What’s New in Process Technology July 2012

0712

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY JULY 2012

CONTENTS

ifm efector, a leading manufacturer of sensors and controls, introduces the TP Series temperature transmitter module.

4

IEC Standard 61131: the benchmark for industrial controllers

The compact TP transmitter turns any Pt100 or

Part 2: Implementing motion control

into a programmable transmitter. Once

8

New products

14

Hot products online

26

Inductive proximity sensors for special applications Not all industrial sensing applications fall into the general

transmitter loop power.

purpose category

The transmitter features a quick-disconnect

38

As I see it

M12 connection that eliminates the wiring

Productivity, quality, risk and safety - the pillars of efficient manufacturing

Pt1000 RTD probe, whether 2-, 3- or 4-wire, connected, the transmitter verifies the type of RTD and automatically makes the correct settings for the application. The modular transmitter can be direct- or remote-mounted in pipes and tanks. A bright LED indicates

errors that can occur with standard terminal chamber head transmitters. An IP69K environmental rating prevents liquid ingress.

The transmitter can be programmed for scaling between -50 and 300째C and is designed for industrial automation and sanitary applications.

The TP3237 is a Micro DC unit with 4-20 mA analog output and a 20-32 VDC operating voltage. Further, set-up is easy - plug-andplay, no wiring needed.

The ifm efector TP Series temperature transmitter module makes the head transmitter a thing of the past. ifm efector pty ltd www.ifm.com

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IEC STANDARD 61131: THE BENCHMARK FOR INDUSTRIAL CONTROLLERS PART 2: IMPLEMENTING MOTION CONTROL Harry Mulder, Engineering Manager, Omron Electronics

4 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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As we saw in Part 1, the IEC 61131 standard has had a profound effect on the industrial controllers market, particularly in the area of programming. In this part, we’ll look at how an additional standard promoted by PLCOpen relating to motion control has dovetailed into IEC 61131-3 and enhanced the overall usefulness of industrial controllers.

M

otion control is the ability to control motion devices such as servos and, to a lesser extent, variable speed drives (VSDs).

These have traditionally been controlled by dedicated controllers, which have limited facilities for interfacing with the rest of the control system that they need to interact with. End users are therefore increasingly demanding that motion control functionality be fully and seamlessly integrated into a single industrial controller, like a PLC, which already controls the rest of the line or machine. Having a single program simplifies both commissioning and maintenance and centralises data for easier collation.

However, as we’ll see, this has presented a number of significant challenges for vendors.

The PLCOpen motion control standard With growing user demands, PLCOpen saw the need to expand the family of industrial standards they promote (see Table 1).

They formed a task force to create Technical Committee 2 (hereafter TC2) to develop a standard for motion control - releasing part 1, ‘Function Blocks for Motion Control’, in 2005.

TC2 now has six parts, each dealing with different aspects of motion control and freely downloadable from the PLCOpen website.

The focus of TC2 is on defining a series of standard function blocks (FBs) to establish commonality for users, regardless of the underlying hardware. The FBs must strictly adhere to the IEC 61131-3 standard defined previously and, when implemented properly, must operate like any other FB, thereby integrating motion control functionality.

Apart from FBs, TC2 also requires a PLC to support a series of multi-level data structures, most notably the _sAXIS_REF and _sGROUP_REF structures, which hold the system parameters for a particular axis or group of axes respectively. As there may be multiple axes within a project, it must be possible to create arrays of such data types. Better implementations also support features such as unions and even enumerated data types to clarify meanings and self documentation.

PLCOpen also created a certification scheme (technical committee TC3) whereby

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vendors, although not needing to comply with all aspects of the standard, gain certification once a prescribed level of compliance has been accomplished. PLCOpen’s motion control logo can be promoted by vendors once they attain certification.

Function blocks beyond the standard TC2 specifies certain FBs that the vendor must provide for compliance. However, in the interests of nurturing development and product differentiation, vendors are allowed to produce FBs additional to the standard.

For example, the FBs MC_MoveRelative and MC_MoveAbsolute are specified in the standard and therefore need to be supported to remain compliant. However, an additional FB like MC_Move, which combines both move modes and stipulates an input parameter to specify which is to be used, can also be provided. This not only increases the choice available to the programmer but also helps overcome one potential downfall of standards generally - that they freeze technology.

Figure 1 shows an FB inserted into a program.

The need for speed Another requirement of motion control systems that becomes immediately apparent is the increase in speed. When multiple servos need to work in a coordinated fashion (ie, as a group, such as when performing interpolating operations), update times of 1 ms or less are required to achieve reasonable accuracy.

PLCs, on the other hand, were never designed for dealing with such speedintensive operations. They had always used a cyclic scan to perform their required tasks.

A scan consisted of several parts: update of I/O, execution of the program, servicing of peripheral devices (eg, communication units) and internal diagnostics. Each cycle ran as fast as it could be executed and was asynchronous to the rest of the operation, most notably the control network. Interrupts were used to handle irregular time-critical operations. Scheduling facilities were also limited. A scan was also heavily program dependent but operated in time frames of around 10-20 ms.

As venders soon discovered, for a P LC t o p ro p e r l y i n t e g ra t e m o t i o n

JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5

Controllers

WHEN DESIGNING AN INTEGRATED LOGIC/MOTION PROGRAM WITH DISTRIBUTED DEVICES ON A NETWORK, THE MOST IMPORTANT CONSIDERATION IS THE NETWORK UPDATE TIME. REALISTIC EXPECTATIONS ARE BETWEEN 500 MS AND 4 MS, WITH 1 MS CONSIDERED AVERAGE.

Figure 1: A motion control Function Block in use - this one is additional to the PLCOpen standard.

Technical committees (TCs)

Promotional committees (PCs)

TC1

The 61131 standard suite

PC1

Promotional activities, including Europe

TC2

Motion control, specifically the FBs used to implement it

PC2

Common training, including certification guidelines

TC3

Certification. Three levels: base, conformity and re-usability

PC3

Promotion in North America

TC4

Communication, particularly OPC UA (Unified Architecture

PC4

Promotion in Japan

TC5

Safety

PC5

Promotion in China

TC6

XML

Table 1: PLCOpen’s activities fall into two categories: overseeing the production of standards through its technical committees and promoting them through its promotional committees. functions and produce reasonable results, not only did the scanning mechanism need to be addressed, but the whole underlying PLC system needed to be completely revised as well. Most notably: • The CPU itself had traditionally been an application-specific integrated circuit (ASIC) to ensure reliability. However, commercially available CPUs such as the Intel Atom and Core series are considerably faster and support multi-core parallel processing.

• The operating system must be well tested but also fast, highly reliable and support true multitasking. It also can’t be subject to viruses and other malware.

• The program needs to be fully compiled rather than semi-compiled or interpreted code. It needs to support multiple IEC languages, which all need to support online editing. This will require significant advances in the development software for the controller.

• The system needs to be capable of synchronisation with the network.

All devices in the control network should be updated concurrently with the PLC program so that the entire system works in synchronicity and produces an outcome that’s both consistent and high speed.

Networking It has been said a control system is only as good as the devices that can be connected to it. After all, the control system itself can be thought of as the ‘brains’ of the overall system; it’s the attached devices that provide the ‘limbs’ that do the actual work. Similarly, vision systems are considered the ‘eyes’ of the system. These devices are nearly always distributed around the plant floor or machine and must therefore be networked.

But, as we’ve seen, networks must be extremely fast for motion devices such as servos to maintain performance, so as to make synchronisation a reality. Motion networks have achieved this in the past by being dedicated networks that limited the number of nodes and restricted services. They also tended to be proprietary, which goes against the modern trend of being ‘open vendor’ so as to allow users to select best-of-breed technology.

EtherCAT (Ethernet for Control Automation Technology) however fulfils the prerequisites for a control network very well. It uses standard ethernet hardware for its high performance and low cost. Nodes link together in a daisychain topology, with each containing two ports for upstream and downstream connections.

6 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

Messages are sent from node to node and frames are modified on the fly at each node.

EtherCAT has a distributed clock working at a predefined synchronisation rate to enable highly precise synchronisation of remote devices. It has jitter of under a microsecond.

The synchronisation rate setting is important; it sets the update rate of the entire network. For effective control, the user program should also synchronise off this rate.

Information/data network However, EtherCAT is only a controller network. Its architecture is not really designed for inter-controller use; or for connection to HMIs or higher-level computers.

For this reason, and so as not to downgrade EtherCAT’s performance, other open-vendor networks like Ethernet/IP are often used in parallel with EtherCAT. Ethernet/IP is a wellestablished, deterministic industrial protocol.

It uses standard ethernet architecture and is administered by the ODVA (Open Device Vendors Association) and is now widely supported by many makers of industrial products.

A new way When designing an integrated logic/motion program with distributed devices on a network, the most important consideration is the

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Controllers

Figure 2: A user program segmented across three periodic tasks, for Omron’s NJ series controllers.

network update time. Realistic expectations are between 500 µS and 4 ms, with 1 ms considered average. Within this time frame, all networked motion devices need to be updated, and at least some user programs (including motion instructions) executed. These demands require a very modern processor, something ASICs have hereto been unable to achieve.

As programs can vary considerably in length and in the types and intensity of instructions they execute, program segmentation and time slicing are essential to ensure regular updates of motion functions. The ability to fragment a program and apply priorities to them is also a requirement of the IEC 61131-3 standard. Once a program is segmented, each segment is assigned to a periodic task, which specifies the order in which segments are executed. Each task also has a task period setting, which regulates the maximum time allowed between executions. It can be difficult to segment a program without knowing how long it takes to execute, but having a simulator built into the development environment will assist with this, as well as with debugging.

One task, called the primary task, always has the highest priority as it contains the motion-control functionality, including the updating of networked axes. Its task period, called the primary period, is set to the network

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update time. The primary task is always run in its entirety every primary period; other tasks are paused when the primary task is scheduled to execute. Data concurrency is supported by assigning exclusive control of variables by selected tasks.

Two final considerations are I/O updates, which can be done in either the primary task or the highest priority periodic task - and the frequency and maximum time allowed for system servicing also needs to be set.

Putting it all together Figure 2 shows a program segmented into three different periodic tasks, each with a different task period. The primary task (4) handles motion updates, some user program and motion control instructions. The first and highest priority periodic task (16) processes the I/O updates and executes more of the user program. In this example, it is able to execute its program at a greater rate than its task period because the user program in the primary task is executed relatively quickly.

A lesser priority periodic task (17) is run at the completion of the higher priority one and system servicing is executed after it. However, scheduled execution of the primary task at the primary task period occurs throughout (because of the motion component), causing

other executing tasks to pause. With this structure, motion updates down to 0.5 ms can be guaranteed.

Conclusion Throughout this two-part article, we’ve seen the enormous contribution standards have made on PLC offerings. In the case of motion control, it has necessitated a complete redesign of the whole PLC system from the ground up. But the resultant advantages that come from having a single, fully integrated controller, such as a single point of data, simplified commissioning and ease of maintenance have made the effort well worthwhile.

Omron Electronics Pty Ltd Contact info and more items like this at wf.net.au/Q273

Reference: http://www.plcopen.org/pages/ tc2_motion_control Lewis, RW, 1996, Programming Industrial Control Systems Using IEC 1131-3, The Institution of Electrical Engineers, London.

JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7

NEW

PLM SOFTWARE

PRODUCTS

Siemens PLM Software has announced the latest release of Teamcenter PLM software. Siemens PLM also recently released Teamcenter Mobility to enable engineers to design and develop while on the move.

INDUSTRIAL COMPUTER CHASSIS

The Teamcenter 9 release adds an integrated systems

Advantech has released its IPC-7132 chassis, which supports both

engineering solution and tightens the integration across

ATX/MicroATX motherboards and 10-slot PICMG 1.3 backplanes.

the unified architecture so companies can make smarter

The chassis is aimed at machine automation applications such

decisions with better visibility into the impact of those

as automated optical inspection (AOI), machine controllers and

decisions. Enhancements across the entire Teamcenter

facility management, as well as factory automation and security

range significantly improve productivity so companies

surveillance.

can get to market faster, while reducing total cost of

The chassis is a cost-effective, wall-mount/desktop chassis

ownership.

designed for industrial environments. Standard 80-plus PS/2 300 W or 400 W power supplies can easily be installed in the chassis for greater power flexibility. The two USB ports on the front panel are designed for easy maintenance and direct data access via thumb drive. The rear I/O ports include four USBs, two DB-9s and one LPT, and are reserved for multifunction communication devices.

Advantech Australia Pty Ltd Contact info and more items like this at wf.net.au/Q283

COMPACT PROCESS CONTROLLER The Endress+Hauser Liquiline CM14 compact controller offers pH, conductivity

Teamcenter 9 Software includes a fully integrated

and dissolved oxygen measurement and control at a lower price. It includes

approach to systems engineering and requirements

high-tech digital Memosens technology.

management, enhanced integration of content manage-

The CM14 is suitable for simple applications requiring measurement of pH,

ment and an extension of Teamcenter’s Service Lifecycle

conductivity or dissolved oxygen. The small 48 x 96 mm housing fits into

Management with a new service scheduling and execu-

standard panels and makes it a useful device for skid builders.

tion module, as well as stylesheets to make it easier to

Though simple and easy to use, the

tailor the user experience.

Liquiline CM14 delivers reliable

Integration is provided with familiar tools like Microsoft’s

and accurate data using

Outlook messaging software, Word, Excel spreadsheet

Endress+Hauser’s digi-

software and Visio software, as well as MathWorks’

tal Memosens technolo-

MATLAB and Simulink environment, supporting a variety

gy to provide troublefree

of methodologies for systems definition and modelling

and low-maintenance

using the tools that engineers are used to using.

operation, and features

Teamcenter now offers a service scheduling and ex-

plug-and-play and reli-

ecution module that integrates the service scheduling

able data transmission

and execution management solutions, enabling com-

immune to moisture or

panies to more effectively control cost by defining and

corrosion. Sensors can be calibrated in the lab to

efficiently scheduling service orders and tasks. It tracks

keep downtime in the process to a minimum.

and captures the execution of service tasks to maintain

The 4-wire technology of the Liquiline CM14 provides reliable measure-

an accurate history of assets and service records.

ment and a Process Check System (PCS) checks the measuring system for

Service personnel can also use the feedback capability

abnormalities. Two adjustable contacts allow an upper and lower limit to be

to provide input to engineers, further helping to increase

set for process control and a second current output displays the temperature.

product performance and reliability.

Endress+Hauser Australia Pty Ltd

Siemens Ltd

Contact info and more items like this at wf.net.au/N910

Contact info and more items like this at wf.net.au/N727

8 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

NETWORK MANAGEMENT SOFTWARE Siemens has developed network management software that continuously monitors and provides visualisation of

SAFETY RELAY Weidmüller’s WRS 24V SIL3 safety relay is designed to be used in areas where a functionally safe switch-off is required.

Created specifically for use in the emergency shutdown of plants and plant components in the process industry, the device meets the requirements of EN61508 as well as the safety demands of Safety Integrity Level 3.

The device’s safety and monitoring circuits each have a yellow LED to indicate the functioning of the relay and ensure faultless

the topology, availability and performance of industrial ethernet networks.

The ‘plug-and-play’ Sinema Server (Simatic Network Manager) software automatically recognises changes in the network and helps to identify and clear malfunctions quickly and easily. In this way, downtime and maintenance costs can be reduced and the availability of the production process can be increased.

operation of the relay. In the output of the safety circuit there is a redundant connection of three relays to guarantee reliable isolation within the output circuit.

The safety relay is fitted with gold-plated contacts and has a switching current range of from 6 mA up to 5 A. In addition, the time span between relay on and response is 4.5 ms at 230 VAC and 5.7 ms at 120 VAC. For added flexibility and user convenience, the SIL 3 safety relay offers a rated operational voltage of 120/230 VAC at the input of the monitoring circuit.

A wide temperature range of -25 up to +50ºC makes it suitable for use in numerous environments including harsh surrounds.

Highly compact, it is 92.4 (l) x 22.5 (w) x 112.4 (h) mm in size and is designed to be DIN rail mounted.

Sinema Server has been specially designed for the continuous monitoring of industrial ethernet and Profinet networks by plant operators and by the maintenance and service personnel.

The use of Sinema Server enables any network problems affecting production, as well as standstills or malfunctions within a plant, to be cleared promptly.

The software supports numerous protocols such as OPC, SNMP, LLDP, DCP and ICMP.

Weidmuller Pty Ltd

Siemens Ltd

Contact info and more items like this at wf.net.au/N733

Contact info and more items like this at wf.net.au/Q188

10 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

SIGNAL CONDITIONING FOR RTD SENSORS National Instruments has announced the NI PXIe-4357 RTD module as an addition to its SC Express sensor measurement family for PXI Express. The high-performance module is optimised for temperature measurements with Pt100 RTD sensors for a variety of thermal monitoring applications.

PLANETARY GEARHEAD The GP 26 A planetary gearhead for DC motors integrates a

The NI PXIe-4357 RTD module integrates sensor-specific sig-

robust, optimised, preloaded ball bearing gearhead geometry, a high permissible motor speed.

nal conditioning with 24-bit,

This gearhead is part of a modular system and is available as

delta-sigma ADCs to sample

one-stage to three-stage versions, with nine different reduction

all 20 channels at 100 Sa/s

ratios, from 5.2:1 up to 236:1. The maximum continuous torque

and offers typical accuracies

of the one-stage version is 0.75 Nm and of the three-stage ver-

of up to 0.09°C. To expand

sion is 4.5 Nm. The short-term torques are 1.1 Nm and 6.2 Nm

a system’s channel count, en-

respectively. Due to the preloaded ball bearings, the tempered,

gineers can integrate additional

rust-free output shaft has no axial play.

NI PXIe-4357 modules or use

The GP 26 A gearhead can be combined with five different DC

other SC Express modules to

motor types, as well as sensor systems (encoders), to build power-

add complementary sensor inputs,

ful drive units. For the control functions, various 1- and 4-quadrant

including thermocouples, strain gages, accelerometers and FBG optical sensors, to the same system.

controllers, as well as positioning controllers, are available.

Applications fields include engineered robotics devices to battery-

National Instruments Australia

operated tools, from medical technology to industrial automation.

Contact info and more items like this at wf.net.au/N989

maxon motor Australia Pty Ltd Contact info and more items like this at wf.net.au/N988

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12 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

INFRARED THERMOMETERS Fluke has released the Fluke 62 Max and 62 Max+ infrared thermometers. These rugged, accurate, easy-to-use test tools

FISCAL METERING SOLUTION

are dust, water and drop resistant, making them suitable for the

Honeywell has announced that its MeterSuite fiscal

harsh conditions faced by technicians in electrical,

metering solution has received European Measuring

service, HVAC, process, industrial and facilities

Instrument Directive (MID) and International Organization

maintenance applications.

of Legal Metrology (OIML) R117 certification. MeterSuite

The thermometers can survive a 3 m drop to a wooden floor, and are IP54 rated to withstand

is available globally and is now a fully MID- and OIMLapproved product.

rain, splashing liquids, dust and dirt. They are

MeterSuite is an advanced, configurable and integrated

small and easy to use - small enough to carry

fiscal flow measurement solution offered by Honeywell

comfortably on a tool belt all day and they

Process Solutions in partnership with Swinton Technology.

measure with a trigger click, diplaying on a

It integrates with Honeywell’s Experion Process Knowledge

multi-angle, backlit display to make them easy

System (PKS) architecture to provide oil and gas flow

to read. Dual, rotating lasers on the 62 Max+

calculation for greater cost efficiency, extended life cycle

accurately identify spot size.

support and improved control. The system also integrates

The 62 Max is designed for quick temperature scans of systems to look for anything from

with all common meter types and supports the ISO, AGA and API standards.

unusual hot spots that signal electrical and

MeterSuite enables oil and gas operations to replace

electro-mechanical malfunctions, to undesir-

their old-generation flow computers with Experion PKS

able air intake/output patterns in the building

and leverage its features and capabilities. This solution

envelope. Because infrared measurement does

helps meet regulatory requirements for fiscal reporting

not require making contact with the surface

of carbon emissions; simplifies integration of raw meter

being measured, technicians can make the

data in accounting and reporting systems; and offers

measurements from a distance, away from

enhanced control features for liquid, loading and proving

moving machinery or live electrical connections.

systems where control and sequencing tasks are critical.

The 62 Max has a distance-to-spot ratio of 10:1 and measures

Users benefit from incorporation of Experion capabili-

temperatures from 30 to 500°C with an accuracy ±1.5% of the

ties, including flexible reporting, web-based access, and

reading. The 62 Max+ has a distance-to-spot ration of 12:1 and

integration with wireless and fieldbus transmitters in the

measures 30 to 650°C with an accuracy ±1.0% of the reading.

metering function.

Both IR thermometers operate on a single AA battery.

MeterSuite is available in all Experion software revisions,

Fluke Australia Pty Ltd

from R201 to the latest R400.2.

Contact info and more items like this at wf.net.au/N607

Honeywell Limited Contact info and more items like this at wf.net.au/Q194

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JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13

HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH REDUNDANT PROFINET CONTROLLER The RFC 460R PN 3TX controller can be used to create a redundant control system for Profinet.

Phoenix Contact Pty Ltd

>

WF.NET.AU/N920

The Drivven C Series engine control modules provide rugged, modular engine-specific I/O for interfacing directly with internal combustion engine subsystems.

>

CONTROL MODULES FOR ENGINE PROTOTYPING

INTRINSICALLY SAFE FIELD DISPLAY

WF.NET.AU/Q334

This intrinsically safe field display provides a cost-

>

National Instruments Australia

effective, easy-to-install solution where a local display is required in hazardous areas.

AMS Instrumentation & Calibration Pty Ltd

WF.NET.AU/Q164

>

VALVE BLOCK ASSEMBLIES

>

DIGITAL CALIBRATION PRESSURE GAUGE

The Inox stainless steel modular

The Series DCGII digital calibration pres-

valve and block package is

sure gauge offers a precise 0.05% full-

designed to help build systems

scale accuracy and large 5-digit display

quickly and easily.

resolution.

B端rkert Fluid Control Systems

Dwyer Instruments (Aust) Pty Ltd

WF.NET.AU/N923

WF.NET.AU/Q160

14 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

NEW White Papers

now available online!

Eliminate impulse piping, heat trace and purge lines on DP level measurements Measuring level with differential pressure is a well understood and reliable method, although accurately measuring differential pressure on tall towers and tanks has always been challenging.

For information on a possible solution to better enable operators to control tank level and pressure, download this paper.

VOLUMETRIC FEEDERS Volumetric feeding involves bulk material being held in a hopper and constantly fed into a process per unit of time.

A gravimetric feed rate may be inferred through a calibration process where a timed sample is taken and weighed, and screw speed adjusted accordingly.

K-Tron offers a range of three volumetric feeders including the highly accurate bulk solids pump (BSP), single screw feeders and twin screw feeders. The company’s weigh feeders are available in a wide range of sizes and configurations to meet specific application requirements.

Alarm rationalisation Alarm rationalisation is a systematic process to evaluate potential or existing alarms, qualify which are legitimate, specify their design and capture rationales which can be used to guide operator response. This paper describes the SILAlarm solution and other tips for setting up and sustaining an effective alarm rationalisation process.

Implementing OEE (overall equipment effectiveness) measures in the packaging hall Overall equipment effectiveness (OEE) is a globally recognised best practice measure to systematically improve your processes for higher efficiencies and better productivity - ultimately leading to lower manufacturing costs and higher profitability. This application paper examines OEE metrics and how to capture them – download now!

End-user experience measurement is critical for your business: managing quality of experience Organisations used to predominately use network uptime measurements to evaluate their performance when delivering business-critical data to end users but are now seeking to reduce the time needed to resolve performance issues and also take actions to prevent these problems before they disrupt business processes. Read more in this paper.

The volumetric screw feeders incorporate exchangeable screw designs to allow handling of a wide range of applications involving pre-feeding, feeding or batching of materials that have a consistent density, particle size and moisture content. Single screw feeders handle free-flowing materials such as pellets and powders, while twin screw feeders handle difficult materials such as pigments, sticky, bridging or flooding powders, fibres and fibreglass.

Bulk solids pump volumetric feeders provide gentle, precise feeding of free-flowing pellets, granules, flakes, powders and friable products.

Brolton Group Contact info and more items like this at wf.net.au/Q333

FIELDBUS DEVICE COUPLERS The Trunkguard Series 200 fieldbus device couplers (TG200) from MooreHawke allow for the fast and easy enabling of fieldbus systems by connecting devices to a main fieldbus trunk in a Foundation fieldbus or Profibus PA network.

The series uses MooreHawke’s Automatic Segment Termination feature to eliminate the common installation error of segment failure from overtermination or under-termination.

It detects if a device coupler is the last fieldbus junction in the segment and either terminates the segment or allows it go to the downstream device coupler.

The series also provides short-circuit protection through the use of a ‘fold-back’ technique to disconnect a shorted instrument from the fieldbus segment to prevent complete segment failure. A logic circuit on each spur detects a short in the instrument, disconnects the spur

For these and more White Paper downloads, visit www.processonline.com.au/white_papers

from the segment and signals a warning to personnel.

Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/N810

16 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

SCADA REMOTE ACCESS SOLUTIONS Two new communication modules have been added to the range of remote access solutions offered by

MANUALLY ENERGISED FAILSAFE VALVE ACTUATORS

Siemens. The TIM 3V-IE DNP3 and TIM 4R-IE DNP3 modules enable PLCs of the Simatic S7-300 and S7-400 series to be controlled and monitored over different communication

The Rotork ManPower range of

networks, such as 3G, 4G mobile and ethernet-based networks.

manually energised spring-return

The second interface enables communication over classic serial networks.

actuators is designed to reduce

The modules support the open DNP3 protocol for communication with

installation time and expense since

the control centre. Extensive diagnostics functions are available to us-

no external electrical, hydraulic

ers, including logging the sent and received message frames. It is also

or pneumatic power supply is

possible to program S7 controllers that are connected to the modules

required. Suitable for a wide

remotely over an IP-based network, which can reduce on-site service visits.

range of ball, butterfly and plug

Siemens Ltd

valves, the scotch-yoke actuators

Contact info and more items like this at wf.net.au/N090

are equipped with a compact, self-contained, manually operated hydraulic power pack. A hydraulic hand pump on the power pack is used to operate the actuator and compress the failsafe spring, holding the valve in the desired open or closed position until a failsafe signal is received, at which point the spring will immediately drive the valve to the safe position.

Failsafe operation of ManPower units can be triggered by electrical signals, high- or low-pressure pilots or fire sensors, enabling the successful fulfilment of many ESD (emergency shutdown) and pressure-related protection duties in the oil, gas, petrochemical and pipeline industries.

Rotork ManPower actuators are available with output torques up to 45,000 Nm, with explosion-proof and watertight certification to international standards. A wide range of options includes local position indication, integral limit switches, speed control, high-speed operation, local electrical controls, manual reset and corrosion-resistant

RYCO hydraulic hose and fittings are designed and manufactured to meet and exceed relevant industry standards. RYCO manufactures hydraulic hose that is dimensionally consistent and matched with RYCO fittings, resulting in increased safety and performance.

A requirement of MDG 41 states that a Hose Assembly (hose with couplings attached) must be fit for purpose and that hose and couplings must be MATCHED. A hose assembly that is made of hose and couplings from different manufacturers is NOT MATCHED unless it has been fully tested and certified. RYCO offers a MATCHED system, with all products clearly branded with a unique RYCO part number and batch code, where practical.

trims. Where space is restricted, Individual part number Batch numbered RYCO branded Matched to hose Series code grooves

the ManPower hydraulic module can be located separately from the valve. Standard units are suitable for a temperature range from -23 to +60ยบC and equipped with built-in temperature compensation.

Rotork Australia

MELBOURNE

+61 3 9680 8000

ADELAIDE

+61 8 8237 0547

SINGLETON

+61 2 6572 3967

SYDNEY

+61 2 9765 2500

NEWCASTLE

+61 2 4014 7000

PORT HEDLAND

+61 8 9140 0000

Contact info and more items like this at wf.net.au/N672

BRISBANE

+61 7 3866 8888

MACKAY

+61 7 4968 2300

GUNNEDAH

+61 2 6742 0089

PERTH

+61 8 9360 3800

KALGOORLIE

+61 8 9093 9800

NEW ZEALAND

+64 9 573 2680

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JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 17

NEW PRODUCTS

ILLUMINATED E-STOP BUTTON The Banner Engineering illuminated emergency stop pushbutton combines status indication and safety in one unit. With bright, highly visible illumination, the E-Stop is suitable for diverse emergency stop safety applications, helping to provide users with enhanced safety and productivity on the manufacturing floor.

Featuring Banner’s EZ-Light logic, the E-Stop pushbuttons provide an illuminated yellow base when the button is armed and the machine is enabled to run or is running. When the button is pushed, the yellow illumination turns to a flashing red indication to alert operators of an emergency stop condition. Users can easily reset only the pushed button or buttons, readying the device efficiently with minimal downtime. The yellow illumination can also turn to a steady red indication when a stop condition exists by applying an external signal via the M12 QD connector. To meet diverse application requirements, the E-Stops are available with two-colour yellow and red lighting, red lighting or a non-illuminated black base.

Offering a robust, IP65-rated design and 30 mm mounting base, the E-Stop pushbuttons allow convenient installation with no assembly, individual wiring or additional enclosure required. For applications requiring a series of E-Stops, multiple buttons can be interfaced and series connected. Flush (surface) mount models are also available.

The E-Stop button has a safe break action to ensure the safety contacts will open if the contact block is separated from the actuator. The push-to-stop, twist-to-release or pull-to-release actuator and direct (positive) opening operation is compliant with ANSI B11.19, ANSI NFPA79, ISO 13850 and IEC/EN 60204-1 Emergency Stop requirements.

Micromax Pty Ltd Contact info and more items like this at wf.net.au/Q091

PROGRAMMABLE AUTOMATION CONTROLLERS The latest Allen-Bradley CompactLogix programmable automation controllers (PACs) are designed to meet the growing need for a higher performance controller in a compact and affordable package. As part of the Rockwell Automation Integrated Architecture system, the controllers use the same programming software, network protocol and information capabilities as all Logix controllers, providing a common development environment for control disciplines.

Cost-saving features of these controllers include support for Integrated Motion on EtherNet/IP; Device Level Ring network topologies; built-in energy storage that removes the need for lithium batteries; re-use of existing 1769 I/O; and kinematics that removes the need for additional robot controllers and software.

In addition, the family features a removable 1 GB secure digital card that improves data integrity and flexible memory options up to 3 MB. The ‘No Stored Energy’ (NSE) version of the family offers additional features for hazardous environments found in industries such as mining and oil and gas. Other capabilities include ‘open socket’ support for Modbus TCP as well as devices such as printers, barcode readers and servers.

The PACs deliver affordable control suited to applications ranging from small, stand-alone equipment to high-performance indexing tables, process skids, case packers and erectors, and packaging.

Rockwell Automation Australia Contact info and more items like this at wf.net.au/N898

18 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

PXI CHASSIS National Instruments has introduced the NI PXIe-1066DC 18-slot chassis, which adds high availability features to the PXI

VALVE ACTUATORS

Express platform to maximise system uptime. These features

Exlar Corporation has announced

improve the system-level MTBF and MTTR of PXI systems

its line of Tritex II DC actuators is now

in many demanding, mission-critical test, measurement and

CSA certified and in compliance with CSA 139

control applications. The chassis adds critical component

(Valve Actuator Standard). The actuators accommodate

redundancy and remote monitoring to the uptime-focused

applications requiring CSA Class I, Division 2 Groups A, B, C

capabilities of existing NI PXI instrumentation.

and D certification - making them suitable for hazardous location operation.

The actuators integrate a servo drive, digital position controller, brushless motor and linear or rotary actuator in one compact, sealed package. Linear actuators employ Exlar’s inverted roller screw mechanism, seamlessly converting rotary motion into linear motion for sliding stem control valve applications.

Rotary actuators are suitable for operating quarter-turn ball and butterfly control valves or shaft-driven dampers and can be mounted directly on the rotary valve, eliminating any linear to rotary conversion hardware.

The actuators overcome performance limitations common in traditional electric actuator technologies for process control applications. The actua-

The chassis features: redundant hot-swappable DC power

tors offer 100% continuous duty with life counts in the hundreds of millions

supplies and fans; a front-accessible power supply and fan

of cycles, response times in milliseconds and accuracy of 0.10 percent of

tray to provide flexibility in position-restrictive applications;

span. Capable of reaching speeds up to 63 cm/s and forces to 4.5 kN, the

and an ethernet port to give engineers remote, in-band

actuators virtually eliminate deadband and prevent stiction in the valve stem

chassis health monitoring capabilities, for advanced system

from causing operation malfunctions, even in continuous duty applications.

management.

Applied Automation

National Instruments Australia

Contact info and more items like this at wf.net.au/N596

Contact info and more items like this at wf.net.au/N990

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JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 19

Chemical plant avoids fugitive emissions with wireless valve monitoring

With 28 branches in 20 US states, the core business of Harcros Chemicals is the distribution of industrial chemicals.

The Harcros Organics Division produces surfactants, emulsifiers, defoamers and myriad specialty products at the plant site in Kansas City, Kansas.

Harcros uses manual valves for sampling, directing, injection and extraction processes at its Kansas City plant. Many of the valves are in hard-to-reach places that are too costly to access with cables. Monitoring was a difficult process requiring operators to travel into hazardous areas, climb up ladders and visually check the valves’ state or position.

Worker safety is a primary concern, not only because of the location of the valves but because of the toxic chemicals the valves contain and control. The facility uses propylene oxide and ethylene oxide for its processing operations, and exposure to either one can irritate a person’s eyes, skin or respiratory tract. Leaks involving toxic chemicals can also result in hefty fines. Plus, the facility must pay cleaning, rework and disposal costs of up to $25,000 per incident.

Sample and drain valves, for example, are opened and purged before and after a batch. Some product may be released, or leaked, during this process, and a new batch begins every eight to 16 hours. Besides the product losses, Harcros managers incur downtime and clean-up with each incident.

The facility needed a better, more flexible and less expensive way to monitor its isolated, manual valves.

For an Emerson Process Management field trial, Harcros added a Fisher 4320 Wireless Position Monitor to a manual valve in its propylene oxide production unit. The device monitors the valve’s position throughout the range of travel, communicates wirelessly via gateway with an existing DeltaV digital automation system and eliminates the need for visual inspections.

“This project was about eliminating mistakes and increasing safety. Wireless valve monitoring with the Fisher 4320 device enabled us to reduce inadvertent emissions and bad batches, as well as avoid the high cost of rework, clean-up and lost material.

Eliminating these costs - which average about

$25,000 per incident, not including fines - is a good thing for our plant,” said Kevin Root, Unit Manager at Harcros.

T h e F i s h e r 4 3 20 W i re l e s s H A RTcommunicating device is an easy-to-install instrument that monitors valve movement throughout the range of travel and provides frequent, wireless updates about the valve’s position. The wireless signals are delivered automatically, reducing the time and risk associated with visual inspections. Harcros installed 22 units on manual valves in the propylene oxide and ethylene oxide areas.

The goal was to improve monitoring for all the reactors and all the critical points in the process.

Adding the 4320 wireless position monitors enabled Harcros personnel to identify valve issues and prevent chemical leaks before they could result in fines, production delays or clean-up costs. The Fisher 4320 wireless monitors easily integrated into the site’s threeyear-old DeltaV digital automation system and Smart Wireless solution, including a Rosemount wireless gateway and AMS SnapOn wireless applications.

The 4320 field-trial units helped HarcrosKC avoid three product release incidents, saving at least $75,000 in clean-up costs. The ability to monitor and control manual valves wirelessly has also enhanced safety, improved the ease and accuracy of audit reporting, and reduced the fines associated with inadvertent emissions.

Lloyd Hale, Director of Manufacturing at Harcros Chemicals, is very happy with the results of the project and sees Harcros using more wireless instruments in the future.

“The 4320 instrument field trial established our confidence about the reliability of wireless technology. We now believe that the more devices you add to a wireless system, the more robust it becomes. Besides applying the Fisher 4320 to more of our manual valves, we would consider Emerson Smart Wireless technology for tank level management, rail-car monitoring, and a host of temperature, pressure and flow applications at the Kansas City site,” he said.

Emerson Process Management Contact info and more items like this at wf.net.au/Q214

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20 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

HARSH ENVIRONMENT PANEL PC The Wolverine III rugged flat panel computer from GE Intelligent Plat-

8-PORT AS-I INTERFACE MODULE

forms is designed specifically to withstand the rigours of deployment in harsh, hazardous applications such as oil and gas exploration and

The IP67-rated FAS8 Advanced I/O Module (AIM) station

drilling where salt, spray, dust, shock, vibration and extremes of tem-

is the latest addition to Turck’s line of AIM stations for

perature provide challenging environments for computers. Used for data

AS-Interface (AS-I) networks. Previously only available in

gathering and the control or operation of sophisticated equipment, it

four-port configurations, the FAS8 provides users with an

represents a complete redesign compared with its predecessor, which

eight-port AIM station model.

delivers significantly higher performance, reliability and maintainability

The FAS8 station includes one digital PNP I/O signal

while weighing substantially less.

per port, with an option of 2 A outputs. The station is

The Wolverine III’s resistive 38 cm antiglare,

designed to meet the latest AS-i v3.0 specification, allow-

scratch-resistant touch screen is

ing increased communication options for analog data and

readable in direct sunlight. Its rug-

detailed diagnostic information.

ged design enables it to operate Featuring PNP short cir-

within a temperature range of -20 to

cuit-protected inputs, the

+60°C as standard and to withstand

FAS8 automatically restricts

extreme shock and vibration. Its low

current to prevent failures in

weight of 10.2 kg makes Wolverine

the event of a sensor mal-

III easier to install and safer and more

function. Users are quickly

convenient to transport.

notified through a fault sig-

The computing platform is a COM

nal indication if there is

Express module and carrier board de-

a short circuit on any I/O

signed by GE for the Wolverine III with

point. This module also

an Intel Core2 Duo 2.26 GHz processor

supports both AS-I standard

with 4 GB of DDR3 memory. Wolverine III also

flat cable and round cable

features a reduced component and subassembly

to accommodate current

count, together with extensive edge connection and a 32 GB solid

connection trends.

state disk drive. Onboard system monitoring allows potential failure

The FAS8 station is fully encapsulated and potted, sealing it against environmental contaminants and eliminating

to be identified, allowing remedial action to be taken while minimally disrupting operations.

the need for a separate enclosure for protection. With its

Designed to be upgradable with future generations of processor, the

durable construction and IP67 rating, the station is suitable

Wolverine III is housed in a NEMA 4 environmentally sealed enclosure

for both indoor and outdoor applications.

with corrosion resistance. An optional heater allows an operational

Turck Australia Pty Ltd

temperature down to -40°C.

Contact info and more items like this at wf.net.au/Q094

Metromatics Pty Ltd Contact info and more items like this at wf.net.au/N610

22 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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NEW PRODUCTS

THERMAL IMAGING CAMERAS

PROCESS VALVE CONTROL HEAD

The FLIR T400-Series was designed for the user looking to com-

The Burkert Type 8681 control

bine ergonomics and performance with a high image quality of

head, integrating pneumatic

320 x 240 pixels. They have a tiltable optical unit which makes

actuation, feedback, diag-

it possible to measure and take images of objects in all angles,

nostics and fieldbus interface,

still in a comfortable working position.

has been engineered to as-

The low-end T420 models provide a 4x digital zoom and

semble with all commercially

a measuring temperature range of -20 to 650ºC (T420bx -20

available hygienic ball valves,

to 350ºC), while the high-end FLIR T440 and T440bx models

butterfly valves, single-seat,

are equipped with the multispectral dynamic imaging (MSX)

double-seat and mix-proof

feature, which produces a more detail-rich image, as well as

valve configurations.

an 8x digital zoom.

Designed for use in hygienic processes in the dairy, food and

MSX produces better texture in a thermal image so that more

beverage, biotechnology or pharmaceutical industries, the 8681

anomalies can be detected. FLIR T440 measures temperatures

head has a smooth and chemically resistant IP65/67 enclosure

between -20 and 1200ºC (T440bx -20 and 650ºC).

that is easily cleaned and suited to use in washdown areas.

Objects of interest, both on the thermal image and the visual image, can be highlighted by sketching directly on the camera

A contactless internal positioning system negates internal wear and there are manual overrides on the pneumatic pilots.

touch screen. An ‘instant report’ of the inspection (with sketches

Its super-bright LED position indication is designed to be visible

or other text comments included) can be created directly in the

from across the plant floor with green, amber and red LEDs indicating

FLIR T440.

valve switching position, or maintenance and fault indication, with status and colour settings customised via DIP switch. This feature has been designed with dairy and food and beverage plants in mind, where process machinery commonly spans a wide distance or stretches high above walkways.

The 8681 control head controls strokes up to 85 mm with three positions, with 200 L/min pneumatic air for each pilot valve, and is certified for explosive environments, with ATEX Cat 3, Zone 2/22. Other features of the 8681 head include automatic configuration ‘teach-in’ software, that auto-commissions the control head, the ability to adjust chamber switching speed individually in both directions of movement, and the inclusion of a non-return valve to prevent faulty switching due

Built-in Wi-Fi allows the connection of smart phones or tablet PCs

to back pressure.

for the wireless transfer of images or remote control of the camera.

Burkert Fluid Control Systems

The Bluetooth-based Meterlink function transfers readings from

Contact info and more items like this at wf.net.au/N866

external measurement instruments to the thermal image.

Every FLIR T400-Series camera comes with FLIR Tools software.

FLIR Tools allow thermal images to be exported directly from the FLIR T400-Series to a PC for basic reporting and analysis.

FLIR Systems Australia Pty Ltd Contact info and more items like this at wf.net.au/N819

FLEXIBLE SEALED KEYBOARD The EKF-108 flexible keyboard from iKey Limited is designed for space-constrained portable use. Manufactured to be more durable than other flexible keyboards, the EKF-108 has a thicker silicone pad to better resist circuit breakage.

The EKF-108 has a completely washable keypad and can be rolled up for storage. It provides 108 keys that include a 17-key numeric keypad and 12 function keys. The EKF-108 is supplied with a 1.8 m USB interface cable and is compatible with the IBM PC standard, and all Windows operating systems. When unrolled, the EKF-108 measures 393.7 x 139.7 x 10.2 mm.

Interworld Electronics & Computer Industries Contact info and more items like this at wf.net.au/Q184

24 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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WE KNOW WE CARE WE CUSTOMISE FOR YOU‌

E LE DRIV CTRIC MO ES T CONT & SOFT S ORS ROL & TA AUTO RTERS MATIO N

TOSHIBA INTERNATIONAL CORPORATION PTY LTD NSW Toshiba International Corporation Pty Ltd 2 Morton Street, Parramatta NSW 2150 Tel: (02) 9768 6600 Fax: (02) 9890 7546

QUEENSLAND Toshiba International Corporation Pty Ltd UNIT 4 / 20 Smallwood Place, Murarrie QLD 4172 Tel: (07) 3902 7888 Fax: (07) 3902 7878

VICTORIA Toshiba International Corporation Pty Ltd 411 Fern Tree Gully Road, Mt Waverley VIC 3149 Tel: (03) 8541 7960 Fax: (03) 8541 7970

NEWCASTLE Toshiba International Corporation Pty Ltd UNIT 1 / 18 Kinta Drive, Beresfield NSW 2322 Tel: (02) 4966 8124 Fax: (02) 4966 8147

MACKAY Toshiba International Corporation Pty Ltd 1st Floor 41 Wood St, Mackay QLD 4740 Tel: (07) 4951 4203 Fax: (07) 4953 4185

WESTERN AUSTRALIA Toshiba International Corporation Pty Ltd 10 Anderson Pl, Perth International Airport WA 6105 Tel: (08) 6272 5600 Fax: (08) 6272 5601

Reliable products from reliable people!

SENSORS & TRANSDUCERS FEATURE

INDUCTIVE PROXIMITY SENSORS FOR SPECIAL APPLICATIONS Users of inductive proximity sensors can select from a vast array of standard types to solve almost any general-purpose sensing application. Unfortunately not all industrial sensing applications fall into the general-purpose category.

M

any applications have unique requirements such as the need to function in extreme hot or cold temperatures; the ability to withstand repeated physical impact with minimal damage; the necessity to be impervious to food industry cleaning agents and high-pressure washdown procedures; and in some applications survive in an aggressive welding environment. What if the available mounting area is confined and even the smallest ‘general purpose’ sensors are still too large? What if the machine being monitored is a vital piece of equipment where unexpected downtime is unacceptable? All of these are legitimate requirements in the industrial environment and specialised inductive proximity sensors exist to meet these unique needs. Each special application will be explored further and the available sensor solutions will be discussed.

26 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

Extended temperature range As specified in IEC 60947-5-2, the standard temperature rating of an inductive proximity sensor is -25 to +70°C. Some applications such as continuous outdoor use or indoor freezers may require sensors to operate below -25°C. Applications close to molten steel or glass operations may require sensors that operate above +70°C. It is common for manufacturers to provide sensors that have extended low and high temperature ranges in the same sensor. Ratings such as -40 to +85°C or -40 to +100°C are typical. These models solve a large number of ‘extended temperature’ requirements but for some applications these combination models cannot meet the temperature levels needed. Other manufacturers concentrate on meeting the true extreme needs of low temperatures (down to -60°C) or extreme high temperatures (up to +250°C). Sensors designed

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Sensors & transducers

© iStockphoto.com/Rainer Plendl

Impact tolerance It is estimated that almost 70% of all inductive proximity sensor failures are caused by direct impact to the sensor face.

Standard sensors are not designed to handle impact; in fact they are non-contact sensing devices. Nevertheless, manufacturers understand the problem is often unavoidable and are continually testing various materials in an effort to create a more robust sensor face.

One of the more popular face materials used today is stainless steel. Because an inductive proximity sensor is designed to detect the presence of metal in front of the sensing coil, it seems counterintuitive that a metal-faced sensor is even possible. However, through careful engineering it is possible to tune an inductive sensor’s internal circuitry to ignore its metal face and respond only to external targets.

Many of these stainless steel-faced sensors feature a housing that is gun drilled from one end of a solid steel bar. Gun drilling results in a single-piece housing where the body and face are one integral unit without any seams or gaps. The housing materials vary, but most are made from 303 or 316 stainless steel. Some sensor models have a stainless steel face almost 0.75 mm thick, providing tremendous physical protection to the vital sensor coil. In repeated impact applications such as manual part loading and unloading, these metal-faced sensors can last up to ten times longer than general-purpose inductive sensors. Metal-faced sensors are available with standard, double and even triple sensing ranges. Some target-selective versions are also available, which are specially tuned to detect ‘ferrous only’ or ‘non-ferrous only’ target materials.

High-pressure washdown

for extreme low temperatures are built with special attention to differences in the coefficient of thermal expansion of the various materials that go into the product. Adjacent materials with incompatible rates of thermal expansion may lead to separation and component breakage.

What about high-temperature models? High temperature-rated sensors can handle temperatures above the maximum ratings of most solid-state components. The vital electronics are housed in a remote-mounted module where they can be protected from direct exposure to extreme temperatures; the basic copper-wound coil is the only component that actually experiences the high ambient heat. The construction of high-temperate sensors typically employs a stainless steel housing and a cable jacket made from Teflon (PTFE) or silicon to resist chemical breakdown at high temperatures.

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Many food and beverage applications require the processing areas to be washed down daily with high-pressure water or cleaning solutions to maintain sanitary standards. As specified in DIN 40050-9, an IP69K rating is defined for high-pressure, high-temperature washdown applications. These enclosures must be dust tight and must also be protected against directed highpressure water (1500 psi) and steam cleaning (up to +80°C).

Many inductive proximity sensors are available with an IP69K rating and are the right models to use for this type of application. An IP69K-rated sensor may cost more than an IP67- or IP68-rated model, but its performance is worth the extra expense. A less-expensive IP67- or IP68-rated model may last for a short while but its repeated replacement costs will squander any savings realised on the initial installation.

IP69K-rated sensors are typically manufactured with stainless steel housings with integral cable or connectors and are available with or without function LEDs. If a connectorised sensor is chosen, a matching IP69K-rated mating cordset should be used to maintain the IP69K environmental rating.

JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 27

Sensors & transducers

IT IS ESTIMATED THAT ALMOST 70% OF ALL INDUCTIVE PROXIMITY SENSOR FAILURES ARE CAUSED BY DIRECT IMPACT TO THE SENSOR FACE. STANDARD SENSORS ARE NOT DESIGNED TO HANDLE IMPACT; IN FACT THEY ARE NON-CONTACT SENSING DEVICES.

Figure 2: Some high-temperature inductive sensors incorporate a polyetheretherketone (PEEK) face material and silicon cable jacket to withstand elevated temperatures.

Figure 1: This SteelFace sensor has a rugged stainless steel face that withstands repeated impacts.

Welding environments The automotive body and frame industry, the whitegoods appliance industry and other metal-forming industries employ many welding operations to produce a final product. These weldments include frame structures, body panels and under-body support components that must be welded to properly form the subassemblies. Automated or manual weld cells create very hostile sensor environments due to high ambient temperatures, weldslag generation, part-loading impact and the presence of strong electromagnetic fields.

Uniquely designed inductive proximity sensors exist specifically to survive in this harsh environment. They have weld field immune (WFI) electronics, incorporate slag-resistant body coatings (such as PTFE) and have high temperature-rated face materials (PTFE or similar material). The faces on these sensors tend to take the brunt of the welding abuse; therefore some manufacturers offer optional ceramic-based face coatings to protect and extend the life of the sensor face. Many WFI sensors on the market also offer multi-metal detection at the same sensing range. These sensors are commonly referred to as Factor 1 or F1 models, since they have no sensing range reduction factor for nonferrous materials like aluminium. Stated another way, the range reduction factor for all metals is equal to the standard sensing distance for steel. Standard inductive proximity sensors typically experience

28 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

a reduction in range of 0.5 or 0.4 when the target material is aluminium or some other nonferrous material. Factor 1 sensors do not have this range reduction and offer a performance advantage to customers who have the need to detect nonferrous metals.

Extremely compact physical size To reduce machinery weight and shipping costs, and to cut costly factory floor space requirements, machine manufacturers strive to keep their equipment designs as compact as possible.

These newer, smaller models are not expected to compromise on performance - in fact they are expected to outperform their larger predecessors. Additional automation is how this added performance is accomplished and sensors play an integral role.

Historically M8, M12, M18 and M30 tubular sensors have been the sensors of choice, but these are starting to be replaced with smaller sensors of 6.5 mm, M5, 4 mm and 3 mm diameter.

This new generation of mini sensors is smaller in diameter, length and weight - all of which are important. To accommodate some of the shorter sensor housing lengths (less than 20 mm long), a separate amplifier module is often placed in line with the sensor cable. This design eliminates many components from the sensor head thus allowing it to be lighter and smaller in size. More recently, ultrashort 6.5 mm diameter and M8 tubular sizes have come on the market incorporating fully integrated

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Sensors & transducers

AUTOMATED OR MANUAL WELD CELLS CREATE VERY HOSTILE SENSOR ENVIRONMENTS DUE TO HIGH AMBIENT TEMPERATURES, WELD SLAG GENERATION, PART LOADING IMPACT, AND THE PRESENCE OF STRONG ELECTROMAGNETIC FIELDS.

Figure 3: This Proxinox IP69K-rated sensor is designed for high-pressure washdown environments.

Figure 4: A ceramic-based coating is used to repel weld slag on this WFI sensor.

Figure 5: Examples of extreme compact sensor designs.

electronics. This new design eliminates the inline amplifier, thus saving overall space and weight. These models are available with integral cables having overall housing lengths of only 6 and 10 mm, and with M8 connectors having body lengths of only 18 mm.

Reliable diagnostics Reliable diagnostics are extremely important for high-throughput machines. These machines depend on the ability to identify process quality issues in real time. Examples of these types of machines can be found in the printing and paper-converting industries.

The sensors on these machines need to be highly reliable and have their proper functioning guaranteed. Some sensor manufacturers are now incorporating internal sensor diagnostics that generate dedicated status outputs for monitoring via the host control system. These diagnostics allow the controller to verify the sensor’s signal integrity and monitor the health of the sensor itself. Rather than experience an unforeseen sensor failure or improper signal output, the status of the sensor can be continu-

ously monitored to recognise the need to replace or readjust the sensor before it fails or fails to operate correctly. This diagnostic capability allows for planned maintenance activities rather than unplanned downtime. This diagnostic functionality is now available with certain inductive, capacitive and photoelectric sensors.

Summary All inductive proximity sensors are not created equal. While the vast majority of inductive proximity sensors work well for general-purpose applications, specialty inductive sensors allow highly reliable sensing performance in applications where generalpurpose types are insufficient. It is important to understand the limitations of a standard inductive proximity sensor and know when to select the unique performing capabilities of a specialpurpose sensor.

Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/Q213

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JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 29

SENSORS & TRANSDUCERS PRODUCTS

PRESSURE SENSORS GE’s trench etched resonant pressure (TERPS) technology is available

ONLINE COLOUR MEASUREMENT SYSTEM

in a range of pressure sensors from GE Energy, Measurement & Control.

The RPS 8000 and the DPS 8000 resonant silicon pressure sensors are claimed to offer accuracy and stability greater by a factor of 10 over existing piezoresistive pressure sensors and to significantly extend the pressure range capability conventionally associated with resonating pressure technology (RPT) sensors. Typical applications range from aerospace to subsea and from process engineering and metrology to industrial instrumentation.

The RPS 8000 and DPS 8000 sensors feature the inherent features of resonant silicon, but with greater pressure range (up to 70 bar), temperature range (-40 to +85°C) and better mechanical packaging.

The TERPS sensors operate in essentially the same way as an RPT sensor. The silicon structure is driven into resonance by the application of an electrostatic field and when pressure is applied to a diaphragm, the silicon

The colorControl ACS 7000 from Micro-Epsilon

resonator is stretched, changing the frequency, much like a guitar string. This

Eltrotec is an online colour measuring system.

change in frequency relates directly to the applied pressure. The RPS 8000

It is suitable for automotive paint inspections and

and the DPS 8000 sensors differ only in their respective outputs. The DPS

interior colour measurements; in the processing

8000 incorporates an integral microprocessor and RS485/RS232 outputs to

of plastics, wood, veneers, textiles; and in printing

provide direct digital output. The RPS 8000 delivers a TTL frequency output

and medical technology.

and an mV temperature measurement from an integral temperature diode.

The system uses spectral imaging, where the

These can be combined in a customer’s digital equipment to provide a pres-

spectrum of reflecting light is compared to the

sure reading. The RPS 8000 is suitable for OEMs and systems developers

white light reference that illuminates the target.

who wish to incorporate high-accuracy, stable pressure measurement.

Colour value resolution exceeds ΔE 0.01 for a

GE Energy

spectral resolution of 5 nm.

Contact info and more items like this at wf.net.au/N717

The colorControl ACS 7000 supports three operating modes. The first mode measures the colour difference ΔE to the reference value.

A maximum of 15 learned reference colours can be

IP69K PHOTOELECTRIC SENSOR

stored. The second mode measures the sample’s reflectivity spectrum. The third mode measures

The Telemecanique OsiSense XUK-S pho-

colours and displays them in the relevant colour

toelectric sensor comes equipped with a

space (XYZ, L*a*b*, L*u*v*). The results are

metal flush level button that is, unlike most

used to calculate CIE-xy colour coordinates for

push-buttons, sealed into the device. This

wavelengths of 390-780 nm.

makes the sensor more compact and more

Observation characteristics such as illumination

suited to installation in strict hygiene zones,

source (A, C, D65, D50, D75, E, F4, F7, F11 or

such as those in the food and beverage,

customised) and 2°/10° standard observers can

pharmaceutical, biomedical technology and

be adjusted. In addition, users can display and

primary packaging industries.

track a trend analysis of ΔE/ΔL*, Δa*, Δb* for

The XUK-S has a resilient, 316L stainless

the individual colours over any period of time.

steel housing rated at IP69K and Ecolab certi-

All modes support measurement speeds of up

fied, well suited to harsh environments, being

to 2 kHz. The system works contact-free for

able to withstand the regular usage of strong

a distance of up to 55 mm with a measuring

disinfectants and high-temperature water rinses

geometry of 30°/0°.

with peaks of up to 100°C.

The system supports online and offline measur-

Detection settings can be directly adjusted through the built-in teach

ing and is operated via a web browser that also

button, which is fully lockable in operating mode to avoid unexpected use.

displays relevant parameters, including a black/

An output status is programmable to NO or NC, and an M12 connector

white balance feature. Process interfaces such

allows for rapid connection. This range of OsiSense XUK-S photoelectric

as Ethernet/EtherCAT, RS422, USB and digital

sensors also includes background suppression, polarised reflex and

I/O are included.

through-beam options, and they can be easily set up for detection through

Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/N669

the use of a visible red light spot.

Schneider Electric (Australia) Pty Ltd Contact info and more items like this at wf.net.au/N908

30 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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Asia Pacific Region

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Motor Controls ...... Starting at $24.00 #1 Value in AC Drives

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9A contactor, non-reversing, 3-pole, 43 mm frame width $24 F502 Thermal overload relay, 53 mm frame width, FLA range 2.2 to 3.0 amps.$39 F587

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*All prices are subject to change, orders will be accepted at the pricing ruling at the time of acceptance of orders and do not include GST.

SENSORS & TRANSDUCERS PRODUCTS

CONVEYOR ROLLER SENSOR TEMPERATURE SWITCH

The Telemecanique XUY fully integrated roller sensor uses a multi-beam

The Sick TBS temperature switch combines temperature

photoelectric sensor across the

measurement, limit temperature detection and in-situ display in

width of the conveyor, and is

a single device. It is available with one analog and up to two

easily installed between the conveyor rollers to detect all objects

digital output signals.

passing over the rollers - no matter their shape, colour or position.

In addition to several installation

Featuring a design that eliminates the time consuming and

lengths of from 25 to 350 mm, the

more costly traditional mounting styles, the XUY can be installed

TBS is also available with four differ-

and moved without the need for tools.

ent screw-in threads. Parts in contact

Encased in a 12 mm diameter aluminium tube, the roller sen-

with the media are entirely made of

sor can be ordered to suit roller conveyor widths from 200 to

stainless steel. The housing can be

900 mm and, depending on the conveyor width, will accom-

twisted in two directions for flexible

modate from one to six sensors across the tube.

integration in differing installation

The roller sensor includes a spring-loaded end and the options

situations, permitting orderly cable routing and optimum alignment

of three types of end-mounting clips: 7/16 hexagonal, 8 mm and

of the display to the operator. The TBS temperature switch has

adhesive types. It has the ability to be installed between the

the same look and feel as the Sick PBS pressure switch, the

conveyor’s rollers, which helps protect the sensor from direct

uniform operation of both devices simplifying commissioning as

mechanical impact. Thirty degree angle adjustment means the

well as parameter adjustment during operation. It is specifically

sensor is easy to set up and align on a target object, and the

designed for monitoring the temperature of operating fluids such

use of special convex lens avoids dust accumulation on the

as hydraulic oil, lubricants or cooling water.

sensor face.

Sick Pty Ltd

Schneider Electric (Australia) Pty Ltd

Contact info and more items like this at wf.net.au/Q215

Contact info and more items like this at wf.net.au/Q280

EtherNet/IP ENABLING HIGH-SPEED SYNCHRONISED MOTION CONTROL ON STANDARD, UNMODIFIED ETHERNET. Coordinate multiple axes for precise motion control and synchronise servo drives with variable frequency drives - all on a standard, unmodified Ethernet network.

EtherNet/IP helps to deliver an open, high performance solution for multi-axis, distributed motion and drive control.

Rockwell Automation and its partner, Cisco, have been driving these developments so that you can take standard, unmodified Ethernet and do extraordinary things.

See something extraordinary at: www.apac.rockwellautomation.com/ethernetip/WNIPTAUM

EIP_wnipt_half-pg_july12.indd 1

32 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

13-Jun-12 2:36:43 PM

www.ProcessOnline.com.au

SENSORS & TRANSDUCERS PRODUCTS

INDUCTIVE SENSORS The Turck Q42 is a long-range factor one inductive proximity sensor using FDA-rated materials for washdown applications that is available in a top-facing model and a front-facing model. The Q42 is designed to deliver optimal performance in applications that require frequent cleaning with chemicals found in food and beverage applications or where the sensor is exposed to wet environments, such as carwashes or outdoor applications. The Q42 features an improved design with a durable stainless steel connector and PA12 thermoplastic housing that delivers resistance to chemicals and caustic cleaning agents, as well as shock from impact.

Additionally, the upgraded housing materials are food safe and meet FDA Regulation 21CFR 177, 1500(9) for the US and FDA/EGVO 1935/2004 for the EU. The Q42 features integrated predamping that gives the designer flexibility to partially recess the sensor into their design.

The existing uprox+ washdown range of sensors from Turck comprises 12, 18 and 30 mm diameter barrels with sensing ranges between 4 and 30 mm.

The Q42 offers a sensing range of 50 mm to all types of metals.

This not only eliminates the need to change the position of the sensors for different metal applications, but also reduces the number of sensor types needed for plant operations. In addition to an extended sensing distance, the Q42 delivers reliable operation in temperatures ranging from -40 to 100째C. Turck Australia Pty Ltd Contact info and more items like this at wf.net.au/N906

www.ProcessOnline.com.au

JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33

NEW PRODUCTS

RING LUG BOLT TERMINAL BLOCKS The RBO Series open-style, ring lug bolt terminal blocks, from Phoenix Contact, are suitable for switchgear systems in telecommunications, HVAC and infrastructure. Conductors are connected using ring and fork-style cable lugs. Depending on the application, the terminal blocks come with rated cross-sections of 10 mm2 and 35 mm2. The rated voltage is 800 V, according to IEC, and 600 V, according to UL. A maximum current of 57 A is permissible with 10 mm2; a maximum current of 125 A is permissible with 35 mm2. There are single and multipole flange terminal blocks for direct mounting in control boxes, which can be connected together using engagement pins. Preassembled blocks are available for easy wiring.

A bridging channel distributes potential. The RBO measuring transducer disconnect terminal blocks, for direct and standard rail mounting, are approved for a rated voltage of 800 V, according to IEC and 600 V, according to UL. The separating plate is anchored using a screw and standard screw bridges distribute potential via the bridging channel. Isolator bridge bars are also available for switchable cross connections.

For applications requiring larger cross-sections, the high-current connector from the RBO series, with a rated cross-section of 70 mm2, is available. This terminal block, with a M8 bolt thread, is approved for a rated voltage of 1000 V and a maximum current of 192 A. A protective cover, which has inspection holes in it to enable checks to be made, can be, optionally, snapped on to provide contact protection.

Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/N813

How do you

select the right sensor

for applications with multiple types of metals? askTURCK.com.au

Š2012 TURCK

UNIVERSAL DRIVE SYNCHRONISER The Motrona BY340/BY641 variable speed drive synchronising units are suitable to operate as electronic synchronous controllers with speed-variable drives of any kind and any size, provided they dispose of an analog input to set the speed. The operation is based on a master/slave principle. The master could basically be any moving part of a machine, provided there is a quadrature incremental encoder signal available from the master motion. The slave would typically be a speed-variable drive like an inverter drive or servo drive or DC drive, but could also be a hydraulic system with a servo valve or similar. In any case, a quadrature feedback signal is also necessary from the slave. Features include: precision angular synchronisation and speed ratio control; high accuracy due to high feedback frequency range (300 kHz with TTL encoders and 200 kHz with HTL encoders); full remote phase control by index pulse operation, trim functions etc; four programmable alert outputs, over speed, under speed etc; compact unit including operator panel for direct access and RS232 interface for remote access; PROFIBUS DP interface available (option).

Plant Control & Automation Contact info and more items like this at wf.net.au/Q181

34 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

www.ProcessOnline.com.au

NEW PRODUCTS

ELECTRICAL POWER SYSTEM DESIGN SOFTWARE National Instruments has announced the LabVIEW Electrical Power Suite, a toolkit specific to the power industry. With this toolkit, engineers can combine an NI CompactRIO system for power measurement with over 50 signal and sensor modules.

Engineers and scientists can now develop a custom threephase power monitoring, metering or quality-analysis application, combining standard IEC, EN and IEEE algorithms, using LabVIEW. LabVIEW Electrical Power Suite features industry-standard power analysis for graphical system design so users can create systems that combine power measurements with other sensors and signals. Full, streaming access to raw, time-based waveform data allows the implementation of site- and service-specific diagnostic algorithms.

Ready-to-run example programs integrate power-analysis functions such as energy, frequency, voltage unbalance and event detection into a full test or monitoring system.

National Instruments Australia Contact info and more items like this at wf.net.au/Q218

VALVE CATALOGUE Noshok has announced an expanded valve product offering and enhanced valve manufacturing capabilities.

The Noshok valve range features standard bore and large bore needle and manifold valves, including block and bleed valves in hard or soft seat/tip designs with ratings up to 10,000 psi. New valve and valve options are also being introduced - such as 3-valve double block and bleed needle valves and meter manifolds. Due to increased and streamlined manufacturing capabilities, Noshok has reduced delivery times and enhanced inventory levels.

Noshok performs helium leak testing on every valve to 1 x 10-4 mL/s before it leaves the factory and offer zinc-nickel plating as standard on carbon steel valves.

The latest Noshok Valve Product Solutions catalogue is available for order showing upgraded valve offerings.

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/Q170

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JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 35

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

Process Technology Regional Roadshow

2012 8

NOW IN ITS TH

YEAR

vend NEW or sess training ions

Western Australia

Coming soon ... to a city near you!

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Regional Roadshows are designed for you.

Don’t miss out ...

NEW TRAINING SESSIONS FOR 2012 • Tune a PID flow loop • Troubleshoot a simple TCP/IP industrial ethernet network using four simple utilities • Write, install and test a motor control PLC ladder logic program • Basics of Modbus data communications protocol installation and troubleshooting • Arc flash protection and protective safety equipment • Variable speed drives— testing and troubleshooting

Perth • 10 Sept Bunbury • 11 Sept Rockingham • 12 Sept Karratha • 14 Sept

Supported by:

Training by:

Exhibiting companies include:

Includes FREE: • Access to exhibition • Training sessions - NEW • Lunch and networking drinks • Product demonstrations • Prize draws

To register or for more info visit: www.regionalroadshows.com.au

NEW

EMBEDDED CONTROLLER

PRODUCTS

National Instruments has announced the NI PXIe-8115 high-performance embedded controller featuring a 2.5 GHz dual-core Intel Core i5 processor, which helps reduce test times and supports multicore applications.

The NI PXIe-8115 controller features six USB 2.0

PORTABLE PM DATA COLLECTOR

ports, minimising the need for external peripheral

The Allen-Bradley Dynamix 2500 is a real-time, multichannel,

adapters to help engineers build cost-effective hybrid

Fast-Fourier Transformer (FFT) signal analyser and data

systems. To improve the serviceability and minimise

collector used for predictive maintenance and machinery

downtime, the NI PXIe-8115 embedded controller

vibration diagnostics. The unit measures, processes,

features In-ROM and hard drive diagnostics to

displays and stores a range of analysis functions.

determine the controller’s health. By combining the

The data collector includes a high-performance comput-

controller with NI LabVIEW system design software,

ing platform running Windows CE 6.0 and a sunlight-

engineers can gain efficiency in a variety of test,

visible colour LCD. It is suitable for harsh environments,

measurement and control applications.

with a MIL 810 spec drop rating, IP65 sealing and

The Intel Core i5-2510E processor uses Intel Turbo

an operating temperature range from -10 to 50°C.

Boost Technology to automatically increase the clock

The combination of the Dynamix 2500 data col-

frequency based on the application type. For example,

lector with Emonitor software provides users with

when running applications that generate only a single

tools for predictive maintenance using noise and

processing thread, the CPU places the one unused

vibration analysis. The data collector can also be used

core into an idle state and increases the active core’s

in other applications such as balancing or bearing analysis.

clock frequency from 2.5 GHz to 3.1 GHz. This feature

Rockwell Automation Australia

removes the need for software applications to be

Contact info and more items like this at wf.net.au/N993

multithreaded to use the latest CPU developments.

LIGHTED OPERATOR The Banner Engineering EZ-Light K50 Touch is a rugged, cost-effective lighted operator designed for easy and efficient pick-to-light and lean manufacturing processes. The device provides simple performance, allowing users to easily change the light from green to red with the touch of a finger, hand or whole palm for bright, clear indication. Featuring an ergonomic design, the lighted operator requires no physical pressure to operate, preventing stress on hands and wrists from constantly pressing buttons to verify correct picks during pick-and-place operations.

The feedback with the device is clear-cut and shows workers exactly where they need In addition, the controller has two display ports to

to touch in order to function properly, which

connect to multiple monitors, dual gigabit ethernet

allows for streamlined operations. Providing

ports and GPIB, as well as serial and parallel ports.

flexible operating capabilities to solve a wide

For memory-intensive applications, the controller

variety of applications, operators are available

comes standard with 2 GB 1333 MHz DDR3 memory

in 1-, 2- and 3-colour models.

with up to 8 GB of maximum memory and support

With a laser-marked surface and a housing rated to IP69K, the operator

for the Windows 7 64-bit operating system. The NI

is durable and can withstand harsh conditions and moisture for challenging

PXIe-8115 controller combined with the NI PXIe-1082

environments. The self-contained device eliminates the need for an external

chassis is suitable for intensive analysis, signal and

controller, and solid-state technology allows for a very long service life compared

image processing and high-speed data acquisition.

to traditional mechanical solutions.

National Instruments Australia

Micromax Pty Ltd

Contact info and more items like this at wf.net.au/N711

Contact info and more items like this at wf.net.au/Q282

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JULY 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 37

AS I SEE IT A.B.N. 22 152 305 336 Head Office

PRODUCTIVITY, QUALITY, RISK AND SAFETY - THE PILLARS OF EFFICIENT MANUFACTURING

I

n today’s complex industrial landscape, maximising productivity is paramount for companies to remain competitive. Implementing an effective safety solution is an important step towards improving productivity in the industrial environment. Australian companies face many challenges in their effort to improve competitiveness, including rising energy prices and increasing environmental regulations.

The philosophy of machine safety has evolved from what used to be an ‘add-on’ approach, where safety features were retrofitted to machinery, to where safety is now increasingly considered part of the overall machine design. Experience has shown the best way to implement safety is to incorporate it from the outset of machine design, enabling it to become part of the whole integrated system.

Safety standards are continually evolving, allowing the introduction of new technology.

Newer standards have become more performance based - the required outcome is dictated - but the method is more open-ended. While incorporating an effective safety solution is a legislated requirement for companies, there are many other important reasons for maintaining a safe working environment including moral and ethical obligations, brand image, public perception, WorkCover premiums, workplace morale, quality and productivity.

While Australia continues to follow the AS4024 standard for machine safety, new standards have been introduced and adopted internationally, such as the new ISO EN 13849 standard in Europe. It’s important for local companies to understand changes in global standards. When importing equipment from overseas machine suppliers, they will want to ensure the equipment supplied meets Australian requirements. Conversely, if exporting equipment into the European Community, their customers will most likely request compliance with this ISO EN standard.

In applying AS4024, a risk assessment provides information about the level of risk by considering the severity of possible injuries, frequency and duration of exposure to potential hazards, and the probability of

Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 www.westwick-farrow.com.au ph: +61 3 9381 2952 Editor Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

avoidance. The risk level of a particular hazard/task combination will then determine, among other things, the safety control system requirements. The new ISO standards acknowledge that machine safety is also impacted by other factors including diagnostic coverage, common-cause failure measures and mean time to dangerous failure - which is related to the quality of components used in the safety parts of the control system. To address this, many manufacturers now provide functional safety data for components commonly used as part of a safety system. This data can be used to help determine Performance Level under ISO EN 13849.

Advances in networking technology provide a new dimension to the integration of industrial safety solutions. Networks are the foundation of integrated safety, providing a backbone for safety control and large amounts of diagnostic and status information to be relayed back to the control system. In the past, networks were only used in complex applications with larger machines and control systems, but as technology has developed we can see it being applied economically to less complex safety systems.

As safety and standard components continue to become more seamlessly integrated into control system designs, implementing safety will no longer be a separate discipline, but rather a concurrent and more natural part of the design process - keeping workers and machines safer while increasing productivity and quality and reducing risk.

Gary Milburn, Product Manager Safety & Sensing Components, Rockwell Automation, has worked in the area of machine safety for over 25 years and is actively involved in promoting Rockwell Automation’s range of safety capabilities. He has been involved in the very early days of machine safety standards being contemplated and developed for Australia.

38 WHAT'S NEW IN PROCESS TECHNOLOGY - JULY 2012

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