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MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 1


0312

ON THE COVER

WHAT'S NEW IN PROCESS TECHNOLOGY MARCH 2012

The Beamex MC6 Advanced Field Calibrator and Communicator is a solution to new

CONTENTS

process industry requirements. The MC6 is an advanced, high-accuracy field calibrator and communicator. It offers calibration capabilities for pressure, temperature and various electrical signals. The MC6 also contains a full fieldbus communicator for HART, FOUNDA-

4 Redundancy in industrial networks Part 1

8

New products

16

Hot products online

20

Changing, machining, compensating

Current trends in robot accessories

34 As I see it Energy saving has benefits beyond compliance

TION Fieldbus and Profibus PA instruments. The ease of use is what really makes the MC6 unique. It has a large 5.7″ colour touch screen with a multilingual user interface. The robust IP65-rated dustproof and waterproof casing, ergonomic design and light weight make it a suitable measurement device for field use in various industries, such as the pharmaceutical, energy, oil and gas, food and beverage, service as well as the petrochemical and chemical industries. The MC6 is one device with five different operational modes, which means that it is fast and easy to use, and you don’t have to carry equipment in the field. The operational modes include meter, calibrator, documenting calibrator, data logger and fieldbus communicator. In addition, the MC6 communicates with Beamex CMX calibration software, enabling fully automated and paperless calibration and documentation. The MC6 is more than a calibrator. Beamex is also introducing a new version of the CMX calibration software that, together with the MC6, offers new and improved possibilities for paperless calibration management. The MC6 takes a unique and unoccupied position on the market, as it is a calibrator and communicator that combines advanced functionality and accuracy with usability. This is groundbreaking because, typically, products with many functions are not very easy to use.

NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag.

http://www.processonline.com.au/latest_issues

AMS Instrumentation & Calibration Pty Ltd www.ams-ic.com.au


© iStockphoto.com/Fernando Alonso Herrero

4 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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REDUNDANCY IN INDUSTRIAL NETWORKS PART 1

Glenn Johnson, Editor

The costs of failure in today’s industrial networks can be very high, making network redundancy essential.

T

he failure of individual components in factory automation, processing and substation applications are inevitable and can never be totally avoided - so they have to be handled in a way that minimises impact on the system. While high availability can be achieved by using completely redundant systems, such as duplicated sensors, actuators, controllers and networks, it is usually far too expensive a proposition to implement. Some parts of the system can provide resilience, however, and one such element is the networking component. While many technologies used in plants are designed to be robust, networking components are wholly electronic and rely on cables and wireless links, all of which can be more easily damaged or interrupted in some way, so the capability to design a ‘self-healing’ network is important. With the increasing use of ethernet as a communication technology in plants and factories, it is possible to take advantage of ethernet redundancy technologies to provide a fault-tolerant network. Most ethernet switches and routers today support various types of redundancy mechanisms that only require some additional cabling and software configuration to implement, and which provide a standby and failover mechanism to secondary network paths. Network redundancy can be achieved at both the data link layer (Layer 2) and the network layer (Layer 3), with Layer 2 re-

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dundancy being provided by switches within a TCP/IP subnet, and Layer 3 redundancy generally being provided by routers, routing traffic via different TCP/IP subnets. Naturally, routing means higher overhead and lower performance, so in this article we will focus only on standardised Layer 2 redundancy techniques. This is not to say that Layer 3 redundancy is not useful in industrial networks in appropriate situations, but this article will focus mainly on redundancy within a single network in which high performance recovery is a must. But there are choices to be made - differing redundancy protocols and designs will provide different levels of protection and performance. So it is necessary to understand the differences to determine what is sufficient for the particular application. For example, can the process tolerate a delay of a few seconds while the network redundancy ‘heals’ a fault, or is millisecond response required? Some ethernet hardware may support different redundancy technologies, so choosing the right technology to support your needs is important - as is the architecture of the network as a whole if you want to successfully implement a fast failover capability.

Ethernet does not tolerate loops It is a basic requirement of a functioning ethernet network that there are not any loops. Loops result in data frames circulating endlessly, flooding the network. So all

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5


Industrial ethernet

Figure 1: Link aggregation allows links between switches to be bundled to increase bandwidth. Redundancy is improved if the links have different physical paths.

Figure 3: In MRP, switches react to received reconfiguration frames from the Media Redundancy Manager (MRM). Subrings are also supported through Subring Managers (SRMs).

(left) Figure 2: Spanning tree protocols (STP and RSTP) create a tree of connections between switches, disabling connections that would form loops.

ethernet networks need to be implemented to make sure there is only a single path between any two devices. For redundancy, however, there must be an alternative path available, in case the primary path becomes unavailable. For this to work, it must be possible to have multiple physical paths between devices, but to make sure that only one path is active at any one time. The main way this has been achieved is through monitoring the communication paths, detecting failures and switching to the backup path if the main communication path fails. There are several protocols that can achieve this functionality, but they vary in their performance. All changeover mechanisms of this type depend on detecting the fault, then reconfiguring the network to a new topology (alternate paths) to re-establish communication - and these steps all take time. The protocols available on the market can differ greatly in their failover speed, which is in turn also affected by the size and design of the network.

Link aggregation A simple form of redundancy is link aggregation, or link redundancy (Figure 1). Link Aggregation Control Protocol (IEEE 802.1ad) provides the ability to bundle groups of switch ports between switches to form one link with the aggregated bandwidth of the individual links. In the event that a single connection fails, the remaining links keep working with reduced bandwidth. To best take advantage

of link redundancy, it is most effective if the physical links (cables) are routed via different paths, to minimise the risk of multiple link failures.

Spanning trees One of the first protocols developed to implement redundancy was the Spanning Tree Protocol (STP) that was developed in the early 1990s. Designed for failover in IT networks, the failover time for this protocol can be as long as 10 seconds, but can handle different network topologies, including mesh networks. Apart from the slow failover time, it also has a limitation in the number of switches between endpoints in the network, due to the time required to converge on a new configuration. Although larger networks can be built, depending on the topology, the original RFC for STP recommended that the number of hops (the number of bridges or switches between any two devices) should be no more than seven. Spanning tree protocols work by creating a tree of connections between switches and by disabling all the connections that are not part of the tree (and that would form loops), as shown in Figure 2. Special frames called Bridge Protocol Data Units (BPDUs) are used to communicate between switches and to set up optimal paths in the network, with one switch defined as the ‘root bridge’ for the tree (by default the switch with the lowest MAC address, but can be manually defined). When the topology changes, Topology Change

6 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

Notification BPDUs are used to announce the change, resulting in a recalculation of the spanning tree, and the activation of backup paths to re-establish the network. STP has generally been replaced by the Rapid Spanning Tree Protocol (RSTP), an improved version of STP that was defined by the IEEE 802.1 working group in 1998. RSTP networks support a larger number of switches (20 in a path) and the typical failover time is around one second. Regardless of the failover time, however, neither STP nor RSTP can provide deterministic failover. The failover time will vary depending on the particular implemented topology and the location of the individual failure. Restricting RSTP to simple ring networks and with careful configuration, it has been shown to be possible to keep failover times down to around 100 ms, however. The main benefit of a spanning tree protocol is that depending on the design, it is possible to design a network that is resilient to more than one simultaneous link failure. For example, the loop configuration in Figure 2 can recover completely from only one failure (a weakness of loop topologies). If a second link were to fail (both links 3 and 5), then a switch or even a whole section of the loop would be isolated. In the alternative configuration of Figure 2 (a partial mesh), there are multiple backup links, and this allows, for example, two links to fail (such as links 4 and 6), and the network should reconfigure to allow the network to keep working (assuming in the example that the two failures disconnected

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Industrial ethernet

Company

Technology

Claimed recovery time

Network size

Topology

URL

Advantech

X-Ring

<10 ms

30

Ring

www.advantech.com

Hirschmann

HiPER Ring

<500 ms

200

Ring

www.belden.com

Fast HiPER Ring

<60 ms

200

Ring

Moxa

Turbo Ring

<20 ms

250

Ring

www.moxa.com

N-Tron

N-Ring

~30 ms

250

Ring

www.n-tron.com

ORing

O-RSTP

~20 ms

40

Any

www.oring-networking.com

O-Ring

<10 ms

250

Ring

Open-Ring

Variable

250

Ring

Rockwell Automation

Cisco REP

20-250 ms

Unknown*

Line/Ring

www.rockwellautomation.com

Weidmüller

Turbo Ring

<20 ms

Unknown*

Ring

www.weidmuller.com.au

Westermo

Cisco REP

<20 ms

200

Ring

www.westermo.com

Table 1: Examples of proprietary ethernet redundancy offerings. (*Some data unavailable to the author at the time of writing.)

both ports of a single switch, which would effectively isolate the switch - such as links 4 and 7). The disadvantage of spanning tree protocols is that while, with careful design, the recovery time can potentially be low, it is also not predictable. The recovery time will depend on the topology, the location of the failure and the number of failures that occur - and the larger the number of switches, the more the recovery time increases.

Media Redundancy Protocol STP and RSTP are enterprise network protocols supported in all managed ethernet switches. A protocol commonly found in industrial ethernet switches that is designed more for industrial applications is Media Redundancy Protocol (MRP). It is defined in IEC 62439 as an industry standard for highavailability networks and is a standardised version of the HIPER-Ring protocol first released by Hirschmann and Siemens in 1999. It is exclusively for ring networks, but can guarantee deterministic ring failover. The reason that MRP can have a predetermined recovery time is that it is not a protocol in which all the switches need to reconfigure their forwarding ports hop-by-hop and ‘converge’ to a new topology, as in Spanning Tree protocols. Instead, one of the switches is configured in the role of Media Redundancy Manager (MRM), which sends frames out of one of its ring ports and receives them on its other ring port, in both directions, while

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maintaining one port closed to normal data. All other switches act as Media Redundancy Clients (MRCs), and can act on configuration frames received from the MRM, as well as detect and signal link changes on their ring ports (Figure 3). With MRP, the failover time is nearly independent of the number of switches in the ring, because MRP control frames are forwarded as multicast frames through the ring, and so can be processed nearly simultaneously in all switches, resulting in a maximum reconfiguration time of around 200 ms and a typical time of less than 80 ms. As stated above, however, ring topologies have the weakness that they cannot tolerate more than one failure. MRP (along with many proprietary ring technologies) also has the ability to support subrings. Depending on the support that is included by your hardware vendor, some switches can be configured as Subring Managers (SRMs), allowing them to take part in two rings. For example, two of the MRC switches in Figure 3 could be configured as SRM switches and connect a subring of additional switches off another of their ports. The two switches then take part in two rings - the original ring being known as the basis ring. The subring will need to have at least one other switch, since there needs to be a switch taking the role of MRM for the subring. It should be pointed out, however, that the subrings need to be configured on different

VLANs, so further configuration is required to share traffic between the rings.

Proprietary solutions Many industrial ethernet switch manufacturers offer their own proprietary redundancy protocols (see Table 1). If you don’t mind being ‘locked in’ to a particular vendor for your network, or at least a part of it, then you may be able to take advantage of redundancy protocols that perform better than RSTP or MRP and offer additional features to enhance the redundancy further. However, if you need interoperability between vendors you will have to either settle for a standardised protocol or design a hybrid architecture in which sections of the network use proprietary redundancy, while others are linked using standard protocols.

In Part 2 The approaches to network redundancy discussed so far have focused on standard network topologies in which there is a single path between any two points. Redundancy depends on the paths being reconfigured in the event of failure and, depending on the protocol used, there may be a trade-off between speed of recovery and the number of concurrent failures that can be recovered. In Part 2 of this article we will discuss fully redundant network architecture approaches in which total redundancy is achieved using independent paths between any two devices - PRP and HSR.

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7


NEW PRODUCTS

FLASHING AND ROTATING BEACONS Banner Engineeringâ&#x20AC;&#x2122;s EZ-Light K50 Beacon is now available in rotating and strobing models that radiate a bright, attention-getting signal with intense LEDs providing a suitable lighting solution for areas with high ambient light, including outdoor environments. The K50â&#x20AC;&#x2122;s intense light is viewable from all directions, and offers three functions for each model - solid ON, single and double strobe for strobing versions and solid ON and two rotating speeds for rotating lights. The K50 strobing model also emits light from the top. Featuring a microprocessor-based design, the K50 offers custom configurations on the strobe rates and rotation speeds, allowing customers to meet application-specific needs. Similar to the original K50 model, the strobing and rotating versions are intended for indoor and outdoor general status indication and are designed for use in areas with high levels of ambient light where a standard indicator light may go unnoticed. With a rugged, sealed IP67and IP69K-rated thermoplastic housing, all models of the K50 are suitable for both dirty and washdown environments. The K50 lights are available in 12-30 VDC operation, as well as cabled or quick disconnect models.

PROFIBUS COMMUNICATION TERMINAL The IB IL PB-MA-PAC inline I/O communication terminal enables the integration of Profibus devices into the Phoenix Contact automation solution. The terminal can be integrated into the I/O system either as a Profibus DPV0 master or slave. With a maximum data width of 64 bytes in/out, its primary use is to connect existing Profibus devices into an automation solution from Phoenix Contact. This is especially true for medium-sized applications built using the Easy Automation system based on compact controllers. Users can connect up to 16 DP slaves at a maximum baud rate of 12 Mbps. A memory stick is integrated into the front side of the terminal for storing the DP master configuration data. If service is required, the terminal can be directly replaced without having to reconfigure it. Profibus parameters such as the transmission speed can be set directly in the PC Worx automation software using a configuration tool. The Profibus terminal expands the Easy Automation system for class 100 compact controllers to provide an additional option for communicating with external fieldbus devices. Phoenix Contact Pty Ltd Contact info and more items like this at wf.net.au/L959

Micromax Pty Ltd Contact info and more items like this at wf.net.au/M742

KPI AND STATUS DISPLAY SYSTEM The Red Lion ProducTVity Station is a solution for collecting, recording and displaying critical key performance indicators (KPIs) and machine status messages on any TV, monitor or projector equipped with a DVI/HDMI interface. The ProducTVity Station is able to collect data from a wide range of automation components. Using a library of over 200 communications drivers, it can communicate with PLCs, VSDs, energy meters and barcode scanners. Additionally, the PTV can be expanded with I/O modules, allowing it to directly accept digital and analog inputs from a range of sensors. A fully programmable graphical interface allows users to create high-definition visual management displays. A built-in data logger can record key performance indicators, as well as alarms and events for later review. It can synchronise its log files with any FTP server or Microsoft SQL Server for further analysis. Control Logic Pty Ltd Contact info and more items like this at wf.net.au/P226

8 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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The ONE event that connects the Air Conditioning, Refrigeration and Building Services industry

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ARBS 2012 is Australia’s ONLY International Air Conditioning, Refrigeration and Building Services trade exhibition. Showcasing the very latest innovations and industry technology ARBS connects over 250 local, national and international manufacturers and suppliers with thousands of decision makers, designers, specifiers, engineers, contractors and technicians. Save the date for this HVAC & R and Building Services mega event held over 3 days and featuring the trade exhibition, an informative seminar program and the national awards gala event.

Register NOW at www.arbs.com.au 7 - 9 May, 2012 Melbourne Convention & Exhibition Centre MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 9


NEW PRODUCTS

SECURE REMOTE ACCESS SOLUTION Providing more than a VPN or RDP, the Secomea secure remote access solution creates a transparent yet highly secure channel over the internet or mobile network between the client terminal and the destination network or host. With the use of an intermediary cloud, GateManager, a number of benefits are realised over other methods. Setup is an easy, almost ‘out of the box’ solution. Authentication is via client certificate,

DISSOLVED OXYGEN SENSORS

eliminating password sharing and

The DO6400 and DO6441 process dissolved oxygen sen-

changing when staff leave the or-

sors from Sensorex are fast-response submersible galvanic

ganisation.

sensors available with either a built-in 4-20 mA output signal

Traffic is initiated by the local Site-

capability for direct connection to a PLC or to a standard

Manager device and can use commonly

4-20 mA transmitter and local display.

accessible TCP ports to work within

The DO6400 and DO6441 are suitable for long-term continu-

firewall rules. The client programming

ous deployment in wastewater and aquaculture applications.

software sees the equipment as if it

Their galvanic sensor construction and electronics combine

were locally connected so there is no

performance, ease of use and low maintenance to offer a

need for intermediate site PCs.

reliable low life-cycle cost instrument for use in submerged

The SiteManager is available with a

water applications.

USB port for accessing devices such

The low maintenance sensors feature reliable galvanic

as low-end PLCs. There is also an

cell technology and a large-volume electrolyte reservoir for

ethernet port, serial port, digital I/O and

long-term continuous deployments. The easily replaceable

the option of a 3G/GPRS modem model.

membrane is available in either durable Teflon or wide-span

All models include pre-defined device

HDPE membrane for faster response. An optional integral

agents for all leading brands of PLCs,

temperature sensor is also available for both models.

HMIs and other industrial devices. Fur-

The DO6400 features a mV output (0.25-20 ppm) and the

thermore, by connecting both the wired and

DO6441 offers a built-in 4-20 mA output (0-100% and 0-200%). The DO6400 series sensors are designed for easy installation and maintenance with a positive fit and easy-to-grip body design. They feature a Noryl body with silver cathode and operate at temperatures up to 50°C. If an external transmitter with local display is required, the

wireless (3G) uplinks, a built-in failover function ensures that the connection is maintained if one uplink fails. Daanet Pty Ltd Contact info and more items like this at wf.net.au/M862

DO6400 series is compatible with the Sensorex DO500 and DOMA 4-20 mA loop-powered transmitters. The transmitter display can be programmed to read per cent saturation, mg/mL or ppm DO. Temperature is also visible on the display via a Pt100 temperature sensor (automatic) or manual input. Envirosensors Pty Ltd Contact info and more items like this at wf.net.au/P048

MANAGED GIGABIT POE ETHERNET SWITCH The ORing RGPS-7084GP-P is an industrial 12-port rackmount managed gigabit PoE ethernet switch with eight 10/100/1000Base-T(X) PSE ports and four 1000Base-FX SFP ports. It provides advanced IP-based bandwidth management that can be used to control each IP device’s maximum bandwidth. The switch is user friendly and can provide IP cameras and NVR’s with more bandwidth and limit other devices’ bandwidth. The switch also supports application-based QoS to set data-stream priority according to the TCP/UDP port number. It also provides advanced DoS/DDoS auto prevention. If there is a surge in IP flow the switch will lock the source IP address for a specified time to prevent the attack. All functions of the switch can be managed centrally or via the internet. ICP Electronics Australia Pty Ltd Contact info and more items like this at wf.net.au/M726

10 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 11


NEW White Papers

now available online!

WIRELESS REMOTE NETWORK MODULE The WNM wireless network module from Moore Industries provides a low-cost wireless communications link between field sites that are in rugged or impassable terrain, with a single unit transmitting for up to 48 km and the ability to act as a repeater for a virtually unlimited transmission range, and in both point-to-point and point-to-multipoint network architectures. The bidirectional WNM employs spread spectrum frequency hopping technology

Oxygen measurement on air separation plants Industry consumes vast quantities of oxygen and nitrogen annually, all of which is obtained from the air around us. There are two main techniques used to separate these two primary gases from air. These processes are cryogenic separation and pressure swing adsorption (PSA).

to avoid interference problems caused by crowded radio spectra. This technology allows multiple radio networks to use the same band while in close proximity. Operating at standard operating frequencies of 902 to 928 MHz (48 km range) or 2.4 to 2.4835 GHz (24 km range), the WNM does not require a regulatory licence and can typically be installed without performing

Portable gas detection for safety in confined spaces In todayâ&#x20AC;&#x2122;s working environment, confined spaces are ongoing areas of review. Nearly all workers can expect to come in contact with a gas detector during their working career but few have the opportunity to understand the basics. Are you safe?

costly RF site surveys. When it is set in the Smart Switch Ethernet (SSE) mode, the WNM enhances the speed and reliability of data packet transmission by determining the most efficient path of broadcast (including direct to a single radio or to some or all radios in a network) on a packetby-packet basis. The WNM can be used with the Moore Industries NCS NET Con-

Machine vision inspection: benefits, applications and vendor selection tips

centrator System, as well as other SCADA and distributed I/O systems.

In recent times, the technology options for machine vision inspection systems have increased, the cost of these solutions has reduced and hence the adoption has dramatically increased. These solutions, if implemented wisely, can provide a competitive advantage for manufacturers as well as provide cost savings.

use ethernet and serial (RS485) communications.

WNM models are available for data communications networks that The WNM utilises 128-bit AES encryption, 32-bit CRC error detection and ARQ for robust and secure communications. The industrial DIN rail-mount metal enclosure also ensures that the WNM can be used in rugged environments, including ambient temperatures from -40 to 75°C and relative humidity of 5 to 95%.

Control systems and operational security - are you properly covered? Security has always been a relevant concern during the design and deployment of automated control systems. But recent worldwide events, combined with technological and industry trends of the last decade, have significantly raised the visibility and public awareness of this issue.

Moore Industries Pacific Inc Contact info and more items like this at wf.net.au/P246

SIMULATION TOOLS MathWorks has released updated versions of two products, Robust Control Toolbox and Simulink Control Design, which enable engineers to automatically tune complex control systems modelled in Simulink. Most embedded control systems have a fixed, decentralised architecture with simple tuneable elements such as gains, PID controllers and low-order filters. Enhancements to Robust Control Toolbox and Simulink Control Design let engineers automatically tune all controller elements without changing the controller structure. This eliminates the need for tedious and time-consuming methods of tuning multiloop, decentralised control systems such as successive loop closure. With the new capabilities, control engineers can select Simulink blocks to tune; specify requirements for bandwidth, stability margins and tracking performance; automatically tune all control system parameters simultaneously; and update selected Simulink blocks with tuned

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

values. The resulting design can be verified by simulating the model. MathWorks Australia Contact info and more items like this at wf.net.au/L961

12 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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Mitsubishi Electric 700 Series drives FR-D700 - the ultra compact inverter FR-D700 DRIVE FEATURES: • Compact performance. • Safe stop function. • In built operation panel with LED multifunction display, operational keys and potentiometer. • Keypad, external or network operation. • Easy start operation function. • RS-485 / MODBUS RTU communications for multidrop networks and / or Mitsubishi PLC inverter instructions. • Space saving footprint mounts directly on matching EMC filters (request separately). • Side by side installation, no clearance required between VSD’s

SINGLE PHASE INPUT FR-D700 SERIES • • • • • •

FR-D720S-008-EC FR-D720S-014-EC FR-D720S-025-EC FR-D720S-042-EC FR-D720S-070-EC FR-D720S-100-EC

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THREE PHASE INPUT FR-D700 SERIES • • • • • • •

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............................0.4 kW ............................0.75 kW ............................1.5 kW ............................2.2 kW ............................3.7 kW ............................5.5 kW ............................7.5 kW

Available from: NSW & Western Victoria

Oceania Automation Ph: (02) 9939 5920 Fax: (02) 9938 5914

Queensland

ESM Australia Ph: (07) 3856 3100 Fax: (07) 3856 3056

Eastern Victoria

Automation Systems & Controls Ph: (03) 9720 0211 Fax: (03) 9720 8712

South Australia Rawsons Electrical Ph: (08) 8297 0222 Fax: (08) 8371 0848

Western Australia AI Automation Ph: (08) 9528 7598 Fax: (08) 9528 7598

MITSUBISHI ELECTRIC AUSTRALIA PTY LTD Ph: (02) 9684 7777 www.mitsubishielectric.com.au

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 13


A major Australian gold mine at Stawell in Central Victoria has far exceeded its own expectations following an upgraded flotation circuit developed in partnership with Outotec Services. The Stawell Gold Mine of Northgate Minerals, Toronto, aimed to increase recoveries by 3.5% from the upgraded plant. This upgrade was implemented after Stawell changed its production profile to process lower grade ore at higher throughput rates. The mine, which has produced more than two million ounces in its 26-year history, previously employed a flotation circuit consisting of a bank of eight mechanical trough cells in the rougher circuit, followed by two banks of two OK3 Outotec cells as cleaners. The feed rate to the cells was between 90-105 tph, at 50-55% solids. The overall flotation circuit was not performing at optimal rate due to entrainment problems in the rougher cells when feed density increased from 45 to 55% solids, typically at 105 tph. In anticipation of future production levels and as part of Stawell's focus on operational excellence, it was decided to upgrade the flotation circuit. Following a site audit from Outotec Services, a two TankCell-20 configuration

equipped with larger TankCell-30 mechanisms was proposed to help optimise flotation. The larger mechanisms would allow operation at very high percent solids (50% and over). The TankCell design also allows a much deeper froth depth and better concentrate grade through optimised launder lip length and surface area. Outotec Services was commissioned to handle the complete turnkey solution of the new rougher circuit, including design, supply, installation and commissioning. The schedule was demanding but achievable, with work to commence in February 2010 and be completed in September 2010, just 30 weeks later. It was decided to adopt the partnering approach between Stawell and Outotec Services, because this collaborative method ensured open communication, with all parties having greater ownership of the project and its aims. The close teamwork between Stawell and Outotec Services resulted in meticulous planning and the site remaining fully operational at all times. Pipework and electrical easement ducts, for example, were rerouted early in the project. Tie-in points for new cells and rerouting of pipework were also planned up front in the project and all disruptive work was completed during shutdowns. The project overcame a number of challenges, including an extremely limited footprint, which was adjacent to a gabion wall, close to the runof-mine pad and also close to a reagents shed, which could not be moved. Additionally, existing process requirements at Stawell required specific elevations for the new TankCells. Structural stability was the main issue when designing the tank support structure due to the height of the tanks and the limited footprint. Sufficient stiffness was required such that the operation frequencies of the TankCells would not interfere with the natural frequency of the tank

14 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

support structure. Through FE modelling of the structure, section sizes and bracing orientations were optimised to produce the required stiffness. The civil work was also highly challenging. Following the discovery of an underground slab during the excavation work, test work on core samples from various layers was required. Fortunately, only part of the slab needed to be removed and all parties worked hard to ensure the project stayed within project timelines. The weather proved to be an additional hurdle as the site experienced the wettest seasonal weather in recorded history during the project. Simple tasks, such as curing of the paintwork, normally taking 24 hours, took days instead. Despite such challenges, the turnkey installation of the new rougher circuit, along with blowers for the complete flotation circuit, was completed within deadlines. Because all tie-in points had been already carefully planned upfront, commissioning was a seamless exercise. On 13 September 2010, just 30 weeks from commencement, the new circuit, complete with TankCell technology, was commissioned and brought on line. Designed to cope with projected increases in production and considerably more operator friendly than its predecessor, the new TankCell-20 cells have quickly proved their worth at the site. The air demand for the old rougher cells, for example, was estimated at over 3000 Am³/h, whereas the estimated air demand on the Outotec TankCells is a maximum of 992 Am³/h. The Outotec FloatForce rotor-stator mechanism, with its unique design, delivers enhanced flotation cell hydrodynamics and improved wear life and maintenance. Following the flotation upgrade at Stawell, the targeted recovery rate improvement was projected at 3.5%. The actual recovery rate, however, improved instantly by 4.5%. Payback was also impressive, occurring within less than four months. "The projected payback was 5.5 months, so it was a pleasant surprise when it happened so soon" explains Jodie Hendy, Senior Metallurgist at Stawell. "Maintenance on the Outotec TankCells has also been minimal since the upgrade. Basically, we check the cells during shutdowns, but there has been no maintenance required in the nine months since commissioning. "The TankCells have really delivered on their reputation. Basically, they do exactly what they are supposed to do." Outotec Pty Ltd Contact info and more items like this at wf.net.au/P314

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© iStockphoto.com/Evgeny Bashta

Stawell Gold recovery exceeds expectations through flotation upgrade


© 2012 Swagelok Company

Our connections deliver so much more than fluid systems.

Your Swagelok representative is your connection to so much more than you expect. Yes they’re experts in their own right. But beyond that, they can tap into the global knowledge accrued in more than 65 years of research, development and innovation. Your authorized Swagelok representative is ready to work with you and provide you with the tools and problem-solving solutions that deliver a real business edge and so much more too – because in this business you need all the right connections. Visit swagelok.com/connections.

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 15


HOT PRODUCTS

ON WWW.PROCESSONLINE.COM.AU THIS MONTH

FIELD-INSTALLABLE RJ45 PLUG

>

The RJ Industrial 10G is an upgrade of Harting’s RJ45 connector that requires no tools for connection, and features a future-proof design for 10 Gigabit Ethernet. Soanar Limited

>

WF.NET.AU/M924

INCLINOMETERS Fraba Posital has introduced industrial and heavyduty versions of its Accelens (ACS) inclinometers, featuring either a plastic or aluminium housing. Plant Control & Automation

POWER QUALITY ANALYSERS

>

WF.NET.AU/M805

The Fluke 430 Series II power quality analysers are designed to help facilities reduce electrical power consumption and improve the performance and lifespan of electromechanical equipment. Fluke Australia Pty Ltd

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> ULTRASONIC GAS FLOW METER The Flexim ultrasonic gas flow meter performs non-invasive ultrasonic

NEPHELOMETER Hach’s Filter Trak FT660 laser nephelometer detects changes in turbidity as low

gas and liquid flow measurements

as 0.0005 NTU.

using clamps with high precision

Hach Company

and speed on both fast and slow

WF.NET.AU/M572

>

flow rates. TechRentals

WF.NET.AU/M926

16 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 17


NEW PRODUCTS

BEACON TOWER LIGHT light is a hybrid of the company’s TL50 tower and

SKID-MOUNTED BAG DISCHARGE SYSTEM

K50 beacon lights. Similarly to the alternative TL50

The Flexicon Bulk Bag

models, the beacon tower is segmented and may

Discharging System with

be ordered with up to four different coloured LED

integral Pneumatic Con-

lights - red, yellow, green or blue - which allows

veying System transfers

several messages to be conveyed at once. These

material from bulk bags

segments can easily flash or rotate their bright sig-

to silos and other stor-

nals, in addition to displaying a solid ON indication.

age vessels. Unlike most

Banner Engineering’s EZ-Light TL50 beacon tower

The bright output of the LED beacons provides

discharging systems that

easy-to-see indication from all directions when

move material from bulk

multiple lights may need to be on simultaneously -

bags to smaller storage vessels and process equipment, this positive

allowing operators to effectively monitor equipment

pressure pneumatic system is designed to fill bulk storage facilities on

from a distance. TL50 audible models with easily

islands, or other locations unable to receive large volumes of bulk mate-

adjustable sound intensity are available, in addition

rial by rail or bulk truck.

to multiple bracketing options, enhancing the beacon

The discharger portion of the skid-mounted system

tower’s functionality and placement options. It also

includes a cantilevered I-beam with electric hoist and

has a wide 12-30 VDC operating

trolley to lift and position bulk bags without the use of

range, enabling it to be used

a forklift. A Spout-Lock clamp ring forms a high-integrity

in battery-powered mobile

seal between the clean side of the bag spout and the

applications.

clean side of the equipment, while a Tele-Tube telescop-

The EZ-Light tower lights

ing tube maintains constant downward pressure on the

come completely preas-

clamp ring and bag spout, elongating the bag as it

sembled and preconfigured,

empties to promote complete discharge.

saving time and money in

Material flow is aided by Flow-Flexer bag activators

the installation process.

that raise and lower opposite bottom sides of the bag

Equipped with LED technol-

in timed intervals.

ogy, these lights reduce power consumption, making them an energy-efficient solution. Both the general purpose and audible models

A Bag-Vac dust collector integral to the dust-tight system creates negative pressure to collapse empty bags prior to retying and disconnection, eliminating dust emitted during manual flattening of empty bags.

of the TL50 beacon tower use Euro integral quick

The unloader's surge hopper is equipped with a high-capacity rotary

disconnect (QD) connectors, while the robust design

airlock valve to feed material into a pneumatic conveying line, leading

of the indicator allows for direct machine mounting.

from a positive displacement blower, at high rates.

Micromax Pty Ltd

Flexicon Corporation (Australia) Pty Limited

Contact info and more items like this at wf.net.au/M488

Contact info and more items like this at wf.net.au/L696

18 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 19


CHANGING, MACHINING, COMPENSATING CURRENT TRENDS IN ROBOT ACCESSORIES

The need for greater robot reliability and efficiency is leading to the development of new technologies in robot accessories.

I

n dealing with industrial robot efficiency, cycle rate and process reliability largely depend on their front ends, the grippers and other tools and also from the effectorsâ&#x20AC;&#x2122; interfaces to the robot arm. Robot accessories have a great influence on the robotâ&#x20AC;&#x2122;s performance, flexibility and fields of application. The latest developments in quick-change systems, driven tools, compensation units and power sensors show that the potentials of modern accessory components are enormous. Experts assume that their importance for handling, assembly and manufacturing will continuously increase.

Quick-change systems provide speed in production Grippers, tools and other effectors can be quickly exchanged by means of quick-change systems. This reduces machine downtime and

20 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

increases the flexibility of the robot. While an experienced operator requires between 10 to 30 minutes for the manual exchange without using a changing system, a quick-change system can reduce the same operation to less than 10 to 30 seconds. The use of a quick-change system always makes sense in areas where new products or product variants have to be regularly exchanged, where various effectors for handling or machining are required and where downtimes, due to maintenance of components and tools, need to be minimised. Quick-change systems usually consist of two components: a quick-change head, mounted on the robot arm and a quick-change adapter, which is connected with the tool. During a tool change, both components are automatically or manually coupled, as well as all the electric, pneumatic and hydraulic feed-throughs. Ideally this is done pneumatically via a self-retaining locking system and is controlled via

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Robotics

THERE IS NO DOUBT THAT PNEUMATICALLY AND MECHANICALLY COMPENSATING ACCESSORY PRODUCTS CAN BE HELPFUL AND IN MANY CASES ARE PERFECTLY SUITABLE. HOWEVER, EXTREMELY PRECISE RESULTS CANNOT BE ACHIEVED WITH THEM WITHOUT IMPROVED SENSITIVITY TO THE WORK PIECE.

but also for jobs with heavy grippers, vacuum gripping systems, hydraulically-, pneumatically- or electrically-driven machining spindles, riveting applications, welding tongs or stud welding applications with automatic material feeding. Moreover, they can be used in the automotive industry for assembly or for presses. Due to their high payload, they can be used for the set-up of flexible production lines, where lightweight and heavy work pieces are alternately machined.

Integrated valves improve energy efficiency A quick-change assembly with three locking systems.

If the energy efficiency of a plant needs to be increased, quick-change systems are also playing an important role. Microvalves that are integrated in a quick-change system can replace a complete valve terminal. At every cycle, the piston area of the actuator is filled with compressed air as well, which saves a lot of time. If you are using a three metre long feeding hose with a 4 mm diameter, the integrated valves will reduce the air consumption by 90%. At the same time, the cycle time increases, since the compressed air is directly actuating. Instead of cable and wire bundles, just one pneumatic line for compressed air and power supply is required. Both lines can usually be fed through the centre bore and can be integrated in the arm of a SCARA robot.

Bending tools for grinding, polishing and deburring

integrated sensors. Since alignment of the effectors is already defined by the quick-change system, no time is lost due to re-adjustment. When selecting a quick-change system, end users and system integrators should pay attention to compact dimensions, a low weight/ force-ratio, short change times and exactly dimensioned energy transfer modules. Modular systems are particularly economic where various electronic and fluid modules can be combined with each other according to the application. Force-free locking and unlocking with a so-called no-touch locking system would be ideal, since it also ensures safe locking, even if the clearance between head and adapter amounts to several millimetres. Since industrial robots are becoming more powerful and weights of several kilograms can be handled, special heavy-load systems are gaining importance. They are suitable for handling heavy work pieces,

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Besides handling, robots are also used in specific machining processes such as drilling or milling. During grinding, polishing, brushing and deburring however, they usually reach their limits, since it is impossible to replace experience, sense of proportion and the sure instinct of a human being compared to a robot. There has always been the risk that burr residues are left, or that more material has been removed than required. Moreover, tools quickly wear out, or break. Now there are driven tools, which are axially or radially seated and can compensate for deviations between the robot path and the work piece contour. In order to machine surfaces of metals and plastics with a robot, the grinding wheels or polishing brushes are clamped in air-driven finishing tools. The slowly running special tools generate a high torque. Since they bend in the axial direction, a uniform contact pressure is also given for uneven surfaces. It can be controlled via air pressure and ranges between 14 N and 74 N. The tools are very rigid crosswise to the surface, but in the machining direction they have a defined flexibility. Tool wear, inaccuracies in work piece

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 21


Robotics

Figure 2: Integrated microvalves can reduce air consumption by up to 90%.

Figure 1: A heavy-duty quick-change locking system capable of loads up to 700 kg.

Figure 3: FTNet force-torque sensor.

position, as well as slight deviations of the robot arm from the given robot path are therefore compensated for. This improves the quality of the machining results, the tool service life of the used tools and programming time is reduced by up to 75%. Chamfering spindles follow a similar concept. They try to imitate the manual chamfering operation as accurately as possible. In contrast to the finishing tools, high frequency spindles work at speeds of up to 65,000 rpm. Their spindle and motor system is flexibly seated on a self-aligning bearing. Several pneumatic pistons assure that the spindles can offset radially or axially up to nine millimetres. Therefore, the compressed air motor can move relative to the housing and deviations between the tool path and the actual work piece contour are compensated. Even in cases of components with an irregular shape, a uniform result can be achieved. The rigidity of the deburring spindle can be controlled via a separate air connection and clean-cut deburring edges can be assured in every installation position. Depending on the adjusted air pressure, forces between 3.1 N and 42.3 N are acting on the milling cutterâ&#x20AC;&#x2122;s cut surface, and depending on the material, working speeds of up to 0.3 m/s are possible. Since less fixed points have to be defined during the robotâ&#x20AC;&#x2122;s path programming, the programming time is reduced if deburring spindles are used.

Compensation units without pneumatics In order to avoid problems during joining, assembly or insertion, compensation units ensure the necessary compliance between effector and robot arm. They avoid plant malfunctions and damages, and increase process reliability. The latest generation of these flexible modules do not require pneumatics. Compliance in two directions is adjusted via springs with adjustment screws and in three directions via elastomer elements. Since the units are working without pneumatic elements, they are very flat and particularly suitable for use in confined areas. Smooth running roller guides can compensate for smaller compensation forces without stick-slip effects. Springactuated return pistons ensure a high repeat accuracy.

22 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

Figure 4: Intelligent sensors such as the FTNet measure exactly the forces and moments occurring during machining.

Force and torque sensors provide more sensitivity There is no doubt that pneumatically and mechanically compensating accessory products can be helpful, and in many cases are perfectly suitable. However, extremely precise results cannot be achieved with them without improved sensitivity to the work piece. Future trends are toward the increased use of intelligent force and torque sensors, which help to provide the robots with the necessary sensitivity. Today, they are being used to record the process forces and to transfer them to the control unit. The robot path can be precisely readjusted, and as a result, consistent force and machining results are obtained. An example of a force-torque sensor is the FTNet from Schunk. It measures the forces and moments in all six degrees of freedom. The sensor is provided with an interface to the robot control unit, and connection is greatly simplified. The high-precision sensor provides a high-speed data output of up to 7 kHz. There are four possible communication protocols (ethernet, EtherNet/IP, DeviceNet and a CAN-Bus), remote control via the LAN and configuration via a web interface that offers interface compatibility with numerous applications. It can be used for product tests, robot assemblies or for machining tasks such as grinding and polishing and also for robot surgery, applications in the field of rehabilitation, in neurology and in many more areas. With sensors such as this, even difficult assembly, machining and finish-machining tasks, which have so far been done manually or with a complex special machine, can be automated.

Conclusion The need for greater robot reliability and efficiency is leading to the development of new technologies in robot accessories. These technologies are leading to dramatic improvements, not only in the efficiency of tool changing, but in the accuracy and repeatability of the work a robot can perform, potentially expanding the application of robots into tasks previously not considered for robotic application. Romheld Automation Pty Ltd Contact info and more items like this at wf.net.au/M586

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PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

Process Technology Regional Roadshow

2012 8

vend NEW or sess training ions

NOW IN ITS TH

YEAR

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

Brisbane • May 14 Gladstone • May 15 Mackay • May 16 Townsville • May 17

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


EXPLOSION-PROOF PRESSURE SWITCHES The United Electric Controls One Series electronic pressure switches and electronic temperature switch have a fully adjustable set point and deadband and 0.1% repeatability, and area available in Type 4X enclosures for explosion-proof and non-incendive area classifications. Each One Series model incorporates intelligent self-diagnostics and can report detected faults before they become major safety issues. Plug port detection protects against sensor clogging. Nuisance trip filtering reduces false and spurious signals. The ability to capture pressure spikes and valleys provides process information to aid in the commissioning and debugging process. These switches are designed to be highly repeatable and fully adjustable deadband switches for applications with a high cycle rate. With no moving parts, the One Series digital solid-state design is suitable for controlling pump and compressor stop/start cycles. With its digital process display and available 4-20 mA output, the One Series can provide the functions of a switch, gauge and a transmitter with one connection to the process. For plant upgrades, 2-wire models use existing plant wiring. Loop-powered models provide high-capacity switching and a 4-20 mA output. External power supply models can handle currents up to 10 A or two fully independent set points and deadbands and the 4-20 mA output. Multiple sensor types and ranges are available - gauge pressure up to 6000 psi, differential pressure up to 200 psid, and RTD temperature from -184 to 538째C. Pryde Measurement Pty Ltd Contact info and more items like this at wf.net.au/M738

LEVEL GAUGE WITH ENHANCED OVERFILL DETECTION Honeywell has announced key enhancements to its 854 Servo level gauge, which is now equipped with a Servo Auto Test feature. This solution has been approved for Safety Integrity Level-2 and 3 (SIL-2/ SIL 3) applications and increases the gauge's diagnostic coverage. The updated gauge provides high-accuracy level measurements in bulk storage tanks during inventory control and custody transfer applications. This provides oil and gas facilities with an updated tank solution that ensures safety, regulatory compliance and cost-effectiveness. The Servo Auto Test feature can be used in overfill protection loops that require SIL-2 or SIL-3 solutions to prevent any spillage, complying with safety and environmental standards. Additionally, the Servo Auto Test solution can be loaded onto all existing 854 Servo units with a simple software patch. The increased diagnostics of the 854 Servo level gauge allow it to detect failures inside the gauge or in the application and report this to higher level systems for further action, mitigating the possibility of mechanical failure. Honeywell Limited Contact info and more items like this at wf.net.au/L721

24 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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NEW PRODUCTS

TABLET PC The IceRock-08A is a fanless industrial tablet PC with an 8″ touch screen. The IceRock-08A is powered by an Intel Atom Z530P with full hardware acceleration and its high graphic performance supports H.264, MPEG1/2/4, VC-1/WMV9 high-definition decoding, eliminating the need for software decoding.

WLAN AP ROUTERS The Hirschmann OpenBAT range is a modular system that enables industry-standard WLAN access points and clients to be configured via the internet. This range, comprising the BAT-R (IP20) and BAT-F (IP67)

Lightweight at only 1 kg, this low-power, easy-to-use tablet

series, supports the IEEE

PC has an IP62-rated front panel providing resistance to

802.11n transmission standard,

spills and dust and features an 8″ LED-backlit TFT LCD

which facilitates data speeds of up to 450 Mbps in both the

touch screen and up to 4 h battery life. A mobile broad-

5 GHz and the 2.4 GHz bands.

band internet connection over 3G mobile phone networks is possible. The wireless LAN integrated PIFA antenna

Suitable for the power supply industry, the gas and oil sectors and rail transportation, they can be used to set up fast and stable infrastructure and meshed networks plus wireless distribution systems (WDS) or point-to-point connections.

on the IceRock ensures

The core component of this new hardware is a wireless module

an uninterrupted wireless

specifically designed for applications in industrial environments,

connection and provides

with integrated ESD protection and bandpass filters. MIMO

up to IEEE 802.11n op-

(multiple-input, multiple output) technology ensures a stable

eration, while the prein-

wireless connection even in the presence of reflections or

stalled Bluetooth mod-

other forms of interference. Fast roaming guarantees

ule (transmission up to

uninterrupted connections when transferring from one

20 m) communicates with

radio cell to another.

a wider range of electronic devices from mobile phones to barcode readers.

The CPU platform facilitates a LAN connection via Gigabit ethernet. The access points and clients also pos-

Other features include an ambient light sensor which au-

sess potential-free contacts as well as one V.24 and one USB

tomatically adjusts the brightness of the screen for optimum

interface that can be used for analog or DSL modem connections

visibility and energy efficiency; eight programmable function

for WAN routing or remote maintenance. All combinations operate

keys to access frequently used applications with the touch

at temperatures up to 70°C and also fulfil stringent demands as

of a button; a built-in 1.3 MP video intercom device for real-

regards shock and vibration resistance.

time communication suitable for use in low light situations;

The access points and clients can be equipped with one or two

and a built-in g-sensor that is used to automatically toggle

wireless modules.The LAN connections can also be configured

between portrait and landscape display modes for a more

with one or two ports and these can be used for twisted pair

comfortable viewing experience.

cables or SFP transceivers.

ICP Electronics Australia Pty Ltd

Belden Australia Pty Ltd

Contact info and more items like this at wf.net.au/P250

Contact info and more items like this at wf.net.au/M492

Quality ISO 9001

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MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 25


TO FEATURE A RECORD 12 PRODUCT ZONES

N

ational Manufacturing Week (NMW) 2012 returns to Sydney this May, and it’s going to be big: 10,000 anticipated visitors, over 300 local and international manufacturing industry suppliers and a record 12 Product Zones. Co-located with Austech - Australia’s premier advanced manufacturing and machine tool exhibition - NMW 2012 will be occupy most of the Sydney Showground from 8 to 11 May. Attendance is free and for trade only. NMW recommends visitors register online to avoid the queues. For exhibitors, NMW 2012 is an opportunity to meet over 10,000 potential clients; for visitors, it’s the place to source the latest products and services across all industry sectors. Visitors can also gain relevant education, debate critical industry issues, obtain technical information and network with peers. This year, NMW will feature innovations from many of the world’s leading manufacturing suppliers. Smaller companies are also featured, reflecting Australia’s growing capabilities in manufacturing for lowvolume, high-value niche markets. NMW 2012 sees two new product zones added to the event: Sustainable Manufacturing and Metals & Composites. Each zone is

colour coded, making it easier for visitors to find areas of specific interest. In addition to the two new Zones, NMW 2012 will once again host the Air Technology, Automation & Robotics, Electrical, Electronics, Engineering, Health & Safety, Information Technology, Materials Handling, Process Control & Instrumentation and Welding Technology Zones. “We intend that all visitors to NMW 2012 come away with new contacts and ideas for their businesses - so that NMW, as a whole, achieves its goal of being the event that strengthens Australia’s manufacturing sector,” said Paul Baker, Exhibition Director for NMW 2012. NSW Premier Barry O’Farrell has backed NMW 2012, saying, “By bringing together customers and suppliers, and promoting new technologies and innovations, trade events such as NMW are crucial to ensuring our local businesses remain internationally competitive.” What’s New in Process Technology is a media partner for the Air Technology Product Zone. Collect your copy of the magazine from the Media Table. By Alice Richard

STATUS SEM710 UNIVERSAL TEMPERATURE TRANSMITTER WITH INTEGRAL DISPLAY • PT100 and Thermocouple (K,J,E,N,T,R & S) inputs • 4-20mA loop powered output with display selectable units (Deg. C/F or output loop current in mA) • ABS or Stainless Steel IP67 housing available • Simple configuration via USB port without the need for external powering • Standard mini USB cable included and free software provided • Galvanic input/output isolation • User trim feature (with lock option) • Economically priced for OEM applications 10-year warranty and this is just the beginning!

26 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

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© iStockphoto.com/Alexey Stiop

NMW 2012 IN SYDNEY


WIRELESS HART INSTRUMENT ADAPTER The Honeywell OneWireless Adapter (OWA) allows manufacturers to improve plant efficiency by converting field devices that use the HART protocol into devices that can transmit data over an ISA100.11a-compliant wireless network. By allowing any HART device to communicate over the wireless network, the OneWireless Adapter helps improve the flow of information and gives operators the data they need to make the right decisions at the right time.

Three of the 500+ panels we built in 2011

Honeywell's OneWireless range includes field instrumentation, input/ output devices, mobile devices, network components and related services. It enables plants to support a wide range of wireless devices from multiple suppliers on a single mesh network. Based on the ISA100.11a standard, OneWireless provides highly reliable data communications in harsh industrial environments, as well as features that provide secure data encryption, fast data response time, prolonged battery life, easy installation and room for future expansion as plant needs change. The OWA adapter provides wireless access to four HART dynamic variables (PV, SV, TV and FV), multivariable data, performance information, calibration information, diagnostics and device configuration parameters. Honeywell Limited Contact info and more items like this at wf.net.au/L893

WIRELESS AP/BRIDGES Moxa has released the AWK-3131 and AWK-4131 series, two high-bandwidth 3-in-1 industrial wireless AP/bridge/ clients that provide secure wireless coverage both indoors and out. Both series are fully compliant with the IEEE 802.11n standard for a maximum bandwidth of 300 Mbps and are backward compatible with existing 802.11 a/b/g deployments. The company's 802.11n products use a combined technique of MIMO (multiple input, multiple output), channel bonding and frame aggregation. MIMO is the key technology for enhanced data rates in 802.11n networks. It enables a link where both the transmitting end and the receiving end are equipped with multiple antennas, creating multiple paths for the radio signals. This technology eliminates the effects of multipath fading on the receiving end for improved wireless range and reliability. The 802.11n standard couples MIMO technology with the channel bonding operation in the physical layer, which bonds two 20 MHz channels together to increase the bandwidth that is available for data transfer to 40 MHz. Finally, frame aggregation technology greatly reduces the average delay by packing multiple frames in a single transmission. Together, these three elements of 802.11n network technology ensure high reliability while satisfying higher throughput demands up to 300 Mbps. Both the AWK-3131 and AWK-4131 series feature rugged housings that are necessary for harsh industrial environments. Both series also feature industrial-grade QoS and VLAN for efficient data traffic man-

Our Sydney Systemhaus is ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions,’ making Bürkert the ideal partner for large and small scope projects. In addition to standard panels, we engineer custom panels with pneumatics, I/O, transmitters and programming to meet your wider control system needs. Call on Bürkert to build your 2012 panels.

agement and integrated DI/DO for on-site monitoring and warnings. The AWK-4131 is an outdoor model with an IP68-rated metal housing that is designed to withstand harsh environments and extreme temperatures from -40 to 75°C. CrispTech Pty Ltd

We make ideas flow www.burkert.com.au | 1300 888 868

Contact info and more items like this at wf.net.au/P049

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MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 27 WNIPT Ad 201203 HP.indd 1

6/02/2012 2:54:58 PM


No profile - fans off!

The apt Hiller Group (apt Hiller GmbH) in Monheim, Germany, makes aluminium semifinished products for markets in Europe. The custom profile solutions are produced on the most modern systems with fully automated process technology. In run-out lengths of up to 60 metres, the profiles are transported via giant cross conveyors to a cold saw roller table. At the same time, the cross conveyors function as refrigerated tables on which the roughly 500째C profiles from the press are cooled down to 30-40째C. Ventilators which blow air from below through the conveying belts accelerate this process. The refrigerated table is equipped with four rows of 45 fans. Each fan has a diameter of 500 mm. "All in all, that amounts to a power consumption of around 80 kW, which, depending on the process, runs through from Sunday evening to Saturday after the last shift," says Hans-Joachim Hopf from apt Hiller. However, since the flexible production of different profiles means the refrigerated table is not always equally full, he wanted to find a solution to control the rows of fans if necessary, to find a way to switch off the fans above which no profile is currently located. What Hopf needed was a sensor solution that detects the presence of profiles, independent of their strength, form, condition and position. In addition,

he wanted a solution that didn't require an opposing installation, like with reflectors or receivers. Scanning sensors were therefore the optimum choice, and in particular he chose the LRS 36 switching light section sensors from Leuze electronic. Mechanical assembly over the refrigerated table was out of the question for him due to the costs and also because he wanted to avoid configuring the sensors in the hot air stream. Even though the assembly of the sensors under the conveying belts meant the danger that their function could be impaired if the optics were to get contaminated, it was decided that this was the better solution. In contrast to light scanners, light section sensors do not create punctual light spots. Instead, they project a divergent light beam by means of line illumination. This allows the height profiles of objects to be determined with an inclined setting angle. In this way, the light section technology offers a large array of functions with regard to safe object detection and a large detection range at the same time. Furthermore, both the transmitter and the receiver are integrated in a single housing. The sensor determines depth and width information and enables the detection of objects on the basis of preconfiguration. To do this, 16 analysis windows and 16 inspection tasks are available which can be set by means of a PC via an ethernet interface. In addition to the measuring variants of the Line Profile Sensors (LPS), which measure object profiles and supply 3D information, switching Line Range Sensors (LRS), as they are used at apt Hiller in Monheim, make completely new functionality possible. Comparable to a laser scanner, the devices detect the presence of objects - even in undefined object positions. With its large detection range of up to 800 millimetres, the LRS opens new

28 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

application fields without complex sensor solutions, sensor combinations or additional evaluation units. The sensor determines depth and width information and enables the detection of objects on the basis of preconfiguration. To do this, 16 analysis windows and 16 inspection tasks are available which can be set by means of a PC via an ethernet interface. The compact design of the LRS 36 devices made placing them between the fans easier. Furthermore, there was enough distance to the conveying level so that, in the end, widening the light beam up to the transport height of the profiles yielded a sufficiently wide detection range which covers the 500 mm 'gauge' of the fans. Since the line range sensors can detect the profiles independent of their position throughout the total detection range, a single sensor per fan row is enough. The profiles, however, are manufactured in differing lengths of at least 20 m and, depending on the profile type, arches can develop due to normal heat expansion, or the profiles can be inclined. This is why a second row of light section sensors is installed at a distance of 18 m from the first. This ensures that profiles are detected by at least one sensor even in the worst case. When neither sensor detects a profile, the fan row is switched off after a short time delay. "With this energy-saving measure, we have reduced the operating time of the fans by about 25%. What that means monetarily for 80 kW of power can be easily calculated," says Hopf, who has since put his worries about the contamination of the optics to rest and confirms that the function is reliable. Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/P316

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NEW PRODUCTS

ETHERNET SWITCHES Weidmuller has released a range of high-performance, unmanaged industrial ethernet equipment. The range includes a choice of fast ethernet or gigabit unmanaged switches and 10/100 media converters. All switches are housed in robust metal casings which act as a heatsink, eliminating the need for fans and case venting. This pro-

PRECISION SERVO COUPLINGS

vides IP40 protection and stops any foreign objects from penetrating the device and causing failures. They have been built to withstand a

ServoClass couplings from Zero-Max are designed to

wide operating temperature up to 85째C as well as high vibration and

increase speeds in electronic assembly systems. They

to deliver high EMC protection.

are also suitable for all types of automation, packaging and other types of automated assembly, including

The plug-and-play switches all come standard with a universal lowvoltage power supply of 18-72 VDC/13-50 VAC.

most systems using ball screws and servo motors.

The gigabit switch

ServoClass couplings provide high torsional stiff-

range incorporates a

ness, zero backlash and low hysteresis to ensure

choice of combina-

repeatable precise positioning at speeds up to

tion ports. Users can

10,000 rpm. Their robust design ensures precise

choose between five

system operation in automated 24/7 applications.

or eight RJ45 ports

This is especially important where stresses occur at

or a gigabit switch

increased speeds in a servo system.

with six RJ45 ports

Designed with 304 stainless steel disc packs and

and two combination

7075-T6 aluminium hubs, ServoClass couplings are in-

ports, totalling eight

herently strong, durable and precisely balanced. To en-

RJ45 outlets. If a sin-

sure precise alignment of the assembled components,

gle or multimode fibre port is required, users can insert up to two

ISO 4762 CL12.9 corrosion resistant socket head

plug-in fibre outlets to convert two gigabit RJ45 ports into fibre ports.

cap screws are used, with a carefully controlled

The gigabit range has an operating temperature of -40 to 85째C.

assembly process.

Other models available include the entry-level IES10 fast ethernet

ServoClass couplings are available in single and

range. These are available in 5- or 8-port switches with a single

double flex models in bore sizes from 4 to 45 mm.

universal power supply. The IES20 fast ethernet range includes both

All models and sizes feature clamp style hubs and

copper and fibre ports and a dual universal power supply. The IES20

operate in temperatures from -30 to +100째C.

models also have an operating temperature range of -40 to 85째C.

Naismith Engineering & Manufacturing Co Pty Ltd

Weidmuller Pty Ltd

Contact info and more items like this at wf.net.au/L892

Contact info and more items like this at wf.net.au/P169

www.ProcessOnline.com.au

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 29


NEW PRODUCTS

COMPRESSORS Sullair has introduced the Champion CSD compressor range, in addition to a larger model to complement its existing CSE family. The CSD range offers a combination of efficiency, output and quiet operation. Likewise, the efficient CSE50 model extends the CSE range with a cost-effective 55 kW compressed air solution that is suitable for a broad spectrum of industrial applications. The gear-driven CSD compressors are currently available in two sizes. The smaller 55 kW unit (CSD55) has an output pressure choice of 7.5 or 10 bar, and is rated for a maximum free air delivery of 163 L/s. The larger 75 kW CSD75 similarly has a choice of output pressures and can deliver a maximum of 210 L/s. The CSE50 (rated at 55 kW) provides a belt-driven alternative and extends the CSE range from 15 to 55 kW. It has an output pressure of either 7.5 or 10 bar and is rated for a maximum of 141 L/s free air delivery. All three compressors have IP55-rated motors which are fully MEPS2 compliant and feature a totally enclosed fan-cooled (TEFC) design for low temperature rise. IP54-rated electrical cabinets are standard, along with 'deluxe control' to provide multiple compressor sequencing, scheduled on/off switching and remote monitoring. The CSD55, CSD75 and the CSE50 can be further upgraded to meet specific application requirements, with options including 'dirty environment packs', mine electrics and complete skid packaging. Sullair Contact info and more items like this at wf.net.au/P168

30 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

MODULARISED 15″ PANEL PC iBase’s iPPC-1500 15″ panel PC with Intel Atom Processor D2700 features a modularised design fitted with the IB806 motherboard, and the slim aluminium chassis has a professional feel that is quite different from the conventional heavy industrial PCs. It comes equipped with a low-power CPU to minimise overall system power consumption. An automatic light control system detects any changes in the lighting environment so that LCD power consumption can be automatically adjusted according to changes in the external environment. The panel PC supports a digital I/O interface, four USB, audio, two LAN ports, CRT and RS232/422/485 serial ports and a DC-in jack for 12 VDC and optional 9-36 V wide range voltage input. Users can expand the RAM modules and storage hardware without the need to disassemble the whole system. Front panel buttons allow adjustment of brightness and sound. Six hot keys are reserved for user definition. It also has a PCI expansion slot and a 2.5″ HDD drive bay. With a resistive touch panel meeting IP65 standards, the panel PC can be deployed into various work environments and interactive applications including factory automation. A flexible VESA-mount support supports wall-mount, desktop or rackmount installations. Backplane Systems Technology Pty Ltd Contact info and more items like this at wf.net.au/M826

www.ProcessOnline.com.au


CLEANROOM ROBOT ABB has launched an ISO 5 (Class 100) cleanroom version of its smallest multipurpose industrial robot, the six-axis IRB 120. It is designed to eliminate

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the potential for contamination of the manufacturing

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area and the components being processed.

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The IRB 120 Cleanroom variant has been indepen-

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dently tested and certified by the Fraunhofer-IPA

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institute in Europe as cleanroom ISO 5 (Class 100). This robot, with specially painted smooth surfaces, has high accuracy while performing very short cycle times. It can also be mounted at any angle, either in a cell, on top of a machine or close to other robots on the manufacturing line, making it suitable for material handling and assembly applications. The robot comes with the ABB IRC5 compact control which includes user friendly FlexPendant programming, RobotStudio of-

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fline programming, flexible RAPID language and powerful communication capabilities. ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/M583

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SOUND AND VIBRATION SOFTWARE The latest version of the NI Sound and Vibration Measurement Suite software provides a comprehensive collection of analysis and signal processing tools for noise, vibration and

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harshness (NVH) testing, machine condition monitoring (MCM) and audio test applications. Engineers can use the suite as stand-alone software or combine it with NI hardware and NI LabVIEW system design software to simplify test system development and control. The Sound and Vibration Measurement Suite 2011 provides several new features, including a ready-to-run data logging virtual instrument that makes it possible for engineers to save data continuously or based on specific criteria such as triggers or time. Engineers can easily configure the data logger and run it as long as necessary for a variety of sensor types including accelerometer, tachometer and proximity probes. The measurement suite also includes the Sound and Vibration Assistant, a stand-alone software module for quickly acquiring, analysing and logging acoustic, noise and vibration data. Additionally, the software provides easy-

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to-use application examples for impact test and swept sine analysis. These enhancements for the 2011 version add superior flexibility and high-performance capabilities to a variety of sound and vibration measurement projects. By integrating with LabVIEW, the software helps engineers increase test throughput with advanced parallel processing capabilities, among many other advantages of LabVIEW. National Instruments Australia

,i«ÀiÃi˜Ìi`ʘ>̈œ˜>Þ]ÊV>Ê £ÎääÊ  /Ê­£ÎääÊÎÓÓÊÈÎn®ÊvœÀÊޜÕÀÊ œV>Ê-iVœ“i>Ê`ˆÃÌÀˆLÕ̜À° `>>˜iÌ°Vœ“°>ÕɓœÛˆi

Contact info and more items like this at wf.net.au/L952

www.ProcessOnline.com.au

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 31


NEW PRODUCTS

THERMAL FLOW SWITCH The Series TDFS thermal flow switch indicates whether the flow rate is above or below a user set flow rate with NO and NC NPN outputs. Setpoint is easily field set, just tap the included magnet

WIDESCREEN HMI PANELS

on the setpoint target three times at the desired flow rate

Advantech has launched a range

indicators on opposite sides of the unit providing visual

of widescreen 4.3 to 10.1″ HMI

switch indication - green when the flow is above setpoint,

industrial panels for controlling

red when the flow is below setpoint.

and it's done. Incorporated into the unit are two LED status

a wide range of programmable

The TDFS uses an impulse thermal dispersion measure-

logic controllers.

ment technique to measure the flow rate where the probe is

Designed for harsh industrial

heated above the process temperature and then is allowed

environments, the NEMA4/IP66

to cool down to the process temperature. Empty pipe is

WebOP-2000 industrial panels

not a problem with the TDFS unlike some competitor units

feature 128 MB of onboard flash memory and a MicroSD card

that may overheat. Thermal flow switches can offer better

slot for additional applications to run from and store data on. The panels

long-term reliability and life expectancy than mechanical

features over 300 drivers and the company will also custom design

flow switches.

drivers to meet customer needs.

Benefits of the TDFS over mechanical flow switches

The panels are supplied with WebOP Designer which is an easy-to-use,

include: no paddles or vanes to break off into the flow;

object-orientated programming application that enables users to create

no jams or material stopping the paddle movement; no

their own application, saving both time and development costs. Once

seals on movement assembly to wear or leak; low pres-

the developer has written the application and compiled, it can then be

sure drop, only needs to be 10% into the flow (eg, 1/8″

installed via the serial, ethernet, USB or MicroSD ports.

for 3/4″ schedule 40 pipe).

Advantech Australia Pty Ltd N M W_ A D 1 7 . p d f Pa ge 1 1 3 / 0 2 / 1 2 , Contact info and more items like this at wf.net.au/L965

4 : 0 1

P MDwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/P223

Making Air Technology

Register to visit >> nationalmanufacturingweek.com.au co-located with

zone sponsor

32 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

zone partner

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NEW PRODUCTS

DIGITAL PANEL METER The Red Lion PAX2D digital panel meter is a single package featuring a dual counter and dual rate meter, with a third counter and rate display that allows the user to perform math functions. With universal features and versatile programming capabilities, this single meter can suit virtually any digital pulse application. Line one consists of an 18 mm high, 6-digit LCD that can be programmed to show counters A, B or C; rate A, B or C; or the high or low values. The main display also offers three programmable, easy-to-read colours: red, orange and green. The colour change can be linked to programmable setpoints. This feature provides the operator with a visual display of changing conditions, even when they are not close enough to read the meter value. A second display line is a 9 mm high, 9-digit, green LCD that can also be programmed for any of the line one parameters. The 9-digit display accommodates totalising applications that exceed normal 6-digit displays. The meter also offers a programmable custom unit indicator for both displays. In addition to the dual displays, the PAX2D offers features allowing users to stock a single meter for numerous applications. The meter accepts inputs from proximity sensors, magnetic sensors, photoelectric sensors, encoders and simple switches. A universal power supply accommodates both AC and DC inputs. Optional plug-in cards allow users to configure the meter for present applications, while allowing easy upgrades to accommodate future needs. Control Logic Pty Ltd Contact info and more items like this at wf.net.au/P227

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MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 33


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

ENERGY SAVING HAS BENEFITS BEYOND COMPLIANCE

Head Office 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

Dino Alessio, CAPS Australia Pty Ltd

Glenn Johnson wnipt@westwick-farrow.com.au Chief Editor

A

ustralia’s new carbon price is increasing demand for compressors with the greatest energy efficiency. We see Australian companies putting greater emphasis on the benefits of premium-quality compressors over budget equipment than ever before. The carbon price calculation is included in the federal government’s Clean Energy Future Plan and will be based on the National Greenhouse Energy Reporting (NGER) data submitted via the scheme’s OSCAR (Online System for Comprehensive Activity Reporting - NGER Reporting Tool) system. Two key elements of the plan will be a ‘price per tonne’ carbon tax and encouragement of energy efficiency. The plan is designed to encourage industry to develop proactive plans to mitigate any environmental impact of its operations. It is regularly reported that approximately 15% of all electricity consumed by industry is used to compress air. With the carbon pricing regime soon to be implemented, we’ve noticed a definite trend towards purchasing premium two-stage VSD compressors instead of lower-cost alternatives. This stems from the marketplace placing greater emphasis on reducing power costs and lowering emissions. Quality compressors can deliver greater efficiency and improved running costs when compared to cheaper alternatives. More companies are looking to identify the real underlying value of their decisions and not just looking for short-term paybacks. Australian companies are adopting a longerterm view and can see both the energy and emission benefits to be gained by investing in premium equipment. To achieve peak efficiency and reduce operating costs, a two-stage compressor uses less energy to compress a given volume of air when compared to a single-stage conventional compressor. Combining this with advanced synchronous motor technology, such as a hybrid permanent magnet, allows these types of compressors to run at 95% operating efficiency throughout their entire speed range. The motor is controlled by variable speed

Janette Woodhouse

inverters that match compressor output to demand at all times. They are designed to produce the most air using the least amounts of energy - and continue to do this down to loads as low as 20%. Energy consumption can represent 80% of the life cycle costs of compressed air generation in a typical manufacturing plant. Significant savings in operating costs and improvements in bottom line profits can be made by simply upgrading an inefficient compressed air system. Businesses must find a balance between strong financial outcomes and the responsibility for sustainable energy consumption and reduced carbon emissions. Changes made in processes to facilitate sustainability should be viewed as a long-term proposition that rewards with more than just regulatory compliance. Premium compressors are a great place to start looking for savings because they are remarkably efficient, reduce energy usage, help offset rising electricity costs and can also help companies achieve their internal carbon and emissions reduction targets. With many tender documents now asking companies to declare their environmental and carbon footprint reduction policies, and then to report on how they are meeting those targets, installing a premium VSD compressor into the correct application will help users achieve both their energy and their emission reduction targets.

Publisher Geoff Hird Art Director/Production Manager Julie Wright Art/Production Tanya Scarselletti, Katie Dean, Colleen Sam Circulation Manager Sue Lavery circulation@westwick-farrow.com.au Copy Control Mitchie Mullins Advertising Sales NSW/QLD - Nicola Fender-Fox ph: 0414 703 780 nfender-fox@westwick-farrow.com.au VIC/SA/WA - Lachlan Rainey ph: 0402 157 167 lrainey@westwick-farrow.com.au NZ - Jordan King ph: 0800 44 2529 jking@westwick-farrow.com.au USA - Huson International Media East Coast ph: +1 212 268 3344 West Coast ph: +1 408 879 6666 ralph@husonusa.com UK - Huson International Media ph: +44 1932 56 4999 gerryb@husonmedia.com Asia - Lachlan Rainey ph: +61 (0) 402 157 167 lrainey@westwick-farrow.com.au Subscriptions For unregistered readers price on application. If you have any queries regarding our privacy policy please email privacy@westwick-farrow.com.au

Sept 2011 total CAB audited circulation (Aust + NZ) 7,451 readers (92% personally requested)

Starting out as a mechanical engineer, Dino A l e s s i o i s n ow t h e National Sales Manager of CAPS Australia. He has more than 20 years’ experience with compressed air applications and is known in the industry for being customer focused - providing the best solutions in terms of reliability, efficiency and low lifetime cost to organisations both large and small.

34 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP255003/00198 ISSN No. 0819-5447

All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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What’s New in Process Technology Mar 2012