rfid

Why RFID is the VIP of 2019
Guest Contributor, Wolfgang Kratzenberg, Balluff

The “most popular” annual lists don’t usually come out until the end of the year, but I think it is worth mentioning now three applications that have gained substantial momentum this year. With the Smart Factory concept being driven around the globe, RFID has emerged from the shadows and taken its place in the spotlight. The demand for a larger amount of data, more security, and increased visibility into the production process has launched RFID into a leading role when it comes to automation.

Machine Access Control

When considering RFID being utilized for access control, they think about readers located near doorways either outside the building or within the plant. While those readers operate much like the industrial readers, they typically cannot communicate over an industrial communication protocol like Ethernet/IP, Profinet, or IO-Link.  With an industrial access control reader one can limit access to HMIs, PLCs, and various control systems by verifying the user and allowing access to the appropriate controls.  This extra layer of security also ensures operator accountability by identifying the user.

Machine Tool ID

RFID has been used in machining centers for decades. However, it was used mostly in larger scale operations where there were acres of machines and hundreds of tools. Today it’s being used in shops with as few as one machine. The ROI is dependent on the number of tool changes in a shift; not necessarily just the number of machines and the number of tools in the building. The greater the number of tool changes, the greater the risk of data input errors, tool breakage, and even a crash.

Content verification

Since RFID is capable of reading through cardboard and plastic, it is commonly used to verify the contents of a container. Tags are fixed to the critical items in the box, like a battery pack or bag of hardware, and passed through a reader to verify their presence. If, in this case, two tags are not read at the final station then the box can be opened and supplied with the missing part before it ships. This prevents an overload on aftersales support and ensures customers get what they ordered.

While RFID is still widely used to address Work in Process (WIP), asset tracking, and logistics applications, the number of alternative applications involving RFID has skyrocketed due to an increase in demand for actionable data.  Manufacturing organizations around the world have standardized on RFID as a solution in cases where accountability, reliability and quality are critical.

 

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

What to Ask Before You Build an RFID System to Meet Your Traceability Needs

Guest contributor, Balluff

overview_rfid

An industrial RFID system is a powerful solution for reliably and comprehensively documenting individual working steps in manufacturing environments. But an industrial RFID system that meets your application needs isn’t available off-the-shelf. To build the system you need, it is important to consider what problems you hope RFID will solve and what return on investments you hope to see.

RFID can deliver many benefits, including process visibility and providing data needed to better manage product quality. It can be used to improve safety, satisfaction and profit margins. It can even be used to help comply with regulatory standards or to manage product recalls. And RFID can be used in a wide range of applications from broad areas like supply management to inventory tracking to more specific applications. These improvements can improve time, cost or performance—though not typically all three.

It is essential to understand and document the goal and how improvements will be measured to in order to plan a RFID system (readers, antennas, tags, cables) to best meet those goals.

Other important questions to consider:

Will the system be centralized or de-centralized? Will the system be license plate only or contain process data on the tag?

How will the data on the tags be used?  Will the information be used to interface with a PLC, database or ERP? Will it be used to provide MES or logical functionality? Or to provide data to an HMI or web browser/cloud interface?

Will the system be required to comply with any international regulations or standards? If so, which ones: EPC Global, Class 1 Gen 2 (UHF only), ISO 15693, or 14443 (HF only)?

What environment does the system need to perform in? Will it be used indoor or outdoor? Will it be exposed to liquids (cleaning fluids, coolants, machine oils, caustics) or high or low temperatures?

Does the RFID system need to work with barcodes or any other human readable information?

What are the performance expectations for the components? What is the read/write range distance from head to tag? What is the station cycle timing? Is the tag metal-mounted? Does the tag need to be reused or be disposable? What communication bus is required?

With a clear set of objectives and goals, the mechanical and physical requirements discovered by answering the questions above, and guidance from an expert, a RFID system can be configured that meets your needs and delivers a strong return on investment.

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

The Evolution of RFID in Metalworking

Guest contributor: Nadine Brandstetter, Balluff

RFID – A key technology in modern production

It’s not just IIoT that has focused attention on RFID as a central component of automation. As a key technology, radio frequency identification has been long established in production. The inductive operating principle guarantees ruggedness and resistance to environmental stress factors. This makes the system highly reliable in function and operation. With unlimited read/write cycles and real-time communication, RFID has become indispensable. The beginnings for the industrial use of RFID go far back. RFID was first successfully used on machine tools in the mid-1980’s. Since the usage of RFID tags on cutting tool holders has been internationally standardized (ISO 7388 for SK shanks, ISO12164 for HSK shanks), there has been strong growth of RFID usage in cutting tool management.

Cutting tool in tool taper with RFID chip

Track-and-trace of workpieces

Modern manufacturing with a wide bandwidth of batch sizes and ever compressed production times demands maximum transparency. This is the only way to meet the high requirements for flexibility and quality, and to minimize costs. Not only do the tools need to be optimally managed, but also the finished parts and materials used must be unambiguously recognized and assigned.

Workpiece tracking with RFID on pallet system

RFID frequencies LF and HF – both RFID worlds come together

In terms of data transmission for cutting tool identification, established systems have settled on LF (Low Frequency), as this band has proven to be especially robust and reliable in metal surroundings. Data is read with LF at a frequency of 455 kHz and written at 70 kHz.

When it comes to intralogistics and tracking of workpieces, HF (High Frequency) has become the standard in recent years. This is because HF systems with a working frequency of 13.56 MHz offer greater traverse speeds and a more generous read/write distance.

As a result, RFID processor units have been introduced that offer frequency-independent application. By using two different read-/write heads (one for tool identification and one for track-and-trace of workpieces) that each interface to a single processor unit, the communication to the control system is achieved in an economical manner.

RFID processor for both tool identification and workpiece tracking

New Hybrid Read-Write Head

Industrial equipment is designed for a working life of 20 years or even more. Therefore, in production you often find machines which were designed in the last century next to new machines that were installed when the production capacity was enlarged. In such a brown field factory you have the coexistence of proven technology and modern innovative equipment. For the topic of industrial RFID, it means that both low frequency and high frequency RFID tags are used. To use both the existing infrastructure and to introduce modern and innovative equipment, RFID read/write heads have been recently developed with LF and HF technology in one housing. It does not matter whether a LF RFID tag or a HF RFID tag approaches the RFID head. The system will automatically detect whether the tag uses LF or HF technology and will start to communicate in the right frequency.

This hybrid read-write head adds flexibility to the machine tools and tool setters as you can use the entire inventory of your cutting tools and tool holders.

RFID Tool ID tag ready for the Cloud

The classical concept of data storage in Tool ID is a decentralized data storage, which means that all relevant data (tool dimensions, tool usage time, machining data, etc.) of a tool/tool holder is stored on the RFID tag which is mounted on the single tool holder. The reliability and availability of this concept data has been proven for more than 25 years now.

With the Internet of Things IIOT, the concept of cloud computing is trendy. All — tool setter, machine tool and tool stock systems — are connected to the cloud and exchange data. In this case only an identifier is needed to move and receive the data to and from the cloud. For this type of data management Tool ID tags with the standard (DIN 69873) size diameter 10 x 4,5 mm are available now in a cost effective version with a 32 Byte memory.

Evergreen – more modern than ever

Learn more about the Evolution of RFID in Metalworking at www.balluff.com  o

Collaborative Automation…It’s Not Just for Robots

Guest Contributor: Tom Rosenberg, Balluff

Manufacturing is made up of hundreds of discrete operations. Some are repetitive, while others are more diverse. Repetitive tasks are ideal for automation while diverse tasks require more flexibility. And while automation can be extremely flexible, that comes with a high initial investment costs and significant deployment time. The alternative? People!

Humans have the unrivaled ability to adapt to a diverse and flexible manufacturing environment. They can be productive relatively quickly with proper guidance without high initial cost investments.

But as we all know, “to err is human” and this is one of the biggest issues with manual operations. People need a little guidance from time to time. Collaboration is not just for robots; It’s for complete automation systems as well.

Collaborative automation is most important at the point-of-use, where humans are performing critical operations. Some of those common operations include:

  • Manual assembly for low volume or highly flexible operations
  • Delivery of raw materials to the point-of-use
  • Kit assembly for down-stream operation
  • Machine setup and change-over
  • Machine maintenance and calibration

All of these functions can be done error-free and with little training by simply guiding people within their current work envelope, also referred to as their point-of-use. This type of a lean function provides hands-free guidance in the form of indication devices connected directly to your automation system allowing workers to stay focused on the task at hand instead of looking elsewhere for instructions.

With the technology of IO-Link, smart indication devices can now show much more information to all the people involved in specific manufacturing tasks. Automation has an immediate and direct connection to the people that are so vital.

For example, in a manually-fed weld-cell, the smart indicators are capable of not only signaling that the part is loaded correctly, but also whether the part is out of alignment (shown here by the red indicator) or that something wrong with one of the automation components such as a stuck pneumatic clamp.

Figure 1A manually-fed weld-cell with smart indicators is capable of not only signaling that the part is loaded correctly, but also if the part is out of alignment (shown by the red indicator) or that there is something wrong with one of the automation components such as a stuck pneumatic clamp.

Even better, with IIoT technology, trends can be analyzed to determine if the fixture/tool could be optimized for production or to identify common failure points. This all leads to tighter collaboration with operations, maintenance personnel and production supervisors.

A traditional kitting station, sometimes referred to as a supermarket, is another ideal application for smart indicators. Not only can they guide a single operator to the intended part to pull, they can guide multiple operators at the same time.  Also, smart indicators can inform of incorrect pulls, potential bin options (a physically closure bin), directional information, and inventory levels. And again, with IIoT technology, trends can be analyzed to determine proper layout, individual personnel performance and system throughput. The automation system collaborates with operations, forklift drivers and production supervisors.

Regal_v06_01_V3A traditional kitting station, sometimes referred to as a supermarket, with smart indicators to guide operators to the intended part to pull.

So, take a look and see what a collaborative automation system utilizing smart indicators can do for your manual operations. You might be surprised.

The digital twin is the key to the Factory of the Future – Part II
Guest Contributor: Hans Michael Krause, Bosch Rexoth
The modular assembly line of Dassault Systèmes and Bosch Rexroth presented at the Hannover Messe is the result of a change in perspective. Planning production processes coming from the product, instead of the machines – that is what the digital twin can put into effect. Marketplaces for digital twins, IoT Gateway software and open standards will mark the route into the factory of the future.

The demo assembly line from Bosch Rexroth shows how digital twins completely reverse the logic of production, if you think of the Factory of the Future. It is no longer the machines that determine the processes, but the products. A customer’s order automatically leads to the creation of a digital twin. This is connected, for example via an RFID chip as a reference to the blank to inform the machines later about the respective processing steps. As a crucial precondition for this evolution, Bosch Rexroth has already created behavioral models for many automation components, which are available on request for systems engineering. As part of the online configuration, customers already receive the CAD models of the components in the appropriate data format automatically.

Next evolutionary step: Marketplaces for digital twins

In a future scenario that is interesting for mechanical engineers, digital twins could be made available from automation components but also via a marketplace in order to bring them into the simulation environment with a single click. As a result, the OEMs could parameterize the automation immediately, test it and put the entire model into virtual operation quickly and safely. In addition, the marketplace could become a PLM platform, where all digital twins for current and past solutions are available. To prepare for this scenario, Bosch Rexroth is currently seeking a dialog with its customers in order to jointly define the exact requirements for the simulation models.

Pioneering: IoT Gateway software and open standards

In order to achieve continuous improvements in production using the digital twin, the real operating data from the assembly line can be compared with its simulation. This allows the quality of the manufacturing process to be monitored in real time and the maintenance to be modeled and optimized based on the current condition. The assembly line shown at the Hannover Messe also depicts the current state of the art in this respect. The IoT Gateway software from Bosch Rexroth, which is installed on a pocket-sized box PC, collects data from the controller via the Industry 4.0 standard OPC UA and transfers it to a higher-level IT system for visualization and analysis using 5G technology. With regard to the investment security of IoT solutions, Bosch Rexroth consistently relies on open standards such as OPC UA.

DC-AE_SMP4_Dassault_AE_Demonstrator_3-768x663

In future, it is no longer the machines that determine the processes, but the products.

Important stage on the way to the Factory of the Future

Dassault Systèmes’ and Bosch Rexroth’s partnership is a powerful testament to the competitive advantages that machine builders and end users derive from a seamless workflow, from virtual engineering to intelligent automation. The digital twin of the demonstration line not only forms the basis for the fastest possible start-up, but also for the quickest possible production changeover and easy continuous process optimization with the help of IoT services. The close partnership of both companies is another stage win along the way to the Factory of the Future.

For more information about the collaboration with Dassault Systèmes and the road to the factory of the future, please read our blog post “With the digital Twin to the Factory of the Future”.

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CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Increase Competitiveness with RFID in the Intralogistics Industry

Guest contributor: Nadine Brandstetter, Balluff

In times of globalization and high labor costs it is a challenge to increase competitiveness in the fashion industry. Within a warehouse, an RFID system supports a high degree of automation as well as short transport distances. To supply dealers and to keep their facility profitable, one of the most successful fashion companies in the world has built a highly modern hanging garment distribution center. Let’s take a look at how they successfully implemented RFID technology to improve their processes.

Separate and sort clothes with just one hybrid module (2D code + RFID)

Within this distribution center 45,000 of these innovative clothes hanger adapters (L-VIS) are used. They replace the previous trolley-based logistics approach by allowing the transportation of a number of different garments that have the same destination.

OLYMPUS DIGITAL CAMERA

With the investment in some additional space in the so-called buffer or storage zone, and by providing empty trolleys at various locations to keep the product flow moving, this project is successfully accomplished. A major advantage of this system, is the usability over the entire intralogistics chain. From receiving, to the hanging storage, to the sorter for single item identification, and from there as a transport unit to shipping.

The clothes hanger contains an RFID chip, that is automatically read by the conveying technology, and the 2D-code. This code is read manually by employees with a portable acquisition unit. The code can be DMC (Data Matrix Code), QR-Code, or any other optical code standard.

OLYMPUS DIGITAL CAMERA

Information exchange without visual contact

An RFID chip from the Balluff BIS-M series is installed. With this identification system, neither direct alignment nor contact is needed to enable data exchange via nearfield communication. Non-contact identification is extremely reliable and wear-free. The identification system consists of a rugged data carrier, a read/write head and an RFID processor unit. The processor unit communicates to the control system via Profibus. Other options available include ProfiNet, Ethernet-IP, etc.

OLYMPUS DIGITAL CAMERA

The following table gives you an overview of which Radio Frequency Identification solutions are available at Balluff:

LF (BIS C) LF (BIS L) HF (BIS M) UHF (BIS U)
Frequency 70/455 kHz 125 kHz 13.56 MHz 860 … 960 MHz
Short description Dedicated solution to tool identification in Metal-Working industry. Standard solutions for simple Track & Trace applications. Fast & reliable – even with high volumes of data in medium distances in assembly, production and intralogistics. Identification at large distances and bunching capability for current material flow concept.

Learn more about Balluff solutions here.

For the customer, the decision to choose Balluff’s BIS-M system among others was the separation between the processor and read/write head. In a widespread facility it would not make sense to have a decoder with 30 read/write heads attached. By interfacing two read/write heads per processor it is possible to track the travel of a transport unit over the entire conveyor line as well as track within the aisles between the individual shelves. With the new BIS-V generation of RFID processors, even 4 read/write heads per processor can be connected.

Convincing product and support

An additional advantage of the BIS system is the compactness of its electronics. The L-VIS and the 30 mm read/write head are an ideal match. The simple mounting of the processors and ready-to-use connection persuaded the system integrators, in addition to the fact that the technology was already perfected and operated flawlessly. In the sorting area, the 2D code was supplemented by the RFID tags to reach speeds of up to 0.6 and 0.7 m/s. This would probably not have been possible with the installation of a corresponding camera technology.

Experiences have shown, that RFID projects need a lot of support. Consultation and assistance from true experts can be provided by the Balluff team. Get to know Balluff at www.balluff.com

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

5 Ways Flexible Manufacturing has Never Been Easier

Guest Contributor: Tom Rosenberg, Balluff

Flexible manufacturing has never been easier or more cost effective to implement, even down to lot-size-one, now that IO-Link has become an accepted standard. Fixed control and buried information is no longer acceptable. Driven by the needs of IIoT and Industry 4.0, IO-Link provides the additional data that unlocks the flexibility in modern automation equipment, and it’s here now!  As evidence, here are the top five examples of IO-Link enabled flexibility:

#5. Quick Change Tooling: The technology of inductive coupling connects standard IO-Link devices through an airgap. Change parts and End of Arm (EOA) tooling can quickly and reliably be changed and verified while maintaining connection with sensors and pneumatic valves. This is really cool technology…power through the air!

Image1

 

#4. On-the-fly Sensors Programming: Many sensor applications require new settings when the target changes, and the targets seem to always change. IO-Link enables this at minimal cost and very little time investment. It’s just built in.

Image 2

 

#3. Flexible Indicator Lights: Detailed communication with the operators no long requires a traditional HMI. In our flexible world, information such as variable process data, timing indication, machine status, run states and change over verification can be displayed at the point of use. This represents endless creativity possibilities.

Powertrain visualisieren

 

#2. Low cost RFID: Radio Frequency Identification (RFID) has been around for a while. But with the cost point of IO-Link, the applications have been rapidly climbing. From traditional manufacturing pallets to change-part tracking, the ease and cost effectiveness of RFID is at a record level. If you have ever thought about RFID, now is the time.

7_1_Produktionsdaten_Dokumentieren

 

#1. Move Away from Discrete to Continuously Variable Sensors: Moving from discrete, on-off sensors to continuously variable sensors (like analog but better) opens up tremendous flexibility. This eliminates multiple discrete sensors or re-positioning of sensors. One sensor can handle multiple types and sizes of products with no cost penalty. IO-Link makes this more economical than traditional analog with much more information available. This could be the best technology shift since the move to Ethernet based I/O networks.

8_1_induktiver_Abstand

So #1 was the move to Continuously Variable sensors using IO-Link. But the term, “Continuously Variable” doesn’t just roll off the tongue. We have discrete and analog sensors, but what should we call these sensors? Let me know your thoughts!

To learn more about RFID and IO-Link technology, visit www.balluff.com.

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

RFID in the Manufacturing Process: A Must-Have for Continuous Improvement

Guest Contributor:  Wolfgang Kratenzenberg, Balluff

There is quite an abundance of continuous improvement methodologies implemented in manufacturing processes around the globe. Whether it’s Lean, Six Sigma, Kaizen, etc., there is one thing that all of these methodologies have in common, they all require actionable data in order to make an improvement.  So, the question becomes: How do I get my hands on actionable data?

All data begins its life as raw data, which has to be manipulated to produce actionable data. Fortunately, there are devices that help automate this process. Automatic data collection (ADC), which includes barcode and RFID technology, provides visibility into the process. RFID has evolved to become the more advanced method of data collection because it doesn’t require a centralized database to store the data like barcode technology. RFID stores the data directly on the product or pallet in the process, which allows for much more in-depth data collection.

rfid

RFID’s greatest impact on the process tends to be improving overall quality and efficiency. For example, Company X is creating widgets and there are thirty-five work cells required to make a widget. Between every work cell there is a quality check with a vision system that looks for imperfections created in the prior station. When a quality issue is identified, it is automatically written to the tag.  In the following work cell the RFID tag is read as soon as it enters the station. This is where the raw data becomes actionable data. As soon as a quality issue has been identified, someone or something will need to take action. At this point the data becomes actionable because it has a detailed story to tell. While the error code written to the tag might just be a “10”, the real story is: Between cells five and six the system found a widget was non-conforming. The action that can be taken now is much more focused. The process at cell five can be studied and fixed immediately, opposed to waiting until an entire batch of widgets are manufactured with a quality issue.

Ultimately, flawless execution is what brings success to organizations.  However, in order to execute with efficiency and precision the company must first have access to not only data, but actionable data. Actionable data is derived from the raw data that RFID systems automatically collect.

Learn more about RFID technology at www.balluff.com.

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Is IO-Link only for Simplifying Sensor Integration?

Guest contributor: Shishir Rege, Balluff

On several occasions, I was asked what other applications IO-Link is suitable for? Is it only for sensor integration? Well the answer is no! There are several uses for IO-Link and we are just beginning to scratch the surface for what IO-Link can do. In this blog post I will cover at least 7 common uses for IO-Link including sensor integration.
IO-Link in essence provides tremendous flexibility. Each available IO-Link port offers the possibility to connect devices from hundreds of manufacturers to build a resilient distributed modular controls architecture — that is essentially independent of the fieldbus or network. IO-Link is the first standardized sensor/actuator communication protocol as defined in IEC61131-9.

USE-CASE #1: Simplify sensor integration
Multitudes of IO-Link sensors from 100+ manufacturers can be connected using the simple 3-wire M12 prox cables. No shielded cables are required. Additionally, using IO-Link provides a parameterization feature and anti-tampering abilities- on the same 3 wires. The sensor can be configured remotely through a PLC or the controller and all the configuration settings can be stored for re-application when the sensor is replaced. This way, on your dreaded night shift changing complex sensor is just plug-n-play. Recipe changes on the line are a breeze too. For example, if you have an IO-Link color sensor configured to detect a green color and for the next batch you want to start detecting red color- with IO-Link it is simply a matter of sending a parameter for the color sensor – instead of sending a maintenance person to change the settings on the sensor itself — saving valuable time on the line.
color sensors

USE-CASE #2: Simplify analog sensor connections
In one of my previous blogs, “Simplify your existing analog sensor connection”, I detailed how connecting an analog sensor with single or multi-channel analog-to-IO-Link (A/D) converters can eliminate expensive shielded cables and expensive analog cards in the controller rack and avoids all the hassle that comes with the analog sensors.

USE-CASE #3: Simplify RFID communication
IO-Link makes applications with RFID particularly intriguing because it takes all the complexity of the RFID systems out for simple applications such as access control, error-proofing, number plate tracking and so on. In an open port on IO-Link master device you can add read/write or read only RFID heads and start programming. A couple of things to note here is this IO-Link based RFID is geared for small data communication where the data is about 100-200 bytes. Of-course if you are getting into high volume data applications a dedicated RFID is preferred. The applications mentioned above are not data intensive and IO-Link RFID is a perfect solution for it.

USE-CASE #4: Simplify Valve Integration
valve manifoldTypically valve banks from major manufacturers come with a D-sub connection with 25 pins. These 25 wires are now required to be routed back to the controls cabinet, cut, stripped, labeled, crimped and then terminated. The other expensive option is to use a network node on the valve bank itself, which requires routing expensive network cable and power cable to the valve bank. Not to mention the added cost for the network node on the valve bank. Several manufacturers now offer IO-Link on the valve manifold itself simplifying connection to 4-wires and utilizing inexpensive M12 prox cables. If you still have the old D-sub connector, an IO-Link to 25-pin D-sub connectors may be a better solution to simplify the valve bank installation. This way, you can easily retrofit your valve bank to get the enhanced diagnostics with IO-Link without much cost. Using IO-Link valve connectors not only saves time on integration by avoiding the labor associated with wire routing, but it also offers a cost effective solution compared to a network node on the valve manifold. Now you can get multiple valve manifolds on the single network node (used by the IO-Link master) rather than providing a single node for each valve manifold in use.

USE-CASE #5 Simplify Process Visualization
Who would have thought IO-Link can add intelligence to a stack light or status indicator? Well, we did. Balluff introduced an IO-Link based fully programmable LED tower light system to disrupt the status indicator market. The LED tower light, or SmartLight, uses a 3-wire M12 prox cable and offers different modes of operations such as standard stack light mode with up to 5 segments of various color lights to show the status of the system, or as a run-light mode to display particular information about your process such as system is running but soon needs a mechanical or electrical maintenance and this is done by simply changing colors of a running segment or the background segment. Another mode of operation could be a level mode where you can show the progress of process or show the fork-lift operators that the station is running low on parts. Since the Smartlight uses LEDs to show the information, the colors, and the intensity of the light can be programmed. If that is not enough you can also add a buzzer that offers programmable chopped, beep or continuous sound. The Smartlight takes all of the complexity of the stack light and adds more features and functions to upgrade your plant floor.

USE-CASE #6: Non-contact connection of power and data exchange
Several times on assembly lines, a question is how to provide power to the moving pallets to energize the sensors and I/O required for the operation? When multi-pin connectors are used the biggest problem is that the pins break by constantly connecting or disconnecting. Utilizing an inductive coupling device that can enable transfer of power and IO-Link data across an air-gap simplifies the installation and eliminates the unplanned down-time. With IO-Link inductive couplers, up to 32 bytes of data and power can be transferred. Yes you can activate valves over the inductive couplers!  More on inductive coupling can be found on my other series of blogs “Simple Concepts for Complex Automation”

USE-CASE #7: Build flexible high density I/O architectures.
IO PointsHow many I/O points are you hosting today on a single network drop? The typical answer is 16 I/O points. What happens when you need one additional I/O point or the end-user demands 20% additional I/O points on the machine? Until now, you were adding more network or fieldbus nodes and maintaining them. With I/O hubs powered by IO-link on that same M12 4-wire cable, now each network node can host up to 480 I/O points if you use 16 port IO-Link masters. Typically most of our customers use 8-port IO-Link masters and they have the capacity to build up to 240 configurable I/O on a single network drop. Each port on the I/O hub hosts two channels of I/O points with each channel configurable as input or output, as normally open or normally closed. Additionally, you can get diagnostics down to each port about over-current or short-circuit. And the good thing is, each I/O hub can be about 20m away.

In a nutshell, IO-Link can be used for more than just simplifying sensor integration and can help significantly reduce your costs for building flexible resilient controls architectures. Still don’t believe it? Contact us and we can work through your particular architecture to see if IO-Link offers a viable option for you on your next project.

cropped-cmafh-logo-with-tagline-caps1.pngCMA/Flodyne/Hydradyne is an authorized  Balluff distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Tool Identification in Metalworking

Guest contributor: Martin Kurzblog, Fan of Industrial Automation

With the start of industry 3.0 (the computer based automation of production) the users of machine tools began to avoid routine work like manually entering tool data into the HMI.  Computerized Numerical Controlled CNC machine tools gained more and more market share in metalworking applications.  These machines are quite often equipped with automatic tool change systems. For a correct production the real tool dimensions need to be entered into the CNC to define the tool path.

Tool ID for Automatic and Reliable Data Handling

Rather than entering the real tool diameter and tool length manually into the CNC, this data may be measured by a tool pre-setter and then stored in the RFID tool chip via an integrated RFID read-/write system. Typically when the tool is entered in the tool magazine the tool data are read by another read-/ write system which is integrated in the machine tool.

Globally in most cases the RFID tool chips are mounted in the tool holder (radially mounted eg. in SK or HSK holders).

In some applications the RFID tool chips are mounted in the pull stud (which holds the tool in the tool holder). Especially in Japan this tag position is used.

Tool Data for Different Levels of the Automation Pyramid

The tool data like tool diameters and tool lengths are relevant for the control level to guarantee a precise production of the workpieces.  Other data like planned and real tool usage times are relevant for industrial engineering and quality control to e.g. secure a defined surface finish of the workpieces.  Industrial engineers perform milling and optimization tests (with different rotational spindle speeds and tool feed rates) in order to find the perfect tool usage time as a balance between efficiency and quality.  These engineering activities typically are on the supervision level.  The procurement of new tools (when the existing tools are worn out after e.g.  5 to 10 grinding cycles) is conducted via the ERP System as a part of the asset management.

Coming back to the beginning of the 3rd industrial revolution the concept of CIM (Computer Integrated Manufacturing) was created, driven by the integration of computers and information technology (IT).

With the 4th industrial revolution, Industry 4.0, the success story of the Internet now adds cyber physical systems to industrial production.  Cloud systems support and speed up the communication between customers and suppliers.  Tool Management covers two areas of the Automation pyramid.

  1. Machine Control: From sensor / actuator level up to the control level (real time )
  2. Asset Management: Up to enterprise level and beyond (even to the “Cloud”)

To learn more about Tool ID visit www.balluff.com

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