Automation Update - Issue 63

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Issue 63

Sustainable growth through automation









+44 (0) 1844 204420 Email us at

Ecopac (UK) Power Ltd, Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Bucks, HP18 9BF

AUTOMATION UPDATE Editorial Assistant Laura Sharpe 01843 580 460 Publishing Director Jodie Little 01843 580 460 Sales Director Tim Johnston 01843 448 443 Advertising Exec Jamie Simmons 01843 580 460

Automation Update is an engaging, editorially led publication & directory giving the reader news and updates on new products and services to our ever Progressing industry. Publishing House Jet Digital Media Ltd The Forge, Spratling Court Offices, Manston, Kent CT12 5AN

Forerunner. Yesterday. Today. Tomorrow. The Sensor People have been setting technological standards in industrial automation for more than 50 years. This is how we ensure the success of our customers in an industry that is ever evolving. We have been a forerunner from the start, and we are working on standardizing industrial communication. Among other things, we make sensors that are capable of transmitting data to control systems and the cloud via IO-Link and OPC-UA.

Visit us at Drives and Controls 2020 21 – 23 April NEC Birmingham Stand D116

Automation Update - 3

ESI Technology Ltd designs and manufactures pressure transducers and transmitters for the aerospace, defence, oil & gas, subsea, medical, automotive, marine, process and general industrial markets. Our customer base extends worldwide, exporting 75% of our sales to more than 45 countries. Formed in 1984, ESI has grown into a worldwide supplier of “in house” manufactured pressure transducer and transmitters. Early success came from designing solutions for challenging military and aerospace applications. More recently, the outstanding quality and performance of our Silicon-on-Sapphire sensing technology, has ensured our position as one of the market leaders in the pressure measurement industry. Our comprehensive range of pressure transmitters and transducers incorporate this technology, together with the latest digital signal processing. All products are rigorously tested to ISO9001 and Mil-I-45208 procedures and conform to CE requirements. EX, IECEx and DNV GL certification is also available.

Pressure Measurement at High Temperatures Accurate pressure measurement in high temperature environments can be a challenge. Standard pressure transmitters simply cannot function in extreme temperatures, mainly due to the internal components which have a low tolerance to heat. Sometimes adapters such as coiling coils or stand-off piping can be used, but are not always convenient in applications with limited space. With this in mind, the compact HI6000 series has been carefully designed with components, including a silicon-on-sapphire sensor, to make accurate measurements at high temperatures. It performs at constant media and ambient temperatures of up to 135°C without loss of performance and for limited periods up to 150°C. Thermal compensation from -25°C to +135°C guarantees stable signal output at all times. The silicon-on sapphire sensor can operate at very high temperatures with high accuracy and stability and without loss of performance. The silicon is grown onto the surface of the sapphire, which protects the silicon strain gauge because of its’ outstanding insulation properties. The result is an incredibly stable sensor that is unbeatable at elevated temperatures. Together with carefully selected electronics, and expert engineering, the result is our most flexible high temperature product yet. The HI6000 series is available in several signal outputs including voltage and current, pressure ranges up to 1500 bar and features all welded titanium wetted parts offering excellent chemical compatibility. With a high accuracy option of 0.1% NLHR it is perfect for applications in aviation, oil & gas, automotive and industrial process. For more information contact our sales department or +44 (0)1978 262 255 4 - Automation Update

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CBI Series Input 90-305 V AC Output 12/24/48 V DC upto 20 A MODbus / CANbus Comms Remote Monitoring via ethernet Status Relay

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Tel: +44 (0) 1206 575755 Email:


Güdel’s Gantry Robots Bring A Gentle Touch to Bakery Automation

Fast food restaurants are popular the world over, no more so than in the USA, where there are some 200,000 sites, serving approximately 50 million customers each day. With around 60,000 of these restaurants dedicated to hamburgers, supporting these businesses are the bakeries that have the challenge of producing vast quantities of fresh buns each day. Production volumes such as this require the implementation of automation, and since 2003, Pennsylvania based Workhorse Automation has been leading the commercial bakery automation sector with a wide range of pan handling and storage equipment, including 4 axis palletizing robots, used for pan stacking applications. However, if greater levels of flexibility and improved capacity are to be achieved, then alternative solutions would be required.

Following extensive research and development, Workhorse Automation settled on a solution based upon a 2-axis Güdel ZP-4 gantry robot module, with Allen-Bradley motion and programmable logic controls. This new solution allows Workhorse Automation’s clients to increase stacking system speeds whilst continuing to deliver the safe, gentle, and accurate stacking systems that customers have come to expect. To create a user and maintenance friendly turnkey automated system, Workhorse Automation’s engineers integrated the conveying systems, end-of-arm tooling and an Allen-Bradley control system to the gantry. The company’s first Güdel gantry-based system, installed several years ago, continues to operate successfully at Northeast Foods – Automatic Rolls of North Carolina. This facility produces 1,400 buns per minute, or 2 million over a 24-hour period, primarily for McDonald’s restaurants, using the Güdel gantry-based pan-stacking systems together with

the Workhorse Automation automated storage and retrieval systems (AS/RSs). Each Workhorse Automation system includes as many Güdel ZP-4 gantry vertical axes as necessary to meet the throughput requirements of the system. Therefore, in some systems, two vertical axes are located over the same bun-pan conveying system to meet processing requirements, with each vertical axis individually capable of stacking and destacking pans. The Z and Y strokes of the gantry will be determined by the individual customers application requirements on the size and number of pans to be handled. The pan stacking / de-stacking system provides a critical function in the process, as pans are specific to the type of bun being produced. The Northeast Foods facility makes four different styles of buns every day, each requiring a different style of pan. The changeover process of the pans is automatically handled by the automation, with the system moving from one pan type to the next without significant loss of throughput. The only time humans interact with the system is to visually check and confirm that the last pan has cleared the system at the end of a production run. “The Güdel gantry system allowed us to significantly improve the pan-stacking process,” says Ken Mentch, Workhorse Automation Sales Manager. “With Güdel’s gantry robots, we can increase the pan size and weight handled, as well as handle multiple pans simultaneously, reducing the motion speed requirements. The gantry gives us the exact work envelope needed for the application, increasing system safety and reducing the floor space required.” In addition, replacing the conventional magnetic machine used previously for pan stacking — known in the industry as the “pan crusher” — reduces the damage to the pans and the noise generated from the pan-handling process. “The gantry allows us to create a gentler, quieter and smoother automation system,” Mentch says. During the past few years, the bakery industry has taken note of the gantry system’s improved operation and reliability, moving the industry away from traditional technologies and toward robotic automation. Not only are current customers installing additional systems but new customers are coming to Workhorse for these proven solutions as well. Güdel has supported Workhorse Automation through this growth phase.

PRODUCT SHOWCASE – ON THE SHELF Stock items available immediately

Tempmaster PRO Precision Thermometer The Tempmaster PRO from Labfacility provides very high precision temperature measurement with Pt100 sensors.

L300 8 Zone Temperature Alarm / Controller with Pt or TC inputs The Labfacility L300 Pt100 and TC temperature alarm / on-off controller can be used in conjunction with a PC to provide accurate monitoring and alarm or on-off control of up to 8- zones simultaneously

L60 Thermocouple & Fine Wire Welder The Thermocouple Welder, manufactured by Labfacility, is a compact, simple-to-use instrument designed for thermocouple and fine wire welding.

Labcal PRO Precision Thermometer The Labcal PRO from Labfacility is fully characterised for Pt100 sensors and all major thermocouples.

Bognor Regis 01243 871280 | Sheffield 01909 569446

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8 - Automation Update

drives and new drive stock which our Engineers have access to. Covering all your VSDs on site regardless of make, size or type. We provide service, maintenance, repair and rental to get you back up and running 24/7/365.

Instant Motor Availability With one phone call, you as an engineer can have a market leading, high efficiency ABB WIMES motor in transit within 30 minutes, with a known delivery time to your site, any time day or night, 365 days a year. Our partnership with logistics specialist, OSE, has allowed us to offer this unique service: •

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COVID-19 Drives & Motors Resilience Plan During these difficult times, we understand that your current engineering teams may be reduced due to a requirement of self-isolation. This will undoubtedly put extra stress onto you and your colleagues to keep vital production lines running. To keep your site running through these testing times, we are offering our customers a free resilience plan to cover your critical assets if they fail over the next 3 months and, of course, a plan to ensure if this does happen, we can get you back up and running with minimum fuss. We know site visits may not be an available option to you right now so we can create this plan on a conference call, a safe environment for everyone. However, if you are still happy for us to visit site, a self-certification document will be issued before we arrive. Our qualified engineers and yourselves will go through your critical drive & motor assets and any specific technical applications that are required, as well as assessing the life cycle position of the asset. We will then draw up a contingency plan based on replacement options, spares, available hire units or direct replacement availability that we can put in place to keep your site running if one of these critical assets were to breakdown.

To book your FREE Drives & Motors resilience plan, contact us: | 01661 835 566

The EL-SIE Range Softwarefree, next generation data logging from Lascar Electronics


lthough Lascar Electronics has been manufacturing data loggers for over 25 years, even for the original inventors of the USB data logger the launch of the new ELSIE range is a major event. The EL-SIE is the first in a new generation of EasyLog products that takes data logging to another level. Capable of measuring ambient temperature, humidity and pressure, each can store over 1 million readings inside the sleek metal housing. The bright and clear display shows readings and device status at a glance, and the coloured LED indicators and sounder mean the EL-SIE can grab your attention when it needs to. Each logger is supplied with batteries (two standard AAAs), a USB cable and a wall bracket so it’s ready to use right away, and one set of batteries will typically last over a year. But the biggest innovation is hidden away inside the EL-SIE itself: all the software needed to configure your logger and view, analyse and download the data. There is nothing to install, simply connect the logger to any PC or Mac and use your existing web browser. You don’t even need internet access, it couldn’t be easier. Of course, the EL-SIE also comes with all the powerful features expected from EasyLog. These include high, low, cumulative and pre-alarms, and also start modes including delayed start at a preset time, or a triggered start based on any selected measurement parameter. In another breakthrough, the EL-SIE is the first USB logger that can be used with the EasyLog Cloud, giving total peace of mind about the security of your data. Once on the Cloud the readings can be 10 - Automation Update

accessed from any internet-connected computer or mobile device, and also used with EasyLog’s powerful online graphing, analysis and report generation tools. The EL-SIE is intelligent and adaptable enough to be perfect for use in a number of markets including facilities and building management, logistics, warehouses and storage, and clean rooms and other pressure sensitive environments. The new EL-SIE range: data logging has evolved. Lascar Electronics +44 (0)1794 884567

BLFT Stainless Steel Turbine Flow Meters BLFT Liquid Flow Turbine Meters are a lower cost alternative to existing products available in the market and can be specified in a wide variety of sizes and connection options. This range has been independently tested to UKAS national standards to guarantee performance. A choice of signal outputs and display options makes this range extremely versatile. This highly accurate Flow Turbine style meter is constructed from either 304 or 316 grade stainless steel and is ideal for the measurement of various low to medium viscosity liquids in a range of different applications. This model is supplied with a square wave pulse output or low voltage coil pulsed signal as standard, with a wide choice of digital flow displays and batch controller’s available. The standard low cost digital display is powered by a lithium battery with a long battery

life of 4 years, providing a choice of 4-20mA signal, pulsed output and programmable alarms. Internal parts of BLFT turbine meters are simple to replace for easy maintenance. This flow meter comes with threaded or flanged connections as standard, alternatively with hygienic tri-clamp fittings depending on the chosen model. Each meter is supplied with a multi-point calibration certificate to ensure traceable accuracy and repeatability. BLFT turbine flow meters are ideally suited for measuring low to medium viscosity liquids and can even handle aggressive fluids or liquids that require

hazardous area ATEX approval. Typical applications include measuring bulk fuels, solvents and light oils as well as chemicals, additives and water. Sanitary flow turbines are widely used in hygienic food and beverage industries to measure wine, spirits and beer as well as fruit juices, milk and other Sizes available range from DN4 to DN200 and models can be specified with a choice of maximum temperature, pressure and even face to face dimensions. BLFT bearings and shaft material is Tungsten carbide, while rotor material is CD4Mcu. Accuracy can be specified at +/- 0.5% or 1% of measured value with repeatability stated at +/-0.2%. This range can be supplied with a wide selection of basic or advanced flow computers offering temperature compensation and flow curve linearization. Turbine meters measure flow using the mechanical energy of the fluid to rotate a turbine rotor within the flow stream inside the meter. The rotations are measured and calculated to provide a proportional measurement relative to flow rate. The Principle is well proven and the application suitability list is very large. Bell Flow Systems or call 01280 817304 for more information on the BLFT flow turbine meter range.

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All in one! The fail-safe SmartPLC from ifm Two separate plc’s in one compact housing: one for safety-related applications, the other as a standard plc or platform for other operations. Both plc’s communicate with each other so that complete machine control, including safety functions and visualisations can be carried out with just one Smartplc, AS-i offers unbeatably simple and flexible wiring of standard and safety-related signals. ifm telephone: (020) 8213 2222

Grab – label – train – run AI with IDS NXT ocean Artificial intelligence opens up new fields of application for camera technology and image processing. It can be used, for example, to classify fruit varieties or to identify damaged parts (e.g. apples with marks or color deviations).

RIGHT: IDS NXT ocean Design-In Kit Below: IDS NXT ocean: AI for industrial applications


o cover all possible variances with classical image processing would be very time-consuming and costly. With artificial intelligence, however, these challenges can be solved in no time at all. With IDS NXT ocean, there is now a user-friendly complete solution for industrial applications available. Camera hardware, software,

infrastructure and support come from a single company: IDS. Users only need sample images and knowledge on how to evaluate them (e.g. "good" / "bad") to create a neural network. This makes the start into AI-based image processing particularly easy.

three basic steps: To upload sample images, to label the images and then to start the fully automatic training. The generated network can then be executed directly on the IDS NXT industrial cameras, turning them into powerful inference cameras.

Train neural networks without prior knowledge

Get started with the Design-In Kit

With the help of the IDS NXT lighthouse cloud software, even non-experts without prior knowledge of artificial intelligence or camera programming can train an AI classifier with their own image data. Since it is a web application all functions and the necessary infrastructure for creating the neural network are immediately available. This means that users do not have to set up their own development environment first, but can start training their own neural network right away. This involves

IDS also offers an IDS NXT ocean design-in kit which is particularly useful for anyone who wants to test the potential of AI for individual vision tasks. It provides all the components a user needs to create, train and run a neural network in his productive environment. In addition to an IDS NXT industrial camera with 1.6 MP Sony sensor, lens and cable, the package includes six months of access to the AI training software. The use of deep learningbased image processing for individual applications can thus be realized in a short time.

More information: 14 - Automation Update

on the other. The integrated display and the easy web interface display all the available status information for the user and support diagnostics in case of a fault. SmartPLC as a data logger: the data logger function records operational system data via AS-i, EtherCAT, Modbus TCP, Profinet, EtherNet /IP, TCP/IP, UDP/IP and stored on the SD card or in the internal flash memory. If necessary, the integrated real-time clock provides a time stamp for each recorded data block. This simplifies the documentation and diagnostics of processes. SmartPLC for process visualisation: SmartPLC features a freely programmable web visualisation based on HTML5 to provide maximum transparency. An internet browser with HTML5 capability is sufficient on the final unit (PC, tablet, smartphone). No further software is required. Even the SmartPLC full graphic display is freely programmable for visualisation tasks.

All-in-one Smart PLC from ifm electronic does it all. There are PLC’s and there are safety PLC’s. Then there is ifm’s SmartPLC. The SmartPLC is an elegant combination in one housing of both a safety PLC and a standard PLC.


martPLC possesses the flexibility for a multitude of tasks, even where the safety rating reaches SIL 3 / PL e. SmartPLC is not just a standard PLC with a standard PLC, it is also an AS-I gateway to either Profinet or Ethernet/IP and it also acts as a datlogger. It’s a visualisation system, a protocol converter and an intelligent evaluation unit in conjunction with the new ifm system solution apps. SmartPLC is all you need in one housing. All-in-one. The two integrated safety and standard PLC’s operate in tandem, using powerful processors, large memory and a multitude of supported protocols for the control of sophisticated systems - and all this at an unbeatable price!

The safety PLC is certified up to SIL3, PL e and handles eight safe local inputs and four safe local outputs. It also includes user-friendly diagnostic functions, such as status indication for safe I/Os and error memory with time stamp for up to 2,000 messages. The safety PLC is programmed using CODESYS V3. The standard PLC can also be freely programmed using CODESYS V3. Its software and hardware operates independently of the safety PLC, but it can of course communicate with it and exchange data. SmartPLC as a gateway: without running a programme, the SmartPLC can simply be used as a direct gateway for AS-i on one side, and Profinet or EtherNet/IP

As easy as using a smart phone: the SmartPLC as a platform for ifm system solutions. The new ifm system solution apps make it a simple task to handle various sensor types. Modern sensors offer more and more intelligent functions that can also be made available to the PLC via interfaces like IOLink or TCP/IP, but to make full use of them the PLC programmer has to individually implement the functionalities in the PLC. This can be very time-consuming and costly, especially when it comes to implementing the required user interfaces. The tailored apps from ifm can be loaded onto the SmartPLC without programming software. The apps are loaded and configured via the integrated web interface, so all necessary settings can be carried out easily using a device with an internet browser. It’s as easy as using a smart phone and is a simple step on the road to Industry 4.0. SmartPLC as a protocol converter: With sensors and Ethernet based devices connected to your fieldbus, the SmartPLC can be used as protocol converter between Profinet, EtherNet /IP on the one hand and AS-i, EtherCAT, Modbus TCP, TCP/IP, UDP/IP and IO-Link on the other. ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products.

Automation Update - 15

Automation - New Decade. New Expectations. As the wholesale and ecommerce industry has grown, so have customer expectations. Today customers are placing orders more frequently, in fewer quantities, later in the day and expecting delivery faster than ever before. Customers now consider 2-day delivery slow with next-day and even same day delivery becoming the standard. Finance and Administration, “Over the next 5-10 years, the industry is going to see more automation with advanced capabilities, and with a much heavier reliance on automation and robotics. In fact, we think it will begin to grow even faster than demand for storage and retrieval equipment has. The idea of a “dark building,” where robotics and automation run autonomously 24/7, is definitely making headway.” As companies transition to automated warehouse systems, the intralogistics industry will also change and grow. It’s important to research and evaluate the best solution and find a reliable intralogistics partner.”


nternally, companies are suffering from obstacles including warehouse space, accuracy, labour problems and theft. Externally, consumer loyalty may be impacted as a result of delivering incorrect orders, letting down shipping expectations and not having the capabilities to manage personalisation or global shipping. When B2B warehouses can’t deliver as promised, chaos is the result. Suppliers are left looking foolish and without the goods they need. Construction crews without

materials…hospitals without supplies… car dealers without prime shopping week inventory: multiple layers of supplier disappointment and revenue impact can occur. On the B2C side, what’s worse than ordering a birthday gift online to have it arrive late and in the wrong colour? It is guaranteed that person will be telling all of their friends about the poor experience and the retailer’s name! According to Mark Dunaway, Kardex Remstar’s North American President

Chocolate World , is a Belgium based chocolate mould manufacturer with customers in more than 110 countries who had a need to optimise their warehouse logistics. With the installation of two LR 35 Vertical Buffer Modules and Power Pick Global, they have changed their process and are now delivering: same-day dispatch for orders placed by 3 pm, they can manage up to 500 orders and store 2,736 customised boxes per day. Another benefit is that their employees now have the tools to guarantee precise inventory overview and storage locations as well as the ability to train personnel without the need for an intense employee training. If you’re seeking modular, flexible and scalable warehouse automation which increases productivity, optimises warehouse space and saves you a whole lot of headaches, then look to automation for the future of your warehouse logistics.

To learn more about the automation and faster picking click here or contact Kardex Remstar at i n f o . r e m s t a r. u k @ k a r d e x . c o m o r v i s it o u r we b s ite at 16 - Automation Update


Deliver Benefits For Automated Assembly Applications Recognised as experts in automation and handling technology, Zimmer Group now offer a series of highly functional and easy to control electrically driven grippers. Designed primarily for assembly tasks and for handling small parts, these latest generation products deliver a number of distinct advantages for automated assembly operations. Electrically operated grippers from Zimmer’s GEP2000 series offer a number of advantages for small parts handling including: adjustable gripping forces of between 80 N and 400 N and jaw strokes of between 10mm and 16mm. Another important feature of this range of grippers is their mechanical self-locking mechanism, which prevents the loss of the workpiece in the event of a power failure. All grippers within the range feature an integrated control system and are available in three control versions: With IO-Link, digital I/O and digital I/O plus an analogue output to set or interrogate the jaw positions. With the IO-Link version, the gripper offers all the system-specific advantages of that interface, which includes not only simple handling and operation, but also easy integration. By connecting a single cable, the gripper can receive data from and transmit data to the master controller. Parameters such as gripping force and gripping speed are set centrally. The gripper uses IODD (IO Device Description) to send signals to the higherlevel control system. The resultant benefits include considerable time savings during initial setup or when replacing the gripper. IO-Link also sets new horizons for advanced diagnostic functions and predictive maintenance, which in turn enhance machine availability. No additional hardware, in the form of other controllers is required thanks to this highly sophisticated control system. The IO-Link master is all that is needed to act as a link between the gripper and the fieldbus, and no additional software needs to be installed on any PLC being used. Zimmer Group also provides its own Human Machine Interface (HMI) for easy operation. This tool, which has a special gripperadjustment user interface, is able to store parameters for up to 32 different workpieces. In the I/O version, the grippers operate as simply as a conventional pneumatic valve. The gripper opens when it receives a control signal, and the jaws are closed when it receives another one. In this cost-effective version, a four-pole cable that supplies the gripper with both electrical energy and control data is all that is required. A commercially available central distributor can be used to control several grippers at the same time. Should gripper position information be required, this can be achieved using magnetic field sensors, which can be accommodated in the two grooves incorporated within the gripper.

The gripper is able to use these sensors to send a signal as soon as a set query position is reached in just the same way as a traditional pneumatic gripper. Zimmer Group has developed a simple solution for adjusting the maximum gripping force, which can be set directly on the gripper using a potentiometer with four separate positions. This is not only quick and easy, but also offers the advantage of the setting being easily visible, even if the power has failed or if the gripper has been removed. For applications where more precise information relating to the position of the gripper jaws is required, Zimmer Group offers a digital I/O version together with analogue sensing. An analogue sensor, which outputs a voltage of between 0 and 10 volts, depending on the jaw position, is integrated into the gripper as standard. This voltage can be evaluated using an analogue card in a higher-level control system, making it possible to determine the position of the gripper jaws with an accuracy of less than 0.05 mm.

Robust Mechanical Design Delivers Longevity In Service Zimmer Group’s GEP2000 series electrically powered grippers feature an industry leading mechanical configuration. The hard anodised aluminium housing is at the heart of the grippers’ robust construction and reliability, and the field proven flat guide design will allow the gripper to perform 10 million part handling or assembly cycles without requiring maintenance. All versions in the range offer a mechanical emergency release, which is an important safety feature. Should there be a need for the gripper to be opened manually, in exceptional circumstances, the screw on the self-locking gearbox can be turned using a separate screw which is easily accessible externally. As a result, the gripper can still be opened, even in the event of a power failure when for example, a workpiece needs to be removed. All grippers are sealed to IP40 standard, and their high accuracy allows for rapid replacement minimising any interruption of production. The grippers in the GEP2000 series are powered by 24 VDC, and the gripper jaws are able to operate with a current draw of less than 500 mA. The current draw only increases to 2 A, a current that all conventional IO-Link masters can supply, for a few milliseconds at the moment of start-up, when the mechanical selflocking mechanism is released, and the motor is being brought up to speed.

DS-OCT12-BLACKFAST_Layout 1 20/09/2012 16:28 Page 1

Tel: 0208 339 7370

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Automation Update - 19


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