easy skid integration start/stop circuit? motion … · maintanance time: all wire terminators use...

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CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfi eld Rd., Suite 400N, Schaum-burg, Illinois 60173. (Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at Schaumburg, IL, and at additional mailing offi ces. Address all correspondence to Editorial and Executive Offi ces, same address. Printed in the United States. ©Putman Media 2015. All rights reserved. The contents of this publication may not be reproduced in whole or part without consent of the copyright owner. POSTMASTER: Send address changes to Control Design, Post Offi ce Box 3430, Northbrook, Illinois 60065-3430. SUBSCRIPTIONS: To apply for a free subscription, fi ll in the form at www.ControlDesign.com/subscribemag. To non-qualifi ed subscribers in the Unites States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) Putman Media also publishes CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING, INDUSTRIAL NETWORKING, PHAR-MACEUTICAL MANUFACTURING and PLANT SERVICES. CONTROL DESIGN assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor information: World Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada N9A 6J5. Printed in the United States.

CONTENTS Volume 19, No. 8

FEATURESCOVER STORY

Multi-purpose designModular approach to machine building puts reusable, customized solutions at your � ngertips

Hank Hogan, contributing editor

20MOTION CONTROL

Join the effi ciency revolutionSmart machine builders are using innovative designs, components, software and production methods to save energy, materials and expenses

Jim Montague, executive editor

29MACHINE INPUT

Solid-state or electromechanical relays?Choosing between SSRs and EMRs involves multiple considerations

Mike Bacidore, chief editor

35PRODUCT ROUNDUP

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Volume 19, No. 8CONTENTS

9 Editor’s Page Up OEE with MTConnectMike Bacidore, chief editor

11 Live Wire How to start and stopDave Perkon, technical editor

13 Machine Builder Mojo Process skid standardizationDan Hebert, senior technical editor

15 Embedded Intelligence Cloud-ready industrial applications?Jeremy Pollard, CET

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16 InDiscreteDo you know a STEM superhero?A3 advancesConnected machines and smart watches

44 Real AnswersBest way to protect low-power circuits

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Mike Bacidore • editor in chief • [email protected] EDITOR’S PAGE

EARLIER THIS YEAR at the ARC

Forum, I met Rocky Rowland, ma-

chining manager at Mazak (www.

mazakusa.com), a Japanese-based

company with its North Ameri-

can headquarters in Florence,

Kentucky. “We manufacture 114

different models in our facility,

and our manufacturing capacity

is more than 200 units a month,”

said Rowland.

“We provide MTConnect solu-

tions to our customers,” said

Rowland. “We wanted to really

know what was going on with our

machines. Our goal was to im-

prove our OEE using the MTCon-

nect technology. We wanted to see

what stopped the machines on

the production floor. We evaluated

six monitoring software packages

and selected Memex Automation.

We wanted something simple that

could monitor all of the NC signals

and a reporting feature that was

easy to use.”

What kind of data can be

gathered from the Mazak CNC?

Programs, CNC status, axis loads,

spindle rpm, temperature and over-

rides, for example.

What kind of ROI can be expect-

ed? “Anywhere between 3% and

15%, depending on how efficient

your operation currently is,” ex-

plained Rowland.

In September 2013, Mazak

implemented a test cell with 12

machines. “We have our own types

of software,” said Rowland. “This

software was exclusive to this type

of machine because of the control-

ler type. We looked at adapters, the

interface and monitoring. ”

Mazak wanted to understand

why its machines would some-

times sit idle. “With this software,

you’re able to look at the machine

output across a scheduled time,”

said Rowland. “We can look at the

reports very easily. We get gauges

that show different aspects of the

machine and calculate OEE. The

biggest thing we were looking at

was runtime vs. downtime. We

had detailed downtime summa-

ries in a daily report, along with

the machine efficiency numbers.”

Idle-time reduction requires

operator awareness. “It’s not one

operator per machine these days,”

explained Rowland. “Most operators

have to move about between mul-

tiple machines. We added two floor

monitors, which allowed operators

to see their equipment and how

their actions impacted production.”

The data opened Mazak’s eyes.

From November to December, in

the test cell, there was a 26% re-

duction in downtime hours. Utili-

zation was up 6.1%. Then, over the

next year, utilization was up 11.4%,

which is an average monthly sav-

ings of $27,506. Downtime dropped

from 604 hours in November 2013

to 182 hours in December 2014.

Benefits of the MTConnect

implementation included live,

accurate data in real time. “You

can see where different pieces

of equipment are,” explained

Rowland. “The biggest benefit is

providing a management tool.

You get immediate feedback on

changes. Any asset can be utilized.

Several software suppliers support

the MTConnect standard.”

Downtime dropped from 604 hours in November 2013 to 182 hours in December 2014.

Up OEE with MTConnect


EDITORIAL TEAMeditor in chief

MIKE [email protected]

technical editor

DAVE [email protected]

managing editor

NANCY [email protected]

associate editor, digital media

GRETA LIESKEeditor, digital media

senior technical editor

DAN [email protected]

associate publisher

STEVE [email protected]

editorial assistant

LORI [email protected]

contributing editor

HANK [email protected]

columnist

JEREMY [email protected]

DESIGN/PRODUCTIONsenior production manager

ANETTA GAUTHIER

assoc. art director

ANGELA LABATE

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CIRCULATION audited december 2014Air & Gas Compressors 698Engineering & Systems Integration Services 8,838Engines & Turbines 1,327Food Products Machinery 1,654Industrial Fans, Blowers & Air Purification Equipment 649Industrial Heating, Refrigeration & Air Conditioning Equipment 1,209Industrial Process Furnaces & Ovens 526Machine Tools 3,015Materials Handling, Conveyors& Conveying Equipment 1,661Metalworking Machinery 3,846Mining Machinery & Equipment 556Oil & Gas Field Machinery & Equipment 1,360Packaging Machinery 1,052Paper Industries Machinery 363Printing Trades Machinery & Equipment 489Pumps & Pumping Equipment 807Rolling Mill Machinery & Equipment 187Semiconductor Manufacturing Machinery 1,071Textile Machinery 210Woodworking Machinery 310Other Industries & Special Industrial Machinery & Equipment NEC 10,192

TOTAL 40,020

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THERE ARE MANY experienced and productive

control designers and programmers in industry today.

The companies they work for know the value of a

good controls engineer. Unfortunately, there are many

inexperienced engineers, such as recent college gradu-

ates or maybe the seasoned engineer who likes to hide

in the corner and just do what’s necessary. Some are

excited to learn, and others not so much. The point

is, engineers come in all types—some great, some

good and some bad, as in life. At no point is this less

obvious than in a job interview or more obvious than

while working on a project.

As an engineer and manager, I’ve interviewed many

controls engineers, electrical designers, programmers

and CAD operators for jobs designing and program-

ming automated equipment throughout my 27 years in

industry. Along with all the typical interview ques-

tions, I had what I consider a basic interview task:

draw a start/stop circuit. Unfortunately, only about

20% of the “experienced” control design and program-

ming applicants could do it.

Clearly, industrial, hands-on experience is all rela-

tive, and each interview was quite the learning experi-

ence both for me and for the interviewee.

If you want to see the circuit, let me know, as it was

a great test. It clearly showed experience with control

design and the applicant’s attention to detail—not

many applicants showed much of either. The experi-

enced designer forgot the wire numbers or cross refer-

ences, and the inexperienced designer used the eraser

quite a bit, along with many other issues.

Perhaps I’m asking too much and shouldn’t expect

an experienced control designer or recent EE graduate

to draw a hardwired start/stop circuit. If they could

not draw a simple hardwired start/stop circuit, I didn’t

think they could program one either. However, many

of the applicants who couldn’t draw it stated on their

resumes that they were experienced PLC program-

mers, as well. This highlighted concerns about the

applicant’s ability to program a PLC step sequence.

If they didn’t know the answer, I showed them

how to do it with the thought that I could develop the

engineer as needed if the candidate was interested in

learning. It’s clear that, even with a four-year degree in

engineering, the interviewee didn’t have any practical

experience. Examples of the problems this causes are

endless, so engineering talent must be developed.

“Developing and training an engineer is a good

thing, although the results will vary,” notes Otto Fest,

president at Otek (www.otekcorp.com). Fest thinks

the real technical education starts after graduation.

“College graduates are expecting $60,000 to $100,000

per year, but are not worth that without experience,”

he says. “Industry needs to invest two or three years’

time and effort to teach them what schools don’t. And

then, once trained in this hands-on work, the engineer

may leave for greener pastures.”

Fest does offer up what I think is an excellent solu-

tion—mandatory internships. “It works great for doc-

tors, and it works great for German college students,”

says Fest. “Maybe we can learn from that. From my

experience, we need to improve the technical educa-

tion of graduates. Although college is a great start, it is

not enough, as real life doesn’t happen in college.”

Colleges in Germany, arguably the world’s top

technical source, have mandatory internships. In the

United States, college has more to do with the “col-

lege experience,” but in Germany it’s more about the

classroom and hands-on experience. Forget the dorm

room, student union and the parties. To graduate

in Germany, you must read, write, understand and

express yourself in three languages and have three

or more six-month internships related to your major

and served in foreign countries. That sounds like an

excellent way to get the technical education needed

for industry.

Nothing beats experience. If you are an engineer

and don’t have the experience, go get it. Wire some

control panels and design some electrical schematics.

It also pays to � nd a mentor to help you get there.

None of these comments are about politics. Let’s

stay away from that; they are about control design

for machine builders and include a few of the many

ways to “re-manufacture America.” I’d like to help re-

manufacture America and hope industry does, also. If

you cannot get it built in the United States, where are

you going to go? My least favorite, but a popular option

for others, is to go to China. They happen to be copy-

ing, which they are good at, the German educational

requirements and � ooding the world with technical

students. Seems like the smart thing to do. Do you

know how to start/stop?


Perhaps I’m asking too much and shouldn’t expect an experienced control designer or recent EE graduate to draw a hardwired start/stop circuit.

How to start and stop

Dave Perkon • technical editor • [email protected] LIVE WIRE

CD1508_11_LIVEWIRE.indd 11 7/28/15 5:12 PM


http://www.otekcorp.com

OEM SKID BUILDERS keep costs down by using the

same automation system time after time. But purchas-

ers want every skid, regardless of the supplier, to have

an automation system compatible with the plant-wide

control system. This conflict is not new, but open sys-

tems and standards often provide a solution.

The main components of a skid’s automation system

interfacing to a plant-wide control system are the HMI,

the controller and the instruments. Let’s first look at

the case where the skid has its own HMI and controller.

In these cases, it’s very expensive for the OEM to

switch from one HMI and controller to another at the

behest of the purchaser, and it will generally add to

lead times. OEM support can also be compromised, as

it’s naturally more difficult for the OEM to support an

unfamiliar automation system.

For these reasons, many purchasers let OEMs use

their preferred automation systems and only require

a standard interface, notes Greg Turner, OEM segment

business manager for process at Rockwell Automa-

tion (www.rockwellautomation.com). “Skid builders

can develop automation solutions which connect

disparate devices and instruments together on a

high-bandwidth, high-performance, secure industrial

network using a standard communications protocol,”

he explains. “The most common of these is Ethernet

Industrial Protocol (E/IP), which allows for the use of

off-the-shelf products adhering to standards such as

IEEE 802.3 and TCP/UDP/IP.”

Siva Kanesvaran, senior application design engi-

neer, Schneider Electric (www.schneider-electric.com),

agrees. “Ethernet-based communication protocols

can support remote maintainability of a process skid

controller,” says Kanesvaran. “Also, many skid devices

now have web servers that provide a means to remote-

ly troubleshoot and visualize device-level operations

at a skid from a control room.”

But many would rather buy skids without an HMI or

a controller, preferring to instead automate the skid

from the existing plant-wide control system. In this

case, the difficulty arises in interfacing to the skid’s

instruments.

“Profibus PA offers many choices of instrument

brands, so a skid builder can vary the brand accord-

ing to user requirements and still provide a consistent

Profibus interface,” says Carl Henning, deputy director

of PI North America (www.us.profinet.com). “Since

almost every DCS maker provides for a Profibus con-

nection, the purchaser can easily integrate the skid.”

A common protocol like Profibus PA helps, but

isn’t the complete answer because smart instru-

ment integration files must also align? “End users

wanted only one integration file for all digital com-

munication variants, which led to the development

of the FDI specification in 2011,” points out Bastian

Engel, the team leader for technology marketing at

Endress+Hauser Process Solutions (www.process-

solutions.endress.com). “The first official FDI speci-

fication release was in 2015, and it will be managed

by FieldComm Group, which currently also oversees

Foundation Fieldbus and HART. The primary objec-

tive is a single, unified information package for each

intelligent device that can work with all host systems

and tools. This should reduce overall development

costs, while preserving and expanding existing

functionality. At this time only HART, Profibus PA and

Foundation fieldbus are covered.”

But what about those situations when a skid builder

wants or needs to use analog instruments but is re-

quired by the purchaser to provide a digital interface

protocol? “Since almost all distributed control sys-

tems and PLCs support Modbus natively or offer third-

party Modbus interface cards, a universal Modbus I/O

interface solution such as our NCS NET Concentrator

System eliminates the need for most process skid

custom interfaces,” explains Jim McConahay, PE, a

senior applications engineer with Moore Industries

(www.miinet.com).

“The NCS accepts temperature, analog and discrete

inputs and offers two independent Modbus RTU out-

puts and one Modbus/TCP output,” says McConahay.

“We also offer HART-to-Modbus converters for process

skid builders using HART instruments on their skids.”

And finally there is the problem of interfacing to

instruments on mobile process skids.

“Our WirelessHART instruments can be easily inter-

faced to a plant’s existing WirelessHART infrastruc-

ture,” says Ravindra Agrawal, manager of projects at

Emerson Process Management (www.emersonprocess.

com). “This allows the skid to be moved around as

needed without having to constantly disconnect and

reconnect wiring.”


Process skid standardization

Dan Hebert, PE • senior technical editor • [email protected] MACHINE BUILDER MOJO

What about those situations when a skid builder wants or needs to use analog instruments but is required by the purchaser to provide a digital interface protocol?

CD1508_13_MOJO.indd 13 7/28/15 5:14 PM



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I VISITED MY local McDonald’s to fill my infrequent

desire for a fish-filet sandwich, with fries, of course. It

was an experience. Because I really don’t want to get

my weight out where I can watch it shake, I ordered

half tartar sauce on the sandwich. It felt good to give

in a little. The gal who was serving me was pleasant,

but you could tell that a simple request would get her

flustered. She had to have training, right? I waited

patiently while she tried to figure out how to enter the

half order. I figured 2 minutes was long enough and

suggested that it was ok to forgo the half sauce. I was

rescued by a manager, and all was well. I wondered

how long ago she had her training and what steps

were taken to ensure that the training worked.

So I ate the sandwich and went camping with Gus,

my son-in-law, an engineering-type guy, who prides

himself on self-learning. He has moved up the ranks

in his current employment position due to his belief

that you have to look after yourself with your continu-

ing education. He just had some training on arc flash—

energy flashover creating air ionization, explosions

and intense heat in electrical panels. Well, I thought,

this is going to be an interesting conversation.

And it was. It ended with the instructor saying,

“If someone can answer this question, then class is

dismissed, and you don’t have to do the end quiz.” So

the question was asked, and Gus answered it correctly.

The question was: “What dielectric withstand voltage

are Class 0 gloves manufactured for?” The answer is

5,000 Vac.

What I found odd was the beginning of the course,

where the instructor was ingraining the importance of

knowing and implementing arc-flash protection while

working in any electrical panel. The instructor was

showing videos of the results of arc-flash events and

included one where an unsuspecting electrician was

working in a control panel and got blown back by an

arc-flash explosion. The group was told the video was

real and the person actually died.

This is Marketing 101—create a need. Well done,

I would say, but something got lost in the transla-

tion as the course wore on. The class members were

introduced to personal safety equipment required to

protect themselves, including specifications for each

class of protection, along with the types of panels that

you need to be protected from when servicing.

Electricians can open and service 480-Vac panels in

the United States and 600-Vac panels in Canada and

work on them when under power. It is required as you

cannot measure and troubleshoot a low-voltage (<600-

Vac) control panel with the power off. So the electri-

cians open the door and start taking voltage measure-

ments. Unfortunately, many times they don’t use the

proper tools or personal safety equipment.

The equipment that they would need to wear in

order to properly protect themselves is daunting. Face

shields, head scarves, jackets, pants, gloves and, yes,

insulated tools are all recommended at a minimum.

So one wonders about the delays in troubleshooting

and startups while the electrician suits up and then

undresses to go into the field, wash and repeat.

Since the inconvenience of gearing up in the personal

protection equipment (PPE) encourages not following

the rules, why are they trained in the first place? They

are trained to cover the liability. The company can say

that all electrical and mechanical employees have had

arc-flash training, so the company can no longer be

held accountable if an accident happens.

So now you have reasons to not follow the training

and can claim ignorance as you were not required to

take a test at the end of the training. Usually it is good

to have some measurement of how well you learned

the material. Since you have been trained in arc-flash

safety, you, as an individual, are now responsible for

your life when working in a control panel and don’t

take the proper precautions.

Don’t let taking too much time to fix an electrical

issue be the fly in the ointment that gives you the

green light to ignore the safety procedures. Once you

have safety training, remember it and follow it, as the

ultimate responsibility lies in your own lap. Safety is

everyone’s responsibility, including yours.

The McDonald’s issue resulted in a customer almost

eating more calories than he wanted. An arc-flash issue

can result in lost lives. Both had similar training from the

outside looking in. Bad training in my mind, but, hey, the

company paid for it and wiped its hands of responsibility.

Remember “Hill Street Blues”? Let’s be careful out there.


Once you have safety training, remember it and follow it, as the ultimate responsibility lies in your own lap.

Unapplied arc-flash training

JEREMY POLLARD, CET, has been writing about technology

and software issues for many years. Pollard has been

involved in control system programming and training for

more than 25 years.

Jeremy Pollard, CET • [email protected] EMBEDDED INTELLIGENCE

CD1508_15_EMBEDDINTEL.indd 15 7/28/15 5:15 PM


16 Control Design August 2015 controldesign.com

IF THE KIDS are unimpressed by lectures about how

STEM careers are cool and pay well, maybe it’s time

to try a new tactic. Perhaps if studying the sciences

held the promise of becoming a big-screen superhero,

maybe more youngsters would be willing to pick up

the mantle and become the next Dr. MegaVolt, just

like Austin Richards, who has a doctorate in physics

from the University of California at Berkeley and is the

subject of a new � lm that premiered at the Comic-Con

International Independent Film Festival in San Diego.

Richards is the subject of an independent � lm

documentary by Victoria Charters called “Dr. MegaVolt:

From Geek to Superhero,” which premiered on July 11

at the festival. The 70-minute � lm chronicles Richards’

journey from a curious young boy who loved to play

with electricity to a graduate student at U.C. Berkeley,

where he built a giant Tesla coil. The movie highlights

Dr. MegaVolt’s escapades as a legendary and popular

performing artist at the Burning Man Festival in Ne-

vada and as the guest star on many science-minded TV

specials. When he added a female performer, Charters,

to his performance, it delighted audiences with “his

and her” high-voltage adventures.

“This is a story about the spirit of science and the

intersection of art and science in industrial art,” said

Charters, who also is the writer, director and pro-

ducer of the � lm. “Themes explored include love of

extreme experiences, a driving passion to understand

the physical world through science, creativity and

collaboration, invention and, ultimately, the respon-

sibility of passing the baton in a world where tactile

learning is out and digital is in.”

Do you know a STEM superhero?

A3 advances

INDISCRETE

MOTION CONTROL ASSN. and Motor & Motion

Assn. have merged to form the Motion Control &

Motor Assn. (MCMA, www.motioncontrolonline.org),

which will serve the full supply chain from material

suppliers and manufacturers to distribution channels

and end users. The new organization is part of the

Assn. for Advancing Automation (A3, www.a3au-

tomate.org), based in Ann Arbor, Michigan. A3 also

includes the Robotic Industries Association (RIA) and

Advancing Vision + Imaging (AIA). MCMA’s key activi-

ties include market data collection, analysis and re-

porting. Members will receive free quarterly reports.

North American sales of machine vision systems

and components grew 22% in the � rst quarter of 2015,

the market’s highest quarter in history, according

to AIA. When totaling machine vision sales, sales of

machine vision systems and components are both

included. The machine vision systems category saw

a year-over-year increase of 24%. Machine vision sys-

tems include smart cameras and application-speci� c

machine vision (ASMV) systems. In the � rst quarter,

smart cameras expanded by 23%, while ASMV sys-

tems increased 24%.

Similarly, machine vision components had a strong

quarter with 11% growth over the � rst quarter of 2014.

The leading product categories within machine vision

components in terms of growth were lighting (28%),

cameras (11%) and software (8%).

“Industry experts remain bullish on machine vision

components for the next two quarters—less so for

machine vision systems however, where 55% of sur-

vey respondents believe the category will be � at, 25%

expect an increase and 20% expect a decline,” said

Alex Shikany, AIA’s director of market analysis.

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INDISCRETE

CELLULAR INTERNET OF Things (IoT) and machine-to-

machine (M2M) connections will increase nearly fourfold

globally from 252 million in 2014 to 908 million in 2019,

according to 451 Research (www.451research.com), an

IT research and advisory company. The increase in ac-

tive cellular IoT/M2M connections will be driven by a

number of key factors. First, hardware and bandwidth

costs have dropped to a point where nearly every enter-

prise can reap the benefits of virtualizing the physical

world, according to the research firm’s report. Second,

cloud-based middleware and data platforms are making

it easier to securely generate insights from machine

data at greater scale. Last, the buzz around this topic is

generating overall awareness of the transformational

potential of IoT/M2M in terms of ROI, competitiveness

and support of completely new business models.

The most recent data from 451 Research shows that

connected passenger vehicles and connected energy will

pace the market in terms of connection volume, while

emerging solutions such as pay-as-you-drive insurance

will grow the fastest.

“We continue to be bullish that ultimately the hype

of IoT will be proven to be warranted based on business

impact,” said Brian Partridge, 451 Research vice presi-

dent. “Over the forecast period, we expect that M2M/IoT

solution suppliers will find fertile ground in vertical mar-

kets such as retail and government that will adopt IoT/

M2M to enable strategic digitization strategies such as

smart cities and the use of digital signage, mobile point

of sale and connected kiosks to drive the transformation

from brick and mortar to click and mortar.”

In a separate report on a recent survey of IT decision-

makers, 451 reported that 39% of U.S. IT decision makers

at companies that use or plan to use wearable technolo-

gies will deploy solutions in the next six months; 24%

plan to deploy in the next 12 months.

In addition, 81% of U.S. IT decision makers who say

their companies plan to deploy wearables in the next six

months will favor smart watches.

“The release of Apple Watch has opened the flood-

gates governing wearables’ adoption,” said Ryan Martin,

analyst, IoT and wearable technologies. “But now that

the river is running, it’s less about where it will end and

more about where and when to start. We expect wear-

able technology to deliver a key interface and input into

the Industrial Internet of Things.”

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Going modular in its machine design was a matter

of survival for Matrix Packaging (www.matrixpm.

com), says Marc Willden, vice president and general

manager. The Saukville, Wisconsin-based company

designs and makes vertical form-� ll-seal machines,

the type of systems that produce potato chip bags

with a sealed top and bottom and chips inside.

The machines typically weigh out, dispense and then

package product. Matrix Packaging also may provide

printers, metal detectors and other peripheral equip-

ment needed to interface with the rest of a food produc-

tion line. Shortly after the company started more than

20 years ago, it was clear that the machines had to be

customized, a challenge for even a large, established

enterprise and a near impossibility for a startup.

“You simply don’t have the time or the money to

design a brand-new machine from scratch. We tried it.

It doesn’t work very well,” Willden says.

In contrast, a modular approach enabled the compa-

ny to deliver customized solutions in a timely manner

without bankrupting the OEM or its customers. Modu-

lar machines can save wiring and installation costs, as

Modular approach to machine building puts reusable customized

solutions at your � ngertips

by Hank Hogan, contributing editor

MULTI-PURPOSE

DESIGNMULTI-PURPOSE

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http://www.matrixpm.com

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compared to a completely custom design. They also

add flexibility and allow a greater variety of product to

be produced in a smaller footprint compared to a one-

of-a-kind approach.

However, pulling off a successful modular machine

design does demand more planning up-front, and the re-

sult can be more costly for the first machine. After that,

the savings can pile up. A look at several cases illustrates

these points and indicates what’s needed for success.

When the chips were downConsider Matrix Packaging’s experience. When it ran

into problems at the beginning with a custom design,

out of necessity the company totally redesigned the

packaging machine it had at the time, putting it on a

tubular frame that had the space needed to add differ-

ent assemblies as required. The functionality changed

little, but that was the beginning of a modular machine

approach that Matrix Packaging follows to this day.

Over the years, the company has developed a

number of options, such as assemblies that tuck the

sides of a bag in before it’s sealed or load shelves to

support very large bags. However, the options cannot

be mixed and matched freely.

“It’s not possible to do physically,” says Mike P.

Krummey, senior controls engineer. “So as a result

of that, the drawing standards that I have require

maintenance. Any time that we build something new,

I have to roll that into the standard.”

Krummey also maintains the software standards.

The company uses PackML, which provides operating

mode management and communication structures.

This and a modular approach to software reduce en-

gineering and integration costs, increase productivity

and improve diagnostics.

One of the latest examples of this modular machine

approach is the company’s Morpheus model (Figure

1), which was unveiled at the Pack Expo Interna-

tional trade show in Chicago in November 2014. The

machine can flexibly fill up to 200 bags a minute and

features continuous motion requiring the mechanical

jaws that seal the bags to be precisely synchronized.

The control system and servo motors are supplied by

Beckhoff Automation (www.beckhoff.com).

Bob Trask, senior system architect at Beckhoff

Automation, notes that the PackML standard started

with the packaging industry and is now finding ap-

plications elsewhere.

Another standard that makes it easier to produce

highly connected modular machinery is OPC UA,

which enables components to provide secure infor-

mation to higher-level systems. This can include

important metadata. For example, if a temperature

reading is being produced, it helps to know if the data

is supplied in Fahrenheit or Celsius.

As for the software side of modular machine de-

sign, object-oriented programming is a possible solu-

tion, but Trask cautions that this does mean making

some changes in how software is created. Instead of a

single block of code that runs from beginning to end,

an object-oriented approach subdivides the task into

smaller and reusable chunks.

When properly designed, this makes the software

easier to maintain or alter. “It’s much less of an issue

to add something or change something. The program-

mer doesn’t have to worry about negatively affecting

other objects,” Trask says.

It does require, though, paying greater attention to

source and version control, along with implementing

systems to ensure both. Suppose that five people instead

of one are working on a piece of software. It is important

to make sure that they aren’t stepping on one another’s

efforts. The use of software with built-in source-code

control or other means can eliminate wasted effort.

Savings by going modularAnother example of a modular design approach

comes from machine maker OCME (www.ocme.

com), a Parma, Italy-based manufacturer of packag-

ing systems. These may, for example, label, pack and

wrap beverage bottles so that they can be shipped

(Figure 2). When it was designing a new system, OCME

wanted to go modular, with distributed I/O and mo-

tion control.

The starting point was a centralized control cabinet

and 33 motors. Cramming everything into a cabinet

produced heat, which had to be dissipated by cool-

ing modules that added to the cost and complexity of

the system. There were more than 650 m of cabling,

requiring 33 hours to wire. Installing the motors and

other components took 20 additional hours.

In going to a modular design, the OEM sought to de-

centralize the architecture while reducing the time to

wire and install everything. To do this, OCME wanted

a machine in which everything could hang off a single

network cable. That would make adding something

like a conveyor as simple as plugging in a cable.

That goal of modularity placed certain require-

ments on the components. For instance, Antonio

Mosca, OCME electrical department manager, says the

company was “looking for a way to combine the motor

and the servo drive into a single compact unit.”


http://www.beckhoff.com

http://www.ocme.com

http://www.ocme.com


When done with its modular design, OCME real-

ized some substantial benefits. These included a 55%

reduction in cable lengths and a similar decrease in

installation time. As a result, the overall cost of the

machine was 10% less.

The combination motor and servo drive that OCME

used was supplied by B&R Industrial Automation

(www.br-automation). It is IP65-rated and so can be

machine-mounted, with a single cable providing com-

munication and power. It also supports IP67 I/O blocks,

so that sensors and other input/output elements can

connect to the drive instead of having to run back to

a controller. Thus, there can be one cable instead of

many. Along with an automatic configuration capabil-

ity, this helps enable modularization, says Derrick

Stacey, solutions engineer with B&R.

A modular approach requires a shift in thinking, he

adds. Solutions must be broken down into the smallest

pieces possible, with the idea being that these will be

common to different applications, and they will then

be snapped together to produce the total, final solu-

tion. This means that the old approach of finishing a

mechanical design and then throwing it over to the

electrical team will not work. Instead, the interactions

between the mechanical and electrical aspects and

how everything will function together have to be estab-

lished beforehand. Similarly, how to break up software

into the appropriate modular chunks has to be settled.

This change in thinking extends to the design tar-

gets of the machine. It must be laid out in such a way

that it allows for every conceivable module, a process

that demands considerable up-front investment of en-

gineering resources. It really epitomizes the approach

of measuring twice and cutting once. “In many cases,

it’s measure 10 times and cut once,” Stacey says.

Quick connectionWhen making a production line changeover, designing

a modular machine to handle the task can prove ben-

eficial. A case in point comes from RedViking (www.

redviking.com). The Plymouth, Michigan-based inte-

grator designs, builds and implements manufactur-

ing and test solutions for the aerospace, off-highway,

MODULAR MOTION AND I/OFigure 2: Going modular with distributed motion and I/O control saved packaging machine maker OCME more than 50% in cable installation time.

OC

ME

AN

D B

&R

IND

UST

RIA

L A

UTO

MA

TIO

N

MODULAR GAGE SYSTEMFigure 3: Automotive exhaust part dimensional gage docking system reduces capital expense and floor space, while increasing flexibility for future products.

RED

VIK

ING

MODULAR FRAMEFigure 1: Matrix Packaging’s latest example of a modular machine is a continuous motion bagger capable of handling up to 200 bags a minute and is designed on a tubular frame so that optional components can be added as needed.

MA

TRIX

PA

CK

AG

ING


http://www.br-automation

http://www.redviking.com

http://www.redviking.com

Control Design - Hands-free - August2015 Outlined.indd 1 7/22/15 1:18 PMCD1508_FPA.indd 23 7/28/15 4:58 PM


military and automotive industries. The company uses

modular designs extensively for its gages, leak testers

and powertrain test systems (Figure 3).

“When applied correctly, customers love it for its

lower acquisition cost and reduced floor space,” says

Mark Sobkow, vice president of manufacturing systems.

He points to automotive exhaust gages as an ex-

ample of modularization. RedViking’s customers have

to change tooling every model year. Previously, this

meant creating an entirely new set of gages on dedi-

cated machines. This was expensive and presented a

logistics challenge, since last year’s machine could not

be used for this year’s models.

With a modular approach, there is a docking sta-

tion with fixtures swapped in and out as needed.

The docking station has a PLC, light screens and

other safety systems, pressure decay or mass flow

instrumentation for testing, welding devices, control

systems and other assembly devices such as strap

guns or nut runners (Figure 4). So if a line is running

10 models or parts, there could be one machine and

10 tooling fixtures instead of 10 machines.

This reduces purchase cost and conserves floor

space. There also is a consistent user interface, simpli-

fying operator training. What’s more, it’s much easier

to integrate new products.

Care must be taken, though, in the design and place-

ment of the machines for several reasons. One is that,

because fixtures are repeatedly attached and removed,

connectors can wear out more quickly if the machine is

not designed properly. Another reason why precautions

must be taken is for operator safety and comfort. Mul-

tiple tools may be competing for a limited amount of

space, complicating ergonomic decisions, says Sobkow.

System integrator Five Lakes Automation (www.

fivelakesautomation.com) of Novi, Michigan, also uses

a modular approach when designing solutions for its

automotive customers. Often, this consists of a robot to

which tooling is coupled and uncoupled. In practice, this

means that the tooling may sit on a conveyor, be shuttled

to a robot, picked up, connected, used and then returned

to the conveyor when no longer needed (Figure 5).

The primary reason for this modular approach is

capital savings, says Dave Jones, project manager, Five

Lakes. “You may invest an initial amount on the first

job, which may be just a small percentage more, 5–10%

more. But then your savings on the second model will

be upwards of 40–50%,” he says.

Jones adds that this modular approach is not suit-

able for all situations. For one thing, there has to be a

common architecture. An example is communication,

such as a form of industrial Ethernet. This common

architecture, though, also applies to such mechanical

aspects as motion. If one tool moves via hydraulics

while a second depends on servo motors, making a

common modular assembly will be challenging.

Another reason not to go modular is the time it

takes for a tooling changeover. If a line or machine is

running too near capacity, there may not be enough

slack to absorb the delay of a switchover, Jones says.

Chopping up a machineYet another illustration of modular machine design

comes courtesy of Fori Automation (www.foriauto.com)

MODULAR TOOLINGFigure 5: Tooling for a robot travels on a conveyor to be automatically added and removed.

FIV

E LA

KES

AU

TOM

ATI

ON

MODULAR WELD AND INSPECTIONFigure 4: Multiple automotive exhaust parts can be tested and repaired by wheeling custom fixtures into stationary docking stations.

RED

VIK

ING

“ You may invest an initial amount on the first job, which may be just a small percentage more, 5–10% more. But then your savings on the second model will be upwards of 40–50%. ”


http://www.fivelakesautomation.com

http://www.fivelakesautomation.com

http://www.foriauto.com

of Shelby Township, Michigan.

Among other things, the company

makes automated assembly lines,

and these have to be shipped to

customer locations. This means the

machines are assembled, tested,

taken apart, transported and then

reassembled on-site, where custom-

ers, quite naturally, expect every-

thing to work.

The company decided in late 2014

to go with a modular approach,

breaking lines down into 30-to-40-

ft sections. Each section was made

self-contained through the use of

machine-mount I/O blocks. The

company also developed standard-

ized boxes for light curtains, safety

gates and servos (Figure 6). The cre-

ation of modular components hasn’t

stopped there.

“We are now generating a stan-

dard electrical enclosure for a robot

electrical interface. We’re going

to generate a junction box, and

it’s going to incorporate the safety

e-stops, gates and circuits,” says

Garry Hagar, controls engineering

supervisor, Fori.

The new approach saves in

excess of 25% of engineering, esti-

mating and installation time and

associated labor, Hagar says. And, if

problems arise, the modular nature

of the system makes troubleshoot-

ing easier, he adds.

For its modular machines, Fori

has used IO-Link-enabled products

from Balluff (www.balluff.com).

Shishir Rege, Balluff marketing

manager for networking and safety,

says that labor cost savings in the

30–50% range are typical when a

modular approach is used. Engi-

neering savings can also be sub-

stantial, due to the ability to reuse

designs and reduce terminations.

The labor cost savings appear im-

mediately, but the benefits of easier

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26 Control Design August 2015

controls engineering may only show up after several

jobs are done, Rege says.

The result of going modular shows up in productiv-

ity gains. “Today, if you’re producing 12 to 13 machines

a year, without investing in additional resources and

additional buildings, you’ll probably produce a few more

machines a year,” Rege says.

Bill Sutton, market development manager for motion

control solution provider Kollmorgen (www.kollmorgen.

com), has worked with a variety of machine builders

looking to improve modularity of their products.

For example, Preco (www.precoinc.com), a Lenexa,

Kansas-based provider of materials processing solu-

tions, wanted a modular rotary converting platform.

The machine can accommodate up to seven convert-

ing stations, each of which can be con� gured for die cut,

laser cut, laser heat treatment, laser marking and mul-

tiple web assembly operations. Consequently, end users

can quickly change over from one product to another.

Modular machines, in general, offer production � ex-

ibility. They also can save space, require less training

of production personnel and offer a better return on

investment on equipment.

Modularity and � exibility do have their drawbacks,

however. “Long-run, purpose-designed machines allow

for narrow focus on accuracy, speed and size. When a

machine is modular and � exible, some capabilities in

those areas may be compromised,” Sutton says.

Keeping it cleanModularity often comes in the form of a networked

system, as GEA of Texas (www.geaoftexas.com) learned.

Variable-frequency drives, I/O, safety and operator in-

terfaces all may be connected over a network, says Lane

Daniels, engineering manager. This approach allows a

system to be developed in sections, which are then re-

used from project to project. Wiring is both reduced and

simpli� ed, and there’s the possibility of adding options.

Daniels points to automated car washes. These sys-

tems use sensors to monitor the position and measure

the size of vehicles, with the position of brushes and

spray nozzles controlled to keep them at the right dis-

tance. Such systems have to be modular because they

are manufactured, disassembled and then reassembled

at a customer site. Modularity cuts the cost of this pro-

cess and the time it takes.

To make modularity work it’s important to select the

right physical and network interconnection, Daniels

notes. On the network side, the choice should be both

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26 Control Design August 2015

common and widely accepted, such

as Ethernet/IP. As for the physical

connection, the familiarity of those

who will be installing and main-

taining the system with a particular

method is the deciding factor.

Reducing or even eliminating the

possibility for error is important,

Daniels says. “Using pre-made

cable assemblies can greatly reduce

mistakes during install or relocating

a system,” he explains. “If pre-made

cable assemblies are not practical,

utilizing a logical connection sys-

tem is imperative.”

Another bene� t of a modular

machine design is that it allows

optional components to be added in

the � eld, notes Joe Landgraf, product

engineer for motion and drives, Om-

ron Automation and Safety (www.

industrial.omron.us).

Lessons learnedAs these cases show, modular ma-

chines provide signi� cant bene� ts.

However, clearly a one-time-only

machine is not a good choice for

this approach, says Matrix Packag-

ing’s Willden.

What’s more, modularity does

impact design methodology. For

instance, Matrix Packaging is in the

process of launching a new plat-

form. In designing such a platform,

it’s important to step back from

the immediate problem in order to

anticipate what might someday be a

part of the machine.

Willden says one of the com-

pany’s engineers “had to think

through every possible option that

would go on this machine, and,

even though he didn’t design all

those options, he kind of roughed

them out in his own mind so that he

knew that the fundamental design

of the base machine would be able

to accommodate that.”

Such anticipation of what might

be a future requirement extends to

more than the hardware. The soft-

ware also should contain code that

provides for expansion and even

platform changes. The latter has be-

come easier due to the development

and use of the open PLC program-

ming environment CODESYS, says

Matrix Packaging’s Krummey.

Five Lakes’ Jones agrees that a

modular approach requires more

up-front work and planning, includ-

ing consideration of communication

protocols, power and � uids. The

planning must also consider what

may come, even if the particulars

are unknown.

For instance, suppose that a robot

is being used to move material from

one point to another. One set of tool-

ing may allow one type of material

to be moved, while a different set

of tooling is needed for another. But

knowing which tooling is needed is

not enough, Jones says.

“If your second product is much

heavier, then you run the risk of

overloading the payload or the

robot,” explains Jones. “So you have

to have an idea of what’s coming in

to that station.”

However, modular systems are

easily recon� gured as requirements

change. “If I have to add something

new to a system that we didn’t have

before, modular design allows for

easier integration,” Hagar says.

Any drawbacks to modularization

are outweighed by the bene� ts it

provides, RedViking’s Sobkow says.

“We see more and more of a de-

mand for modular machines due to

decreasing budgets and limited � oor

space,” he explains. “We’re also an-

ticipating a higher level of standard-

ization so that manufacturers can

purchase interchangeable � xtures

from multiple vendors.”


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CD1508_FPA.indd 28 7/28/15 4:58 PM

INTELLIGENCE IS JUST like a Swiss Army knife or

other multipurpose tool that you can apply in different

situations to solve many types of problems.

What’s different now is that some machines and

their controls are being endowed with more of the

analytical capabilities of their human counterparts,

so they can make better operating decisions and save

power and other expenses more quickly and easily.

These skills may be rooted in combinations of more

powerful microprocessors, better software, more

sophisticated robotics, more pervasive networks or

cloud-based data processing, but, whatever their

source, they’re enabling new levels of efficiency for

machine builders and their end users.

Savings start with motionIn recent years, probably the most popular way to make

machines more energy-efficient has been moving from

less-flexible induction motors and drives, which are

typically on at full power or off, and implementing

variable-frequency drives (VFDs) and servo motors,

which allow much wider ranges of speeds and power

levels and can save a lot of power doing the same jobs.

For instance, BW Container Systems (www.bwcon-

tainersystems.com), in Lynchburg, Virginia, recently

developed its latest AdaptA Series mini-buffering (MB)

and multilane (ML) conveyor systems for preventing

traditional slips, gaps, bumping, pressure, damage and

other line inefficiencies among containers running

between close-coupled machines. AdaptA MB runs

containers around a U-turn wheel that automatically

extends or retracts to lengthen or shorten the contain-

ers’ single-file path, which helps with queuing and

feeding to reduce damage (Figure 1). This buffering

also helps AdaptA ML, which employs pressureless in-

feeding to accumulate containers in a transfer station

with four to 24 lanes.

“The real estate between machines is at a premium,

but this means conveyors often run inefficiently, so

containers need buffering,” says Tom Spangenberg,

business unit director at BW Container Systems.

“There’s a wide variety of buffering approaches, but

users also want easy access and the ability to handle

many different products and containers with stability.”

To achieve optimal efficiency, simplify control and

minimize energy use, AdaptA MB is driven by a 2-hp

Nord motor with VFD and a switch chain, while AdaptA

ML uses two servo motors and a ControlLogix PLC.

Meanwhile, AdaptA MB’s wheel uses two motors and

two VFDs, and the transfer station relies on three servos.

So far, AdaptA has been implemented by about a doz-

en food, beverage and consumer product manufacturers,

and Spangenberg reports it’s achieving 5-20% efficiency

gains. “One customer said they saved about $200,000

in damage to their food containers,” adds Spangenberg.

“However, AdaptA is also transforming us beyond being

a machine provider to doing data acquisition for our cus-

tomers and also delivering higher-level line efficiencies

and overall system improvements.”

Likewise, Komo Machine (www.komo.com) in Lake-


by Jim Montague, executive editor

Smart machine builders are using innovative designs, components, software

and production methods to save energy, materials and expenses

Join the efficiency revolution

MOTION CONTROL

CONTAINER-GO-ROUNDFigure 1: BW Container’s AdaptA uses VFDs and servo motors to run containers around a U-turn wheel that lengthens or shortens the containers’ single-file path, which improves efficiency, saves energy and helps with queuing and feeding to reduce damage.

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CD1508_29_33_MOTIONCONTROL.indd 29 7/28/15 6:28 PM

http://www.bwcon-tainersystems.com



http://www.komo.com

MOTION CONTROL


wood, New Jersey, recently needed to build a new, more

affordable version of its Mach One GT MTX open-bed,

gantry-style router for milling wood, plastics, compos-

ites and sheet metal at about 80 sheets per day (Figure

2). Consequently, Komo decided to control its x and y

gentry axes and z spindle axis by integrating an Indra-

Motion MTX micro CNC system and IndraDyn S MSK

60 servo motors from Bosch Rexroth.

MTX micro includes high-capacity CNC controls, an

integrated PLC compliant with IEC 61131-C program-

ming standards, integrated HMI and a 32-bit processor

that supports up to six CNC motion axes with control

of up to four interpolated axes of motion at any time.

Optimized for milling applications, MTX micro sup-

ports 2.5D and 3D milling and free positioning of the

workpiece coordinate system in space, and it includes

many NC capabilities in a compact platform, such as

1,000 NC blocks with look-ahead functions, axis-

specific jerk limitations and control of interpolated

milling sequences down to the nanometer level.

“These look-ahead capabilities will allow milling

shops to run the machine faster, but maintain accurate

control of the axes,” says Jeff Erickson, Komo’s vice

president. “Mach One GT MTX supports a high feed

rate of 1,500 in/min, but, as it comes to a corner, it will

ramp down to precisely cut a sharp corner without

rounding it and then quickly ramp back up to 1,500 in/

min, while maintaining control of all the axes. This

will enable it to sustain a higher rate of throughput

without sacrificing milling quality, enhancing the

return on investment for Komo’s customers.”

Besides reducing milling time, Komo Engineering

Manager Steve Ostermann reports that Mach One and

MTX micro CNC also save energy by supplying power

to all four axes through one interface, rather than sep-

arately to each drive. “MTX micro features enough I/O

interfaces to support the Mach One’s requirements,

and the fully integrated HMI is easier to configure

than a separate HMI package,” explains Ostermann.

Precise control, duhOf course, one of the primary paths to efficiency

and power savings has always been tighter control

and running machines and applications closer to

required specifications.

For example, founded in 1926, Gehring Technologies

(www.gehring.de) in Ostfildern, Germany, invented

and continues to build high-accuracy honing machines

for making sure cylinders used in engines, hydraulics,

pumps, landing gear and connecting rods are as close to

critical tolerances as possible, so all the equipment they

PREDICTING A ROUTFigure 2: Komo’s Mach One GT MTX router for wood milling uses Bosch Rexroth’s IndraMotion MTX micro CNC system to control the router’s servo motors and perform look-ahead functions that accelerate production while maintaining accuracy.

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HONING IN A HEXAGONFigure 3: Gehring’s Lifehone machines use proprietary software and PLCs to control a two-axis spindle and a three-axis table in six- or eight-sided inner columns, and they perform up to 16 tasks in one machine.

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http://www.gehring.de

go into can optimize the fuel and

power they consume and use less

lubricating oil. Honing is usually the

last step in machining cylinders.

The Gehring form-honing

process uses tooling with eight

to 12 diamond stones and car-

bide guides, runs at 400 rpm and

specializes in creating “negative

forms of deformation” to ensure

that cylinders will be even closer

to perfectly cylindrical when run-

ning at high temperatures. Unlike

typical honing machines that

use a fixed spindle and one- or

two-axis table, Gehring’s Lifehone

line and its Hexahone and Octo-

hone models employ a two-axis

spindle and three-axis table in a

six- or eight-sided inner column

to perform up to 16 tasks in one

machine, including pre- and post-

gauging (Figure 3).

“Our machines automati-

cally compensate for the form

and shape of bores to increase

accuracy and make them per-

fectly straight, which takes some

burden off their operators,” says

Thorsten Botzenhardt, Gehring’s

key account manager. “We also

invented a piezo-based feed head

that independently extends each

of the abrasive stones on the hon-

ing tool, which is better than the

traditional feed heads that extend

all the honing tool fins at once.”

These complex components

and processes are controlled

by Gehring’s proprietary Hon-

ing Control software and then

coordinated by a Siemens Simatic

S7 320 DP safety-integrated PLC,

which can also interact with us-

ers’ support robots for loading

and unloading the machining

center. In-process air gauging pro-

vides results to the control and

feedback systems, which manage

Compared to the competition, we offer :

Even better than expected.

The most popular way to make machines more energy- efficient has been moving from less-flexible induction

motors and drives, which are typically on at full power or off, and implementing variable-frequency drives

(VFDs) and servo motors.


MOTION CONTROL


speed, feeds, force control and pressure better than

regular numerical controls, according to Botzen-

hardt. Lifehone also uses Festo’s pneumatic safety

brakes on guide rails for air-sizing and handling

tasks, Lumberg’s distribution blocks for proximity

switches and minimizing cabling, and Profinet pro-

tocol for network communications, including remote

monitoring and diagnostics.

“Integrating all these functions, such as our safety

PLC and regular controls, enables our machines to

work faster and more efficiently,” adds Botzenhardt.

Robots to the rescueAlong with saving energy while gaining productivity,

many builders report that users also want greater

flexibility and machines that can adapt and produce

more varied types and sizes of products with less

changeover than in the past. One way to simultaneously

save power and gain flexibility is to use robots for tasks

that formerly required multiple integrated components.

For instance, Sugino (www.suginocorp.com) in

Itasca, Illinois, and Toyama, Japan, builds drilling,

tapping, machining and high-pressure water deburr-

ing equipment, and it recently improved its solutions

by implementing robotic functions in some of them.

The company’s JCC-Wide high-pressure washer runs

at up to 7,000 psi, but it was recently updated with

robot-type CNC software and renamed JCC-Robo. This

upgrade allows Sugino to go beyond the usual x, y and

z axes and articulate at horizontal and vertical turn-

ing axes, as well, which enables users to wash any

area of parts at any desired angle (Figure 4).

“We can get to anywhere on a part with CNC pro-

gramming and wash it with 6.4 mega-Pascals, which

is almost 1,000 psi,” says David Becker, Sugino’s sales

manager. “Beyond this robotic flexibility, a couple of

customers are even simulating putting a standard

drill unit, such as an ES2 air/electric, on the end of

a Fanuc M710iC robot, so it can also achieve more

flexible positioning and work on much larger aircraft,

composite or other oversized parts without compara-

bly larger operating or energy costs.”

WORKING AT THE PART WASHFigure 4: Sugino’s JCC-Robo uses CNC programming to articulate at horizontal and vertical turning axes and achieve robot-like flexibility that allows its high-pressure water deburring components to reach any angle of the parts it’s washing.

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Designing and building more energy-efficient machines, production lines, facilities and end products requires users, system integrators and suppliers to implement improved practices. Although each machine and application is different, here are some fundamental procedures that can be used across many applications and industries.• Investigate and document the power, raw

materials, water, compressed air and other resources your processes and company are using presently and draft a plan for conserving them. Typical solutions include selectively powering down or turning off equipment when not in use and switching to induction motors and drives with variable-speed motors and drives or servo drives that can more precisely follow production requirements with power consumed.

• Evaluate if your machine, process or factory could employ regeneration equipment, which usually employs an integrated power source and drives to secure power from decelerating devices, and use it to drive or ramp up other components.

• Perform an audit of a single machine or production line, determine which options will help it save power or materials, conduct tests and evaluate the savings it produced.

• Reevaluate the raw materials and components that your machines use or make into products, and investigate ways to eliminate waste, possibly via redesigns or by operating closer to tolerances or by recycling materials. Also, investigate whether more sustainable alternative materials could be used, and check which design changes they might need in your machines or production lines.

BASIC STEPS FOR ENERGY SAVINGS


http://www.suginocorp.com


John Kalkowski, marketing director at Delkor Systems

(www.delkorsystems.com) in St. Paul, Minnesota, re-

ports his packaging clients have been demanding simi-

lar levels of flexibility and increased productivity. As a

result, Delkor also opted for robotic solutions to achieve

these goals, merged previously separate operations and

reduced material and energy costs at the same time.

“Several years ago, our users began asking for faster,

higher-variety changeovers of multiple packaging for-

mats, so they could handle more unexpected require-

ments,” says Kalkowski. “So, we developed our MSP-200

case packer, which relies on robots to combine several

formerly separate tray forming, loading and closing

machines into one unified solution.”

For example, MSP-200 uses a Fanuc M-2iA 3SL

delta-style, vision-guided robot to align and set up

pouches for pick-and-place, and then a Fanuc M-

710iC 50H robot puts them in their cases. Both are

coordinated by Fanuc’s R-30iB controller and can load

up to 150 pouches per minute.

PC-based smarts show offGiven the intense and growing emphasis on machine

intelligence, it was inevitable that PC-based control

would arrive to help improve machine and production

line efficiency and save energy.

For example, Fabri-Kal (www.fabri-kal.com) in

Kalamazoo, Michigan, designs and builds plastic

processing and thermoforming equipment for making

plastic cups and packaging for yogurt, smoothies,

milk shakes and other food products. However, Fabri-

Kal also needed to improve throughput and speed,

while reducing energy consumption.

Fabri-Kal uses extruders to form deep-drawing

plastic sheets of precisely defined thickness, which are

then shaped in a separate deep-drawing machine. In

the extruder, PC-based control technology regulates

the temperature and pressure, as well as the setpoint

for the frequency inverter. Consequently, Fabri-Kal

implemented CX2030 and CX1020 embedded PCs from

Beckhoff Automation to serve as the control hard-

ware for Fabri-Kal’s machines. In the deep-drawing

machine, the PC control platform with Beckhoff’s

TwinCAT NC regulates the drawing unit, along with the

composition and separation of the end product. In ad-

dition, the PC-based automation technology monitors

and documents the factory’s entire production process.

“What we were aiming for was a dynamic control

system with flexible connectivity solutions for linking

to the other equipment in the factory, plus the option

of capturing and centrally managing large amounts

of data in an SQL database,” says Dale Michaels,

Fabri-Kal’s electrical engineer. “Thanks to TwinCAT’s

open architecture, we were able to achieve just that.

CX2030 is equipped with a 1.5-GHz Intel Core i7 dual-

core CPU, which offers high performance in a compact

design. Besides handling the PLC and motion control,

the embedded PCs also govern the temperature and

pressure throughout the production process.”

Fabri-Kal also uses EtherCAT for fieldbus network-

ing, which enables communication speeds in the

microsecond range. “EtherCAT significantly improves

the performance of our machines,” adds Michaels.

“For motion control as well, we’re increasingly using

AX5000 series EtherCAT servo drives that offer us

both high speed and precision.”

In addition, the I/O stations and drives interspersed

along the line of machines are connected via EK1100

EtherCAT couplers. Precise temperature control and

performance monitoring ensure efficient use of ener-

gy (Figure 5). Precise temperature control plays a key

role in the extrusion of high-quality plastics, affecting

both resource consumption and product quality. “Now

that we have an integrated PC-based control platform

with EtherCAT thermocouple I/O modules, we can

precisely maintain the desired temperature on the ba-

sis of process data that is captured in real time,” adds

Michaels. “Integrating PC-based control hardware and

software has given us a flexible way to upgrade our

machines without coming into conflict with existing

control systems as we migrate technologies.”

CREATING CLEAR CUPSFigure 5: Fabri-Kal’s thermoforming machine needed to improve throughput and speed, while reducing energy consumption.

FABR

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FF

Many builders report that users also want greater flexibility and machines that can adapt and produce more varied types and

sizes of products with less changeover.


http://www.delkorsystems.com

http://www.fabri-kal.com

Our diverse offering of pressure

and temperature instruments

combined with our custom

engineered solutions (CES)

provide the form, fit, function

and validation you need for

your application.

Call 203-385-0635

[email protected]

No need to recite ourproduct specifications.It all starts with your requirements.

PRESSURE GAUGES

Custom Dials,Leak and Cycle

Testing

PRESSURESWITCHES

Non-StandardConnections

DIGITAL GAUGES

ModifiedFirmware

PRESSURETRANSDUCERS

Unique Outputsand Terminations

BIMETAL THERMOMETERS

Custom StemLengths

First, We Listen

15 July Cont Des 015-5780.qxp_Layout 1 7/21/15 11:00 AM Page 3

CD1508_FPA.indd 34 7/28/15 4:59 PM

http://www.ashcroft.com


SOMETIMES, CHOOSING Acomponent is up to the customer’s

discretion. Sometimes, it’s based

on the application. And sometimes

it’s just what the machine builder

is most familiar with. With relays,

there are a few clear-cut ways to

go, but often there are trade-offs.

Choosing between electromechan-

ical relays (EMRs) and solid-state

relays (SSRs) is sometimes more

difficult than you get credit for.

This panel of industry veterans

will give you a few insights that

might remind you of some basics

you already know and could help

you make a more-informed deci-

sion on your next machine.

Thomas Stevic is

controls engineer at

Zed Industries (www.

zedindustries.com), a

thermoforming and

plastic packaging machine builder

in Vandalia, Ohio.

Stephen Kirk is

project manager at

Industrial Automa-

tion Group

(www.automation-

group.com), a system integrator in

Modesto, California.

Michael P. Collins is

president of MPC

Management (www.

mpcmgt.com), a

consulting company

in Portland, Oregon.

Danny Weiss is senior

product manager at

Newark element 14

(www.newark.com).

Kurt Wadowick is I/O

and safety product

specialist at Beckhoff

Automation

(www.beckhoff.com).

Rafal Pabich is senior

product manager

at Carlo Gavazzi

Automation

(www.carlogavazzi.

com).

Dan Nigro is product

marketing manager,

industrial compo-

nents, at Omron

(www.omron247.com).

Steve Massie is

product manager at

IDEC (us.idec.com).

Daniel M. Loflin is

product manager at

Siemens (www.

industry.usa.siemens.

com).

Tina Lockhart is

director of engineer-

ing at Moore

Industries (www.

miinet.com).

Terry Harmon is

offer marketing

specialist at Schnei-

der Electric

(www.schneider-

electric.com).

Rick Frauton is

senior product

marketing manager

at United Electric

Controls (www.

ueonline.com).

Tom Edwards is

senior engineer at

Opto 22 (www.

opto22.com).

Traci Bretz is relay

product marketing

specialist at Phoenix

Contact USA

(www.phoenixcon-

tact.com).


MACHINE INPUT

Choosing between SSRs and EMRs involves multiple considerations

Solid-state or electromechanical relays?

by Mike Bacidore, editor in chief

CD1508_35_39_ROUNDTABLE.indd 35 7/28/15 6:42 PM

http://www.zedindustries.com

http://www.zedindustries.com

http://www.automation-group.com



http://www.mpcmgt.com

http://www.mpcmgt.com

http://www.newark.com

http://www.beckhoff.com

http://www.carlogavazzi.com

http://www.carlogavazzi.com


http://www.industry.usa.siemens.com








http://www.ueonline.com

http://www.ueonline.com

http://www.opto22.com

http://www.opto22.com

http://www.phoenixcon-tact.com



In which applications are electromechanical relays (EMRs) still more advantageous than solid-state relays (SSRs), and why?

Stevic: EMRs have several distinct advantages over

SSRs when it comes to the power/cost ratio, switching

voltage capabilities, power dissipation characteristics

and failure mode. An EMR with a rating of 30 A can

be had for as little as $10, where an SSR of the same

power-handling capability will cost about four to five

times as much.

An EMR can switch 440 Vac or 24 Vdc without any

change in design. Switching very small voltages often

requires special contact construction, such as gold

plating, but for most industrial applications, general-

purpose relays work fine.

When an EMR switches off, the stored power in the

load needs to be dealt with in some manner. Surge-

suppressing devices such as MOVs, varistors, RC

circuits or, for dc applications, diodes can be used to

channel the energy stored in the load, but, for many

applications, just opening the contacts and letting

the energy spark between is quite often an acceptable

solution. The decision as to whether to use spark-

suppression circuits is usually a matter of the relay

duty cycle.

An SSR may or may not require external suppres-

sion, but, for higher currents, it is a best practice to

use a heat-sink device to remove the operational heat

generated by the relay. The heat production of an SSR

might also be a consideration when designing a circuit

that will operate in high ambient temperatures.

Not always, but in my experience, when an EMR fails,

it typically fails in an open-circuit condition. The open

circuit can be due to the coil failing, the mechanical

spring on the contacts failing or the contact material

becoming corroded or pitted and failing to make a

good electrical connection. In some cases, the contacts

will become welded closed, and the failure results in a

closed circuit. SSRs typically fail in a shorted condition,

allowing the power circuit to remain energized even

when the control voltage is removed.

Collins: I am not an electrical engineer, but I will tell

you what I remember from my role as general manager.

The biggest problem with solid-state relays is that they

have the possibility of shorting out in the “on” stage.

The disadvantage of electromechanical relays is that

they wear out faster than SSRs.

Bretz: Electromechanical relays are generally the top

choice for applications on a budget. They generally

cost less because they have a life expectancy. Solid-

state relays virtually last forever if used within specs

and normally cost more for this reason. Electrome-

chanical relays have contacts that open and close,

turning on or off the circuit to the load. EMRs are gen-

erally selected for applications that require the circuit

to be completely on or off without any leakage current.

In SSRs, the contacts are switched with a semiconduc-

tor, and off-state leakage current is possible.

Frauton: Mechanical contacts have much wider com-

patibility with different load sizes. You could send a

low-voltage, low-current signal as input for a PLC or,

with the same EMR, transmit 250 Vac, 10 A of power.

With SSRs, on the other hand, different models are

required for different loads.

EMRs are what are known as dry contact. There

are no power leakage issues with the EMRs. They are

either fully open or fully closed.

SSRs, in contrast, have some leakage in both direc-

tions. When they are open, they are not fully open;

when they are closed, they are not fully closed, which

results in some dissipation of energy.

Nigro: EMRs are still more advantageous in applica-

tions where space is very limited and heat buildup

in a panel is a concern. EMRs are still more advanta-

geous due to extremely low metal-to-metal contact

resistance compared to an SSR—thus, very low heat

buildup on the contacts. This allows EMRs to have a

smaller profile than an SSR with the correct heat sink

applied. EMRs allow either ac or dc loads, whereas

SSRs need to be specified and ordered based on the

load. Typically EMRs are lower in cost than a SSR.

EMRs are offered with multi-pole configurations along

with normally closed contacts. EMRs have no off-state

leakage current to deal with.

Lockhart: EMRs work well in applications where it is

desired to have normally closed contacts in the ab-

sence of power. SSRs only have closed contacts when

the input is energized. EMRs can do multiple contact

functions more easily—for example, DPDT—and can

handle both dc and ac loads through the same relay.

EMRs have no ac leakage current in the off state, un-

like many ac SSRs. EMRs don’t need heat sinks. And

EMRs can also have lower on-state voltage drop.


MACHINE INPUT


Harmon: Solid-state relays are taking advantage of

innovations in packaging, internal bonding and ther-

mal management to increase their performance and

reduce their size. Similarly, electromechanical relays

are utilizing new materials and mounting options to

increase load ratings and simplify installation. While

the technologies used in the design and manufactur-

ing of these components differ, it’s the advantages of

each that ultimately help customers to decide.

Edwards: EMRs still have an advantage over SSRs

in applications like motors and transformers that

require high inrush current.

Pabich: EMRs are advantageous in applications where

loads are being switched infrequently. EMRs typically

offer lower initial cost. However, lifespan cost of a re-

lay has to be evaluated carefully. In a typical applica-

tion, EMRs have to be replaced more often than SSRs.

Massie: EMRs are still preferred for many applications

due to their wide output range. For example, one EMR

can switch from 50 mA to 25 A, ac and dc. Switching the

same range of loads would require three or four differ-

ent SSRs with different output devices. For example, you

would need a Triac, thyristor or back-to-back SSRs for

an ac load, and a transistor, SCR or MOSFET for a dc load.

EMRs have a slight edge in terms of ambient tempera-

ture, since the SSR’s semiconductors must stay within

thermal limits. The limit for EMRs is the temperature

rise of the contacts and coil temperature because the

relay coil’s resistance will go up 0.39% per °C.

Since relay contacts are silver alloys, the on resis-

tance is less than 50 mΩ, and closer to 10-25 mΩ ini-

tially; this results in cool operation when compared

to an SSR. EMRs don’t need heat sinks.

Finally, SSRs have limited pole con� gurations. For

the most part, SSRs are SPST (form 1A normally open),

where EMRs come in many con� gurations from one to

six poles, multiple throws and a combination of nor-

mally open and normally closed throws. For example, a

force-guided EMR is available with six poles, which are

a combination of normally open and normally closed

contact sets.

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Wadowick: EMRs are often more advantageous in the

case of higher value voltages, or perhaps “odd value”

voltages, and certainly at times when higher current

is needed. Furthermore, in the case of maximum

signal isolation, relays remain the preferred method to

achieve the highest level of electrical isolation.

Weiss: EMRs are more advantageous than SSRs in the

HVAC unit in the home and in the thermostats in the

home, as consumers like to hear the click of the relay

that comes with EMRs. This way, they are confident

the units are working properly; the click gives the

consumer the assurance all is well.

Where does it make better sense to use SSRs, and why are they a better fit than EMRs in cer-tain applications?

Kirk: We had a job last year with Pom Wonderful,

and we used an SSR with an electric shell heater. The

heater was used for a continuous spray system, and

originally it had its own thermostat. The thermostat

could not keep the desired range, so we used an SSR

and a PID loop to control it. The solutions worked well.

Stevic: SSRs are best suited for high-speed switching

applications such as heating circuits. EMRs all have a

rated lifecycle of x number of switching operations. In

solid-state relays, this rating is many times higher. as

there are no mechanical moving parts to wear out. SSRs

are also better in high-vibration applications.

Massie: SSRs are great for high-repetition type loads

such as molding machinery and solenoids for manu-

facturing machines. In molding, the temperature

controller is constantly turning the heaters on and off,

using PID or another type of control. Thus, the relay

will require a life well over 1 million operations. Typi-

cally, EMRs are only rated for 1 to 50 million mechani-

cal operations at no load.

Lockhart: SSRs have an advantage in applications

where there will be frequent on-off cycling. Unlike

the electrical and mechanical life limits of EMRs, SSRs

have very long cycle life and no contact bounce.

Bretz: Over time, the plating on the contacts inside

EMRs can erode. This erosion can cause the contacts

to weld shut; therefore, they no longer open/close

properly, and the relay has to be replaced. Solid-state

relays do not have contacts; therefore, this contact

erosion is not a problem. Solid-state relays operate

silently and produce little electrical interference. They

do not make noise when the output contacts change

states. EMRs create electromagnetic noise.

Pabich: The main advantage to using SSRs is their lon-

gevity. SSRs should be used in applications where load

has to be switched frequently or for extended periods

of time.

Wadowick: Traditional electromechanical relays have

some noteworthy problems inherent to their design:

switching speed and the fact that the number of

switch cycles the device can perform over its lifetime

is quite low when compared to solid-state electronic

equivalents. The advent of power MOSFET (metal–ox-

ide–semiconductor field-effect transistor) technologies

has greatly improved the competitive advantages of

solid-state devices compared to the mechanical relays

because the on resistance is so low—only a few mΩ—

and the off resistance is so high—hundreds of megaΩ.

This type of device is, for all practical purposes, a very

close approximation to the mechanical switch in its

electrical properties. However, the MOSFET can be

switched many orders of magnitude times more than

a mechanical relay and with much greater speed and

repeatability.

Loflin: Solid-state relays are used if the switching

frequency is high, especially for heating applications

or in control systems.

SSRs switch silently, so they can allow control

equipment to be placed inside noise-sensitive areas.

They typically have a wider temperature range in

which they can function or function without de-rating

the ampacity. They are resistant to shocks, strong

vibrations and electromagnetic fields. They can be

used in moist and heavily soiled environments as

the semiconductors are completely potted. And SSRs

switch without arcing and, therefore, assure mini-

mum interference emission.

Nigro: SSRs are best used in applications where high-

speed switching is occurring, as they do not contain

any movable parts. Since their internal components

are electronic, they last longer than traditional gener-

al-purpose relays, which allows them to be used for


MACHINE INPUT


switching inductive loads, as they can handle large

initial inrush.

A solid-state relay being powered by a temperature

controller could control a heater element in heat-treat-

ing application.

Frauton: One disadvantage of the mechanical relay

has to do with the hold current of the power coil.

Activating an electromagnetic relay energizes a coil

to create the magnetic field that physically forces the

contacts together, which requires more hold current.

The solid-state relay accomplishes effectively the

same thing with much less current.

Instead of a coil, it uses an optical isolation circuit

and a microcontroller chip signal, which sends an

ultra-low power signal to tell the relay when it is time

to open or close.

The solid-state relay has no moving parts; all

switching is done at the transistor level, which makes

the SSR more appropriate for applications in which

there are high cycle rates, for example, switching on

and off several times a minute. The SSR doesn’t wear

out on such applications, where the EMR would wear

and eventually fail.

The fact the SSRs have no moving parts also makes

them immune to shock and vibration and as such

would be a much better choice for mounting on a com-

pressor or turbine, for example. The SSR has better

inductive load protection. When power in an ac circuit

is cut, the energy surges in the direction of the source,

sometimes causing damage. In a mechanical switch,

this can result in pitting, arcing and eventual failure.

SSRs have built-in protection against this.

Harmon: Why are SSRs important? Simply put—re-

liability and long operating life. Designed with an

opto-isolator on the input and either a triac, SCR or

FET on the output, solid-state relays have no moving

parts, which allows them to operate silently and with

remarkable speed—on the order of microseconds with

some models—making them perfectly suited for auto-

mated processes that run 24/7 and require high-speed

timing. The relays simply keep going for hundreds of

millions of operations. The input for a solid-state relay

requires very little current to turn on, making them

compatible with TTL- and CMOS-controlled circuits.

DIN-rail-mount SSRs are typically used because of

their slim design and integrated heat sinks. In heating

control applications, the largest segment for solid-

state relays, panel-mount relays are used in industrial

ovens, HVAC/R, sterilization equipment, molding and

extrusion machinery and welding equipment, because

of their reliability, operating life and ability to switch

currents as high as 125 A. Heavy-duty conveyor sys-

tems, such as those in construction, mining, packag-

ing and material handling, benefit from the resistance

to shock and vibration, as well as the reduced mainte-

nance provided by three-phase solid-state relays.

In contrast, general purpose electromechanical

relays have the advantage in cost and flexibility. If the

relay is called upon to switch multiple circuits simul-

taneously, the need for additional outputs or channels

drives the SSR expense even higher. For proper ther-

mal regulation, heat sinks are required, adding even

more to the overall cost. EMRs create more design

options for customers with multiple contact sets—

typically one to four—to switch individual circuits

simultaneously. They also offer the option of change-

over contacts to switch between separate circuits, the

ability to switch both ac and dc loads, DIN-rail and

panel-mounting options with sockets and adapters

and accessories, such as bus jumpers, and protection

modules to configure and speed installation. Some

electromechanical relays are even available with fea-

ture sets such as lockable test buttons, LED indicators

and mechanical flags, which aid in the validation and

commissioning of automation panels. EMRs are better

suited for withstanding surge currents and voltage

spikes that would not only damage a solid-state relay,

but also potentially any surrounding components.

The advantages of electromechanical relays can be

most commonly seen in heavily populated automation

panels. Plug-in interface relays are commonly used

on the outputs of PLCs to deliver more current and

motor load switching capability, while adding a level

of protection with their built-in air gaps. Some EMRs

even come with optional protection modules to further

guard against any voltage transients that may come

through the system.

Electromechanical relays designed with special cov-

ers expedite and validate the installation with features

such as LED indicators that show when the relay is

powered and mechanical flags that indicate contact

operation. Some have lockable test buttons that allow

installers to verify proper wiring connections without

having to power up the entire panel; this particular

feature saves both time and money by reducing the risk

of harm to equipment and operators.



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SAFETY LIMIT SWITCHESThe SI Series safety limit switches monitor the

position of guards, gates, covers and other movable

machine fixtures and tooling. The series features

a limit-switch style, complying with Type 1 per ISO

14119 standards, with actuating elements integrat-

ed with the enclosure.

Configured with a

positive-opening

design of the normally

closed contacts, per

IEC 60947-5-1 stan-

dards, these switches

provide reliable

monitoring regardless

of environmental con-

ditions and withstand

any attempt to override the switch and defeat the

system. The series offers multiple actuating sys-

tems, including plunger, roller, spindle-mount lever

and two lever styles. The actuator head is rotatable

in 90° increments.

Banner Engineering; 888/373-6767;

www.bannerengineering.com

EMERGENCY STOPCONTROL STATIONSIDEM emergency

stop control

stations for

emergency stop

protection are

equipped with

switches that use

a lid safety trip mechanism to open the contacts

if the station lid is removed. Two styles of stations

are available and are fitted with a 40-mm twist-

to-release mushroom head operator. The standard

box features three-pole positive guided contacts

and comes with plastic IP67-rated or IP69K-rated

(NEMA 6) stainless steel housings and two conduit

entries, while the long box features a stainless steel

housing, four-pole positive guided contacts, three

conduit entries, a two-color LED for status indica-

tion and an emergency stop legend plate.

AutomationDirect; 800/633-0405;

www.automationdirect.com

SAFETY DEVICESThe EU2B family of safety devices, including pushbut-

tons, pilot lights, selector switches and ammeters, are

fully sealed to prevent the release of sufficient electri-

cal energy to ignite explosive gases or particles in

the environment for which they are rated. They are

UL-listed for use in Class I, Zone 1 applications and

are rated AEx de IIC T6 Gb for use in explosive gas

atmospheres. The devices are rated IP65 and Type

4X for protection against water and are available

with exposed or finger-safe IP20 screw terminals.

IDEC; 800/262-4332; www.idec.com

PROCESS AND LEVEL METERThe 4-20 mA loop-powered PD6800-0L1

process and level meter features a 20-seg-

ment bar graph level indicator, making it

suitable for level applications. Other features

include an easy-to-read 14-character bottom

display for units, tag or alarm indication. Through-glass

SafeTouch buttons allow programming and operation

without removing the cover. The explosion-proof meter

is rated NEMA 4X/IP68 and carries worldwide agency

approvals for use in hazardous locations.

Precision Digital; www.predig.com

PUSHBUTTONS, SELECTORS AND PILOT LIGHTSThe A22N Series offers a variety

of 22-mm-diameter pushbuttons,

selector switches and pilot lights

designed for simple installation,

operation and customization. Three contact blocks can

be mounted in a series (up to six for non-lighted mod-

els) and can be attached in any direction. The series

includes safety features such as easy-mounting contact

blocks with finger protection, a lock lever for secure

locking and different colors of contact blocks, helping

prevent wiring errors. Pushbuttons are available in flat,

projected, full guard and mushroom style. Pilot lights

can be flat, semi-spherical, projected or brushed plastic.

Omron Automation and Safety; 866/88-omron;

www.omron247.com

[email protected] PRODUCT ROUNDUP


Accessorize with functionalityButtons, switches and indicators for better machine control

CD1508_41_43_ROUNDUP.indd 41 7/28/15 7:08 PM

http://www.bannerengineering.com

http://www.automationdirect.com


http://www.idec.com

http://www.predig.com


ALL-GIGABIT SWITCHThe Allen-Bradley

Stratix 5400 switch

is an all-gigabit op-

tion that supports

both Layer 2 switching and Layer 3 routing for a

range of network configurations. When used as a

Layer 2 switch, it is suitable for industrial environ-

ments experiencing an influx of high-performance,

gigabit-speed end devices. When used as a Layer 3

switch, routing is enabled between segmented net-

works. The GE power over Ethernet and additional

GE fiber port options enhance scalability. The switch

is available in 18 models, offers up to 20 gigabit

ports in a single switch and comes with network

address translation.

Rockwell Automation; www.rockwellautomation.com

ALL-IN-ONE LIGHTThe compact

NE-CL7 multi-

color signal light

is designed for a

long service life.

The LED protects

against moisture

and dust with a protection rating of IP66 and IP67,

making it suitable for most environments. Colors

are red, yellow, green, light blue, blue, purple and

white.

Patlite; www.patlite.com

COMPACT MODULARPRESSURE SWITCHESThe PSW8 series of

compact modular pres-

sure switches feature

easy field setting with

hex 5 Allen screws.

This CE-compliant

product is available in a range of configurations.

Low-pressure ranges feature a diaphragm pressure

switch design, and higher-pressure ranges feature

a compact piston design. The series can be used

for stationary or mobile hydraulic applications.

Applications include factory automation, compac-

tors, overload controls, machine tools and hydraulic

power packs.

Omega Engineering; www.omega.com

SNAP-ON PUSHBUTTONSSirius Act is a line of

22-mm IEC pushbuttons,

indicator lights and

selector switches. Four

designs and various op-

tions are available for

combining actuator and indicator, material, color,

type of front ring and lighting. The pushbuttons use

a snap-on concept for installation, and installation

can be completed with one hand for the actuator,

holder and contact block. Visible installation mark-

ers and indicators on the components help to reduce

the risk of incorrect installation. The devices are

IP69K-rated and can be cleaned with a high-pressure

jet at high temperatures. The product line provides

flexible communication, allowing connection to AS-

I, IO-Link and Profinet.

Siemens; www.industry.usa.siemens.com

FUSED DISCONNECT SWITCHThe Bussmann series low-profile

compact circuit protector is

designed to streamline panel

installation and simplify selec-

tive coordination requirements

in mission-critical environments.

The UL 98-listed fused disconnect

switch accepts branch-rated fuses

that are current-limiting and up to a 200-kA inter-

rupting rating. All configurations are designed for use

in global applications and offer full ac voltage ratings

for the installed fuses. To support application flex-

ibility, mounting and panel layout dimensions match

common low-profile circuit breakers. All versions are

disconnect-rated to provide means for load isolation.

The switches are IP20-rated and meet International

Electrotechnical Commission finger-safe requirements

for panel mount installations.

Eaton; www.cooperbussmann.com/ccplp

PC-PROGRAMMABLE LOOP DISPLAYThe PSD PC-programmable loop display

reads any 4-20 mA signal and displays

the information with accuracy as high as

±0.012% of input scale. It will not burden

loops with its low-voltage requirement of

less than 2.3 V. Featuring two rows of al-

phanumeric characters on a large integral

[email protected] ROUNDUP



http://www.rockwellautomation.com

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http://www.cooperbussmann.com/ccplp


display, real-time process status

can be viewed in the field and dis-

played in mA, percent or any other

designated five-character EGU. A

complete setup of all application-

specific operating parameters

including input range, display

range, tag information, damp-

ing and filtering frequency can be

programmed on a single software

screen in less than five minutes.

Moore Industries; www.miinet.com

ANTI-VANDAL PUSHBUTTONThe Series 82 pushbutton features

an all-metal front, IK10 shock

protection and IP67 sealing. It is

designed for reliability even in

extreme temperature fluctuations

from -30 °C to 70 °C (-22 °F to 158 °F)

and humidity up 85%. The devices

are equipped with 16-, 19- and

22.5-mm-diameter industry-stan-

dard mounting hole sizes; momen-

tary or maintained switch action;

capability to handle up to 5 A/250

Vac; sunlight-readable LED illumi-

nation in either dot or ring-style

versions; a smooth, tactile feel; flat,

raised or convex lens shapes; and

are oil- and watertight to meet IP67

requirements. It is vandal-resistant

to the IK10 standard.

EAO; 203/951-4600; www.eao.com

CURRENT OPERATED SWITCHESASC Series current-operated

switches combine a current

transformer, microprocessor-based

signal conditioner and limit alarm

contact in one package. Compatible

with most automation systems,

ASC switches provide a magneti-

cally isolated NO or NC solid-state

output for control circuits rated

up to 135 Vac or Vdc. The user-

specified trip point (2 to 150 A) is

calibrated at the factory. The units

meet UL, CUL and CE standards.

NK Technologies; 800/959-4014; www.

nktechnologies.com

LIMIT SWITCHESThese limit switches are designed

for quick installation, wiring ease,

simple setup,

modularity, stur-

diness and reli-

ability. The body

cover has a cap-

tive closing screw

and is hinged at

the bottom and

removable. The

heads have axial

rotation in any of four positions

at 90° angles and are made of

metal, while the body housing is

made of self-extinguishing poly-

mer thermoplastic. The auxiliary

contact blocks are removable. The

limit switches are available with

a hinge operator, slotted lever

or key-operated. In addition to

meeting international standards,

the safety limit switch series is

cUL-recognized.

ASI; www.asi-ez.com

controldesign.com

Turn Angular PositionInto:

RFC 4800 Series sensors measure angular rotation using a magnet attached to your application’s shaft. Since they’re absolute sensors, they keep measuring even if you lose power and report the correct position when power is restored. Voltage, current and digital output options provide design flexibility to choose the interface that works best for you.

Other key specifications include:• Repeatability - 0.1°• Measurement range - 0 to 360°

• Resolution - versions to 14 bit• Linearity - ≤ ±0.5 % of F. S.

Novotechnik U.S., Inc. Telephone: 508-485-2244Email: [email protected]

For more information visit www.novotechnik.com/rfc48



http://www.eao.com

http://www.nktechnologies.com

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http://www.asi-ez.com

http://www.novotechnik.com/rfc48


AS WE’RE BUILDING panels with more and more

24-Vdc circuits, what are the best options for protec-

tion? Fuses have always been a mainstay. What about

electronic circuit protection modules? Electrostatic

discharge devices? Miniature circuit breakers? Does

each component warrant a different type of protec-

tion? How do we guard against overcurrent? Will a

two-pole MCB suffice?

ANSWERS

Pop-out buttonI like the new electronic circuit protection modules.

There are some out now that are the same size as

a fuse holder but function like a push-style circuit

breaker where you push once to engage and a second

time to disengage. If the circuit overloads, the button

pops out and must be pushed back in to re-engage.

Rick Rice, applications specialist, engineering,

Crest Foods, www.crestfoods.com

Many considerationsThere’s no one “best” option for circuit protection.

Several factors need to be considered. First, what are

the code requirements? Are there UL, CSA or EN safety

standards that must be met? What types of hazards

are likely to be encountered? And what customer ex-

pectations must be met in terms of cost and features?

Fuses are low-cost and available with a wide variety of

electrical characteristics ranging from ultra-fast types

designed to protect semiconductor devices to time-

delay types designed to work with inductive devices

such as transformers and relays. Where fuses fall

short is convenience and control. If a fuse opens in the

field, an exact replacement may not be readily avail-

able, which could lead to down time in a production

setting or the temptation to use whatever is available

to get the equipment up and running. An end user’s

actions in this situation are beyond the designer’s

control, and an inappropriate substitution could lead

to equipment damage or a safety hazard.

Circuit breakers are a good choice for many applica-

tions. Thermal circuit breakers are rugged and cost-

competitive with fuses. In fact, many are designed

to fit in cutouts originally designed for fuse holders.

Where thermal circuit breakers come up short is

reaction time and precision. Thermal circuit breakers

are relatively slow-acting, and the trip point can vary

considerably with temperature. These characteristics

may render them inappropriate in applications where

there are large variations in ambient temperature or

where fast reaction time is required. Magnetic circuit

breakers overcome most of the limitations of thermal

circuit breakers, but are considerably more expensive.

Polymeric positive temperature coefficient (PPTC)

devices, or resettable fuses, are another viable option,

but, like thermal circuit breakers, their trip current

and time are affected by changes in temperature.

Each of these options deal with over-current protec-

tion. Many designs also require over-voltage protec-

tion. Varistors, gas discharge tubes, Zener diodes

and TVS diodes can all be used to provide protection

against transient voltages, and crowbar circuits can

be designed to protect against over-voltage conditions.

Reverse-polarity protection may also be appropriate

for designs where the end user will be connecting the

power source.

Electronic circuit protection modules attempt to

combine the best features of fuses and circuit break-

ers while adding a few new tricks including, in some

cases, circuit isolation, remote monitoring and reset

and better tolerance to inrush current while still pro-

viding adequate overload protection. Electronic circuit

protection modules provide a solution in a box, which

makes them a fantastic solution for industrial automa-

tion projects or low-volume production, saving count-

less hours of engineering time; however, for volume

production or price-sensitive applications, electronic-

circuit-protection modules may offer more features

than are required or come at a cost too high to justify.

Herm L. Harrison, vice president,

Foster Transformer, www.foster-transformer.com

Sensitive signalsWhile a specific power level was not mentioned in the

question, we’ve had good results with resettable PTC

fuses. We’ve used them to protect sensitive signal

conditioning circuits powered from line voltages up to

250 Vac.

Roy Cabral, product marketing engineer,

Murata, www.murata.com

Fuse or circuit breaker?While fuses have their strengths and are a popular

choice for 24-Vdc circuit protection, there are also

reasons that a circuit breaker may be better suited for

24-Vdc applications. One major reason is because fuses

are a one-and-done kind of deal. Circuit breakers allow


Best way to protect low-power circuits

[email protected] ANSWERS

CD1508_44_46_REALANSWERS.indd 44 7/28/15 7:04 PM


http://www.crestfoods.com

http://www.foster-transformer.com

http://www.murata.com


you to reset and reuse the device

over and over again; fuses do not.

Circuit breakers also offer more

functionality options. Many circuit

breakers provide options for on/

off switch capabilities, single and

multi-pole configurations, auxil-

iary contacts and more.

And generally, circuit breakers

are more robust in design. They

have more stable trip curves that

enable them to be used for unique

applications, like with identically

current-rated wiring conductors.

In terms of using miniature

circuit breakers, the user would

need to analyze his/her applica-

tion’s specific requirements to

protect in the right situations.

Some applications require a faster

or slower tripping time than oth-

ers. Three of the most common

circuit breaker categories are

thermal, thermal-magnetic and

electronic. Each type of breaker

reacts at various speeds due to

the factors that trigger its tripping

mechanisms.

Thermal breakers are great

for tripping when things get too

hot. They are programmed to

trip when they heat up beyond

a certain temperature. This heat

is generated when its connected

equipment is drawing too much

current over a long period of

time. Thermal breakers are great

for protecting things like mo-

tors, transformers and electrical

systems used in air, land and sea

vehicles.

Thermal-magnetic breakers trip

under both excess heat and mag-

netic effects. This means they trip

when things get too hot or when

they draw too much current over a

short period of time. The thermal

part is the same as before. The

magnetic parts refer to the way

the breaker responds to high over-

load and short-circuit currents.

The breaker can also trip when

there’s a rapid increase in current

flowing through it. This is known

as the magnetic tripping effect.

Thermal-magnetic breakers are

good for protecting in the event of

overload, short circuits and long

cable paths.

Electronic breakers are designed

to trip at an exact point. They are

highly sensitive in the event of

overload, short circuit and long

cable paths. They are ideal for

protecting extremely expensive,

critical equipment.

This leads to the next point: Be-

cause of their sensitivity, electron-

ic breakers should be strategically

placed. For example, if something

such as a motor has a huge start-

up current, the breaker could trip

before you could even turn it on.

You may be able to turn it on for a

second, but it will shut off almost

immediately after that. This is

known as nuisance tripping. In

this case, an electronic breaker

would be too sensitive.

Finally, electro-static discharge

protection is not actually related

to circuit breakers. To properly

mitigate ESD transient anoma-

lies, your design would require

comprehensive shielding, ground-

ing and bonding techniques, along

with the implementation of ap-

propriate surge-protective devices,

which is a completely different

topic in and of itself.

Jessica Yeh,

product marketing specialist,

Phoenix Contact

www.phoenixcontact.com

Do you UL?Some contributors have com-

mented that the location of the

installation will determine what

standards you will need to follow.

In more general terms, if you can

assume that this protection will

need to be in an industrial control

panel installed in the United

States, a great reference is the UL

508A Standard for Industrial Con-

trol Panels, Sec 42.1.3.2. This part

of the UL standard describes how

you would size your protection

device. Once you have determined

the protection required, cost,

certification, size and performance

of the protection device will most

likely need to be considered. In

most cases, a fuse will be the obvi-

ous choice due to size and cost. If

quick visual or electronic notifica-

tion is required, then there are

good options with circuit breakers.

Mark Lovell, proposals manager,

Pepperl+Fuchs, www.pepperl-fuchs.us

Device to match the taskWhich device to implement is de-

termined by what task is required

by such devices. For example,

many codes and standards require

that each branch be protected,

which includes protecting the

load and the conductors. In many

cases, a branch-circuit-rated fuse

or circuit breaker can perform this

task. As with any protective de-

vice, there are trip time character-

istics associated with each unit for

which a certain amount of current

must flow within a specific time

frame in order to open the fuse or

trip the circuit breaker. However,

many power supplies limit current

quickly, preventing the necessary

current needed to trip a protective

device. Even robust high-quality

power supplies capable of deliv-

ering high peak current are still

dependent on the length of wire,

wire gauge and where the fault

occurs to determine if the imped-

ance is too high to allow sufficient

current to flow. Electronic fuses

are also available, but sometimes

the trip characteristics can be too

sensitive causing a nuisance trip.


http://www.phoenixcontact.com

http://www.pepperl-fuchs.us

controldesign.com

REAL ANSWERS

Depending on the severity of an

overload on a power supply, the

output voltage can drop signifi-

cantly, causing the connected loads

to shut down. If the protective

devices do not open fast enough,

even the controller can shut

down, causing a loss of control

within the application, as lack of

control voltage is not present. So

although a fuse or circuit breaker

is in the circuit and is provid-

ing the necessary branch circuit

protection by code, if they do not

open, this condition can render

the power supply useless. For

this reason, the market has seen

an increase in the offering of dc

protection modules.

Ed Merkle, engineering manager,

Puls, www.pulspower.us

ECP devicesWhen Murrelektronik meets with

integrators and OEM customers to

consult on power management,

electronic circuit protection is

always an important topic. In the

past, breakers and fuses were as-

sumed to be adequate for protec-

tion on branch circuits. However,

when you take the time to ana-

lyze the applications, you quickly

find that in dc applications, spe-

cifically low-voltage applications

(<48 Vdc), fuses and breakers are

marginal at best.

There are two main conditions

to protect from—short circuit and

overload. Sizing fuses and break-

ers to satisfy both of the condi-

tions and then provide a device

that actually can protect the

installation is difficult. Trip curves

for the respective device will nor-

mally only satisfy one condition

or the other. ECP devices satisfy

both conditions and add consider-

able monitoring and reset benefits.

Adjustable current ranges for each

branch, resettable circuits, no

replacement parts needed, visual

indicators and remote monitoring

and reset capabilities are among

the features that ECP devices and

our products can provide.

These features become more

and more important when you

consider the costs associated

with replacing a fuse or resetting

a breaker. These are minimized

with ECP devices. You can find

the problem, fix it and reset the

circuit without ever opening a

cabinet.

Aaron Henry, marketing manager,

Murrelektronik, www.murrinc.com

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“THERE IS NO existing protocol standard for fast de-

ployment and easy maintenance of managed Ethernet

switches,” says Ken Kao, product manager, Advan-

tech (www.advantech.com) . “Advantech created the

proprietary protocol, now built in to our industrial

Ethernet switches, based on real user installation

scenarios in real applications. We set out to solve the

user’s current network con� guration, management

and maintenance pain points.”

Advantech developed an industrial Ethernet switch

solution to help the users deploy the industrial Ether-

net switch hardware. Advantech IXM technology al-

lows users with multiple managed Ethernet switches

in the � eld to eliminate the need to individually con-

nect to each device to con� gure it.

All that’s required is to connect to a single IXM-en-

abled switch on the network and log in. This managed

switch can connect to and con� gure all other IXM-

enabled switches on the network at the same time in

the same topology.

Kao describes the IXM technology as a “cross man-

agement” feature built into Advantech’s industrial-

grade managed Ethernet switch family to help the

user deploy and maintain the application. The VPN

router is the L3 core network router; the EKI-7000

series is the L2 distributed network level managed

switch; and the ProView EKI-5000 series is the L2 edge

network level, lite-managed switch.

Cross management allows an IXM-enabled switch

anywhere in the network topology to be cross-man-

aged by a neighboring VPN router or EKI-7000 man-

aged switch in the same environment (networking

subnet). The cross management can be used for con-

� guration synchronization, � rmware synchronization

and IP address assignment.

“It’s the major bene� t of this switch—the ability

to do a fast deployment,” notes Kao. The web server

allows all switches in one topology to be con� gured

through one connection. The switches can be con� g-

ured as a group or individually from a single location.

“We have seen the customers facing the challenge

of installation in the � eld. The one-by-one con� gura-

tion of each switch requires signi� cant effort, and

there is the potential for human error due to the large

number of manual settings required,” comments Kao.

“Normally, the engineer has to spend around 15 to 20

minutes to � nish the initial setting for each managed

switch. Imagine if you have to install 100 managed

switches. Then imagine from the maintenance point

of view, updating the � rmware in these 100 switches.

It takes a signi� cant amount of time, and now Advan-

tech has a more ef� cient way to help our customer

con� gure and upgrade managed switches.”

With the IXM Ethernet switches, the con� guration

tools are built-in. The software is on the switch and

accessible with a simple network connection.

“Advantech uses wizards to walk you through

deployment,” comments Kao. “The IXM functionality

steps you through instructions on source device selec-

tion and target device selection and features con� gu-

ration selection and then requests con� rmation of

selections before processing.”

The IXM technology is supported in a wide-ranging

product family. The Advantech ProView EKI-5000 se-

ries is an unmanaged Ethernet switch but has a built-

in real-time remote-monitoring capability through

SNMP or Modbus/TCP agent. The remote monitoring

capability was the � rst to the market and is a great

option for machine monitoring. While it doesn’t have

the IXM deployment wizard, ProView can easily be

con� gured by an EKI-7000 series managed switch via

IXM technology and comes in a variety of port counts

and speeds.

The EKI-7000 switch is available in both DIN-rail

and 19-in rack-mount versions with a variety of port

counts (8 to 24) and speeds (10/100/1000 Mbps). This

device also comes in a wide temperature range (-40 to

75 °C) and offers a proprietary X-ring feature for self-

healing as a networking redundancy capability.


Confi gure multiple Ethernet switches

FOR MORE INFORMATIONCall 513/742-8895, ext. 332, email [email protected] or browse to www.advantech.com.

FOR MORE INFORMATION

EXCLUSIVE

CD1508_47_EXCLUSIVE_Advantech.indd 47 7/28/15 7:02 PM




TWO TABLET-SIZED HMI displays from Maple

Systems, the HMI5097XL and HMI5097NXL, bring an

expanded operator � eld of vision and in-cabinet pro-

tection to the industrial marketplace.

A 70° viewing angle enables an improved � eld of vi-

sion for ef� cient monitoring and control of operational

status. “These particular displays have an extremely

wide viewing angle,” explains Larry St.Peter, CEO of

Maple Systems. “It’s virtually from side to side. With

previous HMI displays, if you went off-axis more than

30°, your ability to see what’s on-screen would go

away. With these new displays, you get resolution all

the way around, from almost every angle. The opera-

tor no longer has to stand directly in front of the HMI.”

Nearly identical in terms of features and functional-

ity the HMI5097XL and HMI5097NXL are both slim-

form HMIs with 512-MB Flash memory and 256 MB of

RAM for complex and graphic-intensive projects. The

main difference between the two models is that only

the HMI5097XL comes UL-certi� ed and with support

for CANbus. Both models are IP65-rated to resist dust

and water. “All of our HMI products support around

200 communication protocols to varying industrial

controllers and motion products,” says St.Peter. “This

offers integration to any PLC, PAC or motion controller.

In addition to being NEMA-4-rated, the CPU board is

PCB–coated, so if the cabinet door is open and water

gets inside, it’s not an issue. That’s an added protec-

tion we supply on all HMI products.”

The 9.7-in units are the third product in this series,

says St.Peter. “All have virtually the same great fea-

tures and functionality, other than the display size,”

he says. “The � rst two products were 12-in and 15-in

HMIs. All three have a high-speed processor and more

memory compared to our smaller-scale HMIs.”

The 9.7-in screen is the display of choice for tablets.

“The new HMIs emulate the viewing experience of an

iPad or Android tablet in terms of display and size,”

explains St.Peter. “This is an HMI product, so it uses

an analog resistive touchscreen and functions as a

typical HMI product does. We also have another 9.7-in

display that’s offered with the same capacitive experi-

ence—swipe, pinch, zoom—as an iPad. That product

has been on the market for a few months now. Display

manufacturers are sourcing this newer technology of

larger screen sizes with high-resolution displays, and

they make them in huge quantities. That generates

very attractive pricing.”

The commercial market drives the display indus-

try, says St.Peter. “We’re taking advantage of that cost

bene� t,” he explains. “It allows us to offer high-level

functionality at a very low price. The 9.7-in units have a

larger display with a high-tech look that’s more robust.

And they have a more powerful processor—1-GHz CPU.

The 9.7-in display is the � rst of its size with 1024 x 768

pixel resolution for a really crisp-looking display.”

The display’s silver sides and dark-grey aesthetic

add a modern look to any machine design. “We sell

into industries such as food processing, packaging,

and oil and gas,” says St.Peter. “With the new 9.7-in

units, a machine manufacturer can integrate a prod-

uct that will be more visible and look more attrac-

tive on the machine at a lower price point. The new

models are sleek and modern looking. With this type

of display, you can have a nice display that comple-

ments the look of the machine design. We’re appealing

to machine builders who are trying to save money, but

also give them the functionality and look they want.

Even better, the 9.7-in models offer the same function-

ality as 15-in displays, but with a smaller footprint.”

The HMI5097XL and HMI5097NXL can be con� gured

to speci� cations with Maple Systems EZwarePlus

software, which includes alarm management, batch

recipes, trending and data logging, says St.Peter. “The

software has virtually anything you could want,” he

explains. “It’s easy to use with an intuitive interface.

And it’s packed with features such as Internet brows-

ing and remote capabilities. Maple Systems also offers

complimentary technical support and a comprehen-

sive online support center.”


EXCLUSIVE

HMI displays larger angle of vision

FOR MORE INFORMATIONCall 425/745-3229, email [email protected] or browse to www.maplesystems.com.

FOR MORE INFORMATION

CD1508_48_EXCLUSIVE_Maple.indd 48 7/28/15 6:59 PM


http://www.maplesystems.com


Advantech Automation . . . . . . . . . . . .17

Allied Electronics. . . . . . . . . . . . . . . . 6

Ashcroft . . . . . . . . . . . . . . . . . . . . . 34

AutomationDirect. . . . . . . . . . . . . . . 52

AVG Automation . . . . . . . . . . . . . . . . 2

B&R Industrial Automation . . . . . . . . 12

Beckhoff Automation . . . . . . . . . . . . . 4

Endress+Hauser . . . . . . . . . . . . . . . .10

Eplan Software . . . . . . . . . . . . . . . . 28

Graybar. . . . . . . . . . . . . . . . . . . . . . .19

Maple Systems . . . . . . . . . . . . . . . . .31

Mettler Toledo . . . . . . . . . . . . . . . . . 27

Murrelektronik. . . . . . . . . . . . . . . . . . 7

Novotechnik . . . . . . . . . . . . . . . . . . 43

Omron Electronics . . . . . . . . . . . . . . . 8

Pepperl + Fuchs . . . . . . . . . . . . . . . 25

Phoenix Contact . . . . . . . . . . . . . . . . 3

Siemens Industry. . . . . . . . . . . . . . . .14

Smart Industry . . . . . . . . . . . . . . . . .51

Telemecanique Sensors . . . . . . . . . . 18

TRC Electronics. . . . . . . . . . . . . . . . 40

Wago . . . . . . . . . . . . . . . . . . . . . . . 23

WEG Electric. . . . . . . . . . . . . . . . . . 37

Weidmuller . . . . . . . . . . . . . . . . . . . 46

AD INDEX

PUBLISHING TEAM

GROUP PUBLISHER & VP, CONTENT

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CREATING MACHINES FOR a

variety of projects certainly keeps

work interesting at Compass

Automation (www.compass-

automation.com) in Elgin, Illi-

nois. The pair programming and

agile engineering methodologies

Compass uses to design machines

add innovation to the mix, as

well. Considering the far-reaching

industries Compass works with,

good design is a must.

“Compass designs and builds

custom automation for a variety

of processes, such as assembly,

inspection, deburring, machine

tending and painting,” notes Bill

Angsten, executive vice president.

Compass was started in 2009 by

two friends, Angsten and Patrick

O’Rahilly, Jr., who went to the

same high school, Marmion Acad-

emy, in Aurora, Illinois. A third

classmate from Marmion, Brian

Greviskes, joined them after the

� rst year. The three of them, just

23 years old at the time, sought

to build custom automation and

help manufacturers in the United

States compete globally.

“Compass grew, at � rst relying

on industry-wide practices but,

as the years went on, by trying

very alternative methodologies to

design and build machines,” says

Angsten. “Some of those diver-

gent strategies included hiring

mechanical engineers fresh out of

MIT, writing our own software to

manage operations and using pair

programming and agile engineer-

ing practices borrowed from the

software development world.”

Compass primarily uses PLCs

for control. However, due to cus-

tomer speci� cations or application

requirements, PC-based control is

sometimes used. “The majority of

our machines utilize PLC-based

controls,” states Vlad Men, control

engineering manager at Compass

Automation. “We work with many

of the popular controllers and also

use PC-based controls when neces-

sary.” Compass utilizes reusable

program templates and function

blocks to simplify project develop-

ment and debug, says Men.

Networked hardware is becoming

popular on Compass equipment.

“Every machine has at least one

kind of industrial network for I/O

and intelligent devices such as ser-

vo drives, variable-frequency drives

(VFDs), smart cameras and barcode

readers,” notes Men. “EtherNet/IP

and Pro� Net have been popular.”

For safety and depending on

the system size, Compass uses a

wide range of safety products—

from hardwired safety relays to

distributed safety systems using

networked safety controllers

and safety PLCs, comments Men.

“Safety is application-speci� c, and

our wide range of machine designs

drives the diversity of our safety

system design,” he notes.

“Compass has been very in-

novative when it comes to design

methodology, and we deviate from

the rest of the industry in doing

so,” states Angsten. “The unique

strategies we employ are driven by

the understanding that designs of

custom equipment are inherently

� awed.” From the project onset,

Compass pairs a mechanical en-

gineer and a controls engineer to

develop the machine.

The two work together, literally

sharing a workstation, utilizing

the pair programming methodol-

ogy to design the machine. “This

strategy allows us to have strong

control logic input from the very

onset,” notes Angsten. “Immedi-

ate sharing of knowledge and

working out problems with a

partner has improved the quality

of our designs.”

The next thing Compass does is

agile engineering: rapidly design-

ing and prototyping individual sta-

tions of the machines, says Men.

“We pull forward the most risky or

complex elements of the system

and perform iterative design and

testing of the tooling—making

sure that our designs actually

work and are debugged early on,”

he explains. “This strategy moves

the most uncertain element of the

custom machine build up to the

very front of the project.”

Engineering with innovative methodologies

PRECISION ROBOTIC MATERIAL REMOVALTim Wilczynski, mechanical engineer at Compass Automation, checks tooling on a robotic assembly machine.

OEM SPOTLIGHT Dave Perkon • technical editor • [email protected]

CD1508_50_OEMSPOTLIGHT.indd 50 7/28/15 6:54 PM


http://www.compass-automation.com



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