boards or connecting cables. The base body is manufactured using an injection moulding process, whereby the thermoplastic material has a non-conductive, inorganic additive.

Dimensioning and positioning Minimum distances between the conductor paths (a): 50 – 150 μm. Minimum width of the conductor paths (b): 50 – 150 μm. Radius (r): 0.2 mm

The additives in the material are "activated" by direct laser structuring so that the plastic material can accommodate the electrical conductor paths. The laser beam writes the areas intended for the conductor paths and creates a micro-rough structure. The released metal particles form the nuclei for the subsequent chemical metallisation. In this way, the electrical conductor paths are applied to the areas marked by the laser. The other areas of the three-dimensional base body remain unchanged. The plastic component can then be assembled in standard SMD processes similar to a conventional PCB. It is also suitable for soldering in a reflow oven. Versatile application of laser technology HARTING 3D-MID AG is the largest supplier of 3D-MID components outside of Asia. HARTING uses high-performance laser systems for the LDS process, with three lasers working in parallel, each offset by 45 degrees. Thanks to an additional axis of rotation, components can be processed by the laser simultaneously from all sides (360 degrees). This technology enables flexible geometric shapes, such as reflector shells or LED lights, to be made. Despite the minimal conductor path thickness of 16 to 20 μm, the conductor paths are still suitable for

demanding automotive components or for applications with currents up to 10 A – for example for heating coils in cameras which are used to prevent the optics from fogging up. Frequent changes during the electronics development phase or new components with modified dimensions can lead to costly adjustments during conventional PCB production. The laser layout, in contrast, can be adapted very flexibly by using the parameters of the laser's control software. No changes in the injection moulding are required for this. The production of prototypes using LDS is also easier compared to conventional processes. HARTING can produce the plastic base body using LDScompatible material and 3D printing. Injection moulding can also be used with inexpensive prototype tools. New trends in the LDS process Several aspects of LDS technology have been improved and further developed over the past few years. The working area of the laser has been enlarged from 160 x 160 x 80 mm to 200 mm x 200 mm x 80 mm, thus enabling a higher packing density and the processing of even larger components. The working speed of the laser can be doubled to 4 m/s by optimising the servo

units and mirrors which guide the laser beam, thereby significantly reducing the processing time. The improvement of the optics enables the use of a laser with a diameter of 100 μm and a laser with a fine focus of 50 μm for processing even smaller structures. H A RT I N G i s t h e o n l y 3 D - M I D manufacturer in the world that has a laser system with three fine focus optics of 50 μm. Even smaller conductor path gaps can be achieved thanks to this fine focus laser. Thus, many conductor paths can be created on the same component and a higher packing density can be implemented. This is used for safety technology, among other things, because the closely spaced and intertwined conductors are capable of triggering safety alarms from even the smallest physical interference. Advances in materials and economics Only specially selected thermoplastics are certified for the LDS process; these are available from stock. The process can be further improved with customer-specific adjustments to the plastic material: • HARTING uses a process which adds LDS additives to non-certified materials to make them MID-compatible. • Specific RAL or Pantone colours can be achieved with MID plastics by 02 - AUTOMATION Mag - OCTOBER 2020



using colour pigments and special LDS additives. • B y selecting suitable additives, special RF characteristics can also be implemented, depending on the frequency range.

Component carrier - Electronic components – such as LEDs, ICs, photodiodes and sensors – can be attached directly onto the component carrier. The assembled component carriers can then be processed as standard SMD components.

To further improve the cost-effectiveness of the manufacturing process, HARTING relies on automated robotic systems. The LDS laser system is equipped with a rotary indexing table so that a component can be inserted or removed while another component is still being processed. The in-feed and unloading procedures are automated by HARTING using robotics. This increases throughput and autonomy, while also enabling integration into automated production processes. An additional automation step is provided during the injection moulding process. Here, too, a robot takes over the removal of the injection moulded parts. The use of robotics also improves the precise reproducibility of the processes and, thus, overall product quality. More growth for 3D-MID HARTING reports increased demand for MID projects and has further expanded the 3D-MID division by investing in machinery and by acquiring a competitor's business. Innovative in-house products are also contributing to further growth. HARTING has developed a solution based on 3D-MID technology which replaces flexible PCBs with a component carrier. Instead of using a flex-PCB, the component carrier can be fitted directly with electronic components, thus saving up to two thirds of the cost. About HARTING 3D-MID

Security caps for payment terminals - The 3D-MID caps protect the electronics from unauthorized access both mechanically and electronically. A highly precise meandering structure detects every access, no matter how small, and consequently prevents theft. 02 - AUTOMATION Mag - OCTOBER 2020



COGNEX LAUNCHES NEW ITEM DETECTION SYSTEM 3D-A1000 Virtual showroom tour of new Customer Experience Center provides an exclusive glance on new and yet to be released solutions.


ognex Corporation, the leader in industrial machine vision, introduces the 3D-A1000 Item Detection System. A motion-capable smart camera, the 3D-A1000 can identify the presence or absence of objects with unmatched accuracy on all types of sorters traveling at production line speeds. This product release extends the existing 3D-A1000 platform into new applications for helping retail and logistics customers reduce delivery errors, improve throughput, and increase fulfillment efficiency.

“As consumers increasingly expect reliable and fast delivery, retailers need to ensure the right products get to the right customers on time, every time, said Carl Gerst, Cognex Senior Vice President. “The 3D-A1000 Item Detection System is a powerful, turnkey solution for detailed inspections in sorting that hasn’t been available until now.” Unlike conventional methods, the 3DA1000 uses patented 3D Symbolic Light technology to freeze motion with a single image. The system gathers precise 3D and 2D information without the need for an encoder, allowing detection of

low contrast objects while avoiding tray hygiene issues. Embedded processing then uses Cognex vision tools to provide detailed inspections of trays and objects. The 3D-A1000 is factory calibrated and can be installed in less than 15 minutes. The new item detection and dimensioning systems, scan tunnels and other advanced logistics automation solutions can be experienced live during a virtual tour at the new Customer Experience Center in Aachen, Germany, on October 27 at 3:00 pm. 02 - AUTOMATION Mag - OCTOBER 2020



NEW INTESIS GATEWAY MAKES COMMUNICATION BETWEEN PROFINET AND BACNET EASY HMS Networks announces a new Intesis™ protocol translator for communication between PROFINET PLCs on factory floors and Building Management Systems with BACnet IP/MSTP. With this, full data integration, monitoring, and control is enabled between factory floors and building facilities.

Key objectives can be achieved with factory-to-building communication In factories, it is essential that environmental dimensions such as temperature, humidity, and air quality are controlled and monitored automatically to ensure optimal conditions for manufacturing and working staff. And, by ensuring efficient control of facilities such as HVAC and lighting systems, factory owners can save a lot of energy and manage emergency situations in a safe way. 02 - AUTOMATION Mag - OCTOBER 2020


Communication enabled with certified Intesis PROFINET - BACnet gateway Focusing on this situation, the new Intesis PROFINET - BACnet IP/MSTP protocol translator from HMS Networks is a costeffective and easy-to-install gateway solution that offers bi-directional communication between PROFINET PLCs and BACnet controllers. Able to connect up to 1200 data points, the gateway is BACnet IP/MSTP server/slave on one side and PROFINET I/O device on the other, featuring independent Ethernet ports. The gateway has been BTL certified for BACnet and carries the UL mark in order to guarantee the highest communication and quality standards. Thanks to its strategic placement between the factory and building systems, the gateway becomes an enabler of very interesting applications such as energy metering of devices and machines in the factory from the BACnet-based BMS system, HVAC monitoring, and control from the PROFINET PLC, as well as easy alarm definition and management. Easy configuration and integration process using Intesis MAPS Intesis MAPS, the common configuration tool for all Intesis protocol translators, offers a very intuitive configuration process for system integrators covering both sides of the gateway. MAPS help integrators further in their projects by providing valuable EDE files for the BACnet integration, as well as GSD files and TIA portal TAG files for fast configuration of any connected PROFINET PLC controller.

However, when system integrators plan for factory-to-building integration, they normally face a heterogeneous and challenging communication situation. BACnet is typically the protocol used in the Building Management System (BMS) to control the facilities inside the building, and PROFINET is one of the most used factory networks for controlling production processes.

The result of HMS’ combined expertise in factory and building communications Extending the comprehensive range of existing Intesis BACnet protocol translators, the new PROFINET - BACnet version is the first product in a new line of Intesis gateways for factory to building integration that will be released step by step by HMS Networks. In these gateways, HMS combines its proven AnybusŽ and Intesis communication technologies for industrial and buildingoriented communication respectively, trusted by customers in millions of installations worldwide.




SOFTING ENHANCES EDGECONNECTOR SIEMENS Softing Industrial releases version v1.20 of edgeConnector Siemens. The software module is based on container technology and connects Siemens controllers with industrial IoT applications. In addition to SIMATIC S7-1200 and S7-1500, the new version also supports SIMATIC S7-300/400 controllers.


dgeConnector Siemens enables access to SIMATIC S7-1200 and S7-1500 data including optimized data blocks. Version v1.20 additionally s u p p o r t s S I M AT I C S 7 - 3 0 0 / 4 0 0 controllers. Client applications have access to data via the interoperability standard OPC UA. The product can be configured locally via a built-in web interface, or remotely via a REST interface. It seamlessly integrates with Azure IoT Edge and AWS IoT Greengrass and is made available via online repositories such as Docker Hub. Users benefit from flexible deployment and ease of use which comes with virtualization and container technology. Valuable process and machine data are made available for innovative IoT applications without any changes to controller or automation network



configuration. Advanced security features such as the management of access right for individual client applications increase the security of the entire solution. “edgeConnector Siemens is the first strategic expansion of our dataFEED product family to include virtualization and container technology”, says Wolfgang Wende, Senior VP Sales at Softing Industrial. It leverages Softing's extensive experience with brownfield connectivity and OPC UA technology and makes it available for new and highly efficient IoT solution architectures.” edgeConnector Siemens can be tested for free. It is currently evaluated by customers in the automotive, aerospace and food & beverage industry. de/produkte/edge-connector-docker/ datafeed-edgeconnector-siemens/


EWON DATAMAILBOX – REMOTE ACCESS TO MACHINE DATA JUST GOT A LOT EASIER! HMS Networks now launches Ewon® DataMailbox, a secure freemium cloudbased solution allowing machine builders and factory owners to easily access data from their machines anywhere in the world.

What is Ewon DataMailbox? DataMailbox is an online data buffer that enables easy retrieval of data from machines. It is a part of the Ewon Talk2M cloud service. How it works The Ewon routers Cosy and Flexy connect to a remote machine and send data via Ethernet or cellular connection to the Talk2M cloud. The DataMailbox is a part of Talk2M allowing application developers to easily retrieve historical data from multiple Ewon gateways using a simple API call. The results Customers can collect data from multiple machines anywhere in the world in a highly secure process in order to analyze this data at their convenience. This allows for big data analytics and dashboards for predictive maintenance and operational intelligence. A fast and secure way to enable access to machine data It is possible to set up a data connection in a couple of hours, no matter how complex

the IT environment is, and also scale up when necessary. Users can add machines to the process in a couple of clicks. With the DataMailbox as a data buffer, users will avoid losing data, no matter how many sites they are collecting from as data is automatically stored and forwarded if the internet connection is down. Users also always have access to a clean historical dataset for analytics applications. Freemium The DataMailbox is a freemium service within the Ewon Talk2M cloud, meaning that customers can utilize it for free for an unlimited time. By moving to the Pro version, customers get covered by a unique Service Level Agreement and can process even more data. The Freemium approach and ease of access in no way compromises the security as Ewon solutions are trendsetters in cybersecurity.

By adding this innovative service to its range of hardware, Ewon proposes an easy and scalable integrated solution to collect and process data from an unlimited number of sites, allowing customers to increase their efficiency. “In a time when it is risky and expensive to allow people into factories, it is our duty to provide customers with an easy, secure and scalable solution to collect data from several sites, allowing users to improve their efficiency”, says Francis Vander Ghinst, General Manager of HMS’s Business Unit Ewon. Available now via a network of partners To help customers maximize the power of their data, Ewon has established a robust ecosystem of 2000 experienced partners, ready to quickly create efficient and integrated solutions based upon customer needs. For more information, visit www.ewon. biz and the knowledge base articles at




“IN THIS INDUSTRY, REPUTATION IS EVERYTHING. THE COMPONENTS THAT YOU SUPPLY MUST BE PERFECT” “The volume of parts produced had never been so high. So, the immediate need was to increase the amount of inspections to ensure a quality product”.


rust Precision Engineering produces precision components for the aerospace sector. In recent years it has invested considerably in quality and is now reaping the rewards of those investments: which includes a major increase in productivity. “My name is Nick Street, and I’m the owner of Trust Precision Engineering. The company was founded in 2012 to produce precision machined components, mainly for the aerospace sector. The volume of components we were producing meant we were struggling to keep up with the amount of inspections we would like to have done on a component. The immediate need was to increase the number of inspections to ensure a quality product.” To solve this conundrum, the company turned to VICIVISION UK, the official dealer of VICIVISION in the UK. TRUST Precision Engineering bought two VICIVISION Techno M304 machines which are designed to perform dimensional inspection on parts directly on the shopfloor, serving several machining centres. They can be used by more than one operator at the same time and measuring time is dramatically reduced as there’s no need to leave the shopfloor. “The return on investment will probably be 2 years for everything in this room. On a single VICIVISION alone, six months to a year, you’re going to get that return back.

radar and ends up being wrong, whereas with VICIVISION you can check everything externally, everything, so nothing gets missed.

When I bought my first machine, I saved £ 15,000. When I bought my second machine, I saved another £ 15,000. When I buy my third machine, I’ll save another £ 15,000.

Our slogan is “reputation is everything”, and in this market, reputation really is everything.

The machine keeps everything under control. Sometimes you can get so focused on a particular critical dimension or area of a component that sometimes something less critical goes under the 02 - AUTOMATION Mag - OCTOBER 2020


From a traceability point of view, you can save all the images every time you load a component and run an inspection, you can choose to save that image in a history file. So, in three months’ time somebody could come back to me and say they’ve potentially found an issue

with a component, we can pull up the images from that order number and literally measure the image again. It all started with a visit from one of the Vici representatives. And one year later, we bought two brand new ones to go in the new inspection room. The machines really are fantastic. It’s one less thing for me to worry about, it’s one more thing to give me confidence in what we’re doing.”


SHARP IMAGES EVEN WITH VARYING OBJECT DISTANCES IDS extends selection of automatically focusable board-level cameras. Thanks to their practical autofocus function, uEye LE AF industrial cameras deliver perfectly focused images even with frequently changing object distances.

uEye LE AF camera models from IDS feature a practical autofocus function.


DS Imaging Development Systems GmbH now offers additional camera variants with 2.1 and 3.1 MP Sony sensors which provide more flexibility in terms of application design and camera integration. For the first time, the company also offers models with upright USB Type-C alignment in this product family. In addition to the previously available uEye LE AF cameras with 6.4 MP (IMX178, 58 fps) and 18.1 MP (AR1820HS, 20 fps) sensors, customers can now also purchase models with 2.1 (IMX290, 120 fps) or 3.1 MP (IMX265, 80 fps). All cameras feature a USB 3.1 Gen 1 interface, USB Power Delivery – which can be used, for example, to power an LED light source or a photoelectric sensor – and allow the use and control of liquid lenses.

distance between the lens and the object changes frequently. The board-level cameras are therefore particularly wellsuited for applications in fields such as logistics (e.g. for parcel acceptance and sorting) or traffic monitoring. Due to their compact design with dimensions of only 36 x 36 x 20 mm they also prove their strengths in embedded vision systems. This means that they are also interesting for integration into small medical or industrial devices. products/cameras/ids-interface/ usb-3.1-gen.-1/ids-family/le/idscamoptions/autofocus.html

The autofocus function ensures sharp images in the blink of an eye, even if the lens is not physically accessible or if the 02 - AUTOMATION Mag - OCTOBER 2020




High demands on products as well as high time and cost pressure are decisive competitive factors across all industries and sectors. Whether in the food or automotive industry quality, safety and speed are today more than ever before factors that determine the success of a company.


ero-defect production is the goal. But how can it be guaranteed that only flawless products leave the production line? In order to make quality inspection as efficient, simple, reliable and cost-effective as possible, the German company sentin GmbH develops solutions that use deep learning and industrial cameras from IDS to enable fast and robust error detection. A sentin VISION system uses AI-based recognition software and can be trained using a few sample images. Together with a GigE Vision CMOS industrial camera from IDS and an evaluation unit, it can be easily embedded in existing processes.



High demands on products as well as high time and cost pressure are decisive competitive factors across all industries and sectors. Whether in the food or automotive industry - quality, safety and speed are today more than ever before factors that determine the success of a company. Zero-defect production is the goal. But how can it be guaranteed that only flawless products leave the production line? How can faulty quality decisions, which lead to high costs, be avoided? In order to test this reliably, a wide variety of methods are used in quality assurance.

dents visible on reflecting and mirroring surfaces), but also in the food industry (object and pattern recognition). Depending on the application, the AI is trained to detect errors or anomalies. With the latter, the system learns to distinguish good from bad parts. If, for example, a surface structure is inspected, see metal part in the automotive industry or ceramic part, errors are detected by Artificial Intelligence as deviations from a comparison with reference images. By using anomaly detection and pre-trained models the system can detect defects based on just a few sample images of good parts.

A visual inspection with the human eye is possible, but it is often error-prone and expensive: the eye tires and working time is costly. A mechanical test, on the other hand, is usually accompanied by complex calibration, i.e. setting up and adjusting all parameters of both software and hardware in order to detect every error. In addition, product or material changes require recalibration. Furthermore, with the classic, rule-based approach, a programmer or image processor must program rules specifically for the system to explain to the system how to detect the errors. This is complex and with a very high variance of errors often a hardly solvable Herculean task. All this can cost disproportionately much time and money. In order to make quality inspection as efficient, simple, reliable and costeffective as possible, the German company sentin GmbH uses IDS industrial

cameras and deep learning to develop solutions that enable fast and robust error detection. This is because, in contrast to conventional image processing, a neural network learns to recognize the features on the basis of images themselves. This is exactly the approach of the intelligent sentin VISION system. It uses an AIbased recognition software and can be trained on the basis of a few sample images. Together with a GigE Vision CMOS industrial camera from IDS and an evaluation unit, it can be easily embedded in existing processes. Application The system is capable of segmenting objects, patterns and even defects. Even surfaces that are difficult to detect cannot stop the system. Classical applications can be found, for example, in the automotive industry (defect detection on metallic surfaces) or in the ceramics industry (defect detection by making

The hardware setup required for the training and evaluation consists of an IDS industrial camera and appropriate lighting. The recognition models used are trained using reference images. For example, a system and AI model was configured for the error-prone inspection of fabric webs in the textile industry. A difficult task, as mistakes can be very subjective and very small. The system camera for optimum image material of textiles and web materials was selected together with IDS on the basis of specific customer requirements. A GigE Vision CMOS camera (GV-5880CP) was selected, which provides high-resolution data, triggered with precise timing, for accurate image evaluation. The system learns what constitutes a "good" fabric structure and knows already from a few shots of the fabric what a clean and flawless product looks like. For quality inspection, the image captured by the IDS Vision CP camera is then forwarded via GigE interface to an evaluation computer and processed with the recognition model. This computer can then reliably distinguish good/bad parts and highlight deviations. It gives an output signal when an error is found. In this way, slippage and pseudo rejects can be reduced quickly and easily. Slippage is the proportion of products that do not meet the standard but are overlooked and therefore not sorted out, often leading to complaints. Pseudo 02 - AUTOMATION Mag - OCTOBER 2020



Anomaly extracted from a recording of a substance – sentin GmbH

The GigE Vision camera GV-5880CP from IDS ensures precise image acquisition and accurate image evaluation when inspecting fabric webs – sentin GmbH



rejects, on the other hand, are those products that meet the quality standard but are nevertheless incorrectly sorted out. Both hardware and software of the system are flexible: For multiple or wider webs, additional cameras can easily be integrated into the setup. If necessary, the software also allows for re-training of the AI models. "Experience simply shows that a certain amount of night training is always necessary due to small individual circumstances. With pre-trained models from our portfolio, you need fewer reference images for individualization and post training," explains Christian Els, CEO and co-founder of sentin. In this case, the images show the structured surface of a fabric and a small anomaly on it, which was filtered out in the image on the left. Camera Extremely accurate image acquisition and precise image evaluation are among the most important requirements for the camera used. Perfectly suitable: The GigE Vision CMOS camera GV-5880CP. The model has a 1/1.8" rolling shutter CMOS sensor Sony IMX178, which enables a very high resolution of 6.4 MP (3088 x 2076 px, aspect ratio 3:2). It delivers frame rates of up to 18 fps at full resolution and is therefore ideal for visualization tasks in quality control. The sensor from the Sony STARVIS series features BSI technology ("back-side-illumination") and is one of the most light-sensitive sensors with a low dark current close to the SCMOS range (Scientific CMOS). It ensures impressive results even under very low light conditions. Thanks to the sensor size of 1/1.8", a wide range of C-Mount lenses is available for the GigE Vision camera model GV-5880CP. "In addition to resolution and frame rate, the interface and the price were decisive factors in the decision for the camera. The direct exchange with the IDS development department has helped us to reduce the time needed for camera integration," says Arkadius Gombos, Technical Manager at sentin. The integration into the sentin VISION system is done via GenTL and a Python interface.

Conclusion Automated, image-based quality control with Artificial Intelligence offers many advantages over human visual inspection or conventional machine vision applications. "In AI-based image interpretation, the aim is to create images on which humans can see the error, because then the AI model can do it too," concludes Christian Els. The system learns to recognize the requirements of the product similar to a human being. But the human brain is beaten at any time by an artificial intelligence in terms of consistency and reliability. Even if the brain is capable of remarkable peak performance, an AI can recognize much more complex error patterns. The human eye, on the other hand, cannot stand up to any camera in terms of fatigue and vision. In combination with deeplearning recognition software, the image processing system therefore enables particularly fast and accurate inspection. Depending on the application, image acquisition and evaluation can take place in just a few milliseconds. The system can also be applied to other areas such as surface testing. Similar applications are e.g. the testing of matte metal/coatings surfaces (automotive interior), natural materials (stone, wood) or technical textiles such as leather. Scratches, cracks and other defects on consumer goods can thus be detected and the respective products sorted out. Exclude quality defects and produce only “good stuff� - an indispensable process within the framework of quality assurance. IDS cameras in combination with the deep learning supported software of sentin GmbH significantly optimize the detection of defects and objects in quality control. This allows the personnel and time expenditure for complaints and rework, as well as pseudo rejects, to be significantly reduced in a wide range of industries and areas.





Setting standards: uEye SE cameras with fourth-generation Sony Pregius sensor.


DS integrates the high-performance, extremely high-resolution sensor IMX541 from the Pregius S series into the versatile uEye SE camera family. Thanks to its compact 1.1" format, the 20.35 MP CMOS sensor is compatible with C-mount lenses. The industrial cameras feature a practical USB3 Vision interface, deliver 20 fps and will be available from September either as board-level models or with a robust metal housing.



Pregius S – the fourth generation of extremely powerful CMOS image sensors from Sony – makes BSI ("Back Side Illuminated") technology available for the first time in global shutter sensors. The benefits are smaller pixels (only 2.74 µm, which allows a significantly higher pixel density), higher resolution and also improved quantum efficiency and sensitivity. The new camera models deliver outstanding image quality that leaves nothing to be desired even in demanding machine vision applications such as surface inspections, detailed image evaluation in medical technology or use in the traffic sector. Anyone who values high-resolution images – for example to detect even the smallest material defects – will hardly be able to overlook these sensors in the future.

The compact industrial cameras are therefore also a sensible alternative to cameras with similar high-resolution, but large-format sensors, for which F-mount lenses are usually required. With the uEye SE models, C-mount lenses can be used – which means considerable cost savings. Thanks to the USB3 Vision interface, the cameras are also uncompromisingly Vision Standards-compliant and can therefore be used comfortably with IDS peak, for example. The free SDK is characterized by an easy-to-use programming interface developed by IDS. Users no longer need to work directly with GenTL and GenAPI. Convenience classes help to reduce programming effort and thus minimize potential sources of error.


INNODISK AND DFI COMBINE EXPERTISE FOR THE BEST IN IOT DEVICE MANAGEMENT Combining DFI’s RemoGuard with Innodisk’s iCAP and InnoAGE provides a dual remote management solution for IoT devices that is even better than the sum of its parts.


he exponential growth of IoT devices brings a new challenge: how to effectively manage and monitor large numbers of connected devices that may be hard to access in widely-scattered remote locations? To answer this challenge, Innodisk, the leading industrial storage company, has combined its expertise with embedded technology specialists, DFI, to bring DFI’s RemoGuard remote management system to its customers. DFI joins Innodisk’s growing network of partners who incorporate Innodisk technology to provide a complete storage solution based around Innodisk’s IoT solutions.

Thanks to the integration of Innodisk’s iCAP and InnoAGE dual-band management technologies with DFI’s hardware design, RemoGuard can reduce maintenance staffing costs and response timesand prevent service downtime with features like real-time monitoringand one-button recovery. These advanced features add up to the world’s most comprehensive device management system. “Created in collaboration with Innodisk, a leader in the industrial Solid-state drive (SSD) market, DFI has launched RemoGuard to provide not only highperformance embedded solutions but also an advanced remote management solution. This add-on service helps customers to get through this difficult period and lets us look into a prospective future of cooperation,” said Steven Tsai, President of DFI.

iCAP Innodisk’s cloud management platform, iCAP, provides easy access to monitor and control local and remote devices. This management product detects and collects data, sends reports and alerts operators if the device crashes or experiences other problems. InnoAGE SSDs are increasingly dominant in responsive enterprise storage. Their unbeatable blend of speed, low power consumption, small size, and low maintenance lets us put SSDs almost anywhere. InnoAGE SSD is Innodisk’s out-of-band management-enabled flash storage solution, equipped with a Microsoft Azure Sphere. InnoAGE enables multifunctional management, smart data analysis and firmware updates, data security, and remote control through the cloud. 02 - AUTOMATION Mag - OCTOBER 2020



RUTRONIK DEVELOPS FIRST DEVELOPMENT KIT FOR AI BASED APPLICATIONS TO IMPLEMENT EDGE INTELLIGENCE The first development kit developed by Rutronik, the RUTDevKit-STM32L5, is a complete solution for AI-based applications running on an MCU platform.


he kit enables hardware and firmware developers to deliver proof-of-concepts within a short space of time. The focus here is firmly on security and data protection, short latency periods, low energy consumption and adequate storage resources.



Data generated by (I)IoT ((Industrial) Internet of Things) devices are increasingly evaluated on MCU platforms within the application or close to the MCU-based embedded system. This is particularly the case in industrial environments, whether for security reasons or because of the required latency periods. When it comes to implementing this Edge AI or Edge Intelligence (EI), Rutronik now offers a unique development kit that contains all the necessary components.

Every single module is from the Rutronik product portfolio, while the complete BOM is available at development-kit The RUTDevKit-STM32L5 is based on the ultra-low-power high-performance microcontroller STM32L562ZET6Q, which operates at 110MHz. Its 32bit RISC-Core Arm Cortex-M33 with Arm TrustZone offers hardware based security features that ensure data security of the EI application during the inference phase. Thanks to Arm TrustZone, one core provides two independent processing environments: A protected one for cyber protection and sensitive code, and an unprotected one for the execution of untrusted code. Further, Arm TrustZone also supports Secure Boot, thereby enabling secure read and write protection for the integrated memory (64Mbit PSRAM and 128Mbit NOR flash) and cryptography acceleration. Arm TrustZone can also include I/O ports, a peripheral function and flash or SRAM regions. The Octo SPI interface to PSRAM and the Quad SPI interface to the NOR flash memory along with the fast A/D converter of the microcontroller support short latency periods. In addition to the microcontroller memory, the RUTDevKit-STM32L5 facilitates use of an SD card with several GB as well as a protected area to securely store both raw data and inference data of the AI model.

all common field buses and on Industrial Ethernet networks, e.g. EtherCat. The kit also includes software and sample firmware, including a TrustZone demo, a test mode demo for CAN FD, an RS485 Modbus demo, a USB power supply and tamper detection demo, and a dual bank flash bootloader demo. The RUTDevKit-STM32L5 is available from Rutronik at development-kit Overview of the RUTDevKit-STM32L5 components: Hardware: • S TM32L562ZET6Q Cortex®-M33 512KB Flash • APS6408L 64Mbit Octo-SPI PS- RAM • EN25QH128A 128Mbit Quad-SPI NOR Flash • CAN FD with TLE9251VLE driver • USB-C Power Supply with TCPP01-M12 Protection IC • RS485 Interface with ST3485EDBRdriver • Slot for Micro-SD card • O n-Board ST-LINK V2 debugger/ programmer • Arduino extension connector • 4-layer design

Software / Firmware: • CAN-FD test mode demo • RS485 Modbus demo • USB power supply demo • Dual bank flash bootloader demo • TrustZone® demo • Tamper detection demo

Equipped with CAN FD and RS485 interface, the kit enables fast transmission of large amounts of data. The USB-C power supply features Protection IC, and low power functions can be tested with a battery. Additionally, there is the on-board ST-LINK V2 debugger / programmer as well as Arduino interfaces for supplementary boards, such as an Anybus communication module that enables products to communicate via 02 - AUTOMATION Mag - OCTOBER 2020



TECHNOLOGY REPORT Efficient material flow with complete safety.


he increasing automation of processes places growing demands on safety concepts. Classic concepts such as muting, for example, are often pushed to their limits. The intelligent safety solutions from Leuze enable complete safety, efficient material flow, and high system availability.



Individually tailored system solutions The innovative safety concepts are at the heart of every Leuze safety solution. They primarily address safeguarding tasks where safety-related processes are part of the solution. The safety concepts are individually adapted to the respective system layout, or even expanded or newly designed where needed. During each project, certified Leuze safety consultants assess the customer's requirements and subsequently accompany them through

to the on-site safety acceptance. In addition to providing the necessary hardware and software components, Leuze safety solutions include the configuration and parameterization of the system as well as start-up support. Leuze can draw from an extensive range of in-house safety products for the implementation of safety solutions.

Access guarding on multi-track transport systems Multi-track transport systems often require a safety concept that ensures smooth processes and complete safety at the same time. The suitable Leuze safety solution is shown at the example of a pallet discharge via gravity conveyors, which is fed by a cross conveyor. Access guarding takes place via two vertically

The advantage of this solution is that the presence of people or their entry is continuously monitored.

Dynamic safeguarding of AGV/robot transfer stations In flexible production processes, AGVs are often loaded and unloaded by robots. This means that the safety concepts for the AGV/robot transfer stations must be designed for automated movements. Leuze's safety solution dynamically safeguards the area of the transfer station. The area is monitored by two safety laser scanners. When the vehicle enters the monitored area, the monitoring dynamically adapts to the vehicle position and blanks out the AGV footprint from the monitored area.

Gapless safeguarding of a AGV/robot transfer station

The advantage of this solution is that the presence of people or their entry is continuously monitored. The vehicle can move through the monitored area during the loading cycle while the surroundings of the vehicle are fully guarded at all times. This means that it is possible to reliably detect whether a person is walking next to the vehicle. The safety solution also allows vehicle loads with different widths and the transport of parts that protrude at the front. The system works autonomously and can be easily integrated into the safety circuit of the system via the 2-channel safety output.

oriented safety laser scanners. These monitor the entire transfer area of the cross conveyor. By switching the protective fields, the protective function is only released for the conveyor on which a pallet is discharged. The safety system receives information about which conveyor is used from system control. Complete access guarding also during pallet discharge The advantage of this solution is that the entire access area is completely monitored at all times. It is also easy to set up and install, as it takes only two safety laser scanners to safeguard the entire transfer area. No additional trigger sensors are required. With conveyors in close proximity, only this solution enables a conveyor-specific safety concept. Summary The safety solutions from Leuze are based on innovative safety concepts that are individually tailored to the customer's system layout as part of the project. They ensure smooth-running processes with gapless safety and high system availability.




HOW STANDARD COMPONENTS MINIMISE DOWNTIME AND PROVIDE BUSINESS CONTINUITY David Messant, Production Manager at standard components specialist norelem, explores how standard components can be used to implement digital, supply chain and robotics solutions to minimise downtime and maximise productivity.


raditionally, engineering and manufacturing has been dependent on human and machine working side by side. However, this reliance also creates risk – if a machine goes into unplanned downtime, or the machinery operator is not available, the whole production line can come to a halt. As a consequence, business revenue and profits suffer, and if not resolved quickly, then the business itself can be put in danger.



For many manufacturers, increasing their resilience to these issues is crucial to survival, but can also be the key to unlocking even greater productivity potential. So-called ‘Industry 4.0’ technologies such as automation, AI and digitisation are already allowing businesses to stay on-line, helping to boost productivity and streamline production. However, while sweeping technological changes in the factory or plant is the ideal, in practice, this can take months, if not years, to fully implement, and may

not always be accessible. This is where manufacturers can look to standard components instead, which have the ability to reduce costs, maximise efficiencies across production, and make plants more resistant to unforeseen circumstances.

Parts like gears, worm drives, guide rails, motorised positioning systems and more are all available in a standardised range of sizes and materials from norelem. It is simply a case of having the knowledge, know-how and access to ensure that businesses assemble new machines.

Resilience and flexibility One such way that standard components contribute to increased resilience is that they provide much needed flexibility. This flexibility is in line with one of the buzz phrases of recent years, the ‘factory of the future’.

With machines made from standard components, it also offers added protection in that if any component needs to be taken out of service, the part can be quickly sourced and replaced, helping to minimise the likelihood of lengthy, unexpected breakdowns.

These factories are defined by their advanced manufacturing technologies and have certain traits, one of which is being able to rapidly shift production and adapt to meet demand. To do this though, production lines need to be reconfigured by engineers fast.

The role of automation in maximising productivity Automation has transformed the manufacturing sector over the past two decades. Large robotic arms which loom over the factory floor are commonplace now. Meanwhile, smaller collaborative robots (or ‘cobots’) are working safely alongside their human counterparts to diligently take care of the repetitive, dull and dirty jobs. It’s clear that automation is key to modern manufacturing.

Here is where standard components have their part to play. Rather than investing in bespoke, complex machinery and costly bespoke components, engineers can use standard components to change the setup of the factory quickly and easily.

While no one can predict next steps for manufacturing, it stands to reason that manufacturers may start to explore how robotics and automation can help their business - both in terms of scaling production and enabling operations to continue in the event of staff shortages. While many people fear that robots are taking over jobs, taking this step does not necessarily negate the need for humans, as people are essential to overseeing operations and interpreting data. However, the obstacle that many smallto-medium manufacturers find is that the initial outlay, maintenance and servicing of new machinery prevents them from deploying robotics. This is where standard components can put automation within reach. With drives, controls, belts, pulleys, gears and more all available in various standardised sizes and materials, manufacturers can quickly and easily automate different parts of their processes, without the need for bespoke, costly components and thirdparty engineers.




Embracing digitisation and remote working Leading on from automation is the need to embrace digitisation and remote working. Certainly, recent events have highlighted an obvious weakness in the manufacturing sector, which is that without people at the side of machines to oversee operations, production grinds to a halt. To overcome this weakness, it is imperative that the manufacturing sector is able to adapt to different working conditions, such as having the ability to manage robots remotely. However, although technology is starting to allow operators to control machines off-site, the maintenance side of manufacturing is a lot trickier. This is because the need for maintenance is usually determined by visual inspections but being off-site does not allow this option. If there is no process in place for remote maintenance alongside remote working, then this can introduce dangers such as components wearing



away beyond repair, and unexpected machinery failure. To resolve this, elements of machinery can be digitised to allow maintenance engineers to diagnose problems and solve issues remotely. For example, by adding sensors to equipment, engineers can monitor physical parameters such as heat and vibration. This eliminates the need for lengthy and tedious diagnosis testing, while increasing the likelihood of a firsttime-fix versus multiple visits to the site. Having access to data also ensures that the right parts and standard components can be ordered, and the machine can be repaired as quickly as possible. Standard components – The backbone of engineering Turbulent times can rock any business, but with the typically hands-on nature of engineering and manufacturing, the effects are felt much more acutely. To ride out any storms in times ahead, manufacturers must be flexible. The ability to monitor, control, adjust and

adapt processes is vital to minimising downtime, increasing productivity and ensuring business continuity in the future. While there’s plenty of noise around the benefits that can be realised by new, disruptive and often confusing technologies, in times of crisis many find solace in what they know. Standard components are the backbone of manufacturing, simplifying the process of ensuring that business can focus on a speedy return to maximum efficiency.



Innodisk’s pioneering solutions enable organizations to take full advantage of next-generation networking and telecommunications.


ltra-fast standards such as 5G and Wi-Fi 6 are ushering in a new era of networking and communications. These exciting new technologies promise higher speeds and lower latencies for both enterprise users and consumers, forming a cornerstone of the future of computing. Innodisk offers optimized flash storage, DRAM modules, and embedded peripherals that equip organizations with the performance and features needed to capitalize on these exciting technologies.

Minimal Latency and Maximum Performance 5G and modern networking technologies mean a critical technological leap forward for edge computing and the Internet of Things. However, this technological leap also requires networking equipment with hardware that is up to the task. Innodisk addresses these demands with flash storage solutions such as the 3IE7 and 3IE6-P series, which are designed to bring all the necessary performance for equipment such as IoT gateways, routers, and servers at the edge; as well as Ethernet switches, gateways, firewalls, routers, and 1U servers in the backend. Featuring functionality such as iData Guard, iCell, and iPower Guard, these storage solutions provide exceptional power management. Meanwhile, iSLC provides endurance of up to 10 times that of typical 2D MLC and 3D TLC – while providing SLC-level speeds and minimal latency.

In-vehicle Networking Innovation Next-generation networking and communications also bring opportunities in transportation. With these new technologies, reliable real-time monitoring of massive vehicle fleets becomes possible, and the added bandwidth allows much more data to be transmitted. Innodisk’s CAN bus modules are fully up to this task, providing invehicle communications optimized for demanding in-vehicle conditions, while iCAP, Innodisk’s browser-accessed management platform provides exceptional remote management capabilities. Together, these state-of-the-art innovations from Innodisk allow businesses to position their applications to take full advantage of the future of networking – at the edge, in the backend, and on the move.





norelem, the global standard components specialist, has boosted its range of stepper motors, with the three most popular sizes NEMA 17, NEMA 23 and NEMA 34 now available to order online.




ith Industry 4.0 well underway, norelem’s new stepper motors enable a wide range of applications to be automated. Whether its rotating robotic arms, automating milling machinery, or moving and sorting parts on production lines, engineers and manufacturers can use the components for a variety of processes.

The new motors are highly precise, efficient and maintenance-free, making them economical and cost-effective. They are fitted with all the typical operating modes of regular positioning systems and control, including automatic setup, referencing, parameter and program input. Marcus Schneck, CEO of norelem, said, “We know that automation is key to many processes and to driving efficiency in engineering and manufacturing. This is why we’ve added the three most common stepper motor sizes to our range.

cables, SMPS's, interface converters and 1-stage gear drives are available as accessories. All stepper motors are suitable for continuous operation. Engineers can find the stepper motors along with the available sizes and versions from norelem’s product reference catalogue THE BIG GREEN BOOK. Alternatively, the components can be ordered direct from norelem’s webshop.

“Adaptable to almost any control system, our standardised products can be integrated into new and legacy machinery. We’ve made them easy to integrate too, with software for the motors downloadable straight from the norelem website, and different interfaces for the components, such as Profibus and CAN, available in the range.” All of norelem’s stepper motors are quiet and provide low-resonance running without step losses. They also enable a constantly controllable operation with self-monitoring of the system and voltage monitoring of the output stage. The components are also designed to withstand harsh environmental settings. All motors are equipped with a robust EMC (electromagnetically compatible) housing and are rated to IP64 for dust and water protection. They can operate in an ambient temperature of up to 50° C without forced ventilation. The flange dimensions of the stepper motors are 42 mm (NEMA 17), 57 mm (NEMA 23) and 86 mm (NEMA 34). The retention torques of the various models range from 0.43 Nm to 8.4 Nm. The step angle is 1.8° for all models. The stepper motors are controlled via braided cables, and engineers can easily program the stepper motors via PC or laptop. They are designed for a control voltage of 24 to 36 V DC and have 2 output ports and 6 input ports. Connection 02 - AUTOMATION Mag - OCTOBER 2020



SHORT LEAD TIMES FOR UK-MADE NSK NH/NS LINEAR GUIDES NSK leverages the competencies of its worldwide manufacturing facilities to bring products closer to the company’s local customer base and reduce lead times. A case in point is NH/NS series linear guides, which are produced at NSK’s UK plant in Newark. As well as stocking standard units, the Newark factory has extensive manufacturing capabilities to ensure that requests for specific lengths, coatings, seals and grease – for example – can be fulfilled in short lead times.


H/NS series linear guides offer double the lifespan of conventional products due to the inclusion of features like specially developed ball groove geometry. Further benefits include high dynamic load rating, high productivity, long maintenance intervals, low noise output, ease of installation and standard accuracy that exceeds conventional alternatives.

The in-house workshop at NSK’s Newark facility is well equipped to meet any special order requirements for NH/NS linear guides.

With so much to offer, the NH/NS series is a popular selection for applications wherever accurate, smooth, even linear motion is required. Typical uses include machine tools, robots, laboratory automation, medical imaging equipment, semiconductor manufacturing equipment, automotive systems, factory automation and healthcare equipment. The centrally located Newark plant manufactures and houses extensive stocks of NH/NS linear guides in sizes 15 to 45, supporting demand from across the UK and Europe. However, for customers that have a specific demand, the inhouse workshop is well equipped to meet special orders. For instance, advanced equipment is in place to ensure rail can be cut to the precise length required. In addition, the workshop is able to provide durable surface treatments that include Duralloy® and Raydent, while stainless steel versions are also stocked. NH/NS linear guides allow a combination of rails and bearings to be used with popular options such as the NSK K1 lubrication unit for long-term, maintenance-free operation. A further capability at Newark is the potential modification of NSK K1 units in line with specific customer requirements. As a result of the extensive in-house competencies at Newark, customers in the UK benefit from short lead times for NH/NS linear guides that meet specific requests, typically 5-10 days from order placement. A virtual tour of the linear guide manufacturing facility at Newark can be viewed at media/videos/virtual-video-tours.html

NH/NS series linear guides offer double the lifespan of conventional alternatives 02 - AUTOMATION Mag - OCTOBER 2020



RED LION’S FLEXEDGE™ INTELLIGENT EDGE AUTOMATION PLATFORM INTEGRATES IT AND OT Advanced Networking and Powerful Automation in One Operating System.


ed Lion’s FlexEdge Intelligent Edge Automation Platform now combines the scalability of Linux® with the power of Crimson® 3.2 software into one user-friendly operating system. This fusion enables a single FlexEdge controller to provide advanced networking, security, and automation. By integrating information technology and operational technology, FlexEdge helps customers reduce costs, improve data security, and increase productivity. Powered by Crimson 3.2 software, the FlexEdge platform provides customers with maximum flexibility to easily modify controller functionality as application needs change. From advanced networking to automation, one controller does it all. Customers can enable additional functionality through field-unlockable software upgrades that eliminate the need to purchase or add more equipment, saving both money and unnecessary downtime. These new capabilities open doors to new product combinations, further expanding the applications to which the FlexEdge platform can be deployed. With FlexEdge’s modular communications sleds, users can now deploy multi-cellular radio gateways for critical communications applications. And, for environments with demanding requirements, the platform offers multiple isolated serial ports, routable Ethernet ports, optional serial, USB, WiFi, and cellular communications sleds, and field-installable I/O.




NEW DC PLATFORM: INTERROLL BRINGS INNOVATIVE DRIVE SOLUTION TO THE AMERICAS Interroll is setting new standards in modern material flow technology in North America. The company’s innovative range of coordinated RollerDrive products, control systems and power supply elements positions system integrators and OEMs to now provide even more individual solutions for their customers, from plug-and-play standard applications to systems with IoT 4.0 functionality.

With the new DC Platform, Interroll offers Industry 4.0 functionality for material flow.


onveyors have long been the workhorse of the material handling industry. Transporting packages, improving workflows, and interfacing with other automated solutions to drive real efficiency in warehouses and manufacturing environments. Today, the requirements placed on zero-pressureaccumulation conveyor systems are becoming more demanding in terms of their technical performance. They need three things: More Data, Higher Precision, and Improved Power Efficiency. With the DC Platform, Interroll has developed a powerful technology platform that fulfills these requirements in an exemplary manner.



"With the new DC Platform, system integrators and Original Equipment Manufacturers in the Americas can now choose from an innovative, coordinated range of conveyor technology solutions from a single supplier, all based on years of development and testing," explains Steven Leavengood, Vice President Sales and Service of Interroll USA. "This technology allows a more customized and user specific approach to meeting throughput needs, data management, power savings, and more. By addressing these specific market needs we strive to revolutionize conveyor performance.�

The DC platform is capable of collecting 100+ parameters of Data from the conveyor system which will drive improved performance and maintenance. This level of visibility provides quick system optimization and flexibility. The DC Platform also allows for precision positioning of totes and goods. This is critical for robotic applications and other situations where millimeter-accurate placement is required. Lastly, the DC Platform includes options for 24V or 48V power. With 48V, our customers can see a significant reduction in equipment needed to power their system – resulting in savings for both maintenance and components. This revolutionary new platform will be used to create a unique range of conveying solutions, from conveyors that can be commissioned without a programmable logic controller (PLC) using plug-and-play, all the way to tailor-made, high-performance systems that can be consistently and transparently integrated into the data universe of Internet of Things 4.0 applications. Experience the benefits of 48 V technology The new modular platform makes it possible for system integrators and plant constructors to design conveying systems according to customers' requests in both 24 V and 48 V versions. With this step, Interroll is driving the technical evolution of protective low-voltage solutions that has been adopted by automotive manufacturers. 48 V systems therefore enable the use of up to 50 percent fewer power supply elements than in 24 V systems. Interroll’s new modular Power Supply also enables the use of smaller wire cross-sections and longer wire

lengths, and reduce the number of error sources, for instance as a result of voltage drops on the wires. This significantly reduces the investment required in the entire system and the risk of errors during commissioning. Three power levels to choose from with the new RollerDrive However, customers don't just have more options when it comes to the voltage type of the new DC Platform. The new RollerDrive EC5000 also offers more flexibility in terms of its mechanical output power. The new motor rollers are available in 20 W, 35 W and 50 W versions that can take on any transport tasks for light or heavy goods. To support the implementation of conveyor solutions for heavy goods, Interroll offers the 50 W power option as well as a RollerDrive version with tubes measuring 60 mm in diameter instead of 50 mm. What's more, the well-known IP66 and Deep Freeze design options are available; these enable RollerDrive solutions to be implemented even in areas that are cleaned using powerful water jets or that reach temperatures as low as -30° C.

of general information about the current operating state and the operating load of the individual drives over time. In parallel, the control systems enable a range of detailed information such as precise error statuses, torque or temperature, for instance, to be read out for each individual drive.

Bus interface opens the door to Industry 4.0 Alongside the tried-and-tested analog interface, the EC5000 can be supplied with a bus interface based on the CANOpen standard, upon request. This means that modern conveying systems can offer data transparency for the first time. In combination with an Interroll control system with multi-protocol capability (PROFINET, EtherNet/IP and EtherCat), this means that users can consistently visualize a range of information and functions on the screen using the PLC or a web interface. One example is the display

At the same time, the new RollerDrive's bus interface enables users to carry out completely new control functions that are required in an automated environment. As a result, users can control the acceleration, speed and deceleration of the conveyed goods in the system more precisely. This solution also allows them to position the relevant goods on the conveyor to the nearest millimeter—a key requirement in order to guarantee seamless conveying interplay between the conveyor solution and robots or automated gripper arms.




INTELLIGENT IMAGE PROCESSING SUPPORTS PRODUCTION WORKERS IN INDUSTRIAL 4.0 APPLICATIONS Automation plays a major role in Industry 4.0. Cost reduction, increased productivity and zero-defect quality are factors that are increasingly prompting companies to digitise their processes.

The BXT motors deliver considerably higher torques than those usual in this drive class.

Easy integration into the respective production equipment, simplified variant management.


ut often full automation also means high investments. At the same time, the focus will continue to be on the human being in the interaction between man and machine. Given the prevailing shortage of skilled workers and high standards of industrial safety, this is no easy task for companies. Additional challenges for a successful process optimisation are a large number of variants, complex tasks and processes, as well as increasing quality requirements. How can this succeed?

With the assistance system "Clever Klaus", the German company Optimum datamanagement solutions GmbH has developed a smart solution: The easyto-integrate, camera-based assistant uses digitisation to optimise and simplify manual inspection processes. By combining industrial image recognition using a high-resolution USB3 industrial camera from IDS and an intelligent database, the assistance system recognizes every step and assists the employee in real time during the entire assembly process. According to the simple principle: Instructing - checking - confirming - documenting even these complex processes become manageable. The intelligent assembly assistance system "Clever Klaus" guides employees step by step with digital assembly



"Clever Klaus" assembly assistance system with USB 3 uEye CP industrial camera from IDS

instructions. The worker scans the order document and the assembly process begins. An IDS camera installed above the worktable records the workpiece or individual parts to be mounted. Both operating instructions and error messages appear on a touch monitor in real time: After each successful work step the worker receives a confirmation. Once assembly is complete, the system provides evidence of fault-free production. "The camera generates the digital shadow", explains Wolfgang Mahanty, managing director of OPTIMUM datamanagement solutions GmbH. All digital data of the process - when and how what is done - is recorded and processed. This enables the creation of a knowledge base and the subsequent

transfer of knowledge to all. "The camera has to capture many details and a wide range of variations and provide stable images. Sensory recognition must be reliable, i.e. the sensor must be able to cope with poor or changing lighting conditions," says Mahanty, summarising the demands on the camera. The reason: "In today's factory, the employee should get as much daylight as possible, which can affect the quality of the recording." No problem for the USB3 industrial camera UI-3590CP from IDS. The light-sensitive AR1820HSSC00SHEA0 rolling shutter CMOS sensor from ON Semiconductor uses BSI ("back-side-illumination") technology to ensure outstanding image quality even in low light conditions. Even when capturing the smallest details, extremely high-resolution images with low image noise are produced. With a

resolution of 18 MP (4912 x 3684) it reaches a frame rate of 21 fps. "Products are detected with deviations of 1mm on DINA 3", confirms Wolfgang Mahanty. Moreover, the small, compact size as well as the easy integration of the camera convinced the team of “Clever Klaus�. The German, Ludwigsburg-based company Mann + Hummel, world market leader and expert in the field of filtration, also appreciates the advantages of the assistance system optimised with the IDS camera model. Peter Sawatzky, Technical Manager at Mann + Hummel, also relies on the use of the "Clever Klaus". "During the final assembly of our filter components, many manual activities are required. This demands changing devices with very complex and therefore failure-prone sensory queries. 02 - AUTOMATION Mag - OCTOBER 2020



Easy integration into the respective production equipment, simplified variant management.

The assistance system has convinced us because we make far fewer mistakes." New variants can be easily learned during work preparation and can be installed by the worker on the same day. "Our variant management has thus become much easier," underlines Sawatzky. Additional benefit: The system can be integrated very easily into the respective production facility and even the use of several camera models is possible very simply and cost-effectively if the customer application requires it. Employees learn new procedures quickly and safely with Klaus' help through the digital step-by-step instructions. The relief of the worker through the individual assembly assistance system as well as easier work organisation allow a significant increase in productivity. Assembly costs are reduced, at the same time complaint costs are minimised by the increased quality assurance. "Since 'Clever Klaus' has been supporting our workers during assembly, the number of complaints has fallen significantly," confirms Sawatzky.



Outlook Particularly in the electronics and automotive sectors, assistance systems such as the one from OPTIMUM datamanagement solutions GmbH are increasingly accelerating processes and ensuring increased efficiency and quality. Manufacturing processes run almost flawlessly, are fully documented and can be traced. In this way, they help companies to increase productivity and, if necessary, to gain a competitive advantage. Simple, intuitive operation is an important basis for the successful introduction of Industry 4.0 and the associated. Optimum is therefore constantly working on how the system can be easily taught. This is done using CAD data, intelligent filters or even artificial intelligence. A further step on the way to digitisation is also the possibility of virtual commissioning. The assistance system must be designed so intuitively that every employee from the maintenance or work preparation department can operate it himself. No doubt: Digitisation is advancing all the time, and the need for solutions to increase efficiency and quality in the

factory of the future is growing. With individual, easily integrated assistance systems and intelligent image processing, it can be covered quickly and easily. An investment that pays for itself in a short time.


WIRELESS SAFETY „Wireless Safety“ for foot controls and command devices.


or press brakes and other forming and bending machines, the foot control is the key human-machine interface. It is actuated very often (up to two million switching cycles per year are realistic for plants working in three shifts around the clock) and assumes an important safety function because operators not only use it to trigger a press stroke, but also to stop one.

As part of its GF/GFS series, steute has developed a three-stage safety foot switch specifically for this task. Features of this switch include high stability and low pedal height, permitting ergonomically comfortable and non-fatiguing actuation. This is particularly desirable when operating an enabling switch because the pedal must be held in the middle position for longer periods of time.

At the SPS 2019, steute presented its latest generation of wireless safety foot controls, all of which eliminate the need for a cable connection to the press brake. They communicate instead via the intrinsically safe wireless protocol sWave 2.4 GHz-safe®, developed by steute for this purpose. Guaranteed stable response times of under 100 ms can be achieved independently of any other wireless devices active in the same frequency band. The steute wireless technology® provides a robust and safe wireless connection (availability) with fast and guaranteed response times. This protocol also features low power consumption, fast connection times and long battery lifetimes. Cable-free signal transmission provides operators with greater freedom of movement and optimal ergonomic comfort at all times. There is also no wear and tear of the cables, making the availability of the foot switches higher. The wireless safety foot switches with up to three pedals can be used in applications to Performance Level e (EN ISO 138491) and SIL 3 (IEC 61508). Leading manufacturers of forming machines are already offering their customers these controls – either as a serial component or as a frequently chosen option. The technology underlying all steute wireless switching devices and sensors also permits use of the sWave 2.4 Ghzsafe® intrinsically safe wireless protocol as a platform for other switchgear and command device series.