What’s New in Process Technology Dec 2012 Jan 2013

C EO 2 01 3

Dec 2012/Jan 2013 vol.26 no.7 PP255003/00198

1212 WHAT'S NEW IN PROCESS TECHNOLOGY DECEMBER 2012 / JANUARY 2013

Cover: © iStockphoto.com/Avatar_023

CONTENTS 4

ensor technologies to detect pneumatic S cylinder position

8 8 10 12 14 16 18

CEO Insights

20

New products

34

Hot products

Dirk Kuiper, AMS Instrumentation & Calibration Andrew Finch, Weidmüller David Delany, ifm efector Jussi Rautee, ABB Australia

Keith Marriner, Invensys Operations Management Santo Gazzo, Advantech Australia

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SENSOR TECHNOLOGIES TO DETECT PNEUMATIC CYLINDER POSITION Jack Moermond, Product Line Manager, Balluff, Inc

4 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

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To integrate a pneumatic cylinder into an automated system, it is necessary to supply signals to the controller indicating the position status of the cylinders. Pneumatic cylinder manufacturers, machine builders and end users have developed a number of ways to detect extension or retraction of a pneumatic cylinder and provide a signal to the control system.

I

n the field of automation, a very popular choice for prime mover duties is the pneumatic cylinder. Pneumatic cylinders carry many advantages in terms of relatively low first cost, application simplicity and durability. To integrate a pneumatic cylinder into an automated system, it is necessary to supply electrical signals to the controller indicating the position status of the cylinders. Toward that end, pneumatic cylinder manufacturers, machine builders and end users have developed a number of ways to detect extension or retraction of a pneumatic cylinder and provide an electrical signal to the control system.

Position sensing techniques One position sensing technique is to install external electromechanical limit switches or inductive proximity switches that detect metal flags on the moving parts of the machine.

The disadvantages of this approach include the cost and complexity of the brackets and associated hardware, the difficulty of making adjustments and the increased physical size of the overall assembly. Another problem is that the external hardware is prone to damage and misalignment due to everyday incidental contact or impact.

A more popular and widely used method is to attach magnetically actuated switches or sensors to the sides of the cylinder, or into

a slot extruded into the body of the cylinder.

Through the aluminium wall of the pneumatic cylinder, magnetic field sensors detect an internal magnet that is mounted on the moving piston. In most applications, magnetic sensors provide end-of-stroke detection in either direction; however, installation of multiple sensors along the length of a cylinder allows detection of several discrete positions. There are commonly two different types of cylinder magnets used with magnetic field sensors. The first and probably the most widespread is the axially magnetised magnet, which is ideal for actuating most reed switches. When viewed from the side, this magnet has the north and south poles next to each other in the axial plane as shown in Figure 2.

The second commonly encountered cylinder magnet is the radially magnetised magnet, which works well with the Hall effect sensor.

Instead of the north and south poles next to each other, one is the inner diameter and the other is the outer diameter, as shown. The Hall effect sensor only looks for a magnetic pole; it does not matter if it is north or south.

Magnetic sensor types Reed switches The simplest magnetic field sensor is the reed switch. This device consists of two flattened ferromagnetic nickel and iron reed elements, enclosed in a hermetically sealed

Reed

Hall

AMR

GMR

Sensing element size

Large

Small

Medium

Small

Construction

Mechanical

Solid state

Solid state

Solid state

Magnet strength required

Medium

High

Low

Low

Sensitivity

Medium

Low

High

High

Temperature stability

Medium

Low

Medium

High

Power consumption

Zero

Low

High

Low

Noise immunity

High

Low

High

High

Switching speed

Low

High

High

High

Mechanical robustness

Low

Medium

High

High

Electrical robustness

Low

Low

High

High

Double switch points

Yes

Possible

No

No

Table: Comparison of sensor technologies.

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DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Sensor technology

Figure 2: Axial and radial magnetic field orientations.

Figure 1: Traditionally, two proximity switches detect flags for end of stroke of a pneumatic carriage.

glass tube. The glass tube is evacuated to a high vacuum to minimise contact arcing. As an axially aligned magnet approaches, the reed elements attract the magnetic flux lines and draw together by magnetic force, thus completing an electrical circuit. The magnet must have a strong enough gauss rating, usually in excess of 50 gauss, to overcome the return force (spring memory) of the reed elements.

The benefits of reed switches are that they are low cost, they require no standby power and they can function with both AC and DC electrical loads. However, reed switches are relatively slow to operate; therefore, they may not respond fast enough for some high-speed applications. Since they are mechanical devices with moving parts, they have a finite number of operating cycles before they eventually fail. Switching high-current electrical loads can further cut into their life expectancy. In addition, low-cost reed switches can sometimes deliver multiple switching points as the twin lobes of certain magnets pass by.

Lastly, reed switches installed in high shock and vibration applications may exhibit contact bounce or even become physically damaged.

In many automated factories, reed switches are a major source of unplanned downtime.

In plants with hundreds of reed switches,

Figure 3: Reed switch.

failures can occur almost hourly and represent a continuous maintenance headache, not to mention lost productivity.

Hall effect sensors Hall effect sensors are solid state electronic devices. They consist of a voltage amplifier and a comparator circuit that drives a switching output. In a Hall effect sensor, a steady DC current passes through the thin Hall effect chip. The distribution of electrons across the element is uniform and the current moves in a straight line, with no potential difference generated at the outputs (located on the sides of the chip). As a radially oriented magnet approaches, the magnetic field is perpendicular to the current flow through the Hall effect element. The presence of the perpendicular magnet pushes the electrons out of their straight-line path and towards one side of the chip. The imbalance of electron charge thus creates a voltage across the Hall effect element. The small microvoltage that is created is proportional to the strength of the magnetic field. Once the voltage amplitude generated across the chip has satisfied the threshold level of a comparator circuit, the sensor output switches on.

Since Hall effect sensors are electronic devices, they have no moving parts. Unlike

6 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

a reed switch, their response time is not dependent on magnetic force overcoming mechanical inertia. They operate faster and are more resistant to shock and vibration.

It might seem like an easy solution to simply replace reed switches with Hall effect sensors. The problem is that the magnetic field orientation of a cylinder designed for reed switches may be axial, whereas the orientation for a Hall effect sensor is radial.

The result? There is a chance that a Hall effect sensor will not operate properly when activated by an axially oriented magnet.

Another concern is that Hall effect sensors typically have rather low sensitivity, such that the magnetic field strength must be in the 30-60 gauss range. Finally, some inexpensive Hall effect sensors are susceptible to double switching, which occurs because the sensor will detect both poles of the magnet, not simply one or the other.

AMR magnetoresistive sensors Another type of solid state magnetic field sensor is called an AMR magnetoresistive sensor. The operating principle of AMR magnetoresistive sensors is simple: the sensor element undergoes a change in resistance when a magnetic field is present, changing the flow of a bias current running through

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Sensor technology

Figure 4: Hall effect sensor and its magnetic field.

Figure 5: AMR magnetoresistive sensor wheatstone bridge.

the sensing element. A comparator circuit detects the change in current and switches the output of the sensor. Compared to Hall effect sensing technology, which generates a tiny microvolt-level signal, the magnetoresistive element responds with a more robust 3-4% change in bias current. This results in more noise immunity and less susceptibility to false tripping.

Magnetoresistive sensors are about 200 times more responsive than a typical Hall effect sensor to a given magnetic field strength. The practical magnetic field strength required to operate a magnetoresistive sensor can be as low as 15 gauss. Improvements in magnetoresistive technology now allow these sensors to detect both axially and radially magnetised magnets.

In addition to the ruggedness benefits of solid state construction, the magnetoresistive sensor offers better noise immunity, smaller physical size and lower mechanical hysteresis (the difference in switch point when approaching the sensor from opposite directions). Quality manufacturers of magnetoresistive sensors incorporate additional output protection circuits to improve overall electrical robustness, such as overload protection, short-circuit

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Figure 6: Basis of GMR technology.

protection and reverse-connection protection. Unlike Hall effect sensors, there are no double switching points, because the higher sensitivity of the magnetoresistive sensor allows it to remain in the ‘on’ state as the low-strength portion of the magnetic field passes under the sensor. Hall effect sensors, being less sensitive, will often drop out when they see a weaker portion of a magnetic field located between two stronger areas, then switch on again when the field strength increases.

Leading manufacturers of magnetoresistive sensors have developed weld field immune versions that can operate reliably in AC welding fields as strong as 200 kA/m with no false signals or electrical damage.

Many of these welding sensors are available with metallic housings to further guard against hot weld spatter that would melt into a plastic-bodied sensor.

GMR giant magnetoresistive sensors The most up-to-date magnetic field sensing technology is called giant magnetoresistive (GMR). Compared to AMR technology, GMR sensors have an even more robust reaction to the presence of a magnetic field - at least 10%.

Due to their high sensitivity, less physical chip material is required to construct a practical GMR magnetic field sensor, so GMR sensors can be packaged in much smaller housings for applications such as short stroke cylinders, very small bore cylinders or miniature pneumatic grippers. Better quality manufacturers of GMR sensors also add advanced output protection circuits such as overload protection, short-circuit protection and reverse-connection protection.

Summary Over the years, many users have abandoned the use of reed switches due to their failure rate and have utilised mechanical or inductive sensors to detect pneumatic cylinder position. AMR and GMR sensors are smaller, faster and easy to integrate, and are much more reliable; however, they must overcome the stigma left by their predecessors. With the vast improvements in sensor technology, AMR and GMR sensors should now be considered the primary solution for detecting cylinder position.

Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/S231

DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

DIRK KUIPER GENERAL MANAGER, AMS INSTRUMENTATION & CALIBRATION PTY LTD

There has been much discussion in the general media of a weakening manufacturing sector in Australia, but there have also been opposing views. How do you see the future for the Australian manufacturing sector?

There is currently a general weakening of the manufacturing sector with one of the reasons being the high Australian dollar making exports more expensive. Wages are also putting a constraint on the manufacturing industry with many companies trying to compete against those in countries with lower working conditions. We only need to watch the news or read the newspapers to see that jobs are on the decline in the manufacturing sector. Having said that, specialised manufacturing industries, such as medical equipment, are doing better because they are more insulated from the impact of developing economies and the import barriers are higher. Innovation and smarter manufacturing techniques can overcome some of these hurdles too.

What do you feel are the three most important things your customers are looking for in a supplier?

There are many factors that can affect the relationship between a customer and supplier, and in general customer service is rated as one of the top factors. The customer wants to know that they can rely on their supplier to deliver what was ordered when they said it would be. It is an expectation in modern business that suppliers can provide timely, accurate advice on demand. Another factor that is important is the reputation of the company, such as how long the company has been in business and whether there have been issues in the past, and also in part the uniqueness and quality of the product lines. Price is always a factor as well, but value offered is the key. Clients will pay more when they can justify it.

What do you see as the single biggest challenge facing your customers in the year ahead?

The biggest challenge for the coming year will be to maintain the momentum gained in 2012. The mining boom appears to be slowing and hence manufacturing and suppliers may suffer accordingly, but with this slowing other opportunities will arise in other industries. It is therefore important to ensure that a close watch is kept on other markets. The introduction of the carbon tax may prove one of these opportunities with more stringent requirements put on various industries. Many state that the Australian dollar is overvalued; if the dollar would drop against other currencies this might open up opportunities in the export market.

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What are your customers demanding of you more today than five years ago, and how will you meet these requirements in 2013?

In comparison with five years ago, the demand from our customers has been the requirement for faster response, due to the communication ‘revolution’. With the internet ever expanding and new technologies arriving virtually every day, many customers in our industry want these technologies implemented whether it is for communication, control or other purposes. The paperless society is becoming more and more of a reality, not only in everyday situations, but also in the instrumentation, control and automation industries. It is important to keep abreast of these innovations and implement these where necessary.

What do you see as the two or three biggest growth opportunities for your customers in 2013?

This is an interesting question, as it is a bit like looking into a crystal ball and it is dependent on the different industries. Growth opportunities always exist, but it is important to find the focus and then go for it. I see three customer growth strategies for 2013 as very important. First it is important to grow the core business and maintain your focus on this, and second to look at investigating where most of the business comes from and concentrate on the top range of customers. The third step is to start looking at alternative or adjacent strategies. Management should begin this process by considering the growth potential within the present core business or the opportunities and growth potential associated with creating innovative value propositions for underserved customer groups.

Dirk Kuiper is General Manager of AMS Instrumentation & Calibration Pty Ltd. His professional experience is wide and varied from engineering functions such as service, commissioning and project management, to sales functions, having been a sales engineer, national sales manager and business owner. Dirk has been managing AMS Instrumentation & Calibration for the last 14 years and last year branched out into manufacturing with Trimec Flow Products, manufacturer of MultiPulse flowmeters.

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ANDREW FINCH MANAGING DIRECTOR, SOUTH EAST ASIA & PACIFIC OPERATIONS, WEIDMÜLLER

What do you see as the single biggest challenge facing your customers in the year ahead?

but also the expectation that customers and suppliers will adopt these technologies in their businesses and products.

I believe that our customers will face increasing economic pressure over the next year and beyond. The world is clearly getting smaller and intense global economic pressure will drive companies in other countries to look for business elsewhere, and in particular, in Australia and the Asia-Pacific region.

Many of the hurdles that were once barriers to entry to new markets have been eliminated. Bottlenecks caused by communication, transport, culture and government regulations have been removed, paving the way for internationalisation of business. This will create fierce competition and exert pressure on prices and commercial conditions. While international competition is inevitable, both customer and suppliers will need to provide innovative solutions and work closer together to create a point of difference.

What do you feel are the three most important things your customers are looking for in a supplier?

Without a doubt, it is service, service and more service. I believe that there are three critical aspects of service that our customers require. The first of these is the fast-track availability and on-time delivery of components and products. The second is the ability to deliver exceptional and knowledgeable support at all times, and via different means of communication - be it email, mobile or social media. And the third crucial aspect of service is innovation. For customers to remain competitive, suppliers must continue to deliver innovative solutions that not only meet the expectations of customers but exceed them.

What emerging trends or developing technologies may influence or change the way your customers will do business in 2013?

Clearly, the green theme is a key trend that will have significant ramifications for businesses universally. The growing demand for environmentally friendly solutions will have both commercial and technological implications. From a commercial perspective there will be increasing demand to comply with environmental standards.

This will include using environmentally friendly manufacturing processes, recycled materials and green packaging, as well as controlling and managing waste disposal. On the technology front, there is a clear trend towards the use of alternative renewable energy. This not only incorporates the development of cleaner, greener energy plants such as photovoltaic, wind or geothermal,

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What are your customers demanding of you more today than five years ago, and how will you meet these requirements in 2013?

Our customers are requiring new solutions for various applications faster. Increasingly, they are demanding smaller, smarter and environmentally friendly products. To meet these needs we are working closer with customers and forming mutually rewarding partnerships. By leveraging these partnerships we are able to design and develop products that meet their industrial needs today and those of the future. I believe these partnerships are pivotal in meeting future challenges and satisfying demand.

What new and innovative technologies do you see emerging in your field of business in 2013, and how will they help your customers?

It is unlikely that any single, innovative technology will dominate our field in the future. Rather, new technologies will probably be fused to develop greater and possibly new capability. For instance, technical know-how in LED lighting together with photovoltaic energy can be used to deliver cost-effective and long-term solutions in energy management while reducing the carbon footprint. Electronic safety and identification devices will merge to become an integral part of the industrial plant and factory automation scene, making the workplace safer. Exploring and combining these new technologies will be integral to product and industrial development in 2013 and beyond.

Andrew Finch started his career in the electrical industry as an electrical fitter apprentice in 1972 with Warburton Franki, primarily working on ships, ferries and various marine installations. Over his career he has held various technical and sales positions within Anitech and later Weidmüller, becoming Australian managing director in 2001. Andrew is now Managing Director, South East Asia & Pacific Operations for Weidmüller, and holds a Diploma in Electrical Engineering.

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DAVID DELANY MANAGING DIRECTOR, IFM EFECTOR

What do you see as the single biggest challenge facing your customers in the year ahead?

I believe that the continued softening of the global economy is the biggest challenge facing customers in the year ahead. This can already be seen in the latter half of 2012 in the mining industry with China’s demand slowing. I believe this will be more of a short-term setback than a long-term one; however, we will all need to make it through this rough patch extending into the first three to six months of 2013.

The high cost of the dollar and high labour costs are also continuing challenges for our customers. The combined force of these challenges is leading customers to be very innovative in reducing overheads and looking for new markets. Challenges can sometimes bring positive outcomes.

Will the resources boom continue to be a primary focus for automation, control and instrumentation vendors?

I think resources will continue to be a primary focus for suppliers of automation, control and instrumentation because although the world economy is having a downward effect on mining at present, the boom is far from over. There will be an ongoing demand for Australian resources for at least the next 10 years. In addition to demand for automation technology in expanding factories or mine sites, it is a very arduous environment that has potential risk for employee safety. Therefore, I am seeing automation companies developing innovative ways to use robots and automation to provide a safer and more productive working environment.

What do you feel are the three most important things your customers are looking for in a supplier?

Customers are looking for product reliability, fast response times and strong partnerships.

In terms of reliability, there is a lot of awareness of the significant costs involved in plant downtime. The days of large planned maintenance shutdowns are becoming less and less. Therefore, component wear and tear must be discovered before failure occurs and fixed during normal production.

As a result of this attitude, supplier response times and delivery are important to customers. Customers do not hold a great deal of spare parts and therefore rely on the supplier to be able to deliver product on time. Reliability also comes from quality product.

The need for a strong partnership is in part related to a shortage of qualified engineers in general and therefore the heavy workload of our customers’ employees as a result.

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What emerging trends or developing technologies may influence or change the way your customers will do business in 2013?

One emerging trend and developing technology is the ability to be able to control a machine or process remotely. For example, mining vehicles being driven and controlled from Perth and operating thousands of kilometres away on sites in the Pilbara area. This will greatly influence the way customers do business. Instead of having people in regional centres they can have more employees working out of major cities or a centralised location. I think this has been driven by the fact that there is a significant shortage of qualified engineers and mining companies are seeking to reduce costs. Advantages of this include reduced need for workers to fly in and fly out of isolated regional areas, increased safety and employee retention through better work/life balance.

What are your customers demanding of you more today than five years ago, and how will you meet these requirements in 2013?

I think customers are demanding a partnership-based relationship rather than a purely supplier-customer relationship.

How ifm efector can meet this demand is to work closely with our customers to truly understand their business. In turn we are able to more effectively meet their needs and help them increase efficiency and productivity. We have to really show that our products are adding value and saving them money in running their business.

As a result, we have had to become more of a solution provider than a component provider and our salespeople all need to be technically competent engineers. Further, the type of product customers are demanding is different compared to five years ago, and as a result we have had to keep developing innovative products to meet their requests.

David Delany helped start the New Zealand subsidiary of ifm efector in 1998 and relocated to Australia as a member of the Board of Directors for ifm efector in 2000. David has an NZCE in electrical engineering and an MBA from Auckland University. He began his career as an industrial electrician and has over 20 years of experience in instrumentation and automation.

In 2010 David became Managing Director of ifm efector Pty Ltd, overseeing Australia and New Zealand.

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JUSSI RAUTEE HEAD – DISCRETE AUTOMATION AND MOTION DIVISION, ABB AUSTRALIA What do you see as the single biggest challenge facing your customers in the year ahead?

The biggest challenge we hear from many customers will be balancing productivity and cost pressures. In a cyclical business environment it can take courage for customers to look beyond the market peaks and troughs and make business decisions on what will ‘future-proof’ their organisations.

The benefits of taking a longer-term view gravitate around staff resources. When markets regain strength, those that have had the foresight and capacity to retain their operative capabilities will be better placed than their competitors to seize these opportunities earlier.

This is a complex challenge in softening markets. It also has a knock-on effect to local communities which can take even longer to re-establish, particularly in remote areas.

Will the resources boom continue to be a primary focus for automation, control and instrumentation vendors?

Yes it will. We believe China’s demand for raw materials will continue, most likely not at the same growth rates we have seen in previous years, but it will continue nonetheless.

Even with a reduction in export demand, China has an enormous domestic market fuelled by an increasingly affluent workforce.

Demand for raw material from both export and domestic demand in China will continue to drive its need for raw materials, which is good news for Australian mining.

Process automation will continue to play a key factor in the resource area. We see an ongoing trend in both mining and manufacturing to drive productivity gains through a greater use of automation and control. Automation is increasingly seen as a vital element of the productivity puzzle, empowering fewer staff with more real-time data, to better monitor and control plants.

What do you feel are the three most important things your customers are looking for in a supplier?

We find customers are seeking innovative product solutions to improve their productivity and energy efficiency, essentially doing more while lowering costs and emissions. Our customers tell us that some of our newer and more innovative products make programming set-up easier, which means they can customise them to their applications quicker and don’t need specialist resources to do so.

End users also expect today’s suppliers to provide support beyond their product warranty. With stretched resources, many customers tell us they need suppliers who can assist them achieve the maximum life and availability of those products in their plant.

For many process industries, the availability of their plant can represent the fine line between success and failure.

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What environmentally sustainable initiatives have been undertaken that will position your company differently before customers and prospects in the year ahead?

Helping our customers use electrical power more efficiently to increase industrial productivity and to reduce environmental impact in a sustainable way is an important part of ABB’s focus, and our dedicated energy appraisal team is one of our environmentally sustainable initiatives. This specially trained team works with clients to determine energy-saving opportunities centred around pump and fan applications.

Another of our environmentally sustainable initiatives was our new sulfur hexafluoride (SF6) gas recycling technology developed in Australia. The purity of recycled SF6 gas using the newly developed technology is about 99.99% and is in accordance with technical grade IEC 60376 (the standard for new gas), which enables SF6 to be re-used again and again in electrical equipment.

What new and innovative technologies do you see emerging in your field of business in 2013, and how will they help your customers?

The main innovations in ABB’s area of business are more efficient motors and drives and better safety technology.

For example, synchronous reluctance motor technology offers both a high output range compared to the same IEC frame size traditional motor and makes it possible to achieve IE4 super premium efficiency down to the 11 kW power level. And variable speed drives with in-built energy calculations, including energy used, saved kWh, CO2 reduction and money saved, help the user finetune processes to ensure optimal energy use.

The latest safety innovations are also now found in drives with an in-built safe torque off function that removes all torque from the motor shaft and prevents unexpected start-up.

Jussi Rautee is head of ABB’s Discrete Automation and Motion Division in Australia. The division employs around 30,000 people globally with an annual turnover of approximately US$10 billion.

The Discrete Automation and Motion Division provides products, solutions and related services that increase industrial productivity and energy efficiency.

Its motors, generators, drives, programmable logic controllers (PLCs), power electronics and robotics provide power, motion and control for a wide range of automation applications.

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KEITH MARRINER MANAGING DIRECTOR, INVENSYS OPERATIONS MANAGEMENT, AUSTRALIA AND NEW ZEALAND

What do you see as the single biggest challenge facing your customers in the year ahead?

What new and innovative technologies do you see emerging in your field of business in 2013, and how will they help your customers?

We expect our customers to experience increased financial pressure on their bottom line. Factors contributing to this pressure are financial uncertainty driven by a slowing of growth in China, the uncertainty in the global market centred on Europe and the strong Australian dollar that is affecting the competitive position of goods produced in Australia.

Human resource factors, with a transition in the workforce from baby boomer to gen Y, will also have an effect, such as the ability to retain this new workforce in order to gain return on investment in staff. People will tend to be in roles and locations for a shorter time, so learning, collaboration and teamwork will be key to overcoming these issues - as well as the capturing and embedding of best operational practices.

We think there will be an increased role for business process workflows as a standard operational practice - not just for the business systems but now including and integrated within automation and operations systems. There will also be a drive to exception-based systems that are ‘self-aware’ and notify based on context.

Increased connectivity solutions will also help to enable the move to mobile and multirole workers, with knowledge systems capturing experience and sharing it across systems seamlessly.

The shift from ‘click’ to multitouch functionality as we see in consumer devices will also become more prevalent, and cloud computing will begin to become a natural part of the automation and operational architecture for sharing, collaboration, and so on.

What emerging trends or developing technologies may influence or change the way your customers will do business in 2013?

Do you see organisations in the mining, processing and manufacturing sectors taking up cloud computing in the near future?

We think customers will begin realising the value of integrating systems across multiple facilities and the manufacturing value chain to improve operational effectiveness. This involves changes to operational practices and the introduction of enabling technology.

The move to operational integration enables increased collaboration across the full manufacturing value chain. This will also mean embracing the trend towards leveraging social media, and collaboration will be natural for interaction and the sharing of information.

The operational experience will go from simply monitoring to being automatically aware, and this situational awareness will be natural, enabling faster collaborative decision-making. Such a flexible operational team requires that a team of users of different roles collaborate while using different user interfaces that all see the same data in the same time in the form they require.

We see tier 1 organisations actively evaluating the reach of cloud computing into the automation space, with the key considerations of functionality, security and availability being assessed. Already we see asset management systems moving to the cloud, and we expect site-based historian and information systems, as well as SOP repositories, to quickly go in this direction.

Knowledge and sharing systems are also a natural fit for the cloud, as well as simulation and offline pattern modelling systems.

As the cloud can be both ‘public’ and ‘private’, the larger organisations will start to use the cloud in a private configuration for cross-site data sharing and collaboration.

What are your customers demanding of you more today than five years ago, and how will you meet these requirements in 2013?

Currently we are seeing an increasing focus away from new systems for plants to trying to extract more value from existing systems. There is also more of an emphasis on standardisation, in that standards and templates are being developed, rolled out and maintained over the operation.

There is also a shift away from replacing people with automation systems (remember ‘lights out manufacturing’?) to the use of automation systems to empower workers to be able to have increased responsibility, make decisions faster and act in a more consistent and sustainable way.

There is also a growing requirement for systems to provide a situational awareness capability so that workers can more effectively deal with the vast amounts of data generated across a plant.

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Keith Marriner is the Managing Director of Invensys Operations Management, Australia and New Zealand, responsible for all sales, engineering and product delivery, marketing and communications.

Keith joined Invensys in 1997 as a technical manager for the Triconex safety systems operations in the Middle East. Since then, he has held a number of senior roles in Invensys. Keith Marriner has an electrical/electronics engineering background and holds an MBA from Heriot Watt University, UK.

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SANTO GAZZO GENERAL MANAGER, ADVANTECH AUSTRALIA What do you feel are the three most important things your customers are looking for in a supplier?

Customers will continue to demand remote access to real-time data via the internet and wireless connectivity for deeper, faster insight into their processes.

Innovative products that keep them one step ahead of their competitors are just the beginning. Customers need to be confident that these products will be available long term so that the solutions they roll out will be supported for a long time.

Customers also are keen to use mature software and programming, as opposed to proprietary systems. This reduces the overall cost of ownership and allows companies to commit to larger projects.

On-demand delivery - products need to be in stock ready for on-demand delivery whenever and wherever. This timeliness needs to be extended to the supply and support of legacy products for the maintenance of customers’ existing projects.

What environmentally sustainable initiatives have been undertaken that will position your company differently before customers and prospects in the year ahead?

Advantech has an environmental program for reducing, re-using and recycling materials and has become a member of an Approved Co-Regulatory Arrangement under the National Television and Computer Recycling Scheme. The scheme involves a combination of government regulation and industry action to reduce the amount of television and computer waste going to landfill and to increase the recovery of resources. The scheme aims to boost the recycling rate of these products from 17% in 2010 to 80% by 2021-22. Advantech has officially joined DHL Supply Chain’s Product Stewardship Arrangement to fulfil its obligations under the government’s Product Stewardship Act 2011. DHL Supply Chain was the first organisation approved to be able deliver services under the scheme.

Advantech has invested a great deal into low power consumption systems and platforms which today provide the same capabilities compared to half a decade ago, while using much less power.

Advantech is also fully compliant with RoHS and none of our products use any heavy metals.

What emerging trends or developing technologies may influence or change the way your customers will do business in 2013?

Connectivity, communication and the cloud are driving technologies that enable real-time data access from anywhere in the world.

This is leading to operational efficiency gains and increased factory automation. Projects are now becoming far more distributed.

Previously a system would be limited by the communications capability of a network, whereas now we are offering a range of products which will allow customers to effectively communicate over far greater distances using various technologies to cover a greater range of needs.

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What are your customers demanding of you more today than five years ago, and how will you meet these requirements in 2013?

As customer applications become ever deeper and more complex, Advantech has needed to become more diverse and flexible - and we have. Our customers expect prompt delivery, support, longer warranties and continued backing for legacy items. On-time delivery is now more essential than ever. Advantech’s online store, buy.advantech.net.au, operates 24/7. In this environment customers can configure a system, and get a quote instantly emailed to them - 24 hours a day.

This is just one of the ways our customers can engage with us and explore our expanding range of products - from basic systems to bespoke requirements, all of which can be maintained within our range of hardware. Advantech’s logistics department is meeting these increasing client demands for delivery and support.

What new and innovative technologies do you see emerging in your field of business in 2013, and how will they help your customers?

Low-cost distributed I/O with localised program application capabilities will help provide more flexibility in how a remote I/O can be used. The advent of multitouch screen technology will allow software developers to create more applications that simplify interactive touch-screen applications.

With flexibility being a driving force, wireless communication will also be a major factor in the market. Advantech is currently working to provide a new set of capabilities to meet the growing needs of end users.

Santo Gazzo has been General Manager of Advantech Australia since 2003. A former employee of Priority Electronics, which was acquired by Advantech, he has considerable experience in the industrial automation and computer systems fields. Coming from both electrical and electronics disciplines with experience in project implementation, technical support, sales and business management, he has a deep appreciation and understanding of the needs of Advantech’s many clients in Australia.

DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

NEW PRODUCTS

WIRELESS PULSE COUNTER

WEIGHING MODULE

ZigSense has extended its Australian-made wireless sen-

Siemens Industry Automation Division has launched

sor node product line to include two new pulse count-

a weighing module for the Simatic S7-1200. Siwarex

ing nodes. Models ZS24-REU-001 (2.4 GHz) and

WP231 is a weighing module suitable for monitoring

ZS09-REU-010 (900 MHz) are designed for ultralow-power

filling levels in silos and bins and for use with goods

pulse counting metering applications.

being weighed on platform scales. The WP231 is

The user can select between ‘AA’ or ‘D’

intended for industries requiring a high level of meas-

Li battery sources or use an external DC

urement accuracy, such as the food and beverage,

supply of up to 24 VDC to power the node.

pharmaceutical and chemical industries. It is also

Low current consumption combined with an

suitable for use in explosive atmospheres.

optimised sleep cycle may enable the node to be powered by a single ‘D’ Li battery for close to eight years.

Up to four contact closure pulse inputs are continuously monitored in the background while the node is in sleep mode. Default pulse frequency is 5 Hz with 50 Hz as an option.

Totalised pulse counting data is transferred from remote wireless nodes to a ZigSense gateway where it is made available as Modbus holding registers. ZigSense pulse counting nodes are built into an IP67 enclosure and can be optionally supplied as OEM boards.

Conlab Pty Ltd

Contact info and more items like this at wf.net.au/R704

The Siwarex WP231 weighing module can be fully integrated into the Simatic S7-1200 control, and its parameters can be quickly and easily set via the TIA Portal engineering platform. The module has four digital inputs and outputs and one analog output. The Siwarex WP231 can be connected to various systems and operator panels via an ethernet or RS485 interface with Modbus protocol and can be operated in standalone mode, independent of the Simatic S7-1200.

Users can define specific limit values and different parameters for the various individual outputs. Additional diagnostic functions, such as the documenting of weight and various process parameter readings (trace), make for greater transparency and facilitate the commissioning and maintenance of the module.

Due to its high resolution - one million parts - and a measurement cycle of 10 ms, the Siwarex WP231 is able to measure with a high degree of accuracy.

Clear menus mean that the weighing module is easy to operate, whether in conjunction with the Simatic S7-1200 or via a directly connected HMI panel.

Siemens Ltd Contact info and more items like this at wf.net.au/S146

20 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

www.ProcessOnline.com.au

NEW PRODUCTS

TEMPERATURE CONTROLLERS WIKA has now completed its portfolio of temperature controllers with two digital instruments for simple thermostat applications. The model SC58 and model SC64 close the gaps in this segment between mechanical products and complex PID instruments.

The SC58 and SC64 digital controllers are designed for a measuring range of -80 to +400°C, and can therefore be used universally. The switch hysteresis can be set via the menu,

OPC SERVER FOR ALLEN-BRADLEY

which assists with flexibility. Both two-point controllers offer a high switching accuracy and contact rating (16 A). They are easy to use and have a highly visible display (13 mm high characters).

MatrikonOPC has expanded the

The SC58 and SC64 have the same design as the corresponding mechanical and mechatronic

functionality of its OPC Server

controllers. Users can therefore change to the digital instrument without any additional expense.

for Allen-Bradley by adding the

WIKA Australia

support for Rockwell’s EN2T

Contact info and more items like this at wf.net.au/R848

communication card, bit writes and revamped graphical user interface. With the added features, the MatrikonOPC Server for Allen-Bradley provides users with a comprehensive connectivity package for all Allen-Bradley PLCs in one OPC Server and an optimised workflow, all of which makes configuration and maintenance faster and more intuitive.

Enabling bit writes through OPC items provides granular control over data access, which allows engineers to perform intricate operations down to the lowest levels. Also, this OPC Server comes with built-in, role-based security down to the per-tag level.

Based on each user’s login, this OPC Server selectively grants or denies access to specific tags, providing only the authorised users with secure access to the right process data. This means the Allen-Bradley OPC Server actively protects the integrity of the overall automation system data.

Key features include comprehensive connectivity support for PLC5s, SLC500s, Micrologix (1100 A, 1400, 1200 etc), and ControlLogix platforms; automatic discovery of Allen Bradley PLCs; and high performance suited to sequential, process, drive and motion control.

MatrikonOPC Contact info and more items like this at wf.net.au/R686

www.ProcessOnline.com.au

DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 21

NEW PRODUCTS

CONTROLLER FOR LEGACY SYSTEM MODERNISATION Honeywell has released the next generation of its widely used industrial process controller, the High-Performance Process Manager (HPM). The Enhanced High-Performance Process Manager (EHPM) allows 25 years of distributed control system installed base to seamlessly migrate to the Experion Process Knowledge System. Cost of migration is significantly reduced by preserving control strategies and wiring.

Honeywell’s EHPM solution streamlines plant modernisation upgrade and reducing plant downtime. This is designed to

WIRELESS RTUS FOR HAZARDOUS AREAS

allow plants to take what was once a legacy system and

The CSE-Semaphore TBox Wireless

gradually, in a step-by-step fashion, move it forward such

Monitor has passed all third-party

that it becomes part of a modern system while at the same

testing criteria for operation in Class

time protecting the plant’s intellectual property.

I, division 2 hazardous areas. This

by significantly reducing risks associated with a legacy system

EHPM maintains a safe and reliable system while mod-

approval applies to configurations

ernising and evolving with the most advanced technolo-

with integral displays; other wireless

gies, keeping established, reliable systems running longer,

monitor configurations have previ-

extending uptime and preserving investment in wiring, control

ously been approved for operation in

algorithms and displays.

Class I, division 1 hazardous areas.

Honeywell’s modernisation roadmap incorporates full

The ultralow-power, battery-op-

flexibility in life cycle planning, including long-term support

erated TBox wireless monitor (WM)

of existing equipment for life expectancy extensions and

is suitable for installation in remote

upgrades for plant performance improvements.

areas in which it supervises assets in

Honeywell Limited

the chemical, environmental, oil and

Contact info and more items like this at wf.net.au/S201

gas, transportation, utility and water/ wastewater industries. The approvals significantly expand the applica-

WIRELESS CONDITION MONITORING

tions for the compact, IP68-rated, TBox WM integrated package.

National Instruments has announced two

Class I, division 1 and division 2

products to help engineers monitor machines,

approvals allow TBox WM to operate

heavy equipment and ageing infrastructure.

in hazardous atmospheres such as

Engineers can integrate the wireless sensor

those in natural gas installations as

network (WSN) strain node and C Series

well as at digesters or sewer lines

module with NI CompactRIO for predictive

in the wastewater treatment industry.

maintenance to predict faults, analyse fatigue,

TBox employs a decentralised

lower operating costs and decrease downtime.

architecture that enables the integra-

The WSN-3214 strain/bridge completion

tion of programmable automation,

node features hardware-timed waveform ac-

alarm management, data logging

quisition and is suitable for wireless structural

and IP telemetry in a single, rug-

health monitoring of bridges, buildings and

ged package. Simple yet powerful

equipment. It has four analog input channels

platforms leverage web technologies

that support quarter-, half- and full-bridge

and push messaging via email, SMS

completion, and also two digital I/O channels for event detection and programmatic con-

text and FTP. TBox systems are easy

trol. It has the ability to perform onboard data processing, save data locally or predict fault

to configure and offer dramatically

conditions with the NI LabVIEW WSN Module.

reduced costs versus traditional PLC

With expanded voltage range, faster sampling rates and higher integrated electronic piezoelectric (IEPE) excitation, the NI 9232 C Series module is a data acquisition card optimised for industrial accelerometers, tachometers and proximity probes in condition monitoring applications. It has a ±30 V input range, 4 mA IEPE current excitation and

and SCADA architectures.

CSE-Semaphore Pty Ltd Contact info and more items like this at wf.net.au/R688

41 kHz bandwidth. Screw terminals and open/short sensor detection are provided for use in permanent industrial monitoring applications.

National Instruments Australia Contact info and more items like this at wf.net.au/R868

22 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

www.ProcessOnline.com.au

A big THANKS to all our valued readers!

You have helped create TWO fantastic new magazines After analysing the results of over 1000 READER SURVEYS completed earlier this year, we are excited to announce a major transformation for longstanding brands Voice+Data and Electrical Solutions.

The new titles (and their respective websites) reflect the changes in technology markets in recent times and will better service YOUR business information needs.

Voice+Data morphs into Technology Decisions • Content shifts to pure IT • Cloud; security; big data; storage; compliance; mobility;

virtualisation & more • More opinion, analysts, peer talk, case studies & articles • New focus on software, both in magazine and online

Electrical Solutions expands with more comms+data content and becomes ECD Solutions (Electrical+Comms+Data) • 30% increase in circulation • Comms+Data; Efficiency+Renewables; Automation+Security and Electrical Distribution • New perfect bound format with heavy cover and section dividers • More products, case studies and articles • Regular content on regulations, compliance, training and business tips Website launch: November

NOTE: Current subscriptions will continue, but if you want to update your magazine and/or online preferences, simply go to www.ECDsolutions.com.au or www.TechnologyDecisions.com.au

NEW PRODUCTS

CLAMP-ON PROCESS METER

DEVICENET TEES AND SPLITTERS Turck has introduced 7/8-16UN minifast tees, splitters and inline diagnos-

Yokogawa’s CL420 clamp-on process meter is designed to make

tic devices, designed for use in DeviceNet applications, including CAN

checks on DC mA lines without breaking the circuit. This com-

networks and mobile equipment. Models are available in a standard

pact instrument is an effective troubleshooting tool for 4-20 mA

option for classic DeviceNet use and a voltage monitoring version that

current loops on equipment such as flowmeters, field instrument

contains an integrated circuit board to serve as a diagnostic tool. Voltage

transmitters, signal conditioners, distributors, valve positioners

monitoring tees and splitters help troubleshoot and prevent downtime

and meters, saving users valuable time on site.

with LEDs that report normal, overvoltage and undervoltage conditions.

The CL420’s clamp has a relatively large hole that allows

The splitters provide parallel wiring, which simplifies installations. The

proper clamping around conductors up to 6 mm in diameter

‘h’ configuration contains a tee connected to the main trunk line with one

and ensures stable readings with an accuracy of 0.2% up to

premoulded cable drop, providing a quick, convenient and space-saving

20 mA. The backlit dual display provides both current value and

way to add additional cabling within the cable tray. The splitters may be

percentage of range information along with battery condition.

specified with any gender, negating the traditional male to female connection

Convenient in low light situations, the CL420 incorporates a LED

requirement. Additionally, the inline diagnostic devices may be used as

torchlight and illuminated panel keys. The unit has two input

gender changers to connect a male to male or female to female cordset.

ranges, 0-20 mA and 0-100 mA, plus an analog DC mV output

Designed to accommodate diverse conditions, the minifast splitters and

for use with a DMM, recorder or data logger. Other functionality

tees can handle up to 30 V in temperatures ranging from -40 to 105°C.

includes an auto-power-off feature and data-hold.

The splitters and tees also feature an IP67 protection rating, providing a

The CL420 comes with a soft carrying case plus batteries and

suitable solution for voltage trouble spots in harsh conditions.

optionally available are output cables with either banana plug or

Turck Australia Pty Ltd

screw terminals.

Contact info and more items like this at wf.net.au/R553

Yokogawa Australia Pty Ltd Contact info and more items like this at wf.net.au/R548

THERMAL IMAGING CAMERA The Dwyer Series TIC thermal imaging camera allows users to see heat contrasts to prevent plant equipment failures, detect air leaks in buildings, and many more applications. Infrared radiation given off by objects is translated by the camera into measured levels in visual light on the bright 2.5″ 160 x 120 resolution LCD. For increased differentiation among temperatures, the camera can automatically adjust the colour band for a narrower range of temperatures throughout the -20 to 250°C temperature range of the camera. Besides taking spot measurements, the camera can also be set for isothermal, area or profile analysis.

All cameras include a Li-Ion battery, battery charger, docking station, SD memory card, SD memory card reader, sun shield, lens cap, video cable, standard reporting software and a calibration report. A Bluetooth earphone and USB cable are also included in TIC-30 units for making voice annotations and real-time recording. Up to nine movable temperature spots can be selected to get specific temperature measurements of objects on the display. On the TIC-20 and TIC-30, there is a flash, a visual light camera and a laser pointer to help identify the objects in the picture. The visual image can be blended with the thermal image for better illustration of where the hot or cold spots are in the image.

Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R682

24 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

www.ProcessOnline.com.au

Air springs overcome demands of fine minerals and powders handling Powder-handling tasks typically impose rigorous demands upon the actuators and isolators used in their materials handling systems.

Not only must they be able to cope with dust, abrasion and fine particles that can damage the rods and seals of conventional cylinders - risking production stoppages - but also they must be able to cycle rapidly in actuation roles and to control high levels of noise, vibration and harshness (NVH) in isolation roles.

“Because fewer moving parts and reduced complexity usually equate to less wear and more reliability, we are encouraging powder processors to consider air spring actuators and isolators in new applications. Firestone air springs - called Airstrokes and Airmounts - are particularly appropriate in situations requiring rapid cycling, high reliability and minimal susceptibility to wear in grimy industrial situations,” says James Maslin, National Sales and Marketing Manager for Air Springs Supply Pty Ltd. Air Springs Supply and Firestone engineers internationally are developing expanding uses for the flexible-wall, bellows-type Airstroke and Airmount air cylinders. These air springs are, in essence, tough, fabric reinforced rubber balloons of different shapes to perform different tasks. Operating without rods or seals, they can be small enough to fit in the palm of a hand, or more than a metre across and capable of producing 40,000 kg of force.

One powder-handling project in which they were employed involved Semi-Bulk Systems Inc, a US company that manufactures state-of-theart equipment and containers for unloading, batching and processing bulk quantities of fine dry powders, including products of industries such as food and beverage, dairy and industrial and chemical products, including paint and paper components.

Semi-Bulk Systems’ process for unloading vinyl bags of powder of 400-3800 kg had previously been simply to discharge the product through a hole in the bottom of the bag. The problem with that was that the product came out in big slugs, rather than evenly and smoothly.

Semi-Bulk’s solution to this issue was to blow air through the powder to break it up and make it fluffy, so it could discharge through a 100 mm hole at the bottom of the container. The container allowed for controlled flow of material through its use of a support stand with a hinged deck, beneath which an Airmount isolator was inflated at about 1 bar. The stand supported the container at its corners with hooks, allowing gravity to dispense the powder through the hole in the container floor.

“Semi-Bulk’s system put the container on the deck and let it begin to empty through gravity. When the powder got down to about 25% left in the container, the pressure in the Airmount was greater than the weight of the container, causing the hinged deck to rise. This tilted the container so the remaining powder flowed evenly toward the discharge port,” says Maslin.

Semi-Bulk used doubleconvoluted Airmounts for smaller bags and the triple-convoluted Model 38s for larger bags. These Airmounts (which already have been in use in Australia for years in heavy industrial plant) have a maximum diameter of approximately 950 mm and load capacity of 40,000 kg at 5.5 bar and maximum stroke of 350 mm. Semi-Bulk’s process also included a smaller Model 16 Airmount that inflated when the hinged deck tilts, activating an air piston vibrator that vibrated against the container base and helped dispense the powder further.

The Airmounts replaced air cylinders used previously. Key advantages of the change were that Semi-Bulk Systems could use one Airmount to replace two conventional cylinders. Also, conventional air cylinders always required some lubrication or maintenance, which the Airmounts did not. And the Airmounts were hidden under the deck, so there was nothing exposed to clean.

Maslin says a major advantage of the Airstrokes and Airmounts is that they don’t use the guides and seals found in traditional pneumatic cylinders. This difference is the key to many of their benefits in rigorous production environments, ranging from metal stamping, vibrating screen and conveyor applications through to labelling, sealing and packaging tasks. Airmounts are used in Australia to isolate equipment as diverse as compressors, computers, generators and refrigeration and airconditioning equipment.

Air Springs Supply Pty Ltd Contact info and more items like this at wf.net.au/R806

RUGGED TABLET PCS Norco has introduced a range of rugged tablet PCs that can be used for factory maintenance or general outdoor work environments. They have been tested for ruggedness to MIL-STD-810G and are IP64 rated and have an 8.4″ touch-screen 800x600 LCD. The standard unit has a 1.5 Ghz CPU with 2 GB ram, Wi-Fi, Bluetooth, 16 GB flash storage, speakers, a camera front and back, USB, headphone and microphone ports and a 2.9 Ah lithium battery.

The total unit weighs 1.3 kg and is suitable for those users requiring greater mobility.

Base and wall mounting cradles are also available.

Other options include G3/G4 cellular capability, GPS capability, a barcode reader and a credit card reader.

PLC Hardware Contact info and more items like this at wf.net.au/S083

www.ProcessOnline.com.au

DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 25

NEW PRODUCTS

WORKPLACE PERSONAL NOISE MONITOR The Quietdose personal dosimeter from Howard Leight by Honeywell is designed to assist in workplace hearing conservation programs.

According to SafeWork Australia, an estimated 1 million Australians are exposed to hazardous levels of noise at work at a cost of at least $30 million annually in compensation payouts alone. Studies show that noise exposure is the most common

SOLID STATE FLASH STORAGE

cause of occupational hearing loss and

Advantech has introduced the SQFlash range of industrial-grade

that most hearing loss occurs in the first

SATAIII solid state storage products.

5-10 years of exposure. The Quietdose is

Working closely with its long-term strategic partners, Advantech

designed to deal with this problem before

now offers a storage solution which strengthens the security function

it occurs.

and durability of the latest high-security SQFlash series product.

The Quietdose is an ‘in-ear’ dosimetry device that measures the

Storage is one of the crucial parts of an integrated system

noise that workers hear accurately and in real time. By avoiding costly

and directly relates to overall stability and performance. Specifi-

engineering changes and accurately measuring noise exposure at its

cally, many industrial solutions are made for working in rugged

source, employers can make significant savings and take steps to

environments. The whole system should be able to work under

adjust workers’ hearing protection.

high temperature, high humidity, and even unstable power condi-

Traditional dosimetry devices measure the ambient noise around the

tions. The storage needs to be strong enough to work stably in

worker and then make assumptions or estimates about the sounds that

such environments. Advantech has partnered with Phison and a

impact the wearer’s ear. Quietdose measures the actual noise hitting

first-tier flash IC designer to deliver reliable flash modules with

the wearer’s eardrum. It is essentially a hearing protector that measures

advanced security features.

itself, taking the guesswork out of traditional dosimetry by providing truly

The SQFlash 820 series is available in both SLC and MLC

accurate data that can be used to adjust hearing protection immediately.

versions with extended temperature support and powered by the

The data allows supervisors to respond when an alarm is activated

latest Phison SATA III controller. The series incorporate secure

if the worker is getting close to the safe noise limit. The Quietdose

management functions by default through Advantech’s SQFlash

measures the ‘dose’ of noise a worker is hearing over the course of

Utility so customers can build-in a high level of security with

the day and can be programmed to send an SMS or email alerting the

little extra effort. The series features advanced algorithms such

supervisor if workers are being overexposed to noise.

as fragment writing technology to prolong overall durability, and

Honeywell Safety Products Australia Pty Ltd

GuaranteedFlush technology to avoid unexpected data loss in

Contact info and more items like this at wf.net.au/R692

power outages. Both technologies are specifically designed for industrial applications.

Advantech Australia Pty Ltd Contact info and more items like this at wf.net.au/R583

RELUCTANCE MOTOR PACKAGES ABB has announced a range of synchronous reluctance motor packages. These combined equipment solutions are designed to address reliability, footprint size and energy efficiency and consist of a low-voltage, super-premium synchronous motor matched with the appropriate ABB drive.

Synchronous reluctance motors provide improved efficiency when compared to standard induction motors and have the ability to go to higher power density and have greater reliability, which provides for longer service intervals. It is the fundamental technology that makes it possible to reach these benefits.

ABB’s high-efficiency solutions are based on the concept of magnetic resistance or reluctance, where the rotor is designed to produce the smallest possible reluctance in one direction and the highest reluctance in the perpendicular direction.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/R955

26 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

www.ProcessOnline.com.au

NEW PRODUCTS

REFINERY OPTIMISATION SOFTWARE Invensys Operations Management has introduced refinery-wide optimisation solutions that complement its existing portfolio of SimSci-Esscor hydrocarbon processing industry (HPI) offerings.

The company is now offering a yield accounting solution and an off-sites solution integrated with planning and scheduling systems.

The company’s recent acquisition of Spiral Software also means that Invensys Operations Management’s SimSci-Esscor solutions will now fully support and optimise the entire refining value chain, from crude trading to supply-chain distribution, including life-cycle modeling from design to start-up to performance optimisation. With this acquisition, Invensys is now able to offer a full-span optimisation solution.

ETHERNET GATEWAY

The Invensys Yield Accounting solution is designed to stream-

Turck has announced the BL67 ethernet gateway for Ethernet/IP

line data transfer between off-site software and yield accounting

and Modbus TCP/IP. Designed to provide a reliable communica-

software to ensure that the correct information is being used.

tion solution for on-machine, modular I/O applications, the BL67

It then converts that process data into reliable operating informa-

is suitable for use in environments where conditions may not

tion by using built-in data reconciliation algorithms. Using the

be conducive to traditional I/O. The BL67 satisfies applications

software is said to increase accuracy and reliability for receipt,

requiring digital or analog inputs and outputs, specialty I/O such

shipment and process data; identify gross errors; correct inac-

as SSI and RFID and serial inputs to industrial ethernet networks.

curacies; and reduce or eliminate losses.

Featuring Turck’s multiprotocol technology, the BL67 gateway

The company has also released an off-sites solution that

combines multiple ethernet protocols in a single device, yet only

integrates planning, scheduling and off-sites systems to its

allows one ethernet master to control the outputs while the input

SimSci-Esscor ROMeo optimisation software. This allows refineries

and diagnostic data is available to the other protocols. The BL67

that already have blend operations and optimisation practices

offers isolated power for 16 inputs and 16 outputs, in addition

in place to leverage these two sources of information, ultimately

to 16 I/O configurations for flexible application requirements.

improving efficiency and profitability.

An integrated ethernet switch allows a line topology between

The newly acquired Spiral knowledge-management software

multiple gateways without using an external switch, eliminating

will provide accurate and timely crude oil information across

the need for additional cable runs to the PLC. BL67 models are

an enterprise, from ranking crude oils in trading to optimising

also available in an IP67-rated housing.

refinery processes and maximising reliability.

Turck Australia Pty Ltd

Invensys Process Systems (Australia) Pty Ltd

Contact info and more items like this at wf.net.au/R507

Contact info and more items like this at wf.net.au/R926

“ EFIC dId morE than provIdE FInanCIal support. thEy hElpEd EstablIsh a landmark projECt.”

mark scherrer, md, Ferra Engineering

read our story at efic.gov.au/pt

overcoming financial barriers for exporters

EFIC12-Ferra-PT-201212.indd 1

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16/11/2012 3:29:49 PM

DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

NEW PRODUCTS

ANGLED RJ45 CONNECTORS Harting has released a range of high-speed and spacesaving angled RJ45 industrial ethernet connectors.

The 45째 cable outlet can be mounted in four different directions. This gives users the option to achieve the right

ETHERNET-TOFIBRE CONVERTERS

cable outlet direction with the same item number every time. The connector offers maximum flexibility for a wide

The Moxa PTC -101-M12

range of conductor and cable diameters when paired with

series EN 50121-4 compli-

insulation displacement connection technology.

ant ethernet-to-fibre media

The insulation displacement terminations are fitted for

converters are designed to

flexible and rigid wires with profiles ranging from AWG 27/7

eliminate the need for ad-

to AWG 22/1. Cables with a diameter of between 4.5 and

ditional wiring.

8 mm can be connected. Easy assembly without tools,

They support IEEE 802.3

secure and rapid connection and data transfer rates up

and IEEE 802.3u/x protocols with 10/100 Mbps, full/

to 1/10 Gb ethernet make the connector twice as fast as

half-duplex and MDI/MDI-X auto-sensing.

previous versions. The robust and industry-compliant IP20

The series meets critical EMC, shock, vibration and

version also has a compact design, making it multiport

environmental requirements in compliance with the

capable. In addition to the IP20 versions, all common

EN 50121-4 standard, which makes them suitable for

IP65/67 types from PushPull to Han 3A are available with

high-vibration applications.

the RJ45 insert.

The models are available with SC/ST connectors

Soanar Limited

in fibre and M12 connector in ethernet.

Contact info and more items like this at wf.net.au/S045

Madison Technologies Contact info and more items like this at wf.net.au/R996

LINEAR ACTUATORS Exlar has expanded its K Series line of linear actuators with the K90 models. Designed for flexibility, this compact, 90 mm frame size actuator offers three distinct performance levels and allows the use of third-party motors.

Featuring dimensions and form-factor consistent with ISO metric pneumatic cylinder specifications, K90 actuators can directly replace pneumatic and hydraulic actuators.

Designed to provide a universal solution for linear motion rod-style actuator applications, K90 actuators are available in three models that offer two grades of roller screws and one Acme screw for an actuator solution that satisfies diverse performance and cost requirements.

KX90 actuators incorporate a high-performance planetary roller screw to deliver performance capabilities for demanding applications in industrial automation, mobile equipment, process control and other applications requiring millions of centimetres of travel under load. KM90 actuators employ a lower cost planetary roller screw for applications lacking the same longevity requirements offered in the KX Series, while the KA90 actuators utilise an Acme screw, making them suitable for slow-speed, low-duty cycle applications where the load must occasionally be repositioned during operation.

The K Series actuators allow flexibility in the type and style of motor selected to drive the actuator, including DC motors, stepper and servo motors. Actuators can also be ordered with or without a preconfigured motor mount, allowing the customer to manufacture their own mount. They are also available in a variety of special materials and coating options for applications that require a higher level of corrosion resistance.

Applied Automation Contact info and more items like this at wf.net.au/R929

28 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

www.ProcessOnline.com.au

NEW PRODUCTS

UPDATED HYGIENIC VALVE RANGE Burkert has expanded its line of Element series valves to include new drive sizes.

The modular range combines controllers, valves and sensors in a high-quality stainless steel housing with an intelligent and flexible system architecture. By expanding the valve line to include drive sizes up to 130 mm, globe valves, angle seat and diaphragm valves of the series can now be used to achieve fittings up to orifice diameter DN 50.

The company has increased the maximum available drive size of the seat valve type 2100 (angle seat on/off), 2101 (globe valve on/off), diaphragm valve family 2103 (2-way on/off and control valve) and the control seat valve type 2300 (angle seat) and 2301 (globe) from 90 to 130 mm.

The expanded area of application now makes it possible to equip many systems entirely with fittings from the series. The valves and sensors reliably control fluids, steam, caustic solutions and chemicals, as well as abrasive or high-purity substances in many applications and process environments. The stainless steel valves are very rugged, hygienic and easy to use. The special drive design facilitates integration of automation units at all levels of the modular valve system, from the position transmitter to the electro-pneumatic positioner or process controller. This concept allows complete decentralised automation of even complex systems with minimal expense for cables and hoses.

Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/R846

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DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

NEW PRODUCTS

PROCESS AUTOMATION SYSTEM Emerson Process Management has announced the release of its DeltaV digital process automation system Version 12.

Key features in the Version 12 release include the expansion of Emerson’s electronic marshalling, combining the DeltaV Safety Instrumented System (SIS) with the installation flexibility and space savings of its Electronic Marshalling technology.

This new SIS offering greatly simplifies design, installation, wiring and commissioning of SIS projects, while at the same time increasing capacity and reducing footprint. Based on what Emerson calls “human-centred design” (HCD) principles, the logic solver architecture uses Electronic Marshalling and characterisation module (CHARM) technology to eliminate the need for conventional marshalling, which simplifies both installation and commissioning processes.

The v12 release also includes integrated virtualisation technology, which enables users to consolidate computer resources and reduce

TERMINATION CARRIERS The latest termination carriers from Phoenix Contact are

implementation and maintenance costs. DeltaV Virtual Studio makes

universal solutions for fast, error-free connections between

it easy to create virtual DeltaV systems from pre-built templates and

standard interfaces and a process control system. The

preconfigured virtual networks.

signal connection is made using standardised system

The Emerson Smart Firewall included in v12 is claimed to allow

cables via plug-and-play.

users to easily set up a safe and secure network for the automation

Using standard interfaces that are also used in indi-

system, locking down the control system network against unauthorised

vidual applications simplifies documentation, commis-

downloads and hacking without costly consulting from security experts.

sioning and engineering. The stable, vibration-resistant

For process industry users who produce in batches, the v12 release

aluminium profile features a DIN rail contour that ac-

includes an easy-to-use analytics application that provides real-time

commodates device families ranging from the compact

quality predictions while the batch is in process. Using sophisticated

Mini analog isolation amplifiers, through Macx analog

models, it can trace the causes of manufacturing variations that can

isolation amplifiers for SIL applications and Ex i-power

render a product below specifications or unmarketable. The applica-

circuits, to functionally safe PSR coupling relays for

tion can help users correct manufacturing problems before the batch

process automation.

becomes irreparably compromised.

Its compact design, space-saving connection arrange-

Emerson Process Management

ment and integrated end mounts mean the carrier is up

Contact info and more items like this at wf.net.au/R858

to 30% smaller than previous solutions. The modular supply concept ensures high system availability. The DIN rail devices are connected via support rail connectors with separate supply and error reporting modules. In addition to a redundant supply and monitoring feature, this also offers the advantage that the termination PCB is not just mechanical but also electronically decoupled and has no moving components.

The product range includes universal termination carriers for up to 16 interface modules with 1:1 signal allocation with or without the extraction of HART data.

Other versions can be optimised for controller-specific I/O modules using various system cables and grid-free lengths.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/R990

30 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

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Environmentally sustainable and grid compliant The exponential growth of the world’s population and our growing reliance on electricity has led to a dramatically increasing energy demand worldwide.

According to IEC, International Energy Agency, over the last decade the average energy consumption per person rose by 10% while the world’s population rose by 27%. In order to meet this growing demand, energy supplies need to be adjusted in a way that is safe, reliable, cost-effective and, most importantly, environmentally sustainable. Taking these factors into consideration, it is no wonder that wind energy production has so rapidly gained in popularity.

The global growth of installed wind power has forced transmission system operators to tighten their grid connection rules in order to maintain the security and quality of the power system. Grid codes have been introduced, defining the technical parameters electricity generating plants have to fulfil to ensure proper functioning of the network. As a consequence, some commonly used turbine designs have difficulty achieving grid code compliance.

One such example is Europe’s largest wind park, Whitelee Windfarm, developed by Scottish Power Renewables.

A recent extension project launched there, involving 75 new turbines, will add another 217 MW of capacity to the existing 322 MW. One of the biggest challenges faced by this impressive investment was that strict national grid code requirements made it necessary for the turbines to compensate for the specified reactive power.

Because the wind turbines in general have more inductive than capacitive output capability, the reactive power contribution of the wind farm was not sufficient, thus calling for additional compensation equipment.

In response to this problem, ABB offered a holistic solution based on PCS 6000 Statcom. As a robust and reliable reactive power compensation product, the Statcom was the ideal option. This unique line-up of state-of-the-art technology adds the missing functionality to the wind farm, making it compliant with the national grid code.

As a pure static device with no switched passive elements, PCS 6000 provides outstanding performance for both steady-state and dynamic operation. In addition, the fast dynamic voltage control which operates during balanced as well as unbalanced grid faults (fault ride-through) allows the system to meet the demanding requirements specified by the transmission operator.

ABB supplied three liquid-cooled PCS 6000 units of ±15 MVAr each at 33 kV, installed within shipping containers. The scope of delivery also included transformers as well as an external water/

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air heat exchanger. In addition, ABB was responsible for project management and commissioning.

The main features of the PCS 6000 system is its efficiency (from 97 to 98.5%) and high reliability. Modular construction utilising leading-edge technology makes Statcom’s design highly configurable and versatile, thereby enabling both indoor and outdoor placement.

The solution is particularly competitive in terms of installation time and space requirements. Furthermore, high efficiency and low maintenance (MTTR <30 min) lead to low operational costs. Owing to maximum flexibility, the solution may be applied to a wide range of applications. These include wind farms, utilities with weak grids or fluctuating reactive loads, as well as industrial applications.

The successful commissioning of ABB’s Statcom units took place in September 2012. With the application of ABB’s solution, Whitelee Windfarm is now in the final phase of its ambitious plan. Gaining additional capacity, Whitelee will be able to generate 539 MW of electricity - enough to power the equivalent of over 304,000 homes.

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/S087

DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 31

NEW PRODUCTS

SERVO COUPLINGS Zero-Max ServoClass couplings now feature improved clamp-style hub design for handling larger shafts and higher torque.

The couplings are designed for high-speed reversing loads and precise positioning requirements in demanding servomotor applications at speeds up to 10,000 rpm. The clamp-style hubs provide superior shaft engagement for these high-speed applications.

The increased clamping strength eliminates the need for keyways while providing a clean, balanced design.

LASER SAFETY SCANNERS The S300 Mini safety laser scanner has construction height of only 116 mm, allowing installation with a minimum of space required. It fulfils the technical safety requirements of performance level d in accordance with EN ISO 13849 as well as SIL2 in accordance with IEC 61508, and also the demands on optoelectronic safety equipment in accordance with Type 3 of IEC 61496.

The S300 Mini Standard has an angular range of the 270째 and a protective field of 2 m, within which a triple field set with one protective and two warning zones can be configured. The device features one pair of OSSDs (output signal switching devices) serving as a direct switching output.

The S300 Mini Remote safety laser scanner allows up to 16 triple field sets - which makes it suitable for AGV applications and also for automated forklift trucks or rail-mounted transverse distribution cars. It is possible to combine up to four electrosensitive protective devices, such as two Sick S3000 Experts and two S300 Mini Remotes, into a network. By doing so, complex protective tasks can be implemented.

Sick Pty Ltd Contact info and more items like this at wf.net.au/R430

Available in 12 sizes in single and double-disc models, the couplings handle torque ratings ranging from 0.5 to 250 Nm. Manufactured of RoHS-compliant materials, the couplings with improved clamp style hubs are designed with 304 stainless steel disc members. To ensure precise alignment of the assembled components, ISO 4762 CL 12.9 corrosion-resistant socket head cap screws are used with a carefully controlled assembly process.

The couplings are suitable for precision positioning requirements and the high reverse load characteristics of AC and DC servo motor systems using ball screws.

Applications include automation of all types, packaging, semiconductor assembly, laboratory automation and medical equipment.

Naismith Engineering & Manufacturing Co Pty Ltd Contact info and more items like this at wf.net.au/R995

GALVANOMETER AND CONTROLLER FOR LASER MACHINING Nmark AGV galvanometers and Nmark CLS galvo controllers from Aerotech are claimed to provide increased throughput with industry-leading resolution for laser micromachining applications.

Using advanced interpolation electronics, the Nmark controller provides greater than 24 bits of effective resolution with 2D positioning accuracy of 10 microns or better.

An Infinite Field of View feature seamlessly synchronises servo and scanner motion to allow fast positioning over the entire servo travel, eliminating galvanometer field-of-view constraints.

The position-synchronised output feature of the controller ties laser pulses directly to galvo position, allowing accurate triggering of the laser without delays to compensate for the response time of the scanner mirror motion. This improves part quality and reduces programming complexity.

Applications that can benefit from these capabilities include placing a series of parallel lines that require consistent line to line spacing and accommodating patterns with small radii that must be traversed at high speeds while maintaining tight dimensional tolerances.

The AGV Galvo Scanners are available with 10, 14 and 20 mm apertures and F-Theta lens interface for maximum flexibility. Many choices of mirror surface treatments accommodate a variety of laser wavelengths.

Lastek Pty Ltd Contact info and more items like this at wf.net.au/R986

32 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

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NEW PRODUCTS

PNEUMATIC LINEAR DRIVE Festo has released a variant of its ADN compact drive with PPS pneumatic end-position cushioning.

The design minimises end-position impact while at the same time improving reliability.

The self-adjusting, end-position cushioning reduces vibration and therefore enables high speed and shorter machine cycles. The ADN with PPS reduces costs and errors. The self-adjusting pneumatic cushioning of the ADN-PPS never needs to be adjusted, which means that sources of error such as incorrect adjustment or accidental re-adjustment are no longer an issue. The PPS cushioning efficiently converts energy and effectively brakes loads, and it can adjust to changing load and speed.

Typically users have to manually adjust the integrated pneumatic end-position cushioning in the cylinder - at the expense of cycle times and noise generation. Manual cushioning adjustment is also time-consuming, prolonging the commissioning of systems when there are many drives to be cushioned. PPS self-adjusting cushioning ensures optimum cushioning performance at all times without the need for any manual intervention.

POSITION CONTROL MODULES Omron Electronics has released the CJ1W-NC4

Festo Pty Ltd

series of position control modules for its CJ1 and

Contact info and more items like this at wf.net.au/R703

CJ2 PLC platforms. The CJ1W-NC4 series are fourth generation and can produce output pulses at up to 4 Mbps, for high-speed, high-resolution position

WIRELESS MESH ACCESS POINTS

control.

Advantech has introduced two new industrial wireless mesh access points

Each CJ1W NC4 card can control two or four

- EKI-6340 series outdoor Mesh AP and EKI-6351 series indoor mesh

axes, using either line driver or open collector output.

AP/station. They feature Intelligent Mesh (iMesh) technology with self-forming

The axes can be coordinated, for a linear or circular

and self-healing scalable flexible wireless network deployment.

interpolated output. They are capable of driving not

When one of the wireless mesh APs shuts down and the surrounding communication network fails, the iMesh technology will automatically switch to a

only stepper motors and rotary servos but also linear drives and direct drive motors.

new route to ensure continuous communication. With its multiple-hop function,

The CJ1W-NC4 cards include advanced features

the wireless mesh network maintains a high throughput rate of over 100 Mbps

such as full closed loop control, where absolute and

even after 10 hops for video transmission. Ultrafast roaming, with a handover

incremental encoder signals are fed back directly

switching time of less than 20 ms, provides seamless mobile connectivity.

into the controller card. This allows actual positions

For example, with an EKI-6351 installed in a moving train and an EKI-6340

to be confirmed.

along the rails, mobile connectivity with fast wireless roaming is guaranteed.

Omronâ&#x20AC;&#x2122;s CX-One package incorporates all the set-up

The EKI-6340-1 is a fast roaming access point designed to work along the

functions within the main PLC programming package.

side of the road where fibre optic cables are installed; the EKI-6340-2 is a

It also provides more than 30 PLCOpen-compliant

wireless multihop AP for use alongside rivers, railways, highways and inside

function blocks, for easy programming.

tunnels where running fibre would be difficult or unnecessary; the third is the

Ready-made cables to Omron servo drives simplify

EKI-6340-3 is a combined mesh node and multinode AP which is used in

wiring significantly. They also remove the possibility

complex expansive areas such as university campuses or factories or along

of incorrect wiring. Start-up times have also been

a road where fibre isnâ&#x20AC;&#x2122;t installed.

reduced to 0.1 ms, for quicker operation.

Advantech Australia Pty Ltd

Omron Electronics Pty Ltd

Contact info and more items like this at wf.net.au/R609

Contact info and more items like this at wf.net.au/R605

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DEC 2012/JAN 2013 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

SAFETY CONTROLLER The PNOZ m B0 is an updated base unit for the PNOZmulti configurable control system that can be expanded with I/O modules.

Pilz Australia Industrial Automation LP

>

WF.NET.AU/S408

RH AND TEMPERATURE TRANSMITTERS The DT722 series RH and temperature transmit-

>

ters are designed for use in harsh or corrosive environments.

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/S447

FLAMEPROOF TEMPERATURE TRANSMITTERS Moore Industriesâ&#x20AC;&#x2122; temperature transmitter assemblies are certified ANZEX Ex d IIC

>

AC DRIVES

T6 for use in flameproof (explosion-proof)

The architecture of the ACS880 drives

applications.

range offers advanced safety options,

Moore Industries Pacific Inc

universal connectivity, compact design,

WF.NET.AU/R985

and a drive and PLC engineering tool.

ABB Australia Pty Ltd

>

WF.NET.AU/S034

SUBMERSIBLE PRESSURE TRANSMITTER The LH-20 submersible pressure transmitter

>

for level measurement has a diameter of only 22 mm and an accuracy of up to 0.1%.

WIKA Australia

WF.NET.AU/S405

34 WHAT'S NEW IN PROCESS TECHNOLOGY - DEC 2012/JAN 2013

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List (A) Job Function 1 Management - Corporate/General 2 Management - Manufacturing/ Engineering/Specialist 3 Engineer - Electrical 4 Engineer - Electronics 5 Engineer - Process 6 Engineer - Project 7 Purchasing/Procurement 8 Technician - Maintenance/Service 9 Technician - IT 10 Technical Officer 11 Scientific Officer - R&D 12 Scientific Officer - QA 13 Consultant 14 Contractor/Tradesperson 15 OHS/EHS 16 Education/Training 17 Student-Undergraduate/Apprentice 18 Analyst 19 Sales/Marketing

List (B) Industry 1 Agriculture/Rural 2 Building/Construction 3 Chemicals/Allied Products 4 Communications Systems 5 Defence/Military 6 Education 7 Emergency Services/Law Enforcement/Security 8 Engineering Services 9 Environmental Services 10 Finance/Banking/Insurance/Legal 11 Food Industry - Bakery 12 Food Industry - Beverages 13 Food Industry - Confectionery 14 Food Industry - Dairy 15 Food Industry - Fruit & Vegetables 16 Food Industry - Meat 17 Government - Federal 18 Government - State 19 Government - Local 20 Health/Hospital 21 Instrumentalities (eg CSIRO) 22 IT - Networking 23 IT - Security 24 IT - Storage 25 IT - Wireless 26 Laboratory - Analytical 27 Laboratory - Clinical/Medical 28 Laboratory - Life Sciences 29 Logistics/Transport/Warehouse 30 Manufacturing 31 Mining 32 Oil/Gas/Coal 33 Packaging 34 Processing 35 Retail/Wholesale/Hire 36 Service/Maintenance 37 Telecommunication 38 Testing/Certification (eg NATA) 39 Utilities