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VOL 06 | OCT-NOV 2013 | ` 100
A U TO M AT I O N & D R I V E S
MEGATRENDS IN AUTOMATION
FOCUS Automotive industry P. 36, 40
Machine tools P. 44
ROUND-TABLE Sensors for the future P. 32
www.AandD24.in
A&D - InterviewDr James TruchardPresident, CEO & Co-founder, National Instruments (p.30)
Capturing the winds of change
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ED I TOR I AL
Automation has the potential to be more objective, more repeatable, more
accurate and quicker to respond. But even then, the most obvious driver fuelling
automation remains the cost and availability of labour, especially in countries
like India. If we consider a pure cost analysis, any manufacturing plant needs to
weigh the cost to acquire, train and retain labour against the cost of purchasing
and maintaining automation systems. In industrialised nations where labour is
scarce and expensive, this analysis is increasingly favouring automation as the
preferred solution, but in case of developing countries such as India it may not.
With increasing globalisation activities, India too is feeling the need to have
global competitiveness, which is making Indian industry look for alternatives to
alleviate their reliance on operators while maintaining high product quality and
production line efficiencies. But to uphold a balanced proposition between the
labour cost and the automation cost, the automation technology is used in
Indian industry mostly in batches and not in a complete package.
With the speed and efficiency of communications today, the value of
maintaining high product quality has increased. At the same time the value of
automation is rising, but the cost of automation is falling. Thus, the equation is
rapidly shifting in favour of automation. So, manufacturers are developing new
technologies, starting with those that offer the greatest value and the fastest
payback for their customers.
A&D India has been reporting on not just the developments in the automation
and robotics sector, but also on new technologies and innovative solutions for
varied application needs of the industry. This issue comes again packed with the
contents that will help you get your wheels running.
Shekhar JitkarPublisher & Chief Editor
shekhar.jitkar@publish-industry.net
Driving automation
3A&D I n d i a | O c t -No v 2013
ED
ITO
RIA
L A
DV
ISO
RY
BO
AR
D Vijay SrinivasanPartner, Effectus Consulting LLP
Anup WadhwaDirector – AIA (Automation Industry Association)
P V SivaramMD – B&R AutomationMember – AIA
Anant MaheshwariManaging Director Honeywell Automation India
Ganapathiraman GVice President & GM (South and South-East Asia)ARC Advisory Group
Ravi AgarwalDirector, Pepperl+Fuchs (Factory Automation)
Raj Singh RatheeManaging DirectorKuka Robotics India
Jasbir SinghVice President – Electrical & InstrumentEssar Project Management Consultants
Dr KLS SharmaAdvisor Automation Education & Training
Mandar PhadkeCEO, Abhisam SoftwareFormer Head – Process ControlLanxess India Pvt Ltd
Arcot RajabahadurAutomation Consultant
Thampy MathewChairman, Fieldbus Foundation IndiaRegional Sales Director, Pepperl+Fuchs (Process Automation)
MICRO-EPSILON | 94496 Ortenburg / GermanyPhone +49 85 42/168-0 | info@micro-epsilon.com
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contents that will help you get your whe
CONTE N T S
Market Management
28 EMERGING MARKETS REMAIN THE KEY
INVESTMENT AREA
Interview with Dr James Truchard,
President, CEO & Cofounder,
National Instruments
Automotive industry
36 AUTOMOTIVE CARRIAGES ON THE MOVE
An article on a major automotive
manufacturer which used wireless
I/O and advanced control for its
EMS conveyor
40 SHAPING THE FUTURE OF AUTOMOTIVE
MANUFACTURING
A read into the various benefits of
using intelligent networked
automation for increased
profitability
Machine tools
44 MACHINE TOOL AUTOMATION
The article highlights machine tools
that have reached a very high
standard in terms of machining
power, accuracy, speed, robustness
and cost efficiency
Focus
10 NEWS
16 “ INNOVATION COMES FROM TARGETED
APPLICATIONS”
Interview with Somshubhro Pal
Chowdhury, MD, Analog Devices
India
18 “DEVICE MANUFACTURERS NEED
MULTI-CONNECTIVITY”
Interview with Umesh Sakle,
CEO & Country Manager,
Hilscher India
20 “CONSISTENT AND STRUCTURED APPROACH
TO DESIGN”
Interview with Mayur Agarwal,
Business Development Consultant,
Honeywell Process Solutions
Market Trends
22 THE FUTURE OF INDUSTRIAL AUTOMATION
An article discussing the roadmap of
the automation industry in the
future
Round-Table
32 SENSORS FOR THE FUTURE
Industry experts in discussion on
the technology developments and
trends in the sensor market
ROBOTICS & HANDLING
48 Moving towards a potential win
A brief insight into the market
forecast for industrial robotics
70 Showcasing new age
technologies
Event report on 11th annual NIDays
2013 held in Bengaluru
CONTENTS
Cover Story
26 CAPTURING THE WINDS OF CHANGE
The article analyses and suggests
measures to make the most of the
current trends in automation for a
sustainable and profitable future
ROBOTICS & HANDLING
52 Taming the robot
A development story on how B&R
boosted robot safety to a level that
allows humans and robots to work
hand-in-hand
56 Innovative milling robot
A case study on the development of
a milling robot as a special purpose
machine
MANUFACTURING IT
60 3D modelling
A look into the use of Siemen’s 3D
modelling software by Vishwakarma
Engineering Works
62 Shortening product
development time
A case study on how Tetra Pak CPS
uses CD-adapco’s STAR-CCM+ for
computer aided engineering
Technology
New Products
76 Spring loaded terminal blocks;
Output circuit protection relay;
Precision regulators; Power
supply units
77 Standardisation & automation
software; CAN repeaters;
Brushless motor; Industrial
wireless access point
78 Compact AC drives; Pressure
transmitters; Online colour
measurements; Frequency
inverters
Columns
07 Editorial
08 Contents
80 Highlights - Next issue
80 Company index
66 EDUCATION & TRAINING
Getting your humanware ready
The article stresses the need to build
human competency for future
automation & instrumentation industry
requirements
TECH TALK
72 Cabling solutions for automotive
applications
An insight into cabling solutions for
crane and drag chain applications
73 Protection from arc flash
The article deals with arc resistant
equipment that can help protect
employees working on or near
energised equipment
74 SENSORS & ENCODERS
Redefining the future
A look at the latest innovations
introduced in the Indian market by
leading sensor manufacturers
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MARKE T | NEWS
10 A&D I nd i a | O c t -No v 2013
Tech Talk on Field Device Integration (FDI)
ISA Bangalore hosted a Tech Talk on 31 August, 2013, by Prasanjeet Padhy,
Senior Engineer, R&D, ABB. The five major automation foundations,
including the FDT Group, Fieldbus Foundation, HART Communication
Foundation, PROFIBUS & PROFINET International and OPC Foundation have
developed a single common solution for Field Device Integration (FDI).
Implementation of the extended scope was supported by seven major
supplier companies — ABB, Emerson Process Management, Endress+Hauser,
Honeywell, Invensys,
Siemens and Yokogawa.
FDI technology is
expected to provide a
common solution for
managing information
of intelligent field devices for the various tasks associated with all phases
of its lifecycle, configuration, commissioning, diagnostics and calibration.
This makes different solutions for different devices obsolete. FDI is a truly
unified solution that addresses end user requirements across the spectrum.
It is focused on device integration for process automation. The goal of FDI
is to provide a common solution based on device integration technologies
EDDL (Electronic Device Description Language) and an FDT based DTM
(Device Type Manager).
wind regime, end-to-end solutions for extraction, transportation and use
of oil & natural gas, to various offerings in breaker solutions for the
electrification industry. The GE
appliances stall boasted a 3D printer
in action and GE Global Research
highlighted futuristic technologies
like contactless power transfer,
battery integrated and wind turbines.
GE ITC also took the opportunity to
showcase some of the great
initiatives at the centre, including
community service projects that are
engaged in, wellness initiatives rolled
out by GE’s corporate wellness
program Health Ahead and GE
Women’s Network for advancing the
careers of diverse employees. The
centre’s cultural club, DRC also
entertained the audience with a flash mob and a concert by the in-house
rock band.
> MORE@CLICK ADI03306 | www.AandD24.in
B&R & Alstom present POWERLINK
The Eleventh India Forum, hosted by the ARC advisory group in Hyderabad,
attracted over 230 delegates, including thought leaders and decision
makers from key industrial segments,
end users and technology solution
providers. As a technological leader
in the automation industry, B&R and
its customer Alstom were invited to
present on the topic of real-time
deterministic, redundant networking
for power plants using POWERLINK.
Alstom uses B&R technology and the
open Ethernet POWERLINK protocol
as a communication backbone to
optimise plant efficiency. Over the
years, the use of Ethernet in power
plants has evolved from shared,
bridged and switched networks to deterministic real-time Ethernet one
thousand times faster than traditional fieldbus technology. “As an open
communication protocol based on standard Ethernet, POWERLINK is well-
prepared for future evolutions,” said Rajeev Sharma, VP & MD, Alstom
Power Automation & Controls.
> MORE@CLICK ADI03307 | www.AandD24.in
Rajeev Sharma, VP & MD, Alstom
Power Automation & Controls
addresses at the Eleventh India
Forum
> MORE@CLICK ADI03305 | www.AandD24.in
Carnival of innovation
GE Technology recently hosted Tech Mela 2013, a two-day technology
extravaganza showcasing innovations, in Bangalore, from 5 to 6 October
2013. With an attendance of over
4,500 employees and family members
from the R&D centre it showcased
products and technologies from
various GE businesses located at the
John F Welch Technology Centre. It
varied from a ‘Tunnel of Innovation’
where GE Healthcare took the audience
through the different stages of life and
the healthcare needs associated with
each, the magnificent CF6 engine that
took pride at the GE Aviation stall, to
the demonstration of GE
Transportation’s railway signaling
solutions on a model track.
Energy businesses GE Power & Water,
Oil & Gas and Energy Management showcased their technologies in the
sectors that varied – from wind offerings customised for the Indian low
Tech Mela 2013 showcased products and technologies from various GE
businesses located at the John F Welch Technology Centre
MARKE T | NEWS
12 A&D I nd i a | O c t -No v 2013
Control Techniques celebrates 40th anniversary
Control Techniques recently celebrated its 40th anniversary. The company,
which is headquartered in the UK, was originally founded as KTK on 4
October 1973. “I am proud to be
leading this fantastic company. I
would like to thank all employees,
past and present, for the hard
work that they have put in over the
past 40 years to make Control
Techniques the global success
story. Last year, Control Techniques
had launched Unidrive M, the first
family of drives that is dedicated
specifically to the manufacturing
automation market. I believe that
our ongoing commitment to
technical innovation will ensure
Control Techniques’ continued
success,” said Enrique Miñarro Viseras, President, Control Techniques.
Control Techniques has manufactured, engineered and designed centres in
the UK, the US, France, China and India, as well as sales operations in over
100 countries. Currently, the company employs about 1,971 people.
> MORE@CLICK ADI03308 | www.AandD24.in
Control Techniques has manufactured,
engineered and designed centres in
the UK, the US, France, China and
India, as well as sales operations in
over 100 countries
Alstom inaugurates its competence centre
Alstom has recently inaugurated the digital substation automation
competence centre in
Pallavaram, Chennai. The
competence centre is a
cornerstone of Alstom’s
commitment to the development
of the Smart Grid in India and
will showcase its leading smart
grid technologies. It is expected
to strengthen Alstom’s know-
how in digital substation
automation technology and
support its strategy to develop the substations of the future.“Energy utilities
worldwide are experimenting with new smart grid systems, adding a new
layer of digital equipment into their existing infrastructures to interconnect
all assets. “The inauguration of the digital substation automation
competence centre is a milestone for Alstom from a global perspective, and
represents our commitment to pursue R&D and deployment of smart grid
technologies in India,” said Patrick Plas, Senior VP — Power Electronics &
Automation, Alstom Grid. The development of a fully digital substation is
vital to the transition from conventional electrical grids to smart grids.
in member services and support.” The Fieldbus Foundation and HART
Communication Foundation have worked extensively together in the past
and have a long history of cooperation. For
example, the two organisations have worked
together on the development of common
international standards such as Electronic
Device Description Language (EDDL) and
recently, the development of the Field Device
Integration (FDI) specification. The merger
offers significant potential to harmonise
many aspects of the two protocols, making it
easier for end users and suppliers to
implement the technology and obtain the full
benefits of each technology in plant
operations and maintenance. In preliminary
discussions, Richard J Timoney, Fieldbus
Foundation and Ted Masters, HART
Communication Foundation, added that many
synergies already exist and the decision will provide momentum for a
major step forward in the evolution of intelligent devices and the world of
industrial communications.
> MORE@CLICK ADI03309 | www.AandD24.in
> MORE@CLICK ADI03310 | www.AandD24.in
The competence centre is a will showcase
its leading smart grid technologies
Dr Gunther Kegel, Chairman & Board of Director; Larry
Obrien, Global Marketing Manager & Rich Timoney,
President & CEO, Fieldbus Foundation in FF Technology
Conference at Automation 2013
Merging plans
Fieldbus Foundation and HART Communication Foundation has announced
their willingness to merge the two organisations into a single industry
foundation dedicated to the needs of
intelligent device communications in the
world of process automation. The Chairmen
of these two organisations—Dr Gunther
Kegel, Fieldbus Foundation and Mark
Schumacher, HART Communication
Foundation—issued the following statement
on behalf of their boards of directors. “We
believe combining the resources and
capabilities of each foundation into a single
organisation that will provide significant
benefits to both end users and suppliers. For
end users, a single organisation that
combines the power of both Fieldbus
Foundation and HART Communication
Foundation would provide a full solution that
addresses every conceivable aspect of field communications and intelligent
device management for the process industries. For suppliers, a single
organisation would create efficiencies in resource utilisation, consistency
of processes and procedures, and would deliver significant improvements
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MARKE T | NEWS
14 A&D I nd i a | O c t -No v 2013
VDMA engineering summit
The 2nd VDMA Engineering Summit was held on 30th September, 2013, at
Taj Vivanta, Bengaluru. Around 110 members attended this prestigious
event. After a successful debut in
Pune last year, the summit was
held in Bangalore offering a
platform for exchange in
engineering sector and expand the
network within VDMA members.
The summit started off with a
welcome message from Rajesh
Nath, MD, VDMA India. Nath
mentioned that the exports of
German machinery to India
touched 3.2 billion euros in 2012.
With this the exports of German
machinery to India have increased
by 7 times in the last 12 years. The
exports of machinery from India to Germany attained a figure of around
500 million euros indicating an increase of 5 times in the last 12 years.
The Chief Guest, Joern Rohde, Consul General, Federal Republic of
Germany, Bengaluru, reiterated the strengthening bonds between India
SPS confirms 2014 edition with 75% of booth space
SPS – Industrial Automation Fair Guangzhou has officially confirmed its
2014 edition. The fair will be hosted at the China Import and Export Fair
Complex in Guangzhou from 3 to 5
March, 2014, where leading
domestic and overseas suppliers
will showcase the latest
advancements in automation
technology. At the 2013 edition, 448
exhibitors from 15 countries and
regions had participated. With the
increasing demand for automation
technology, especially in China’s manufacturing sector, the 2014 fair is
expected to achieve an even higher figure in exhibitor recruitment.
“We had reached some great heights for our niche sector in 2013, and I
believe we will continue this momentum into 2014. For the next edition,
we expect to attract over 500 exhibitors from around the world, and
utilise 35,000 sqm of exhibition space,” said Louis Leung, Deputy
General Manager, Messe Frankfurt. Approximately 75% of booth space
has already been reserved by top firms such as Autonics, Beckhoff,
Contrinex, Higen Motor, Kacon, Mecano, Sanyo Denki and Ushio.
Red Lion panel meters win control design
Red Lion Controls, the global experts in communication, monitoring and
control for industrial automation and networking, was recently recognised
for its industry-leading panel meters by Control Design Readers‘ Choice
Awards 2013. This is the 13th
consecutive year that the readers
of Control Design have selected
Red Lion as the top provider of
panel meters in the industry.
“Being recognised by our customers
for the 13th time in a row in the face
of fierce market competition reaffirms our determination to continually
develop the best industrial automation solutions in the industry,” said
Jesse Benefiel, VP - Product Management, Red Lion Controls. To
determine this year’s winners, Control Design had sent questionnaires to
approximately 15,000 magazine subscribers who work directly with
industrial automation and control products. The questionnaire included
an unaided ballot in which participants were asked to identify the
vendors that came to mind in response to the questions. Respondents
had to pull Red Lion’s name from memory or experience, further
validating the company’s products and services.
The 2nd VDMA Engineering Summit was held on 30th September, 2013, at
Taj Vivanta, Bengaluru
SPS – Industrial Automation Fair
Guangzhou will be hosted at the China
Import and Export Fair Complex in
Guangzhou from 3 to 5 March, 2014
and Germany and the increased bilateral trade between the 2 countries
that crossed 17 billion euros in 2012. This was followed by the address
of M Maheshwar Rao, Commissioner,
Industrial Development & Director,
Industries and Commerce, who
elaborated on the skilled labour
problem that India has been facing
and the measures that has been
taken by the Karnataka government
to counteract these problems.
Ulrich Ackermann, Managing
Director — Foreign Trade Division,
VDMA Frankfurt, elaborated on the
growth of Indo-German relationship
over the years. He stated that India
was Germany’s 20th largest trade
partner in 2011 (Statistisches
Bundesamt, 2012), the previous year witnessed India climbing up the
ladder finishing as 10th largest partner in the mechanical engineering
sector.
> MORE@CLICK ADI03312 | www.AandD24.in > MORE@CLICK ADI03313 | www.AandD24.in
> MORE@CLICK ADI03311 | www.AandD24.in
16
MARKE T | I N TERV I EW
A&D I nd i a | O c t -No v 201316
‘Innovation comes from targeted applications’
Somshubhro Pal Choudhury, Managing Director, Analog Devices India, shares his insights on the
recent technologies emerging in the industrial automation and control industry, and
the challenges in automation & instrumentation, during an interview with Srimoyee Lahiri
What is the size & potential of the industrial automation and
control market in India?
In the process control and industrial automation space,
the hardware equipment market in India is approximately
$1.5 billion. It does not include electricity generation
automation equipment, which is captured under the energy
domain. The overall market includes turnkey projects.
Presently, the software market is larger than the equipment
sales. Opportunity for the process control
and industrial automation sector is huge, as
India has barely scratched the surface. The
market is likely to grow at 10-12% CAGR for
the next few years, almost double the rate of
GDP.
Which are the emerging market trends shaping
up in industrial automation and control
segment?
Innovation in this industry typically comes
from targeted applications and less from
application of latest technologies. Wide
ranging sensors for measuring various
ranging parameters in the field and touch
screen interfaces are growing. Another unique characteristic
of such automation is decades of reliability and shelf life of
the equipment. From a communication perspective, industrial
Ethernet is getting much more prominence compared to RS-485
that have been used for generations. Wireless MBus, SubGHz
Zigbee, 6LowPan and are other wireless sensor protocols are
emerging. With myriad of communication protocols in use,
conversion of one protocol to another is a major requirement
to make the system more flexible and evolve to work with
newer and more standardised protocols.
Another area where activity has been witnessed is the
machine vision technology in the shop floor to look and flag for
defects in production. Mounted digital cameras on the assembly
line can check a high resolution image of the unfinished or
finished product and compare against a known good image to
highlight and provide alert on defects during the production.
This can also be used as a screening tool. Improving energy
efficiency at the factory level, with accurate measurement of
energy in real time, power factor measurement and ways to
improve it, time of use metering, effective temperature control,
energy management systems and energy efficient machinery
are some of the latest trends in the industry.
Which challenges lie in the Indian manufacturing sector in terms
of automation and instrumentation?
Cost of automation is one big reason
why small to medium size Indian
manufacturers have slowed down to take
up automation and justify their ROI. The
good news is that Indian manufacturers,
who are adopting automation now, do
not have legacy systems in place like
their counterparts in more developed
manufacturing intensive economies.
Therefore, Indian manufacturers need
to go for the latest standard based
technologies.
What is your agenda for 2013-3014?
To help Indian manufacturers and designers go to market
faster, we are working on more ready solutions in the form
of reference designs and ‘circuits from the labs’. We are doing
regular and targeted webinars & seminars to educate our
customers on the technology and solutions available with us in
these domains. We are also doing matchmaking between the
customers and Indian design houses if they want to partner for
quick technology development to reach market faster.
In 2013-2014, our goal is to gain market share. We will
add field application engineers and sales staff to augment our
coverage with our customers, add system specialists as and
when required and leverage the large design team we have
in our Analog Devices India product development centre in
Bangaluru. ☐
> MORE@CLICK ADI03314 | www.AandD24.in
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18
MARKE T | I N TERV I EW
A&D I nd i a | O c t -No v 201318
‘Device manufacturers need multi-connectivity’Umesh Sakle, CEO & Country Manager, Hilscher India, briefs on the strategic plans of the company
in India, technology trends in industrial communication and how Indian firms
are open to experimenting the hi-tech industrial communication technology with more
functionality. Excerpts from his interview with Shekhar Jitkar…
What are your strategic plans for the company, as you take over
as the CEO of the company?
Adaptation to the customer needs with swift expert response is
very important to succeed in India.
My aspiration is to help Indian people use hi-tech
industrial communication products. Unfortunately, India
being a very cost sensitive market, our strategy for the next
few years is not the profit, but penetration of our products in
the market so that Indian customers will benefit from our low
cost & technologically advanced gateways,
embedded modules, PC cards, net analysers
& other communication solutions.
Industrial communication technology is
going beyond the traditional industrial
automation solutions from fieldbus systems
to technologies based on the Ethernet. What
are the trends today?
From traditional discreet wired control
systems to de-centralised control systems
such as fieldbus, industrial communication
technology is moving towards distributed
intelligence using industrial Ethernet.
Fieldbus is still the dominating technology
but all network development and news are focused on industrial
Ethernet which is replacing common fieldbuses and there are
different standards in the world for Ethernet like Profinet,
Ethernet/IP, Modbus TCP, etc.
Hilscher deals with technologies that cover a very broad range
from CANOpen, CC-Link & DeviceNet to Profibus & Profinet.
Which are the fast-moving technologies in India?
As far as Hilscher is concerned, apart from the sales of our
standard protocol solutions, we also provide customised
solutions as per the customers’ requirements. With this, we
offer R&D, programming & customisation support as we want
to simplify technological maze for our clients to help them in
attaining results in a faster and smarter manner. The market for
industrial communication is very fragmented and there will be
no single standard protocol neither today nor in future.
Training is an important element in such hi-tech industrial
communication field. How does Hilscher take care of the training
for its customers, in India and globally?
Products, technologies and service at the leading edge of
industrial communication technology is our requirement.
We want to be measured by the success of our customers
with their competitive products. Being a world leader in hi-
tech industrial communication our staff
of R&D engineers, sales & application
engineers must have wide and deep
product knowledge. They always must be
prepared to support customers. For that,
we invest a lot in training and education
of our engineers. Together with our
customers we have to develop hi-tech
industrial communication solutions.
Therefore, a close partnership with our
customers is very important globally as
well as locally. We train engineers & sales
team from India at our headquarters
in Germany for technical support and
innovative use of our products. After this
traineeship they return to India and impart the same training
to our distributors & customers in India.
Do you find Indian firms open to experimenting hi-tech
industrial communication technology with more functionality?
How is your experience so far?
In India, device manufacturers need multi-connectivity to
serve a wide range of automation applications and vertical
market segments in order to grow business. Multi-network
connectivity being an entry ticket into the global automation,
Indian firms are quiet open to experiment our hi-tech
industrial communication solutions and this trend is increasing
day-by-day. ☐
> MORE@CLICK ADI03315 | www.AandD24.in
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20
MARKE T | I N TERV I EW
A&D I nd i a | O c t -No v 201320
‘Consistent and structured approach to design’
Mayur Agrawal, Business Development Consultant, Honeywell Process Solutions,
discusses the various benefits of design solutions for the process industry,
during an interaction with Sumedha Mahorey
Please elaborate on the benefits of design solutions for the
process industry.
Today, every process industry needs to optimise their process
designs to achieve more reliable and stable operations. Such
companies should quickly identify optimum designs with
minimum risk of rework to remain competitive and maximise
business performance. At times, process engineers are
challenged with making timely decisions to meet the
business objectives of designing and operating efficient, safe
and profitable plants. Additionally, the industry also faces
challenges with regards to project cost
savings, risk management, engineering time
saving, reducing reengineering, etc. Design
solutions can help mitigate these challenges.
With process design solutions, users can
reduce engineering costs as it provides a
common environment to manage consistent
use of data and models. It also helps mitigate
risks associated with project execution and
reduce feedstock waste (or rework), resulting
in millions of dollars in savings. The design
solution saves 95% of an engineer’s time with
easy-to-maintain optimisation solutions as
well.
Which are the latest technology trends shaping up in this
domain? Lifecycle modeling solution is a powerful methodology that
demonstrates how an investment in simulation software that
can provide comprehensive coverage throughout the entire
lifecycle of a plant, from Front End Engineering Design
(FEED), to operator training, to operation optimisation can be
utilised for maximising the returns. A key enabler for sharing
process modeling information across disciplines is a set of well
integrated tools which allow users to seamlessly expand models
at each stage of the plant lifecycle to meet their specific needs.
The selection of compression system configuration is
also one of the key decisions made during the concept
design stage of new processing facilities. The compression
system configuration not only impacts initial project capital
expenditure but significantly influences the overall system
performance, availability, operating costs and flexibility
throughout the life of the facility.
Which demand trends are emerging in the design solutions
market for process industries?
Some demand trends identified through Honeywell Voice of
Customer program include the customers’
need to be able to select optimum process
and control design through use of steady
state and dynamic simulation; customers’
need of selection of unit operations that
enable them to efficiently construct models
of the required fidelity for the processes
under consideration; customers’ need
to design flare system facilities based on
industry and company standard protocols.
Please highlight the challenges and
opportunities for implementation of design
solutions in India.
Market opportunities by implementing
design solutions can be summarised by certain challenges that
the process industries face. These are project cost savings and
risk mitigation – assessing the effect of the different process
alternatives early in the project lifecycle will have significant
impact in the project economics.
Also, allowing engineers to quickly and easily determine
the cost implications of their process design choices will
reduce the number of hours spent on evaluating expensive
process configurations and validating data to support decision
trade-offs. ☐
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22 A&D I nd i a | O c t -No v 2013
MARK E T | TR ENDS
22
The future of industrial automation
Since the turn of the century, the global recession has affected most
businesses, including industrial automation. Here are the author’s
views on the directions in which the automation industry is moving
Because of the relatively small production volumes and
huge varieties of applications, industrial automation typically
utilises new technologies developed in other markets.
Automation companies tend to customise products for specific
applications and requirements. So, the innovation comes from
targeted applications, rather than any hot, new technology.
Over the past few decades, some innovations have indeed
given industrial automation new surges of growth. The
PLC – developed by Dick Morley and others – was designed to
replace relay-logic and generated growth in applications where
custom logic was difficult to implement and change. The PLC
was a lot more reliable than relay-contacts, and much easier to
program and reprogram. Growth was rapid in automobile
test-installations, which had to be re-programmed often for
new car models. The PLC has had a long and productive life,
since last three decades and has now become a commodity.
At about the same time, another surge of innovation came
through the use of computers for control systems.
Minicomputers replaced large central mainframes in central
control rooms, and gave rise to DCS, pioneered by Honeywell
with its TDC 2000. But, these were not really ‘distributed’ as
they were still relatively large clumps of computer hardware
and cabinets filled with I/O connections.
The arrival of the PC brought low-cost PC-based hardware
and software which provided DCS functionality with
significantly reduced cost and complexity. There was no
Jim PintoTechnology futurist, international speaker & automation industry commentator jim@jimpinto.com
Imag
e co
urt
esy
- S
iem
ens
MARKE T | TR ENDS
23A&D I n d i a | O c t -No v 2013
TRENDS | MARKET
fundamental technology innovation here rather, these were
innovative extensions of technology developed for other mass
markets, modified and adapted for industrial automation
requirements.
On the sensor side were indeed some significant innovations
and developments which generated good growth for specific
companies. With better specifications and good marketing,
Rosemount‘s differential pressure flow-sensor quickly
displaced lesser products. And there were a host of other
smaller technology developments that caused pockets of
growth for some companies. But few grew beyond a few
hundred million dollars in annual revenue.
Automation software has had its day, and can’t go much
further. In the future, software will embed within products
and systems, with no major independent innovation on the
horizon. The plethora of manufacturing software solutions
and services will yield significant results, but all as part of
other systems.
So, in general, innovation and technology can and will
reestablish growth in industrial automation. But, there won‘t
be any technology innovations that will generate the next
Cisco, Apple or Microsoft.
We cannot figure out future trends merely by extending
past trends; it’s like trying to drive by looking only at a
rear-view mirror. The automation industry does not extrapolate
to smaller and cheaper PLCs, DCSs, and supervisory control
and data acquisition systems; those functions will simply be
embedded in hardware and software. Instead, future growth
will come from totally new directions.
New technology directions
Industrial automation can generate explosive growth with
technology related to new inflection points: nanotechnology
and nanoscale assembly systems; MEMS & this includes
nanotech sensors (tiny, low-power, low-cost sensors) which
can measure everything and anything; and the pervasive
internet, machine-to-machine (M2M) networking.
Real-time systems will give way to complex adaptive
systems and multi-processing. The future belongs to nanotech,
wireless everything, and complex adaptive systems.
Major new software applications will be in wireless sensors
and distributed peer-to-peer networks – tiny operating systems
in wireless sensor nodes, and the software that allows nodes to
communicate with each other as a larger complex adaptive
system. That is the wave of the future.
The fully-automated factory
Automated factories and processes are too expensive to be
rebuilt for every modification and design change – so they
have to be highly configurable and flexible. To successfully
reconfigure an entire production line or process requires direct
access to most of its control elements – switches, valves, motors
and drives – down to a fine level of detail.
The vision of fully automated factories has already existed
for some time now. Customers order online, with electronic
transactions that negotiate batch size (in some cases as low as
one), price, size and color; intelligent robots and sophisticated
machines smoothly and rapidly fabricate a variety of
customised products on demand.
The promise of remote-controlled automation is finally
making headway in manufacturing settings and maintenance
applications. The decades-old machine-based vision of
automation – powerful super-robots without people to tend
them – underestimated the importance of communications.
But today, this is purely a matter of networked intelligence
which is now well developed and widely available.
The large, centralised production plant is a thing of the
past. The factory of the future will be small, movable (to where
“The promise of remote-controlled automation is finally making headway in manufacturing settings and maintenance applications”Jim Pinto
24 A&D I nd i a | O c t -No v 2013
MARK E T | TR ENDS
the resources are, and where the customers are). For example,
there is really no need to transport raw materials long distances
to a plant, for processing, and then transport the resulting
product long distances to the consumer. Today, those things
are available globally.
Hard truths about globalisation
The assumption has always been that the US and other
industrialised nations will keep leading in knowledge-intensive
industries while developing nations focus on lower skills and
lower labour costs. That is changed now. The impact of the
wholesale entry of 2.5 billion people (China and India) into
the global economy will bring big new challenges and amazing
opportunities.
Beyond just labour, many businesses (including major
automation companies) are also outsourcing knowledge work
such as design and engineering services. This trend has already
become significant, causing joblessness not only for
manufacturing labour, but also for traditionally high-paying
engineering positions.
Innovation is the true source of value, and that is in danger
of being dissipated – sacrificed to a short-term search for
profit, the capitalistic quarterly profits syndrome. Countries
like Japan and Germany will tend to benefit from their longer-
term business perspectives. But, significant competition is
coming from many rapidly developing countries with
expanding technology prowess. So, marketing speed and
business agility will be offsetting advantages.
The winning differences
In a global market, there are three keys that constitute the
winning edge:
Proprietary products: developed quickly and inexpensively
(and perhaps globally), with a continuous stream of
upgrade and adaptation to maintain leadership.
High-value-added products: proprietary products and
knowledge offered through effective global service
providers, tailored to specific customer needs.
Global yet local services: the special needs and custom
requirements of remote customers must be handled locally,
giving them the feeling of partnership and proximity.
To implementing these directions demands management
and leadership abilities that are different from old, financially-
driven models. In the global economy, automation companies
have little choice – they must find more ways and means to
expand globally. To do this, they need to minimise domination
of central corporate cultures, and maximise responsiveness to
local customer needs. Multi-cultural countries, like the US,
will have significant advantages in these important business
aspects.
In the new and different business environment of the 21st
century, the companies that can adapt, innovate and utilise
global resources will generate significant growth
and success. ☐
Real-time systems will give way to complex
adaptive systems and multi-processing
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26 A&D I nd i a | O c t -No v 2013
COVER STO RY | T ECHNOLOG Y
26
CAPTURING THE WINDS OF CHANGEWith the megatrends in automation sweeping across the global markets
and radically changing the business landscape, companies need to
adapt and modify their business processes to reap the benefits and
emerge as winners in the future
G Ganapathiraman Country Manager ARC Advisory Group, India RamanG@ARCweb.com
COVER STO RY | T ECHNOLOG Y
A&D I nd i a | O c t -No v 2013
27A&D I n d i a | O c t -No v 2013
TECHNOLOGY | COVER STORY
27
Megatrends in automation are altering the way businesses
are conducted globally. The automation landscape is shaped by
a convergence of largely internet and IT-based enabling
technologies. This convergence is likely to remove many
existing constraints to help transform the way manufacturers
and other industrial enterprises operate and collaborate, both
internally and across their extended value chain. In 2011,
automation companies globally saw good growth, but the
subsequent eight quarters showed a decline in growth. This is
largely attributed to the global slowdown.
Megatrends that are changing the direction of automation
and helping companies to succeed in a competitive market
include intelligent devices (ID) and the Internet of Things
(IoT); predictive analytics for big data; cloud computing and
services-based solutions; virtualisation 3D simulation;
mobility-enabled applications; and remote operations/asset
management.
As new technologies and new ways of doing things surface,
more companies feel the need to use the solutions and more
employees throughout the enterprise want more and better
decision-support tools. From top to bottom, the industrial
space is becoming much more dynamic. Manufacturers need
to recognise (or even better, anticipate) rapidly changing
situations in order to take appropriate measures in time to
make a difference. It is evident that in the competitive
marketplace, operations management is the battleground and
the winner is the one who provides better service.
Machine automation trends
Some of the major trends emerging in machine automation
include streamlining production processes and improving the
bottomline. Hardware is becoming ‘smarter’ and
self-configuring, with faster networking capabilities and
built-in diagnostics. This has reduced downtime and increased
productivity as well. Mechatronics is another emerging trend
which integrates mechanical hardware, electronics and
software, leading to more standardised machine sub-assemblies.
Meanwhile, PLM tools are revolutionising engineering with
their holistic approach to products, systems design and ability
to do simulation testing in a virtual environment. DCS
technology has also evolved and emerged as more flexible and
extensible with the merging of IT, increasing use of standards,
building the system around Ethernet and more collaboration
between business and production management functions.
Advanced process control and real-time optimisation are other
emerging automation trends. The range of APC applications
has increased and it has become more practical & adaptive,
and no longer needs an ‘expert’ to keep it tuned. Digital
networks have emerged, Ethernet has become
all-pervasive and process Fieldbus standards – Foundation
Fieldbus, Profibus-PA and HART have a market stronghold.
The demand for intelligent instruments and software to
manage assets (PAM, APM, EAM) is also projected to grow.
Today, most major automation suppliers are supporting
virtualisation in one form or another, predominantly for PC
and/or server virtualisation. Virtualisation also lowers cost of
ownership, empowers disaster recovery for critical production
processes and reduces hardware failures due to its
high-availability architecture. System deployment and disaster
recovery leverages virtualisation technology to quickly get
systems back up and running when computers fail. 3D virtual
technology allows plant engineering and operations groups to
create comprehensive and accurate virtual environments that
represent the complete physical plant/facility. These are used
to help plan operational procedures, train operators and
maintenance technicians and meet health and safety
requirements; all within a computer-simulated 3D environment.
Increasingly, planners also take advantage of this advanced
technology to improve their scheduling activities.
Another visible trend is wireless technology. The prospect
of adding wireless devices to the process automation
architecture is a compelling one from the perspective of
tangible business benefits and incremental operational
improvements. Process industry customers are increasingly
aware of the potential inherent in applying wireless to business
28 A&D I nd i a | O c t -No v 2013
COVER STO RY | T ECHNOLOG Y
challenges ranging from improved process performance,
reliability, and efficiency to conformance with government
mandates.
Cyber security
The fallout of rapid progress in automation is the threat to
cyber security. With organisations becoming more dependent
on network connectivity through mobile systems and other
emerging platforms, security of operations is critical for
business continuity and delivery of services. The growing
complexity of organisational operations, numerous applications,
global architecture, and all-pervasive nature of cyber threats
make security more difficult to achieve. The appearance of the
Stuxnet malware in 2010 dramatically changed the general
attitude toward cyber security for industrial automation
systems and equipment. Post-Stuxnet, it has been a
demonstrated fact that malware can be deployed by countries
as a weapon of war, as well as by hackers, malicious or otherwise.
Such weapons may be extremely difficult to develop, but are
also very difficult to trace to an individual, group, or country.
They may also prove widely effective against ‘soft targets,’
meaning industrial devices and systems that are relatively
insecure.
Industrial cyber security standards and regulations have
generally been developed by vertical industry organisations. A
wide variety of systems and equipment are deployed in critical
automation and control applications (DCS, safety shutdown
systems, PLCs, SCADA systems, drives, intelligent relays,
industrial Ethernet switches, etc). Vertical industry experts
have the specific domain expertise to comprehend how to
prioritise and protect their specific types of assets from cyber-
attack. Every industrial organisation needs to address the
growing challenges of protecting its plants and facilities from
cyber intrusions. Implementing a good security technology
infrastructure is essential, but not a complete answer. Persistent
hackers and cyber criminals will always find new vulnerabilities
and novel ways to exploit organisational weaknesses. A broad
strategy that anticipates change and includes ongoing vigilance
is the only real defence. To prevent cyber-attacks, automation
and IT need to be closely coupled.
Workforce mobility
The emergence of people-centric collaboration technologies
and social networking is an important trend as business
dynamics are changing and the workforce is getting better-
connected. Mobility has also blurred the lines between home
and office. The era of connected devices is already upon us. In
2012, there were more than 10 billion Wi-Fi-connected devices,
with projections for more than 50 billion devices to be
connected by 2020. This will include more than 5 billion
smartphone and internet users, most cars, and many home
appliances. Free or inexpensive mobile platforms will dominate
the market. Intelligent devices and IoT have broad ramifications
for industry, particularly for asset management, process
management, remote operations management, safety and
security, and supply chain applications.
This is just one side of the story. With the advancement of
technology and workforce mobility, another important angle
emerges – the retirement of the ‘Baby Boomers’ (those born
between 1946-62) and the entry of the Millennials. According
to an ARC report, “The Millennials are a generation of digital
natives that adapt quickly to new technology with a penchant
for experiential learning over extensive training and manuals.”
The retiring generation, the ‘Baby Boomers’, has certain
characteristics that will be missed when they leave the
workforce – mainly experience and knowhow. Due to this
impending loss of experience, companies will need to put a
combination of technologies, processes, and training in place
to allow the new generation, the ‘Millennials’, to be effective.
The middle generation, the ‘Gen Xers’, will also be impacted
and, in many organisations, will be expected to fill leadership
roles.
28
Hardware is becoming ‘smarter’ and
self-configuring, with faster networking
capabilities and built-in diagnostics
Co
urte
sy: H
anno
ver
Mes
se
29A&D I n d i a | O c t -No v 2013
TECHNOLOGY | COVER STORY
Cloud computing
Cloud computing is a new computing model that features
the intensive use of remote computing services (processing,
storage, networking, and software). Cloud architectures are
particularly useful for scaling up computing tasks that can be
parallelised. Though relatively new in the commercial/
industrial space, it already has tremendous industry patronage
as it has been developed to support internet applications of
major software and internet firms such as Google, Amazon,
Apple and Microsoft.
Cloud represents a new model for IT, challenging an
organisation’s established IT practices in every area; new
platforms, new services, new deployment, licensing, and
support models. Cloud forces an IT organisation to examine
each application within its portfolio and reevaluate the way the
application is currently deployed and supported. From a
business standpoint, the cloud model offers several potential
advantages over the traditional IT service model, including
rapid deployment, elasticity, reduced capital investment, and
increased access and mobility across a global enterprise.
The cloud model can form part of the answer to the huge
explosion of smartphones and tablet devices that now confront
IT organisations. Since cloud services are by nature external to
an enterprise, the gap that develops between internal and
external capabilities becomes less relevant for cloud-based
applications. While there are other solutions for mobility
problems, cloud-enabled location-independent support for
user mobility is one potential advantage of cloud services.
Information-driven companies
Today, there is a glut of information and companies who
can filter, record and easily access this information will succeed.
Information-driven companies are moving to a culture and
business model in which all decisions are made based on
analysis of process and business process data. Throughout the
organisation, these companies employ software to collect,
contextualise, visualise, and analyse data to gain new insights.
Armed with new insights, organisations can anticipate changes
and drive better business results. The culture of an
information-driven company is based on real-time analytical-,
data-, and information-based decisions.
Information-driven companies employ advanced analytics
throughout their value networks, business processes, and
decision-making to support corporate initiatives such as
energy management and sustainability programmes; global
growth initiatives; and innovation in product, process, systems,
and business models. They also employ advanced analytics
throughout the supply chain in design & engineering,
production, and with partners and customers. Interest in
analytics and business intelligence (BI) software has surged
over the last few years. Leading software providers offer full
analytics suites for enterprises to use to monitor, analyse, and
manage a wide range of business activities. Manufacturers use
analytics in a number of applications. They benefit by applying
analytic techniques to support continuous improvement
initiatives, plant performance monitoring, decision support,
predictive maintenance, generating KPIs, process control, and
quality control. Analytics can also be used to identify and
correct production anomalies, improve control, and make
continuous improvements.
With megatrends in automation sweeping across the global
markets, radically changing the business landscape, companies
which adapt to these winds of change will reap the benefits and
emerge as winners in the long run. ☐
> MORE@CLICK ADI03318 | www.AandD24.in
CLOUD DEPLOYMENT MODEL
Private cloud
The cloud infrastructure is provisioned for exclusive use by a single
organisation comprising multiple consumers (e.g. business units). It may be
owned, managed, and operated by the organisation, a third party, or some
combination of them, and it may exist on or off premises.
Community cloud
The cloud infrastructure is provisioned for exclusive use by a specific
community of consumers from organisations that have shared concerns
(e.g. mission, security requirements, policy, and compliance considera-
tions). It may be owned, managed, and operated by one or more of the
organisations in the community, a third party, or some combination of them,
and it may exist on or off premises.
Public cloud
The cloud infrastructure is provisioned for open use by the general public. It
may be owned, managed, and operated by a business, academic, or
government organisation, or some combination of them. It exists on the
premises of the cloud provider.
Hybrid cloud
The cloud infrastructure is a composition of two or more distinct cloud
infrastructures (private, community, or public) that remain unique entities,
but are bound together by standardised or proprietary technology that
enables data and application portability (e.g. cloud bursting for load
balancing between clouds).
SOURCE: NATIONAL INSTITUTE FOR STANDARDS AND TECHNOLOGY – USA
MANAGE ME N T | I N TERV I EW
A&D I nd i a | O c t -No v 201330
‘Emerging markets remain the key investment area’Discussing at length, how cyber physical systems
have enabled integrated decision-making across
the enterprise, Dr James Truchard, President,
CEO & Co-founder of National Instruments
(NI), in this conversation with Sumedha
Mahorey, points out the roadmap & benefits of
open systems and NI’s focus on emerging markets
As per Industry 4.0, do you see cyber physical system as the backbone of the next industrial revolution? Presently, many technologies have converged. Today, we have
outstanding information technology infrastructure in terms of
the cloud, internet, computing power, etc available locally in
the form of servers. We have also added front-end capabilities
for data acquisition, analysis and control. So far, we can scale
across an enterprise, use big analog data that is required from
the systems to make better decisions, make more efficient
use of energy, initiate better components with less failure
rate, in other words, make the work processes more efficient,
adding value throughout the whole chain of manufacturing
till the customers’ end. These new age processes have also
enabled the flow of information from the customer in terms
of feedback which helps in integrated decision making across
the enterprise.
Can you elaborate on the evolution of cyber physical system since the incubation of Industry 4.0 concept?One of the key ideas based on the cyber physical system that
has been put forward in Industry 4.0 is that historically certain
advanced control algorithms, analysis and measurements
are accessible, within a small number of companies. Now,
with open systems, the availability of algorithm, technology,
software, and with a platform-based approach, for almost any
technical problem, we can develop algorithms as any specialist
somewhere in the world can apply his expertise to the platform
and make the right solution available.
This can really change the perspective on what’s proprietary
technology and what’s open & available across the globe. For
example, with this platform-based approach, iOS has enabled
1 million different applications. We see the same trend for
cyber physical systems. Engineers will use these platforms to
A&D I n d i a | O c t -No v 2013 31
I N TERV I EW | M ANAGEMENT
Basically, at the core we leverage Moore’s law to give us more
performance, capability, higher speed, acute measurement and
so forth. Our investment is to make technology available to
scientists and engineers. To do that we have to stay on the top
of the technology curve, stay up with Moore’s law and make
software space compatible as we scale it. In our demonstrations
during NI days in India, we have showcased how we have
moved from one processor to another, one operating system
to another in the customer’s application range. This is the
philosophy that we have and it takes a great deal of investment
to give customers the benefit of ‘convenient use’.
Any global investment plans in the offing?We are constantly looking at what we can do. We have done
quite a bit of expansion over the last couple of years and will
continue to be looking at where we need to expand and invest.
The emerging markets remain the key investment area as we
have seen the fastest growth for our products in these regions.
We will continue to invest in these emerging markets.
How is NI aligned to the future roadmap of Industry 4.0?Our first goal is to make certain that our technology addresses
some of the key needs in that space – Wi-Fi technology, ability
to work in the cloud with analysis and complication, the ability
to aggregate multiple sites, so that one can make decision to
control over distributed networks and also have the algorithm
available to address advanced complex needs.
As the leader at NI, what is your agenda till 2015?In the time frame till 2015, we will be very focused on educating
engineers and scientists on our vision for graphical system
design and cyber physical systems using our technology, and
how it can be applied for solving specific problems in R&D, in
testing of products, and in newer areas. ☐
create thousands of applications that serve a diverse range of
industries.
Which is the top trend that has emerged from the cyber physical concept?The top level is currently using information throughout the
whole process, from the front line, i.e. acquisition of material
to construction of the products throughout the backend
service, including bringing in the feedback from the customer
with real-time information integrated throughout the whole
process.
With over 700 attendees, how significant is NI Days for the Indian market?The most important thing that we do is to educate engineers on
the present opportunities that they have in solving problems.
That is why we work with over 7000 universities around the
world and around 600 in India. Education is a very important
part of our operations, and we want to make that information
available, train engineers on how to use these tools, so they can
be most productive. NI Days is one of the key initiatives where
we stress on education, and showcasing new solutions.
With new launches and new product portfolios in your domain, which demand trends are you witnessing globally?We have been quite successful as we have evolved our vision
from virtual instrumentation to graphical system design, where
we are doing some of the most advanced measurements for
RF & communication applications as well as general purpose
data acquisition. We are now getting into implementation of
next generation systems using our technologies as the base, for
example, CompactRIO, or BST PXI system for implementing
very complex next generation systems.
With innovation coming in with every product, how has been investment in R&D worked out?
“With open systems, any specialist somewhere in the world can apply his expertise to the platform and make the right solution available”Dr James Truchard
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Sensors for the futureWith multiple sensor categories gaining traction amid the current
recessionary times, this feature analyses the various new age
applications and technologies that are making the rounds in
the Indian sensor segment and suggests the themes of future
developments in this domain.
As per recent reports, the Indian sensor market is growing
rapidly with the fastest growing segments being gas sensors,
image, accelerometers and position sensors. Continuous
technological innovation and increasing application areas for
these new age sensors are pushing their demand in the market.
With this in the backdrop, the sensors market is expected to
grow at the CAGR of 14% till 2018. Analysing the current
technology trends that are satisfying the need for innovative
products and futuristic technologies in the Indian market are
industry experts – Johann Salzberger, Managing Director –
Marketing and Sales, Micro-Epsilon; Ravi Agarwal, Director,
Pepperl+Fuchs (Factory Automation); Sunil Hasabnis,
Managing Director, Baumer India; Bipin Jirge, Managing
Director, ifm electronic India Pvt Ltd; Deepak Aran, Country
Manager – Sales & Marketing, Contrinex Automation Pvt Ltd;
Deenar Patil, Senior Manager – Key Accounts, Schmersal
India; and Vikrant Agashe , Sales Manager – Sensors &
Components, Gefran India.
Technology landscape
Globally, the sensor technology has changed from purely
electrical transducers to mechatronic-based systems.
Commenting on this, Salzberger notes, “This means, today
sensors are equipped with more electronics and integrated
intelligence, micro-computers and software. In terms of
measurement principles, the importance of optical, laser sensor
systems and vision technology is constantly increasing.” In
today’s scenario, every sensor company is also focusing on
smart & miniaturisation technology coupled with designs
amenable to modern production techniques that ensure least
human error and improve overall product reliability. There is
also a growing trend towards developing industry specific
sensors. Highlighting this, Hasabnis says, “Advanced sensing
technologies are offered for edge, positioning, profile
measurement & sensing applications at higher speeds &
accuracies which were not possible till date. Some latest design
Sumedha MahoreyDeputy Editor sumedha.mahorey@publish-industry.net
ROUND - TABLE | MA NA GEME N T
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throw challenges for manufacturing and automation.
Elaborating on the market factors that are influencing sensor
technology developments, Agarwal explains, “Speed, reliability
and consistent performance in an application are the governing
factors for proven solutions. The cutting edge designs are
pushing for detection and measurement.” On similar lines,
Aran says, “Major influencing factors are the latest
communication protocols of automation, environmental
conditions of sensing applications and the economy.
Technocrats want sensors which are compatible with latest
communication protocols, sensors with high accuracy, able to
work in high temperatures, pressures and all sorts of
environment like underwater, space, etc and at competitive
prices.” As per Agashe, the influencing market factors include
competitive differentiation. He notes, “Over the past few years,
a number of developments in the industrial sector have
facilitated low-cost sensor solutions. Reduced operating costs,
enhanced performance and a high return on investment all
drive technology development.” Summarising the factors for
new product development, Hasabnis says, “Product versatility
trends include Internet bus communication; analogue output;
modular & flexible designs and IP rating up to IP 69K.” Adding
to his thoughts, Agarwal points out, “There seems to be a
paradigm shift along two streams. Traditional domain of
industrial sensing is seemingly pushing for sensors to be
smarter and communicating. Not only are the sensors being
expected to measure absolute value of the parameter but also
to effectively communicate it into the network. This is also
impacting diagnostics, interoperability and machine/process/
network design and management. In the embedded technology,
MEMS which relates to motion and orientation sensing is
doing wonders.”
Market demand-supply position by 2015
The demand is increasing for automation, safety & control
devices as users now demand more safe solutions. Asserting
this, Patil avers, “By 2015, the market demand will increase as
the machines are getting smarter with minimum wiring
between control system and field sensors. Now, control devices
for cranes/hydraulics press machines can be controlled
remotely, safely and efficiently.” Sharing his views, Hasabnis
avers, “Market demand and supply position address and meet
the changing customer profile. On one hand, demand for
automation & sensing products is increasing even under
difficult economic conditions in sheer volume terms. However,
other side of the same trend is increasing pressure on price and
number of ‘me too’ products offered at ridiculously low prices.
On the positive side, there is increasing trend towards global
standard suppliers by all the major global OEMs and end users.”
Adding further he says, “The trend towards 2015 is definitively
that technology gap among different manufacturers will
narrow and great companies will get more distinguished by
value addition they offer rather than just the product & price.”
Adding to this, Salzberger says, “The future market will need
more sensors in general and more sophisticated sensor
solutions in particular. In the field of displacement
measurement different sensor technologies will be required,
because there is no universal measuring principle which can
solve the whole variety of measuring tasks. There will be a
trend to more integration, more miniaturisation and more
intelligence.”
Factors influencing technology developments
New age industrial and consumer products consistently
“Speed, reliability and consistent performance in an application are the governing factors for proven solutions”Ravi Agarwal, Director, Pepperl+Fuchs (Factory Automation)
“By 2015, the market demand will increase as the machines are getting smarter with minimum wiring between control system and field sensors”Deenar Patil, Senior Manager – Key Accounts, Schmersal India
“The future trend will be towards more integration, miniaturisation and intelligence”Johann Salzberger, Managing Director – Marketing and Sales, Micro-Epsilon
“The future of wireless technology will much depend on the reliability they can offer in the field”Sunil Hasabnis, Managing Director, Baumer India
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for different applications; compact size; low-cost manufacturing
cost; reliability & one box design; exactly engineered products;
better cost to performance ratio; shift towards robust
technologies such as magnetic; wireless technologies; and
user-friendly internet connectively for monitoring control and
configuration of the sensor, are the major factors influencing
the sensor technology developments.” Thus, as per Jirge, with
the Indian market accepting appropriate automation levels in
many industries, as the market develops further, the demand
or the acceptance for higher technology sensors will only
increase. This will lead to development of complex sensors at
more affordable price points with the growing market.
Sensors gaining market traction
So, with multiple reasons for new technology development,
which type of sensors will be gaining traction in the current
market scenario? Answering this, Aran points out that apart
from higher expectations from inductive and photoelectric
sensors, a lot of interest and thrust is seen on RFID Identification
sensors. Elaborating in brief on the topic, Agashe asserts, “The
future of sensors is highly dependent on sensor technologies
such as microelectromechanical system sensors, wireless
sensor, radar and many more. Hasabnis adds, “Inductive
sensors with extended sensing distance; smart vision sensors
with integrated programming and software; smart diffused
with background suppression photo electric sensors; advanced
measurement sensors; linear & inclination sensors used for
position sensing; position & speed sensing in one unit; and
programmable sensors in field of colour mark are some of the
sensors which are gaining traction in the current market
scenario.” Also, as per Jirge, position and fluid parameter
sensors are gaining more acceptance, while for Agarwal, photo
sensor and ultrasonic technologies are turning out to be more
coveted solutions in the current market scenario.
Future roadmap of smart technologies
With many companies introducing the ‘smart’ factor into
sensors and wireless sensor networks, how does the future
roadmap for these new age sensors look like? Answering this,
Agarwal suggests, “Although the adoption has been slow due to
inherent needs of such platforms, they are here to stay. Sensors
necessarily would need to and are already becoming smart.
Industry 4.0 and cyber physical systems are no more very
distant but are already a future in the making.” Aran notes,
“There is limited response to smart sensors due to various
reasons like adaptation to existing system, environmental
interference, etc. But the future of these sensors is definitely
bright. These sensors will eliminate many problems related to
hard wired connectivity when the technology is improved and
proven further.” On the other hand, Agashe believes, “High-
capacity wireless sensor networking is still an emerging
technology. The existing systems need enhancements in terms
of real-time performance. As the technology is new, the cost is
too expensive to adapt.” Making his point, Hasabnis suggests,
“The future of wireless technology will much depend on the
reliability they can offer in the field. Smart technologies such
as sensors without reflectors, tape encoders which offer easy
retrofitting and much accurate feedback are much in demand.
In other words, market prefers technologies that are advancing
in linear continuity over the past product line.” Adding his
thoughts, Jirge says, “As on today, we have not seen large scale
use of wireless sensors, but as the battery technology improves,
we will certainly see more and more sensors going wireless.”
With the sensor market rampantly scaling up on the
technology & innovation front, and the demand for various
categories of sensors going up amid sluggish growth in the
manufacturing sector, the growing momentum of the Indian
sensor market is likely to continue during the
2015-16 period. ☐
“Sensors are becoming more intelligent & capable of taking decisions locally ” Bipin Jirge, Managing Director, ifm electronic India
“The technology trend being adopted by the sensor industry is towards smaller, faster, and cheaper solutions”Vikrant Agashe, Sales Manager – Sensors & Components, Gefran India
> MORE@CLICK ADI03320 | www.AandD24.in
“2015 will see more requirement of special sensors, though standard sensors will continue to enjoy the current status as automation basics will remain the same”Deepak Aran, Country Manager – Sales & Marketing, Contrinex Automation
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SwitchPCB relaysIndustrial relaysRelay interface modules Sockets and accessories
Dealership Enquiries Solicited
36
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FFFFFFOOOCOCOCOCOCOOCOCOCFOCOCOFFFFOOFFF CUUUUUUUUSSSS UUUSS SUSSUUUSUUUUSUUUUSUUUU ||| A U A UA UA UA TOMTOMO MMMMMMMO MOO MMOOOOOOOOO TTTT IIIOO TTOOOOO T VVVVVVEEEEEEVVVEEEVVVEEEVVEVEEE
36633636363 A&A&A&DA&DA&DD&DA&DDD I nI nI nI nI n I nI ddddd ii aaaaad iaadd ad iad ii aaaaaadd i ai aaaaad iai aa |||||| | OOOOOOOOOc t -c tc tc tc tcc t NNo vNo vNo vNNoo vNo vo vvvNNovoooo vvvNNovNo vNoooooo vvvvvNNoooo vvvvvvNo vNo vNo vooNo vNo vvNNoooooo vvvvvvoooo vvvvooooNovNNooo v 2222222000002222222200022222200020 2200002220000000 2220002000022200 2000001333331133311313311311111133111336
AUTOMOTIVE CARRIAGES ON THE MOVE
An article on a major automotive manufacturer that
boosted uptime and reliability using wireless I/O and
advanced control to ensure safe and productive operation
of its Electrified Monorail System (EMS) conveyor
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optimise reliability and uptime of the EMS conveyor system
and deliver real-time communication with Programmable
Automation Controllers (PACs) and Inputs/Output (I/O)
modules for enhanced conveyor control.
Yantra Automation began the challenge of designing a
complex wireless communication system for the assembly
manufacturing line; an ambitious goal in a large-scale project
involving multiple carriers in continuous motion along the
overhead electric monorail system. Together, the team selected
a Rockwell Automation control solution supported by ProSoft
Technology wireless Ethernet communication. The challenge
was to create a seamless and reliable communication system
between each carrier and the controller as they move
throughout the plant.
Implementation
PARI was commissioned for the design and implementation
of the specific assembly line. PARI is a turnkey integration
company specialising in top-to-bottom conveyor system
design, controls & communication automation and robotics
for automotive industry in India.
PARI has designed the full vehicle assembly line to operate
in real-time on the EtherNet/IP control network, using several
Rockwell Automation ControlLogix PACs and supporting
peripherals on the shop floor, including I/O and variable
frequency drives. The decision to go with ProSoft Technology
industrial hotspot radios was made primarily because of their
industrial hardware and solid reputation for supporting
Rockwell controls and communication interfaces seamlessly,
in addition to the ease of operation.
Movement of the EMS carriers for transporting vehicles
through the different stages of assembly is handled over a
wireless EtherNet/IP network. The control system consists of
In the education capital of India, Pune, a market leading
manufacturer of utility vehicles built a modern Greenfield
facility from the ground up with state-of-the-art equipment.
At the heart of the plant is the Electrified Monorail System
(EMS) conveyor, designed to deliver reliable, safe, quiet and
efficient transportation of the vehicles from one work station
to another along the assembly line. The EMS runs throughout
the entire length of the Trim, Chassis and Final assembly
(TCF) line of the vehicle in the general assembly shop. The
light truck manufactured in this facility is transported by a
wireless EMS conveyor. The TCF line is considered the final
stage in production, where components are added to the
vehicle including ‘trim’ components such as windshield glass
and seats, as well as operational components such as the
engine and wheels before final vehicle testing.
Control and communication automation
For consulting, specifying and planning of this project, the
manufacturer worked with Yantra Automation, in conjunction
with their local Rockwell Automation Account Manager and
with system integration company, Precision Automation
Robotics India Limited (PARI). The team worked closely to
develop the best overall solution for this sophisticated
project.
This being a new system and a Greenfield plant, they were
not bound by constraints associated with some of the older
monorail systems found in manufacturing plants. Thus, they
were able to design a sophisticated system that easily
conformed to the goals of the project and the manufacturer’s
commitment towards flexible and lean manufacturing. Its
aims to eliminate communication issues and concerns
associated with rigid copper bus bars and brush collectors
commonly used for communication with EMS carriers. To
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The EMS runs throughout the entire
length of the Trim, Chassis and Final
assembly (TCF) line of the vehicle in
the general assembly shop
one ControlLogix PAC on the conveyor and one ControlLogix
PAC on engine decking system for body marriage. The
conveyor PAC is hardwired to two ProSoft Technology Master
radios while the Engine Decking PAC is hardwired to a third
Master radio. The conveyor PAC is wirelessly connected with
33 individual carriers along the EMS, while the Engine
Decking PAC is connected with 3 engine carriers. Each
independent EMS carrier has a local control panel with
Rockwell Automation I/O and a variable frequency drive
(VFD), with a ProSoft technology access point acting as
repeater to establish wireless communication between the
main control panel equipment and their respective PAC. The
carrier radios communicate with each other and with
Master radio.
This EMS application time is critical, so each repeater
radio is connected with its parent Master radio at all times to
avoid switching delays as communications change from one
Master radio to another while the carriers are in motion. The
Master radio in each conveyor PAC has two Omni antennas
with a splitter to deal with multipath fading effect. The
architecture fully supports seamless roaming by the carriers.
Benefits
After some initial challenges with line-of-sight issues
which were resolved by adding another Master radio and
elevating their locations, the system is now able to provide
real-time communication between the EMS carriers and the
PACs on the assembly plant floor, including real-time I/O
status for conveyor movement control. The system also
enables wireless synchronisation between the floor-mounted
engine trolleys and the overhead EMS carrier, for the smooth
decking of the engine.
The benefits that the manufacturer was able to avail were
the ability to control EMS conveyor and the engine decking
carrier in real time and synchronising the VFDs with the
Engine Decking Carriers. Eliminated complex wiring/cabling
and cat tracks for communication cable. It obtained seamless
and robust communication between the PACs and the I/O .
Conclusion
The project went live in November 2009. Since then, the
manufacturer has seen an increase in uptime, reliability and
consistency in production output, enhancing their
commitment towards lean manufacturing. With the success of
the Rockwell Automation control and ProSoft Technology
communication solutions, five similar applications consisting
of both EMS conveyor system and material handling in the
vehicle assembly shops are being installed. ☐
Courtesy: Rockwell Automation
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AUTAUTOMOOMOT IVT IV EE IIN DN DUUSS TTRYRY || FO FOCUSCUS
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SHAPING THE FUTURE OF AUTOMOTIVE MANUFACTURING
The automotive manufacturing industry needs to focus more on
the intelligent networked automation that creates a synchronised
environment for seamless production of vehicles on the
production line. This helps the industry continue operating
profitably against the changing economic backdrop
Nitin S NairChief Manager, Automotive VerticalSiemens Ltdnitin.nair@siemens.com
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Material flow to the line is synchronised; production
information available to the operator is relevant to the current
vehicle at his station, quality gates have the right check
parameters programmed for the incoming vehicle and robots/
machines have the right programs for the planned operations
on the incoming vehicle. All this ensures optimum interlinking
between all the different automation components within the
production process and maximises productivity through the
Siemens developed totally integrated (TIA) concept. With its
TIA Portal, in 2011, Siemens has created a central engineering
platform which is now being adopted by an ever increasing
number of key players throughout the automotive industry.
The TIA Portal concentrates all the relevant applications and
tools in a standardised and intuitively operated user interface.
Collation of all the relevant data in a standardised database
eliminates the need for multiple input and data matching.
Lesser time to market
Time is a key competitive factor in the launch of new
vehicle models and variants. Globalisation and social change
are speeding up the cycle of market trends. The response of
automakers is to extend their product ranges and target ever
shorter product launch times. The Siemens PLM software
allows product variants and their influence on production to
be simulated at the computer. In addition, processes which
have traditionally been performed in sequence are now
increasingly running in parallel. For instance, many
manufacturers are already busy planning their production
facilities while the product is still under development. Use of
the TIA Portal facilitates the increasing parallelisation of
product design, plant engineering and commissioning by
allowing virtual engineering on a single platform.
With this integrated plant engineering, the planning teams
can verify various manufacturing scenarios with multi models
in the digital factory, thus giving them the flexibility to
produce multi models in different mixed batches on the real
manufacturing line which is finally set up.
Also helping to improve flexibility in the automotive
industry is the Siemens industrial identification portfolio.
Using radio frequency identification (RFID), products and
components can be seamlessly tracked through the entire
procurement, manufacturing and shipping process. Assuming
Global Automotive experts have forecasted that the
attention of the automotive industry over the next ten to
fifteen years will be focused on the shift of automotive business
towards Asia (China & India), the global demographic change,
the demand for greater sustainability and the ever growing
proportion of alternative propulsion systems. If they are to
continue operating profitably against this changing backdrop,
automakers will have to continue to step up their endeavors.
The major challenges for automotive manufacturers are:
How to shorten the intervals between new model and
variant launches?
How to reduce the total cost of ownership?
How to have flexible manufacturing lines with short model
changeover times?
How to improve plant availability?
How to reduce energy costs?
Fewer hours per vehicle
The automotive industry has traditionally played a
trendsetting role in terms of improving productivity. With an
hour of production time in the automotive industry costing
up to $100,000, automakers still continue to concentrate their
efforts on driving down the number of operating hours needed
to produce a vehicle and on increasing plant availability.
This is achieved by continuous improvement in production
times on the manufacturing line by reduction in all types of
wastes on the line such as idle times, unnecessary material
flow, storage on the manufacturing line and other non-value
added work.
In order to achieve this reduction in wastes, it is necessary
that accurate information is available quickly at the point of
decision-making on the manufacturing line. This improvement
is brought about by intelligent networked automation on a
manufacturing line which is dynamically interlinked with
PLM & ERP systems.
The vehicle manufacturing schedule based on the incoming
orders is available from the ERP system. The process &
component bill of materials for various models and variants
are made available from the PLM system. With these inputs,
the intelligent networked automation creates a synchronised
environment for seamless production of vehicles on the
production line.
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Siemens PLM software allows pro-
duct variants and their influence on
production to be simulated at the
computer
a key role in this process is the RFID data carrier which
remains with each vehicle through every one of its many
production stages. As part of a just-in-sequence production
process, this allows automakers to produce different vehicle
and equipment variants on the same production line without
problems, and to comply with individual customer
specifications.
Energy saving with a concept
Energy consumption is a significant environmental and
cost factor in automotive production. Added to this is the
need to comply with statutory requirements relating to energy-
efficient production and reduced carbon emissions. The ISO
50001 energy management system standard sets out to define
internationally applicable parameters for reducing energy
costs, greenhouse gases and other environmental impacts.
The energy management software B Data from Siemens is
tailored precisely to the implementation of wide-ranging
requirements. It records the status quo of all the energy and
material flows such as water, electrical energy, pressure or
steam required in production and in all ancillary processes.
The different consumption levels are allocated based on actual
usage, and documentation is drawn up. Using key performance
indicators (KPI), B Data delivers a solid basis for decisions
relating to energy optimisation. For automakers, even the
implementation of a few simple measures such as leak
detection or even load distribution will make use of the energy
management system worthwhile. In this way, energy savings
between five and ten per cent can already be achieved even
without any additional investment. This effect is compounded
by the implementation of additional measures such as the use
of modern energy-efficient motors from the Siemens
environmental portfolio which can reduce energy consumption
by up to 40 per cent, or alternatively by implementing electric
drives which can be used as required in conjunction with
Siemens frequency converters, permitting up to 70 per cent
reductions in the energy consumption of fans, pumps or
compressors. Additional energy saving potential can be
leveraged through the identification and compensation of
load peaks and the coordinated shutdown of plant sections
during idle periods using the PROFIenergy data interface.
By taking an integral approach, Siemens is able to keep a
watchful eye on the entire process and value chain, offering
not just products but also competent advice. On the subject of
energy saving, automotive customers may rely on a team of
experts ready to offer the benefit of their energy, automation
and technology-specific expertise.
Fit for the future
The world of automotive industry is fast changing,
alongside the development of combustion engine; the
emphasis is set to shift increasingly towards alternative
propulsion methods. Electric and hybrid vehicles in particular
are making rapid advances and will become an established
feature on our roads within the next ten to fifteen years. Three
focal challenges facing the industry will be to develop new
lightweight construction concepts, find ways of reducing the
cost of producing lithium ion batteries, and fine-tune the
manufacture of electric motors. Siemens is ready with a series
of smart concepts for the automation of new production
processes. Here too, the spotlight is on integral and efficient
solutions based on the Totally Integrated Automation concept.
The use of new approaches opens up scope for simple, cost-
efficient and modular-based vehicle production. ☐
> MORE@CLICK ADI03322 | www.AandD24.in
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MACMACMACH INH INH IN E TE TE TO O LO OO O LS S | F OCUS
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MACHINE TOOL AUTOMATION
This article highlights machine tools that have reached a
very high standard in terms of machining power, accuracy,
speed, robustness and cost efficiency which has led to high
productivity
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Shriniwas VidwansArea Manager — SalesGüdel Indiashriniwas.vidwans@gudelindia.com
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Selection
Rigid automation: Generally used for custom-engineered,
special-purpose equipment to automate a fixed sequence of
operations. It is mainly used for high production rates and
inflexible product designs.
Recoverable automation: Equipment designed to
accommodate a specific class of product changes and is
particularly used in batch production and medium volume.
Flexible automation: It is designed to manufacture a
variety of products or parts used mainly for low production
rates or varying product design and demands.
Need for automation
The requirement for automation includes economic
advantage through increased productivity with reduced labour
uncertainty and costs. Automation initiates improved accuracy
& repeatability with consistency of quality parameters; it is
suitable for mass production with better material handling
and also helps to reduce WIP.
The potential areas of automation consist of loading and
unloading of parts; in-process gauging (to enhance quality
assurance); deburring of parts machined; adhesive dispensing
requirements (3-axis manipulation); assembly operations and
Machine tool analysis is the result of common evolutionary
efforts made by generations of engineers to understand the
manufacturing of machines from a more scientific point of
view, i.e. to consider the main factors influencing the
productivity of manufacturing cells and to gain mathematical
models to describe performance with suitable precision. In
this way, concept optimisation and trouble-shooting for
existing machines can be realised with more sophistication
than by trial-and-error strategies. Manufacturing cells are
combinations of machine tools, industrial robots and transfer
devices for efficient and automatic part production with a
high degree of precision and reliability.
Features
The features of manufacturing cell include gantry robots
to generate relative movements between part and tools or
storage devices. Part and tool transfer requires high-path
velocities with moderate accuracy, while processing requires
slower but very precise movements. The control units generate
the set-point commands for the gantry robots, it helps to
communicate with other cell parts (e.g. via fieldbus or cell
bus) and the operator (via human-machine interface – HMI).
The graphical user interface (GUI) is used to control virtually
the position of end-effector of the gantry mechanism.
Automation has provided the
desired and extended system
functionality well beyond
existing human capabilities
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Manufacturing cells are
combinations of machine tools,
industrial robots and transfer
devices for efficient and automatic
part production with a high degree
of precision and reliability
replace human labour in hazardous conditions. Gantry robots
are an efficient alternative for the automation of machine
tools. Access to the machine is maintained loading from the
top. This will make the shop floor space free for other activities
with the help of utilising the space above the machine. The
linear axes support operating, programming and training at
the machine. This is of particular importance to set up the
processes and observe the activities.
Challenges
Automation involves machines, or integrated groups of
machines, that automatically perform required machining,
forming assembly, handling and inspection operations within
the cell. Through sensing and feedback devices, these systems
automatically make necessary actions.
The integration of automation system into cellular
arrangements with machine tools to process families of
component parts where the system performs tasks right along
with one or more human beings is very efficient. The
automation can perform part loading and unloading, as well
as material processing (like joining).
The real mechatronic challenge is the machine tool
manipulator. While almost all other parts are bought from
specialised suppliers, the design and optimisation of the
manipulator remains the key competence of machine tool
manufacturers. It is still the physical feasibility of the
manipulator that defines the level of productivity which can
be reached by a manufacturing cell. In order to prevent
time-consuming and ruinous trial-and-error prototype
developments, suitable analysis methods like feasibility study,
proper cycle time calculations etc are required which optimise
design as far as possible in the concept phase and identify
problems in the running system for effective trouble
shooting.
In most of the cases, automation has provided the desired
and extended system functionality well beyond existing
human capabilities. The role of human operator has changed
dramatically. Instead of performing tasks, the job has turned
into monitoring over the system.
Also the robot manipulator design is becoming challenging
due to the increasing need for path accuracy and velocity. To
craft appropriate automation for the machine tools that will
result in maximum yield includes terms like accuracy —
related to target manufacturing deliverance; consistency —
related to part orientation as per process sequence, in line
gauging processes etc and repeatability — related to
part positioning. ☐
> MORE@CLICK ADI03323 | www.AandD24.in
TURNKEYSOLUTION
SENSORS SYSTEM & COMPONENTSFOR AUTOMATION
MOTIONCONTROL
48
Ro bot ics & H andl ing | m arke t
a&d i nd i a | O c t -No v 2013
“The robotics industry is looking into a bright future!” stated Dr Shinsuke Sakakibara, President, IFR, on the occasion of the publication of the study ‘World Robotics 2013 - Industrial Robots’. “In 2013, global robot sales will increase by about 2% to 162,000 units. The IFR Statistical Department expects that between 2014 and 2016, worldwide robot sales will increase by about 6% on average per year. In 2016, the annual supply of industrial robots will reach more than 190,000 units.”
2013: Demand will vary among the regions and the industries
In 2013, the demand of the automotive industry will start to slow down in certain markets after three years of continued increasing robot installations in the traditional as well as the
48
Moving towards a potential win The recently released IFR study ‘World Robotics 2013 - Industrial Robots’ estimates that by 2016 the annual supply of industrial robots will reach more than 190,000 units. A brief insight into the market forecast…
emerging markets. The electrical/electronics industry will increase robot investments in production automation as well as in retooling for new production processes. A further increase of robot orders from other industries is also expected, particularly from pharmaceutical, food & beverage, metal and machinery industries.
Growth of robot sales is expected in North America, Brazil, the Republic of Korea, China, in most of all other South East Asian markets as well as in most of the Central and Eastern European markets, and in Turkey. Robot sales to Japan will decrease due to the continuing weak economic position of its electrical/electronics industry. Also, in Germany a decrease in robot sales is likely after the significant robot investments of the automotive industry over the past three years. The United Kingdom is in a similar situation and will also have a reduction
HANNING MOTORS INDIA Pvt. Ltd. · E-115/A GIDC Manjusar Savli · Vadodara 391 775 · Gujarat · India · Tel +91 2667 264820 Fax +91 2667 264819 · info@hanning-hmi.com · www.hanning-hmi.com
Your requirementis our driveHANNING pumps, motors and drives perfectlymeet the growing demand within India forcustomer-specific designs, software orinterfaces. Our drive systems are speciallydeveloped for winding applications, textileor plastic industry as well as for elevatorapplications. Regardless of the nature of yourrequirement, our components increase yourmachine performance and decrease theenergy consumption of your entire system.
Our engineering knowledge combined withlocal presence and German expertise ensurethe perfect product.
Anzeige India_Allgemein_210x134_1.QXD_Anzeige India_Allgemein_210x134 11.09.12 11:25 Seite 1
49
market | Rob ot ic s & Handl ing
a& d i nd i a | O c t -N o v 2013
Industrial Robot Suppliers Group. “These technologies are opening doors to completely new applications for robots. Impressive for me are the developments regarding human-robot cooperation and opportunities that are provided in new fields for automation, especially in areas where no robots are currently used.”
The challenges and opportunities include cost-efficiency requirements which drive higher levels of automation globally; energy-efficiency and new materials requirements, e.g. carbon-composites, require retooling of production; growing consumer markets require expansion of production capacities; decreasing life-cycles of products and increasing variety of products require flexible automation; technical improvements of industrial robots that will increase the use of robots in the general industry and in small & medium-sized companies, e.g. easier to use robots for simple applications, collaboration of
in robot installations in 2013. Due to the continuing tight economic situation, robot sales will either decrease or stagnate in Italy, France and Spain. However, due to the more complex robot systems entering the market, the increase in turnover might be higher, just as in 2011 and 2012.
Promising prospects for 2014-2016
The IFR Statistical Department estimates a further growth of robot installations between 2014 and 2016 by 6% on average per year. “The growth is based on huge potentials of further penetration of the industrial segments like electronics or food and on the on-going industrialisation of the emerging countries. But there are even additional growth potentials in the future based on breathtaking advanced and innovative technological developments”, commented Dr Andreas Bauer, Chairman, IFR
HANNING MOTORS INDIA Pvt. Ltd. · E-115/A GIDC Manjusar Savli · Vadodara 391 775 · Gujarat · India · Tel +91 2667 264820 Fax +91 2667 264819 · info@hanning-hmi.com · www.hanning-hmi.com
Your requirementis our driveHANNING pumps, motors and drives perfectlymeet the growing demand within India forcustomer-specific designs, software orinterfaces. Our drive systems are speciallydeveloped for winding applications, textileor plastic industry as well as for elevatorapplications. Regardless of the nature of yourrequirement, our components increase yourmachine performance and decrease theenergy consumption of your entire system.
Our engineering knowledge combined withlocal presence and German expertise ensurethe perfect product.
Anzeige India_Allgemein_210x134_1.QXD_Anzeige India_Allgemein_210x134 11.09.12 11:25 Seite 1
50
ROBOT ICS & H AN D L IN G | M ARKE T
A&D I nd i a | O c t -No v 2013
> MORE@CLICK ADI03324 | www.AandD24.in
robots with human workers; improved quality requires
sophisticated high-tech robot systems; and robots improve the
quality of work by taking over dangerous, tedious and dirty
jobs that are not possible or safe for humans to perform.
“Whilst these challenges are not insignificant, they are also
far from insurmountable. In fact, our industry and governments
around the world have already made significant progress in
addressing them. They represent exciting opportunities for us
and should be embraced to the fullest extent,” stated Per Vegard
Nerseth, Head – ABB Robotics, Switzerland.
Booming robot market: China
Between 2005 and 2012, sales of industrial robots to China
have increased by about 25% on average per year and reached
23,000 units in 2012. This supply does not include sales of local
Chinese robot manufacturers. At the joint event of the IFR and
the Chinese Robot Industry Alliance (CRIA), the IFR-CRIA
CEO Round Table at the CIROS trade show in July 2013 in
Shanghai, it was reported that in 2011, local Chinese robot
suppliers sold about 2,000 units and in 2012, 3,200 units.
The Taiwanese company, Foxconn Electronics (enterprise
Hon Hai Precision) is producing robots for their own use in
their manufacturing plants in China. These robots are not
counted in the statistics because the information on the
installed number of the so called ‘Foxbot’ robots installed in
mainland China is rather vague. The numbers differ between
total 10,000 and 30,000 units over the last years.
Taking into account the above mentioned information, the
total number of robots installed in China in 2012 was between
28,000 and 35,000 units. Hence, China was already the largest
robot market in 2012.
China will continue to have a substantial economic growth
rate in the coming years. Strong investments in automation
will continue in order to increase productivity and to establish
more eco-friendly production processes. China is one of the
most rapidly growing and largest consumer markets in the
world with an emerging middle class escalating the demand for
consumer goods, medical care and high quality lifestyle, all
great reasons for pushing the manufacturing sector to automate.
Besides modernisation of the existing production sites, various
types of industries are building new production sites in order
to gain market share in this huge consumer market.
The potential for automation in the Chinese manufacturing
industry is still huge. Compared to highly automated countries
like Japan, Korea and Germany with robot densities in the
manufacturing industry between 270 and 400 industrial robots
per 10,000 employees, the robot density in China is comparably
low with about 20 robots. To reach such a level of robot density,
about one million new robots would have to be installed in the
coming years in China.
In China, the faltering economic growth in 2013 may
somewhat affect robot investments. In 2013, the robot supply
of foreign companies will increase by about 5% to 10% to about
25,000 units. And from 2014 to 2016, robot sales from non
local robot suppliers will again gain momentum and increase
between by 15% on average per year reaching about 38,000
units in 2016.
Chinese robot manufacturers will increase their robot
production in the near future, and robot suppliers from abroad
will increase assembly of robots in China. Taking in account
that China is already one of the biggest markets but is still in
the beginning phase of utilising robotics, the Chinese market
will offer huge potentials for installation for local and foreign
robot suppliers in the coming years. ☐
Courtesy: IFR (International Federation of Robotics)
“While the automation challenges are not insignificant, they are also far from insurmountable. In fact, our industry and governments around the world have already made significant progress in addressing them” Per Vegard Nerseth, Head – ABB Robotics, Switzerland
“There are even additional growth potentials in the future based on breathtaking advanced and innovative technological developments”Dr Andreas Bauer, Chairman, IFR Industrial Robot Suppliers Group
© 2013 Schneider Electric Industries SAS. All trademarks are owned by Schneider Electric Industries S.A.S. or their affiliated companies. • 998-1211487_IN 35 rue Joseph Monier, CS 30323, 95506 Rueil Malmaison Cedex (France) • Tel. +33 (0) 1 41 29 70 00
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3 core values of PlantStruxure PES:
52
ROBOT ICS & H AN D L IN G | APPL I CAT I ON
A&D I nd i a | O c t -No v 2013
Following the footsteps of their machine colleagues,
industrial robots are assuming more and more responsibility
in modern production lines. The most widely used type is an
articulated arm robot with six electromechanical axes of
movement. B&R has taken it upon itself to make industrial
robots so safe that they can work hand-in-hand with humans,
liberated from the confines of safety gates and enclosures.
The safety requirements for industrial robots and robotic
systems and their integration in workplace environments with
human workers are defined in ISO 10218. Among other things,
these standards specify the maximum strain to which the
human body is permitted to be subjected. These defined upper
limits ensure that humans working alongside robots are not
exposed to any serious danger. As a general guideline it can be
said that a safe limited force of up to 150 N, a reduced speed of
52
Taming the robotIndustrial robots have witnessed increasing usage in automated
production lines. Until now, these have been isolated in cells to
ensure the safety of those working in the proximity. Using
TÜV-certified function blocks, B&R has now boosted robot safety
to a level that allows humans and robots to work hand-in-hand
up to 250 mm/s and automatic stop capabilities ensure that any
collisions will be harmless.
TÜV-certified safety
The traverse paths followed by the tools and grippers used
by industrial robots to perform their tasks are the product of
highly complex axis movement patterns of multi-jointed
machines. It is important that safe monitoring of speed
accounts not only for each individual axis, but also for the
robotic system including the tool center point.
The first step towards B&R’s goal of expanding robot safety
was taken in 2011 with the creation of the function SLS at TCP
(Safely Limited Speed at the Tool Center Point). This
SafeROBOTICS library contains TÜV-certified parameter and
Dr Gernot BachlerTechnical Manager - Motion B&R
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Compensated pressure transmitters (≥ Ø 11 mm) with hermetically protected sensor electronics.The unique combination of smallest size, outstanding performance and media compatibility.Pressure Ranges: 0,3…1000 bar / Accuracy: 0,15 %FS / Stainless Steel Housing
54
ROBOT ICS & H AN D L IN G | APPL I CAT I ON
A&D I nd i a | O c t -No v 2013
A TÜV-certified function block provides monitoring of the tool centre point. The parameters used to do this are standardised and loaded from a table containing the respective values. This is a versatile solution that can easily be used with different kinematic systems without requiring recertification
standardised parameter blocks that can be applied to any
conceivable kinematic chain with up to 11 revolute and
prismatic axes, regardless of the specific values they contain.
Transformation parameters also permit modeling of mixed
configurations where the robot itself is mounted on a linear
portal axis or rotary table. The parameters can also handle
constructions where multiple axes are coupled mechanically.
In these cases, rotating Axis 4, e.g. changes the orientation of
Axis 5. One of the advanced features of SafeROBOTICS is a
new function block designed to manage the additional degrees
of freedom in complex systems. This function block verifies
the plausibility of stored parameters. All of this makes SLC at
TCP an easy-to-use safety block, especially when users take
advantage of the preinstalled parameter blocks for standard
robot types provided by robot manufacturers.
Users are optimally supported
Users are free to select whatever type of control works best,
be it the robot controller from the manufacturer of the
kinematic chain or integration in an overall control system.
This is possible thanks to the open and bus-independent safety
protocol, openSAFETY. The only requirement is providing
safety-related position data and the ability to drive, safe to
handle responses. Users of SafeROBOTICS do not need to
know how the path curves and velocities are calculated. This is
handled by integrated transformation functions. With this
optimal support, they are free to focus on their core activities.
Since the invention of the electro-mechanically driven six-axis
articulated robot, 40 years ago it has never been so easy to let
man and machine work together safely. ☐
function blocks for use in B&R’s safe programming environment.
These function blocks are used to program safety control
applications that run on SafeLOGIC controllers. Safety
applications read data regarding the status, position and
velocity of individual axes and apply transformations to
calculate the actual velocity at the tool centre point, which in
turn is compared with the specified safe values.
Safe motion control
SafeMC is an integrated standard component of all
ACOPOSmulti servo drives from B&R. These drives boast a
typical error detection and response time of 7 ms – about a
tenth of the time possible with relay safety circuits – which
shortens the stopping distance by a factor of 100.
On drives equipped with B&R’s safe motion control feature,
both the reading of the safety-related data and the execution of
the safety functions are performed directly on the drive. Data
is carried safely over the fieldbus-independent, safety-oriented
transfer protocol known as openSAFETY.
A highly efficient solution
In the first version of the SafeROBOTICS solution, the
software module in charge of monitoring utilised a kinematic
model parameter block, which can be configured for all
commonly used types of robots. This had a significant
disadvantage, however, as the resulting safety application had
to be certified separately for each type of robot.
To spare its customers this expense and inconvenience,
B&R developed a more efficient solution based on a standardised
block of kinematic modeling parameters. Its advantages include > MORE@CLICK ADI03325 | www.AandD24.in
56
ROBOT ICS & H AN D L IN G | T E CH N OL OG Y
A&D I nd i a | O c t -No v 2013
If a company that specialises in manufacturing customised
machinery goes for an alternative solution, then it will have a
valid reason – in this case, the Stäubli RX170 hsm. This
innovative milling robot, working away within a cell supplied,
by plant manufacturer Riexinger, ensures abundant flexibility
in the complete machining of large plastic parts. The five-axis
robot also scores in terms of maximum availability and short
cycle times.
Established half a century ago, Riexinger GmbH & Co KG
operates on a global scale, specialising in plant and machinery
for the processing of all types of plastics.
When one of their customers, plastics and piping specialist
Kubra GmbH, enquired about plant for the production of
drainage chamber bases, Riexinger’s initial idea was to construct
a special purpose machine. In the case of the deep-drawn parts
made of polyethylene which have a diameter of
1 m, machining the external contour and the pipe connections
is part of the process. Reliable and consistently reproducible
processing of these chamber bases is essential for their
56
Innovative milling robot
A case study on the development
of Stäubli RX170 hsm, a milling
robot by Riexinger GmbH to
satisfy the plastics and piping
specialist Kubra GmbH’s
requirement of a special purpose
machine for the production of
drainage chamber bases
subsequent use in drainage and sewage systems.
In the search for appropriate alternatives, Otto Angerhofer
(former CEO of Manz and now a consultant for Riexinger)
came up with a persuasive concept – the robotics specialist
knew of the new Stäubli RX170 hsm milling robot and informed
the Riexinger designers about this innovation.
The job in terms of flexibility
“In fact, the robotic solution turned out to be just the job,”
says Markus Theobald, Managing Director, Riexinger. “With
its operating range of nearly 2 m and the freedom of movement
afforded by a five-axis model, the Stäubli robot can easily reach
any working position on the large plastic parts. So, we had
found the perfect machine for this application and now only
had to supply the system peripherals.”
The realisation went smoothly and quickly, and soon the
machining centre for chamber bases proved its worth in terms
of flexibility and easily met all other customer specifications
58
ROBOT ICS & H AN D L IN G | T E CH N OL OG Y
A&D I nd i a | O c t -No v 2013
RX170 hsm milling robot is intended precisely for
applications such as fast and accurate processing of
plastic and composite materials
Although Riexinger actually specialises in special-purpose
machinery, Theobald is excited about the use of the milling
robot. “In the Stäubli RX170 hsm, we have a turnkey plug-and-
play solution that works absolutely reliably. By contrast with
the time-consuming and expensive construction of a dedicated
machine, the robot solution makes huge savings in terms of
engineering costs. In addition, we have an integrated system
with a significantly more manageable level of complexity,
which in turn means higher availability, plus we also benefit
from almost unlimited flexibility.”
Milling with a robot
Stäubli’s newly developed RX170 hsm milling robot is
intended precisely for applications such as fast and accurate
processing of plastic and composite materials. It introduces a
new element of freedom and flexibility into the production
line and is able to process large workpieces rapidly with facility.
In terms of performance too, the RX170 hsm is ideal for
machining plastic parts: its repeatability is ±0.04 millimeters,
which falls well within the requirements for the processing of
the chamber bases.
The Stäubli robot operates reliably in any working position
within its two-metre range. A lot of professional expertise has
gone into the making of this robot. The entire power supply as
well as the spindle cooling and lubrication are contained within
the arm. This represents a compact and highly reliable solution.
Stäubli engineers also designed a new upper arm and a special
wrist in which the sixth axis is replaced by a milling spindle.
Here, Riexinger opted for the exceptionally high-quality
Fischer Precise milling spindle. As the end customer operates
the robot cell on a three-shift system around the clock,
Riexinger quite logically uses only the best components
available on the market. ☐
Courtesy: Stäubli
with regard to cycle times and quality. The machining centre is
currently handling chamber bases in various versions with
pipe connections of between 110 mm and 315 mm but all with
an outer diameter of precisely 1.0 m.
The chamber bases arrive at the machining centre as
deep-drawn parts made of polyethylene or polypropylene, with
their outer contours and pipe connections as yet unformed.
The job of the milling robot is to remove excess plastic material
and thereby ensure a consistent outer radius. The five-axis
robot is further tasked with the precise machining of the
different pipe connections. The switch from one variant to the
next is performed by the plant operator pressing a couple of
buttons on the robot control console.
Because the plastic material is easy to cut, the milling robot
can go about its work in dynamic fashion. The Stäubli machine
is equipped with a high-precision milling spindle supplied by
Fischer Precise. To facilitate uninterrupted complete machining,
the cell is equipped with an automatic tool changing station.
Operating the robot is easy to learn and can be a lot of fun.
No matter how many new variants may follow, the end user is
well equipped for all eventualities with the Riexinger system.
“The system is set up for maximum variation,” adds Theobald.
“Loading and unloading of the robot cell takes place manually.
The Stäubli RX170 hsm milling robot then takes complete
charge of machining the chamber base. Thanks to its enormous
range, the five-axis robot readily copes with all the many
possible designs and - by comparison with a CNC machining
centre - guarantees almost unlimited flexibility.”
Here, the RX170 hsm autonomously selects the optimum
cutter for each machining process. The quality of work done by
the robot is in no way inferior to the result that might be
expected from a machining centre handling this same
application. Because the plastic material is easy to cut, the
RX170 hsm can go about its business in dynamic fashion,
thereby reducing the cycle time for machining a chamber base
to less than two minutes. The machined surfaces pass all tests
in terms of fit and quality, ensuring that no rework is required. > MORE@CLICK ADI03326 | www.AandD24.in
60
MANUFACT UR IN G I T | T ECH N OL OG Y
A&D I nd i a | O c t -No v 2013
Although 2D drawings had been the primary design
deliverable for many years, Vishwakarma Engineering Works
(VEWorks) found that there were drawbacks to a 2D approach.
If there was a design change, 2D drawings could not be easily
updated in a timely manner. Changing complex assemblies
involved considerable drafting hours. Engineers faced pressure
to revise the drawings, which was not only time-consuming, but
also arduous. Moreover, VEWorks often is tasked with producing
a prototype to be approved by customers before getting the go-
ahead for production. “The conventional way of designing in
2D was an impediment. It was time-consuming & often human
errors would surface during the manufacturing stage. Our
production orders are usually for small batches in varying sizes.
Any change in dimension requires updating the entire assembly.
This is more common when we are manufacturing process
equipment,” says Jay Patel, CEO, Vishwakarma Engineering
Works. The solution was to convert to a 3D design process.
Choosing Solid Edge
VEWorks chose to implement Solid Edge® software, with
synchronous technology, from Siemens PLM Software, a
specialist in product lifecycle management. The synchronous
technology of Solid Edge® software enables a company to
accelerate design, make changes faster and improve the re-use
of imported data.
Patel elaborates, “One meeting with Siemens PLM Software
was sufficient for our management to understand the advantages
Solid Edge had to offer. The biggest advantage with Solid Edge
is that it offers far better editing and updating capabilities than
any of its competitors.
It is backed by support that is among the best in the industry.
Siemens PLM Software also offers a comprehensive range of
product development solutions that can be easily integrated
into our growing organisational structure.”
3D MODELING An application story on the use of 3D modeling software — Solid Edge by Vishwakarma
Engineering Works to make design changes quickly and easily
61
TECHNOLOGY | M ANUFACTUR ING I T
A&D I n d i a | O c t -No v 2013
Making changes is easy
The company’s objectives included a faster design process
that would allow for changes to be made rapidly without
extensive time spent updating 2D drawings. This would help
VEWorks produce sample parts or components as quickly as
possible, enabling the company to provide samples to customers
for review and approval. VEWorks’ objectives were met.
The synchronous technology functionality of Solid Edge
enables designers to make changes quickly ‘on the fly’ without
concern for modeling history. This helped VEWorks eliminate
the time-consuming and error-prone problem of having to
constantly revise 2D drawings. VEWorks now designs more > MORE@CLICK ADI03327 | www.AandD24.in
from a conceptual standpoint. Patel explains, “Using Solid Edge,
we design products based on mere concepts and client input
without any specific drawings or samples, then we manufacture
the designed assembly in the volumes required by our customers.”
The organisation’s staff received software training and shortly
after implementation, the software was being used for all of
VEWorks’ design and drafting needs. “We expect to be able to
manufacture products faster than our competitors & look
forward to upgrade our engineering solutions to further
improve our products,” says Patel. ☐
Courtesy: Siemens PLM
62
TECH N O LO GY | MA NUFACT UR I N G I T
A&D I nd i a | O c t -No v 2013
Specialised engineering and simulation software are
important innovation tools. At Tetra Pak Cheese and Powder
Systems (CPS), basic engineering (collecting key data from a
process) and detailed engineering (designing and optimising
the pipelines and individual components of a plant) are carried
out via computer-aided engineering (CAE). The result is a
digital representation of the plant, ideally as a 3D CAD model.
With CAE, it is now possible to virtually perform
experiments that previously required elaborate laboratories or
pilot plants, making it easier to compare alternatives, perform
marginal analyses and therefore, support the optimisation
process.
CAE at work
The fact that CAE offers an efficient and cost-effective way
Hans-Jürgen Bittermann Dipl-Ing (qualified engineer) Freelance specialised journalistLambsheim
Shortening product development time
Computational Fluid Dynamics (CFD) is a proven tool for the
detailed design of equipment and plants. The main advantage of
numerical simulation is the three-dimensional flow information
that can be generated to explore optimisation possibilities. Here
is a case study on how Tetra Pak CPS uses CD-adapco’s STAR-
CCM+ to carry out this process.
63
MANUFACTUR ING I T | TECHNOLOGY
A&D I n d i a | O c t -No v 2013
to optimise equipment and plants proved decisive in convincing
Tetra Pak to use this tool. This is because their customers, who
are operators in the food industry, place a great deal of value on
continual improvement — their goal is always to produce better
products in increasingly smaller plants while reducing their
production, operating and service costs.
One of the tools Tetra Pak CPS relies on is STAR-CCM+
from CD-adapco. “We actively use STAR-CCM+ for design
optimisation, troubleshooting & research and development
projects,” said Alfred Jongsma, Manager — Research &
Development, Tetra Pak CPS.
The company had a very good experience using this tool in
a wide range of areas, such as investigating non-newtonian
fluid flow in evaporation, minimising the loss of pressure in
falling film evaporators, optimising the separation efficiency in
separators, optimising the air flow in a spray dryer and analysing
the recovery of waste heat at the dryer outlet, among many
other applications.
Spray dryer — the goal is dry milk
The spray dryer is based on the principle of surface
enlargement in which liquid products, such as milk or whey,
are atomised into fine droplets through a flow of hot air, whose
temperature ranges between 150°C and 250°C. The droplets,
which are dried during their falls, are only exposed to the
airflow for 0.5 to 1 second.
The operator can only achieve a high-quality solid product
64
TECHNO LO GY | MA NUFA C TUR I N G I T
A&D I nd i a | O c t -No v 2013
objective here was to optimise the spray dryer output and
minimise fouling. Fouling limits the running time of a spray
dryer; after several weeks it needs to be cleaned. It appeared
that the factors that minimise fouling also favourably affect the
capacity. The factors that were optimised are the air flow into
the system and the way the liquid is introduced (by high-
pressure spray nozzles).”
The benefits to the customer include improved production
capacity, powder quality and a longer period of time between
necessary cleaning of the spray dryer.
STAR-CCM+
STAR-CCM+ provides the world’s most comprehensive
engineering simulation inside a single integrated package. More
than just a CFD solver, it is an entire engineering process for
solving problems involving flow (of fluids or solids), heat
transfer, and stress.
While this might sound complicated but it is actually very
functional and easy to learn, confirmed Jongsma. “It is
demonstrated time and again even on the basis of relatively
simple models, computer-controlled simulation leads to
astonishing results. The unique way in which STAR-CCM+ is
set up means the learning curve is really short. Creating a mesh,
performing the simulation, and analysing the results take place
in a single interface. The fact that post-processing can be
carried out while the simulation is running, is very helpful in
arriving at a converged solution.” ☐
retaining a small particle size with the smallest possible droplet
size distribution. Its size depends on the drying time (fall time)
and the desired size of the droplet/particle. “A typical spray
dryer has a volume of 700 m3 (diameter: 8.5 m; height: 20 m),
processing 5 t milk or whey an hour and using 5 MW of power.
The energy efficiency lies between 40 and 65% – that makes
every step towards optimisation worthwhile,” said Jongsma.
The significant parameters of a spray dryer are chemical
composition and the initial concentration; the temperature of
the hot air flow; mixing properties of the droplets and air; flight
path and the agglomeration properties.
The quality of a simulation relies on the accuracy of the
model; how realistic the relevant physical, chemical and
technical processes are numerically described. In addition, to
ensure a quick turn-around, the simulation set-up and execution
should be easy, intuitive and efficient. STAR-CCM+, with its
unrivaled meshing technology, high-fidelity physics and
user-friendly interface, meets all these requirements. “I could
not put a scale to it, I am very satisfied with the package itself,
the workflow and the support that is given. There are of course
limitations in what one can describe (in terms of physics)
through CFD at the moment, but I see a steady growth in
capabilities of the STAR-CCM+ solution. The increased
capabilities are made possible by the research efforts of
numerous institutes around the world and it seems this trend is
not coming to an end any time soon,” said Jongsma.
“In general terms, I can state that by actively using CFD we
have greatly improved our understanding of the complex
physics in spray dryers. We now know more about the
conditions that are favourable for spray dryer operation. The > MORE@CLICK ADI03328 | www.AandD24.in
STAR-CCM+ provides the world’s most
comprehensive engineering simulation
inside a single integrated package
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A&D I nd i a | O c t -No v 2013
Manufacturing has had its share of innovation with the
introduction of industrial automation systems that brought
about speed, agility, efficiency and productivity. If one
compares the decade prior to 80’s with 90’s and now, the
growing dependence on the need for productivity, growth,
sustainability and the need to be lean & competitive is clearly
seen.
Productivity levels are at an all-time high, and in the 2000s,
with the convergence of IT, productivity growth, peaking was
faster than that in the 1990s. We are close to that moment in
66
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Getting your humanware ready Suggesting measures to build the knowledge base for the
automation industry, this article deals with the current status of
educational infrastructure and hiring methods while stressing
on the need to build human competency to cater to future
automation and instrumentation industry demands.
manufacturing history when we will perhaps be able to talk to
our machines and our machines will understand our
instructions and even carry them out. We will see some
amazing innovation and big advances which will include
improvements in vision; sensing systems, fine motor control
and more autonomous robots.
As some advanced economies recover from this Great
Recession, hiring in manufacturing may accelerate, and some
nations may even raise net exports. Manufacturers will
continue to hire workers, both in production and non-
Debashish GhoshRetired Industry Marketing Specialistdgrockwell@hotmail.com
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TECHNOLOGY | EDUCAT I ON & TRA IN ING
A& D I n d i a | O c t - N o v 2013
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production roles (such as design, after-sales service including
logistics). But in the long run, manufacturing’s share of
employment will remain under pressure as a result of ongoing
consumer focused products, like in food and health care
products; global competition, will push advanced economies
to specialise in activities requiring more skill and efficiency.
Automation and its role in modern day manufacturing
Man’s quest to improve on efficiency, earn more money
and save energy has driven technology innovation to enable
manufacturing with new instruments which has pushed him
beyond barriers to an age where automation plays an integral
part in the life of a manufacturer. Today, we find automation
in homes, workplace and in manufacturing units. It is
understanding information on measurements, sensing and
controlling speed, controlling process variables within a
production, or manufacturing area, detecting foreign objects
in beverage bottles, picking up steel bars from open hearth
furnaces managing inventory, detecting and preventing
machine downtime and performing many other critical
functions on the production floor.
Humanware: Critical for growth
The discipline of instrumentation and automation
engineering branched out of the streams of electrical and
electronic engineering sometime in the mid 80’s. It is a multi-
disciplinary stream and covers subjects from various branches
such as chemical, mechanical, electrical, electronics and
computers. With the growth and scale of manufacturing and
process units in India the requirement of humanware along
with hardware & software has become critical. To induct the
right candidate has become a compelling need.
How some organisations hire?
What some organisations have done and are still doing is
to hire candidates whom they believe have requisite education,
intelligence and personal characteristics to become successful
revenue producing employees. Other organisations prefer to
start with a blank canvas, in the sense they hire college
graduates with the intent of teaching everything they need to
know about the company’s offerings, adoption patterns of
vertical markets, etc. We have seen that compared to the lucre
promised by IT outfits the automation industry is left wanting
in terms of salary and work life balance. As a result, some
automation companies lure college graduates by power points
stressing on the magic of global brand presence and pick up
laggards as GITs from reputed colleges. These graduate
trainees somehow tend to get disillusioned with their
companies and usually do not last more than two years. For
the automation companies, the search begins once again and
the net result, wastage of time and money. There are other
automation companies who poach and some hire rejects which
have been let go from large companies. They hire without any
due diligence, as a result, unethical practices gets transferred
from one company to the other.
The pattern of induction differ from industry to industry,
job profiles, its needs, immediacy, expectations on its RoI
cycles and market competitiveness. Sometimes, indoctrination
Some automation companies lure college graduates by power points
stressing on the magic of global brand presence and pick up laggards
as GITs from reputed colleges
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EDUCAT IO N & T RA IN IN G | T E CH N OL OG Y
A&D I nd i a | O c t -No v 2013
A typical automation lab
This happens to all fresh graduates who join the automation
industry without any hands-on knowledge hardware, software.
No end-user buyer wants to talk to a solution seller who does
not have industry/application knowledge, least of all the
delivery expertise. There is a need to be able to offer appropriate
solution for a machine, manufacturing line or a process across
the table and close the sale. Today, salesperson must be the
beacon light for his customer. He needs to be ready with value
propositions that can impress his customer and vendors can
get him to pay any price premiums they demand. He must be
able to steer his customer with the trust quotient and help
customers gain in productivity improvements in his
organisation. The gestation time for these engineers is long
before they become application savvy.
Many colleges in India have taken cognisance of the role
automation in manufacturing and have in the past few years
shown interest in wanting to invest in automation education.
These colleges have seen how industries are able to save
precious rupees by sheer management of energy. With the
government adding new Indian Institutes of Technology (IIT)
and National Institutes of Technology (NIT) to the existing
list in tier-II cities, and with the birth of more private institutes,
we will perhaps see the emergence of newer centres of
engineering excellence in cities such as Indore, Jodhpur, Jaipur
and Bhopal, Baroda. Aside many popular courses being
offered, inclusion of appropriate automation education and
knowledge of automation application will help the
manufacturing units source prospective candidates who are
automation aware and ready to deliver faster and able to
shorten the ROI cycle time. This will help better prepare and
deliver ‘the soldiers’ to face the manufacturing battle of
tomorrow.
South and West continue to be the hub of machine building.
There are colleges coming up in states like Uttar Pradesh,
sessions can range from a few days to few months depending
on the complexity of product basket, technology and
candidate’s ability to absorb quickly and convincingly. But can
you afford to slowdown your manufacturing or sales with this
outdated indoctrination process?
The answer is a plain ‘no’. No one can wait, not at least your
customers. We need a ‘ready to deliver’ model. Candidates will
be required to hit the road running. Today, there are world-
class players in the country and some more savvy than the
other. The enterprise must be equipped with relevant
sustainable industry knowledge in order to give them that
cutting edge with customers, and one that can garner
productivity and efficiency in the customer’s or manufacturing
organisation. Today’s learning models should begin early
because both the automation vendors and manufacturers
cannot wait. They must in turn respond to their customers on
time and at the right place.
How do we change and respond?
In an era of choices, engineering still dominates as a
favoured discipline. India is now home to 3,393 engineering
colleges that have 14.86 lakh seats across 36 courses approved
by the All India Council of Technical Education (AICTE). Of
the total number of colleges, 65% are in the south and 35% in
the north. Maharashtra, Andhra Pradesh, Tamil Nadu,
Karnataka and Uttar Pradesh have about 70% tech institutes.
Somewhere between a fifth to a third of the million students
graduating out of India’s engineering colleges run the risk of
being unemployed because either their college does not offer
the desired curriculum required by the manufacturing or
automation vendors; hence, falling short of the desired
expectation of the prospective employer to hire the right talent
relevant for his industry.
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> MORE@CLICK ADI03329 | www.AandD24.in
69
Rajasthan and Madhya Pradesh. Also, since electrical is a
popular choice, implementing automation education can
create a differentiation and help students become competent
for the automation industry.
Need to incorporate automation education
Almost all process and manufacturing industries such as
steel, oil, petrochemical, power and defence production, have
a separate instrumentation department, which is manned and
managed by instrumentation engineers. Automation is the
main driver in the process industry, and it is the core job of
instrumentation engineers. Hence, the demand for
instrumentation will always be there in pharma, food,
petrochemical, chemical or any continuous process plant. The
growth in avionics, aeronautical and space science sectors has
also increased the scope for automation. Skilled in automation
engineers can also fit in both software and hardware sectors.
Nature of work of an automation/instrumentation engineer
ranges from designing, developing, installing, managing and
supporting automation systems that are used to monitor and
control machinery and processes.
In addition to the standard engineering degree, many
colleges today are offering 2-year or 4-year degree programmes
in engineering technology. These programmes, which usually
include various hands-on laboratory classes that focus on
current issues in the application of engineering principles,
prepare students for practical design and production work,
rather than for jobs that require more theoretical and scientific
knowledge. Graduates of 4-year technology programmes may
get jobs similar to those obtained by graduates with a Bachelor’s
degree in engineering.
About 1,830 programmes at colleges and universities offer
Bachelor’s degrees in engineering that are accredited by the
Accreditation Board for Engineering and Technology (ABET),
Inc, and there are another 710 accredited programmes in
engineering technology.
Curriculum @ present
Out of the multitudes of engineering colleges, a few have
started implementing Industrial Automation in their
curriculum in Coimbatore and the College of Engineering,
Pune, have established labs showcasing architecture of various
products integrated with one another. In these labs, 20-30
students can develop PLC programs on 10-15 stations. Once
the PLC program is ready, they download the program to PLC
through a communication network. Multiple PLCs, HMI and
SCADA are connected to this network (Ethernet). A screen
developed in the individual stations can be downloaded to
HMI and SCADA through Ethernet.
Competency development
Enhancing employability and skill development should be
the responsibility of various manufacturing associations and
the automation industry – the two single largest consumers of
the end product. They should provide cross-border
collaboration with colleges and institutes all over the country.
Automation industry should keep aside a promotional budget
for university programmes and scholarship grants for
encouraging students to undertake research projects and build
careers in this industry. They should also donate or sell
hardware at subsidised prices and assist in setting up labs for
the benefit of students. India will indeed benefit by the private
sector’s participation in transforming the skills’ landscape
of India. ☐
Many colleges in India have taken cognisance of the role automation in manufacturing
and have in the past few years shown interest in wanting to
invest in automation education
70
EVENT | R EP ORT
A&D I nd i a | O c t -No v 2013
Showcasing new age technologiesTo highlight the impact of latest technologies for solving
engineering challenges in India and introduce futuristic
technologies, National Instruments recently held the
10th annual NIDays 2013 in Bengaluru. A report…
National Instruments, a worldwide leader in the test and
measurement industry, recently hosted the 10th annual NIDays
2013 in Bengaluru. The event was attended by more than 700
engineers, researchers, scientists and witnessed participation
from NI customers & alliance partners across a range of
industries including healthcare, semiconductor, aerospace,
automotive, life sciences, robotics and telecommunication.
The keynote during the event was delivered by Dr James
Truchard, President, CEO & Cofounder, NI. Addressing the
conference, Dr Truchard said, “It is extremely rewarding to see
our Indian customers solve some interesting challenges with
NI tools. We are seeing the idea of ubiquitous computing and
real-time systems becoming center stage to the next industrial
revolution. We feel like we have got the technology that can
really help redefine how industry works to continue solving
the world’s grand challenges.” Adding further on the importance
of NIDays for the Indian market, he noted, “The most
important thing that we do is to educate engineers on the
present opportunities that they have in solving problems. That
is why we work with over 7000 universities around the world
and around 600 in India. Education is a very important part of
our operations, and we want to make that information available,
train engineers on how to use these tools, so they can be most
productive. NI Days is one of the key initiatives where we
stress on education, while showcasing new solutions.”
Addressing the conference, Victor Mieres, Vice President,
Emerging Markets, Asia/Rest of World, said, “NI leads the
revolution in the instrumentation field with a software-defined
approach to building systems. Being a global organisation, NI
has some region specific programmes including ‘Planet NI’.
The mission of ‘Planet NI’ is to empower engineers in emerging
countries to achieve sustainable prosperity by providing
Sumedha MahoreyDeputy Editorsumedha.mahorey@publish-industry.net
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A&D I n d i a | O c t -No v 2013
The various pavilions at NIDays 2013
showcased the latest NI technologies for
the power, renewable and manufacturing
sector, among others
Do engineering
National Instruments (NI) and the NICE (Nurturing
Innovation and Creativity in Education) Committee also
hosted the 12th Annual Educator’s Day 2013 in Chennai. The
conference showcased the latest tools and best practices in
engineering education. It was a compelling success with
participation of over 500 researchers, professors and eminent
academicians across the country. It emphasised the necessity
of hands-on learning in making engineers industry ready.
National Instruments also announced NI myRIO, an
embedded hardware device to help students design real,
complex engineering systems more quickly and affordably
than ever before.
Based on the same powerful technology as the popular
NICompactRIO platform, NI myRIO is smaller and more
student-friendly than its industrial counterpart. NI myRIO
includes the latest Zynq® all programmable system on a chip
(SoC) technology from Xilinx, which combines a dual-core
ARM Cortex-A9 processor and an FPGA with 28,000
programmable logic cells. Using the power of the NI LabVIEW
graphical programming environment, students can program
the FPGA and evolve their systems in real time, giving them
the flexibility to prototype and quickly iterate on their
designs.
“NI believes in inspiring the next generation of innovators
to solve the world’s engineering grand challenges. By giving
the students of today access to hands-on learning, students
have the opportunity to do engineering and gain valuable skills
that prepare them for the jobs of tomorrow,” said Dr Truchard
during the event. ☐
increased access to NI technology.”
According to Jayaram Pillai, Managing Director, NI (India,
Russia and Arabia), “NIDays 2013 brought together LabVIEW
developers from all over India to share best practices. The
annual Graphical System Design Achievement Awards aimed
to highlight efforts by engineers, scientists and researchers for
their innovative test, measurement and embedded control
applications. With the large pool of knowledge in India, NI’s
open platform provides an opportunity to quickly bring ideas
to reality and, through the LabVIEW Tools Network, gain
market access around the world.”
The conference at Bengaluru highlighted the impact of NI
technology on solving engineering challenges in India. The NI
Application of the Year was awarded to the team from VSSC
Trivandrum (ISRO), AERO Department, for their application
titled ‘Development of 1 m hypersonic wind tunnel control,
networking, data acquisition system and graphical display
system.’
Highlights
During the NIDays 2013, the company introduced the
latest version of LabVIEW system design software, LabVIEW
2013, that utilises the most current and powerful technologies
to make the design of complex systems more intuitive than
ever. It facilitates the management, documentation and
debugging of increasingly complex systems. It adds support for
the Linux Real-Time OS, giving developers access to dynamic,
community-sourced libraries. LabVIEW 2013 focuses on three
primary areas – integrating access to the latest technologies
that make systems better, enhancing the environment so
developers are more efficient, and providing access to an
ecosystem of training and partner tools. > MORE@CLICK ADI03330 | www.AandD24.in
72
TECHN O LO GY | TA LK
A&D I nd i a | O c t -No v 2013
The automotive industry is one of the
most rapidly growing industrial sectors in
the country. With the cumulative FDI
inflow into the market, India is becoming
the magnet for car makers. The industry
is highly competitive with a mix of Indian
and foreign players and is also one of the
most important sectors from the economic
point of view. India‘s passenger car and
commercial vehicle manufacturing
industry is the sixth largest in the world,
with an annual production of more than
3.9 million units in 2011. The production
of passenger vehicles in India was
recorded at 3.23 million in 2012-13 and is
expected to grow at a compound annual
growth rate (CAGR) of 13 per cent during
2012-2021, as per data published by
Automotive Component Manufacturers
Association of India (ACMA).
The automotive industry has been
facing the challenge of maximising
efficiency due to the extreme pressure of
the market demands and expectations.
Automobile manufacturing involves
managing several large and complex
processes. Hence it is imperative to
maintain the health of the machines. Thus,
it is very important to install proper
cabling to ensure operations do not come
to a halt.
Lapp India recently catered to a
leading automotive manufacturing
company that is popularly known for
making conscious efforts in
implementation of several environmentally
sensitive technologies in the
manufacturing process. The company
SOLUTIONS FOR AUTOMOTIVE APPLICATIONSSuggesting the right cabling solutions for crane and drag chain applications, here is a case
study on the customised solutions provided by Lapp Cables for the automotive industry
uses some of the world’s most advanced
technologies for emission check and
control.
Cabling requirements
Flexible and long lasting cables for
crane and drag chain applications include
data communication cables for
transferring data from one part of the
plant to another; cables for critical
applications on the factory floors;
automation cables for remote monitoring;
flat cables for space constrained
applications and power cables for
supplying power to the machines.
Cabling solutions
Lapp India has provided flat cables for
cross travel and crane operations that
need less space than round cables. These
cables are resistant to abrasion and are
able to withstand harsh environmental
conditions. For data transfer purposes it
has supplied communication cables that
are ideal for locations with space
constraints with an added advantage of
low-loss data transmission between the
control panels and the factory floor.
Depending on where the cables would be
used, Lapp India has provided specific
type of cables. It has supplied robot cables
for welding division, for powering and
controlling its gun welding equipments.
These cables are HFFR compliant, flame
retardant and can withstand temperature
load upto 1200o C. These are made up of > MORE@CLICK ADI03331 | www.AandD24.in
extra-fine strands of bare copper wire
and a twisted core thereby making the
cables ideal for flexing and torsion load
application. For body shop division, it
has supplied cables which adhere to space
constraint factors and are capable of
withstanding mechanical stress. Because
of their high durability and flexibility
these cables are ideal for power and
control solutions in drag chains. The
company has provided cables for paint
division that are chemically inert and are
highly temperature resistant. They are
silicon-free cables with high current
carrying capacity and offer enhanced
resistance to oxidation and PWIS. ☐
Courtesy: Lapp Cables
Flexible and long lasting cables for crane
and drag chain applications include data
communication cables for transferring
data from one part of the plant to another
73A&D I n d i a | O c t -No v 2013
TALK | TECHNOLOGY
An electric arc flash is the result of an
arc fault that superheats the air around it,
expanding and creating a pressure wave
within an electrical enclosure. This arc
plasma vaporises everything it comes in
contact with, such as copper, insulating
materials, bolts and steel enclosures. This
massive heat and energy wave can inflict
serious injuries, including severe burns,
damaged hearing from the powerful
sound waves, impalement from projectiles
and impaired eyesight from the high-
intensity flash.
Arc resistant equipment can help
protect employees working on or near
energised equipment. IEEE codes set
standards for protective equipment and
‘limits of approach’ focused on
withstanding an arc flash. These and other
guidelines include technical specifications
to help companies choose appropriately
rated equipment with proper protection
levels.
Arc resistant equipment & accessibility
Arc resistant equipment is electrical
equipment designed for controlling the
exposure and/or release of the dynamic
elements associated with an internal arc
flash. The equipment is defined by the
level to which these elements are
extinguished or controlled, or prevented
from seriously injuring personnel or from
propagating. Generally, the protection
applies only when all equipment doors
are closed and latched; the manufacturer
must test the equipment to validate the
level of protection.
A fundamental approach to arc flash
safety must include all personnel, whether
IEEE codes set standards for protective
equipment and ‘limits of approach’
focused on withstanding an arc flash
PROTECTION FROM ARC FLASHThe article deals with the arc resistant equipment that can help protect employees working
on or near energised equipment
electrically qualified or not. For
equipment to meet the IEEE C37.20.7 arc
resistant standard, all doors and covers
must remain closed during an arc flash
incident. No parts can be ejected from
the equipment, and the arc does not burn
any holes in the exterior of the test
structure. The grounding connections
must remain effective through the entire
test cycle. Per IEEE C37.20.7, levels of arc
resistant accessibility are defined in three
types. The Type 1 includes equipment
shields personnel from arc exhaust
materials only when in front of the
equipment. This equipment does not
provide any specific level of protection
outside the protected zone, and all doors
must be closed and latched. The Type 2
offers equipment shields personnel from
the arc dynamic components on the front,
sides and rear of the equipment. Doors
must also be closed and latched. A third
level of protection, Type 2B, shields
personnel from arc exhaust materials on
the front, sides and rear of the equipment,
even when the low-voltage control
compartment door is open.
Rating choice and selection
Equipment is determined to be arc
resistant based on applied voltage, source
impedance and the duration of the arc
event. The duration of the arc can be
specified in time or by relying on a
specified upstream protective device. A
duration rating is strictly based on
quenching the arc in a maximum amount
of time. This rating is independent of
other protective devices. Device limited
ratings use a tested protective device to
limit the duration of an arcing fault. In > MORE@CLICK ADI03332 | www.AandD24.in
device limited rating, no specific time
duration is stated. In arc resistant
equipment that has been duration rated,
the vendor name plate will include
accessibility type, the standard or guide
used for validation testing, and the
maximum short circuit current and
duration. The vendor nameplate for
equipment that has a device limited rating
includes accessibility type, maximum
short circuit current and a list of tested,
protective devices.
When buying arc resistant equipment,
it is important to consider the overall
system requirements to purchase exactly
what the system needs. The system short
circuit current at the point of the
equipment’s use can help determine the
correct rating for the system. Operators
will also need to consider how long their
system can sustain an arcing fault. The
longer the time, the greater amount of
energy is released and the higher degree
of internal damage is sustained to
equipment. ☐
Courtesy: Rockwell Automation
SENSO RS & E N CO D E RS | I N N OVAT I ON S
74 A&D I nd i a | O c t -No v 2013
REDEFINING THE FUTUREOpening up a world of possibilities, the new age sensors have completely changed the way
automation was perceived in this decade. A look at the latest innovations introduced in the
Indian market by leading sensor manufacturers…
Innovation: Mini Mini Sensor – the world’s smallest inductive sensor
Technical details: The enormous reduction in size was made possible by using the latest
mixed-signal ASIC technology. This technique combines analog signal processing with digital
computing power on a single chip, making it particularly suitable for all applications where
signals are recorded in analog form, but must be digitised for transmission. Another advantage
is that, by eliminating the need to use analog components, device reliability is increased.
Applicability: ASIC technology in sensors which gives a
high level of accuracy, repeatability, and reliability.
Advantage: The sensor is in the size range of 12 mm length and diameter 3 mm having
inbuilt sensing including amplifier and processing circuits. It also impresses with its high
switching frequency of 8 kHz and excellent temperature stability from -25° C to +70° C.
Alongside the standard version with a plastic cap.
Innovation: SmartReflect light barrier
Technical details: With the SmartReflect light barriers, the light beam – in contrast to a
retro-reflective or through beam sensor – is set up between the sensor and a machine part. An
object interrupts the light beam and triggers the sensor. The only condition is that there must
be a background, for example, any machine part, in the sensing distance of the sensor. In this
way, the separate reflector becomes superfluous and a common weak point is rectified.
Special SmartReflect variants can use the same principle to detect transparent objects like
bottles, trays or even foils.
Applicability: It can be used for diverse industrial environments to address the need for a
robust light barrier solution, which would not have the disadvantages of conventional sensors.
Advantage: The product is capable of enabling a very high ROI due to savings in maintenance
costs. No need to replace reflectors, downtime is reduced and productivity is improved. It not
only ensures substantial reduction in operating costs, but also cost savings due to easier
installation, commissioning and alignment.
Company: Contrinex Automation
Innovation: efector pmd 3d – the first industrial 3D sensor that can detect objects in three dimensions at a
glance
Technical details: The measurement and the evaluation of the time of flight are integrated on one chip.
The dimensions of the extraordinarily compact sensor housing are just 60 x 42 x 35 mm. The resolution of
the sensor is 64 x 48 pixels. Each pixel of this matrix evaluates its distance to the object. This results in
3072 distance values at the same time. The image of the object on the matrix and the respective distance
values correspond to a 3D image. The geometrical characteristics of the object result from these values.
Applicability: The award-winning PMD technology enables the evaluation of geometrical characteristics
such as volume, distance, level or surface area. Irrespective of the distance between sensor and object, the
volume is determined from a top view.
Advantage: By means of the 3D sensor, the measurement of distances to uneven surfaces is no longer a
problem – a clever alternative to ultrasonic measurement. Levels can also be determined on the basis of a
defined background and search zone.
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Company: ifm electronic
A&D I nd i a | O c t -No v 2013
Company: Baumer
I NNOVAT IONS | SENSORS & ENCODERS
75A&D I n d i a | O c t -No v 2013
> MORE@CLICK ADI03333 | www.AandD24.in
Innovation: 360° high speed rotating scanner
Technical details: The company has successfully developed a very futuristic 360° high
speed rotating scanner on a platform that measures the time of flight of a pulse of light
and delivers a highly fast and very accurately scanned 360° view of the area around it.
Applicability: The excellence of this technology is in its high scanning frequency of up to
50 Hz and the sampling rate of 250,000 measurements which allows a gapless vision of
360° and ensures that the scanner has a direct view on the environment at any
measuring angle.
Advantage: The equipment simulates an on-board beautiful, highly visible multi
directional display through which status reports can be displayed or application-specific
information like distance values, measuring profiles etc can be easily displayed.
Innovation: High precision high speed triangulation sensor optoNCDT 2300
Technical details: The measurement principle of laser triangulation is simple: the sensor
operates with a laser diode, which projects a visible light spot onto the measurement target. The
reflected light is imaged by an optical receiving system onto a position sensitive element. If the
light spot changes its position, this change is imaged on the receiving element and evaluated.
Applicability: The sensor can be used to monitor vibrations on difficult, uneven surfaces.
Advantage: This new series offers adjustable measuring rates up to 49 kHz. The sensor is
offered as a set of 5 models with measuring ranges between 2 mm and 100 mm. With the entire
electronics integrated, the sensor is very compact and measures 80 mm x 75 mm.
Innovation: The BNS series
Technical details: The sensors have high-quality stainless steel, making it
resistant to corrosion and cleaning liquids; it meets ECOLAB test requirements for
wash down with acid and alkaline-based cleaning agents.
Applicability: The switch and matching coded actuator are IP69K rated for use
in high-temperature (176°F) and high-pressure (1450 psi) wash down
applications. The sensors have more tolerance to misalignment, individual coding
to avoid bypassing of the switches by the operator.
Advantage: Many other variants are available for installation in hazardous area
in petroleum, refineries industries with ATEX approved products for compliant to
Zone 1 & 2.
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> MORE@CLICK ADI03333 | www.AandD24.in
Company: Schmersal Group
Innovation: New Performance Level ‘c’ version pressure sensors
Technical details: The Melt pressure filled sensors with an extensimetric technology have been
enriched by new versions specifically designed to increase the safety level of machinery imposed
by current international standards.
Applicability: The product is an ideal solution for increasing the safety of extruders.
Advantage: This version features smart electronics with auto-diagnostics that detects all possible
fault conditions. Additional safety is ensured by an integrated relay that changes state in case of
over-pressures or passing of the set limit in conformity to the requirements of Namur NE21 and
NE43. The benefits are tangible and immediate – lower risks for operators, higher safety levels for
the machinery and complete respect of the environment.
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Company: Gefran Group
TECHN O LO GY | NEWS
76 A&D I nd i a | O c t -No v 2013
Spring loaded terminal blocks
Connectwell’s spring loaded feed through terminal blocks come with
springs below the clamps. These terminal blocks are preferred for
connections that involve safety
requirements of the electric
supply industry (ESI) standards,
British CEGB regulations and
NTPC applications. In addition to
high torque screws, these blocks
have a built-in spring loading
feature. It is recommended to use
hook type lug / ferrule for
terminating wires in such
connections. These terminal
blocks have specially designed
current bar for the right location &
placement of wires crimped in hook type
lug / ferrule, thus preventing loosening of
the wires even when the screw clamps
are not tightened. The terminal pitch
includes CTS4USC-6 mm, CTS6USC-
8 mm and CTS10USC-10 mm.
Precision regulators
Janatics India has recently launched its light weight, compact, diaphragm
operated, relieving type (exhaust)
precision regulators. These
regulators are designed to provide a
constant output pressure with high
degree of accuracy to ensure that
the output pressure is maintained
precisely irrespective of
fluctuations in the inlet pressure.
The company has offered
precision regulators in 1/4” port
size, with supply pressure of
maximum 10 kg/cm² and
regulating pressure range of 0.1
to 8 kg/cm². The sensitivity of the
precision regulator is ≤ 0.02 kg/cm and
repeatability is within ± 0.04 Kg/cm²,
with a flow 1100 lts/min.The precision
regulator has wide use applications like
metrology gauging systems, printing,
textile, packaging and medical
equipments and many more.
The terminal blocks are
preferred for connections that
involve safety requirements
of the electric supply Industry
(ESI) standards, British
CEGB regulations and NTPC
applications
The precision regulators are
designed to provide a constant
output pressure with high
degree of accuracy to ensure
that the output pressure
is maintained precisely
irrespective of fluctuations in
the inlet pressure
Output circuit protection replay
Finder Relays has recently introduced the new Master Plus series that is
equipped with a fuse module at
the contact side, for a standard
20x5 mm glass fuse. This gives
the relay interface a complete
modularity along with the
pluggable relay which can be
mounted over a DIN Rail base/
socket. Optional fuse bypass
switch allows the user to
operate the relay even without
a fuse module due to the internal
electrical link. This provides an
advantage to use the relay and in
turn the complete system without
affecting the signal continuity, if required. Condition of the fuse is easily
visible through a window. The features of this series include complete
output protection with unique replaceable glass fuse; reliability in wiring
and is equally cost and time saving. It offers advantages like pluggable
electromechanical or solid state relay, plug-in jumper links (for looping) in
red, blue and black colour and protection for leakage current suppression.
Power supply units
Phoenix Contact has recently offered power supply units for AC to DC
conversion, DC to DC conversion, redundant module and design to fulfil
the requirements of various different sectors. Compact power supply units
from the QUINT POWER ranges
maximises the availability of the
system. Even standard circuit
breakers can be tripped quickly with
the SFB (Selective Fuse Breaking)
technology. Comprehensive
diagnostics are provided through
constant monitoring of the output
voltage and output current. The
preventive function monitoring
visualises critical operating state and
indicates them to the controller
before errors can occur. In order to
trip standard circuit breakers
magnetically and quickly, power supply units must be able to supply
several times the nominal current for a short period. With SFB technology,
which supplies up to six times the nominal current for 12 ms it ensures
the reliable tripping of the circuit breakers as a result of the availability of
dynamic power reserve.
Optional fuse bypass switch allows the user
to operate the relay even without a fuse
module due to the internal electrical link
Compact power supply units from
the QUINT POWER ranges maximises
the availability of the system
> MORE@CLICK ADI03336 | www.AandD24.in
> MORE@CLICK ADI03334 | www.AandD24.in
> MORE@CLICK ADI03337 | www.AandD24.in
> MORE@CLICK ADI03335 | www.AandD24.in
NEWS | TECHNOLOGY
77A&D I n d i a | O c t -No v 2013
Standardisation & automation software
Eplan Platform has launched Version 2.3 that focuses on standardisation
& automation and opens up new opportunities for users for standard-
compliant design & handling safety values. Simple macro editing and
extended search functions for system settings
guarantee highly productive engineering for
users. Another benefit is the central
administration of phased-out devices and
associated test runs to give transparency and
safety to existing projects. The latest version
is characterised by standardised and largely
automated engineering across a consistent
database. There is a comprehensive support
for new standard-compliant designations
based on EN 81346 and the safety values
focused VDMA 66413 exchange format. The
central administration of phased-out items and a new search function for
system settings are additional new features of the CAE software to allow
interdisciplinary cooperation and configuration. Version 2.3 offers
extensive options for handling macros/partial circuits and their variations.
These macros can be edited and if required can be updated across the
entire project within a clear table view.
Eplan 2.3 focuses on
standardisation & automation
and opens up new opportunities
for users for standard-compliant
design & handling safety values
CAN repeaters
HMS Industrial Networks has launched a range of CAN repeaters under
the IXXAT brand. These products enable coupling of two or more CAN
network segments, provide them with galvanic
isolation and eliminate the effects of EMI
(Electromagnetic Interference). The CAN
repeaters are offered under HMS’s recently
acquired IXXAT brand and enable machine
builders and system integrators to use extended
CAN topologies including tree or star
topologies. Furthermore, the integrated
galvanic isolation provides a built-in protection
against over voltage and the anti-noise circuit
of the units eliminates the effects of EMI.
IXXAT repeaters are especially designed for
use in industrial environments, meeting high
demands for robustness, temperature ranges
and safety. With the use of a repeater, it is possible to build independent
electric segments that can be optimally terminated in terms of signals.
The repeater substantially increases system reliability, partly because it
increases the signal quality and it makes it possible to isolate
malfunctions – keeping the remaining CAN-system fully operational.
IXXAT CAN repeaters enable
coupling of two or more CAN
network segments, provide
them with galvanic isolation and
eliminate the effects of EMI
> MORE@CLICK ADI03338 | www.AandD24.in > MORE@CLICK ADI03339 | www.AandD24.in
Industrial wireless access point
ProSoft Technology has released the 802.11n industrial wireless access
point/bridge/repeater with fast roam technology. The
802.11abgn fast industrial hotspot is an advanced,
high-speed wireless Ethernet solution designed for
plant-floor automation, SCADA systems, mobile worker
Wi-Fi infrastructure and process control systems. The
hotspot offers a broad range of industrial wireless
capabilities including unique features such as fast
roaming and has excellent packet-per-second
performance and robust communications in
demanding industrial environments. These new
capabilities provide seamless high-speed Ethernet
connections for moving machines and vehicles
traveling long distances in assembly plants, crane
systems and mining. The secure, high speed wireless
network reduces project costs, while improving
productivity by eliminating mechanical festooning,
rails and slip rings for economical and reliable mobile
applications. The radio’s fast roaming technology
uses less than 50 msec time between access points and provides full
device bridging. The module provides secure 802.11i and 128-bit AES
Encryption and operates securely in the 2.4 GHz or 5 GHz bands.
The 802.11abgn fast
industrial hotspot is an
advanced, high-speed
wireless Ethernet solution
designed for plant-floor
automation, SCADA
systems, mobile worker
Wi-Fi infrastructure and
process control systems
> MORE@CLICK ADI03341 | www.AandD24.in
Brushless motor
Portescap has recently introduced the 22ECS brushless motor. Designed
to deliver exceptional efficiency in high speed applications, the 22ECS
runs up to 30 per cent cooler than
similar motors, at speeds greater
than 50K RPM. As a result, the
brushless slotless motor stays much
cooler and offers greater power
density than equivalent models at a
given operating point. The 22ECS also
uses unique high performance lubrication
and ball bearings to extend motor life
and maximise performance at high
speeds. Due to its high power, efficiency
and low rotor inertia, the 22ECS can
change speed and accelerate rapidly.
The superior efficiency not only enables
cooler operation at high speeds, but also
offers battery capacity and life
advantages. The motor’s superior
efficiency allows battery operated applications to run longer between
charging cycles and can reduce the size of the battery.
gi
uses
a
u
The 22ECS brushless motor is
designed to deliver exceptional
efficiency in high speed
applications, the 22ECS runs up
to 30 per cent cooler than similar
motors, at speeds greater than
50K RPM
> MORE@CLICK ADI03340 | www.AandD24.in
TECHN O LO GY | NEWS
78 A&D I nd i a | O c t -No v 2013
Flexible compact AC drives
Rockwell Automation has recently designed PowerFlex 520-series of
compact AC drives, including the new, economical PowerFlex 523 AC drive,
with flexible features that help users be more competitive. Ideal for
builders of simple, stand-alone machines, the PowerFlex 523 AC drive
balances user needs for control with a
design that lowers the cost, to develop and
deliver machines. To make configuration
easier, machine builders can use a standard
USB connection for uploading and
downloading drive-configuration files. They
can also program the drive through its
built-in human interface module (HIM), which
displays data on the drive’s LCD with
scrolling QuickView text and detailed
explanations of parameters and other codes.
The HIM has multiple language options to
address global needs. Unique to the
PowerFlex 520-series AC drives, app view
and custom view tools help speed up
configuration by providing groups of parameters for common applications
and by allowing users to save their settings to new parameter groups.
PowerFlex 520-series help
speed up configuration
by providing groups of
parameters for common
applications and by allowing
users to save their settings to
new parameter groups
Pressure transmitters
Keller AG has introduced a complete range of pressure transmitters for
use in hazardous areas. These intrinsically safe transmitters offer
measurement ranges between 0.2 bar and 1000 bar, so they can be used
for measurements of all types in areas subject to explosion hazards in
Group II (Gas), and as per the relevant
ATEX directive. Individual types from the
product range are also approved for
Group I (mining) respectively Group II
(dust). Common features of all Y-line
pressure transmitters include a very low
temperature error, with correspondingly
high measurement accuracy. Thanks to
the integrated temperature sensor and
an additional digital circuit, the range of
envisaged operating temperatures can be
divided into as many as 120 sections with
a width of 1.5 K. During factory calibration,
a mathematical model is used to calculate
individual compensation values for TK zero
point and TK amplification for each of these sections; the values are then
stored in the transmitter.
Frequency inverters
Nord Drivesystems has introduced SK 180E which is mounted on
asynchronous motors, just like its larger counterparts. Featuring proven
ISD vector control, the SK 180E is more cost-effective than the currently
available range of
decentralised units. The new
inverter focuses on the core
requirements of speed control
and efficiency. Featuring two
analog inputs and integrated
process and PI controller
functions, it can autonomously
manage simple drive
applications. It is suitable
both for stand-alone variable
frequency drives and for
synchronised operation with several units. It can save upto 30 % energy
by automatic magnetisation adjustment under partial load. Providing class
C1 radio interference suppression and a discharge current below 16 mA,
the SK 180E can be operated in residential and business buildings. For
use in mobile pumps, shredders, or mixers, variable frequency drives are
available with a conventional mains plug.
The pluggable series is an
excellent solution for creating
wire harnesses which ease field
wire connections
The new inverter focuses on the core
requirements of speed control and efficiency
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> MORE@CLICK ADI03345 | www.AandD24.in
Online colour measurement system
Micro-Epsilon Eltrotec has introduced colorCONTROL ACS 7000 with a
ΔE < 0.08. The innovative colorCONTROL ACS 7000 colour measurement
system is used where colour
sensor measurements are not
accurate enough. The
measurement system provides a
number of operating modes. The
users can employ one of several
methods to perform simple
measurements between colour
distance ΔE and the reference
value: ΔE(CMC), ΔE99, ΔE94,
ΔEDE2000. The measuring spot is
9 mm with a measurement
accuracy of ΔE < 0.08. All modes
support measurement speed up to
2 kHz. It can be used for both production line measurements (inline) and
for laboratory or sample measurements (offline). The measurement
system is suitable for automotive paint inspection, interior colour
measurements, forensics, foils, injection moulding, wood, veneers, textiles,
printing, medical technologies, and coating technology.
The innovative colorCONTROL ACS 7000
colour measurement system is used
where colour sensor measurements are
not accurate
> MORE@CLICK ADI03344 | www.AandD24.in
80 A&D I nd i a | O c t -No v 2013
Highlights - Dec’13-Jan’14
H IGHL IGH T S | CO MPAN Y INDEX | IMPR INT
COMPANY INDEX
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page
Analog Devices India. . . . . . . . . . . . . . . . . . 16
Alstom . . . . . . . . . . . . . . . . . . . . . . . . 10, 12
AIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ARC Advisory Group . . . . . . . . . . . . . . . . . . 26
B&R Industrial Automation . . .Cover, 8, 9, 10, 52
Beckhoff Automation . . . . . . . . . . . . . . . . . . 1
Baumer. . . . . . . . . . . . . . . . . . . . . . . . 32, 76
Connectwell Industries . . . . . . . . . . . . . 11, 76
Control Techniques . . . . . . . . . . . . . . . . . . . 12
Contrinex Automation . . . . . . . . . . . 19, 32, 76
Delta India Electronics . . . . . . . . . . . . . . . . 39
EPLAN . . . . . . . . . . . . . . . . . . . . . . . . 57, 77
Fieldbus Foundation . . . . . . . . . . . . . . . . . . 12
Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 2
Finder India . . . . . . . . . . . . . . . . . . . . . 35, 76
GE Technology . . . . . . . . . . . . . . . . . . . . . . 10
Galil Motion Control . . . . . . . .Back Inside Cover
Güdel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Gefran India . . . . . . . . . . . . . . . . . 32, 47, 77
HART Communication Foundation. . . . . . . . . 12
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page
Hilscher India . . . . . . . . . . . . . . . . . . . . . . 13
Hummel Connector Systems . . . . . . Back Cover
Hilscher India . . . . . . . . . . . . . . . . . . . . . . . 18
Honeywell Process Solutions . . . . . . . . . . . . 20
Hanning Motors . . . . . . . . . . . . . . . . . . . . . 49
HMS Industrial Networks . . . . . . . . . . . . 21, 77
IFR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ifm electronic India . . . . . . . . . . . . . 32, 43, 76
ISA Bengaluru . . . . . . . . . . . . . . . . . . . . . . 10
Janatics . . . . . . . . . . . . . . . . . . . . . . . . 6, 76
Keller . . . . . . . . . . . . . . . . . . . . . . . . . 53, 78
Katlax Enterprises . . . . . . . . . . . . . . . . . . . . 4
Kubler Automation . . . . . . . . . . . . . . . . . . . 15
Lapp India . . . . . . . . . . . . . . . . . . . . . . . . . 72
Mitsubishi Electric. . . . . . . . . . . . . . . . . . . . . 3
Micro-Epsilon. . . . . . . . . . . . . . . . . . 7, 32, 78
Nord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
National Instruments . . . . . . . . . . . . . . . 30, 70
Omron Automation . . . . . . . . . . . . . . . . . . . . 5
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page
Pepperl+Fuchs . . . . . . . . . . . . . . . . . . 32, 77
Protescap . . . . . . . . . . . . . . . . . . . . . . . . . 77
Prosoft . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Red Lion Controls. . . . . . . . . . . . . . . . . . . . 14
Rockwell Automation. . . . . . . . . . . . 36, 73, 78
Renu Electronics . . . . . . . . . . . . . . . . . . . . 25
SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Stäubli . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Siemens PLM . . . . . . . . . . . . . . . . . . . . . . 60
Schunk Intec India . . . . . . . . .Front Inside Cover
Schmersal India . . . . . . . . . . . . . . . 17, 32, 77
Schneider . . . . . . . . . . . . . . . . . . . . . . . . . 51
Tetra-Pak . . . . . . . . . . . . . . . . . . . . . . . . . 62
Kirpekar Engineering . . . . . . . . . . . . . . . . . 59
Mifa Systems . . . . . . . . . . . . . . . . . . . . . . 61
Phoenix Contact . . . . . . . . . . . . . . . . . 63, 76
VDMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Machine Vision »Machine vision technology is used in a variety of different industries to automate the production, increase production speed and yield, and to improve product quality. This industry is a knowledge driven industry which experiences an ever increasing complexity of components and modules of machine vision systems. The next edition of A&D India will present case studies on the use of new machine vision systems in various applications.
Industrial Computers »An equipment optimisation of the industrial computers targeted at ‘increased system availability’ is one of the easiest possibilities of improving productivity by minimising downtimes, even though the ambient conditions in the industrial sector are much harsher than in offices. A&D India will provide the technology trends in industrial computers in the next issue.
Food & Beverage Industry »The food & beverage industries are as diverse as the global consumer base they serve. There is a continuous demand for a greater variety of packaged products to satisfy a wide range of demographics. Faced with these challenges, producers still need to improve the bottomline and grow. The next issue will highlight the advanced automation solutions in the food & beverage industry.
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