New Design for Hydraulic Power Units

Guest contributor:  Andreas Günder, Bosch Rexoth

Optimum power, less installation space: Thanks to new intellectual and design approaches, compact hydraulic power units increase the economic efficiency of machine tools.

Powerful force in a very confined space

In the production world, hydraulics are firmly established. Machine tool manufacturers appreciate hydraulics for their high power density, toughness and modular design. In the lower performance range up to 4 kW, however, there are also some challenges. Since the installation space is often limited, designers and technical purchasers are constantly looking for increasingly compact solutions.

Installation space is valuable

The demand for compact hydraulic drives is not only due to the structurally limited flexibility regarding extensions, modernization measures and refittings but also due to the requirements regarding acquisition costs and assembly times or structural extensions of the working space with given machine dimensions. In addition to the level of integration of the functions, energy efficiency often plays an important role as well. Last but not least, many manufacturers are following the miniaturization trend. If workpieces become increasingly smaller, the moved mass of the machine tool has to be decreased accordingly.

“Installation space eaters” hydraulic power units

To reduce the installation space, solution manufacturers can start mainly with the following components: hydraulic power unit and control cabinet. When considering this split, it becomes evident that compact power units which are also easy to integrate require completely new design approaches to eliminate all features which waste unnecessary space in the performance spectrum up to 4 kW and to ensure that the units are still compatible with many different machine designs.

Highly integrated design approaches

The features of such innovative design concepts according to the EU Eco-Design Directive 2009/125/EC for example include a tank which is optimized for efficient degassing and reduces the oil volume by up to 80 percent. A much more decisive factor for gaining space is, however, that all functions can actually be integrated in one small power unit – from an economic variable-speed drive for demand-based power output to sensor technology with filling level, temperature, pressure and filter contamination sensors to a completely wired frequency converter.

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Compact and ready for Industry 4.0

For the future viability of this approach with regard to Industry 4.0, a data interface is essential as well. Only with permanent condition monitoring can the operating conditions be optimized comfortably and relevant faults be detected early on. With this equipment, the user only has to connect the electric power, the data interface and the hydraulic supply during installation and the hydraulic power unit is ready for operation

New cooling with heatpipe

So-called “heatpipes” are considered to be a space-saving innovation regarding the cooling of hydraulic power units. Their high-performance passive thermal conduction allows for a further reduction of the frame size. The heatpipes absorb the thermal energy of frequency converter, motor and hydraulic oil and efficiently transfer it to a central heat sink such as e. g. cooling water…
This ensures an intelligently optimized thermal management within the hydraulic power unit and optimally utilizes the cooling power of the cooling water. There is no need for a separate hydraulic circuit for oil cooling. This reduces installation space, noise emissions, energy consumption and possibilities for leakage.

Heatpipe – Functional principle

Basically, a heatpipe consists of air-tightly sealed copper pipes with underpressure. Inside, there is a medium which transfers thermal energy. In the temperature range of hydraulic power units, the medium may be e.g. distilled water. The boiling temperature of the water is significantly reduced by the low pressure within the heatpipe, which means that a boiling or condensation process can already take place at low temperatures.

Functionality: If you dip the heatpipe for example in hot hydraulic oil, the thermal energy at the lower immersed part of the heatpipe is transferred to the water. The water exceeds the boiling point, evaporates and absorbs a large amount of thermal energy with low temperature difference (latent heat). The water steam rises to the upper part of the heat pipe which is cooled by e. g. a cooling element. Here, the water steam condensates and gives off the thermal energy to the cooling water. Thanks to the latent heatabsorption and dissipation, the thermal conductivity of heatpipes can be up to 1000 times higher than the thermal conductivity of copper pipes. Due to the high elasticity of the copper pipes, the heat pipe can be easily shaped. In this way, ideal heat paths can be formed inside the hydraulic power unit and the installation space can be considerably optimized. Similar application ranges with equal optimization potential can be found in computer technology. Here, the thermal energy in laptops caused by heat sources such as the CPU are transferred to the central cooling elements using heatpipes.

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Plug & Play: no control cabinet

The frequency converter has a high potential for gaining installation space as well. If it has already been equipped with Multi-Ethernet interface for Sercos, Profinet and other standards by the manufacturer, machine and plant manufacturers are able to reduce the control cabinet requirement for the hydraulic unit by up to 100 percent. As a precondition, however, the sensor technology and the motor in the power unit have to be wired to the frequency converter in such a way that the frequency converter can control the hydraulic pressure autonomously. This means that the control cabinet can not only be designed with smaller dimensions. Sometimes it can even be completely omitted together with the corresponding installation effort and related sources of error.

Conclusion

Fully integrated small power units based on a completely innovative design approach for the performance range up to 4 kW provide machine and plant manufacturers with the advantages of hydraulic drives with very little space requirements. As an alternative to purely electrical solutions, the required energy can be converted into a linear movement in a precise and costeffective manner directly at the working area using a simple hydraulic cylinder. If sensor technology, frequency converter and data interface are integrated as well, users not only benefit from comprehensive condition monitoring but also from a significantly reduced control cabinet footprint or even from a design without control cabinet.
More information fully integrated power units: www.boschrexroth.com/cytropac

Operating principle: https://www.youtube.com/watch?v=sSPemS94G2I

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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.

Avoiding a mental breakdown when choosing circuit breakers

Guest contributor: Jessica Yeh, Phoenix Contact USA

Sizing circuit breakers is confusing because there are so many factors to take into consideration. Of course, there are the typical concerns: price, size, and delivery time. But what about everything else?

What trip mechanism should be used? What ampere rating? Dual rated or regular voltage ratings? Why do I need a lockout/tagout? Does a shunt do the same thing as an auxiliary? What does bidirectional mean? What approvals do I need to take into consideration? Do I need NEC Class 2? NEMA? CSA? UL? IEC or IEEE certifications?

These are just a few of the things to consider when choosing a circuit breaker for a specific application.

Stop the ride, I want to get off!

Here’s the thing. Selecting breakers is a complex task, but the following list will give you a few basic ideas to get started in the right direction. This is by no means everything you should consider, but it’s a nice breakdown.

(The good kind, not the mental kind.)

What type of protection are you looking for?

Breakers are activated by various factors including PCB components in the case of electronic breakers, heat in terms of thermal breakers, magnetism for both thermal-magnetic and hydraulic-magnetic breakers, and more. Each trigger has a different reaction time. Depending on how critical the equipment you’re protecting is, you may want to use this basic guide.

Size matters (Use the 80 percent rule)

It’s common practice to choose a breaker with an ampere rating at around 80 percent of the nominal rating of your application. This ensures that you have a nice little buffer in case the current spike is particularly strong. The breaker will be able to trip well before the current level can get too high and cause damage.

Embrace the trip curves  

When someone says “trip curve,” you either have one of two reactions.

A) Cringe and gulp down the nauseating feeling at the thought of having to squint over all those lines and numbers, or

B) Pass the information along to someone else so that they can exhibit reaction A.

While many companies add their own custom trip curves, the most common include B, C, and D curves, which are considered industry standard.

What you want to keep in mind when it comes to trip curves is that it’s not about all the little calculations, but the overall picture. Besides thinking “how fast does this thing need to trip?” also consider it in terms of your equipment.  Sensitive devices should be protected by a breaker that reacts quickly. On the opposite end, equipment with higher startup currents like motors would probably be best protected by a breaker with a delayed trip curve.

Need for approvals

You may have heard the term “Listed” or “Recognized.” You may have also heard the terms “supplemental” and “branch” protection. Depending on your requirements and the type of breaker you’re using, you might need to select a specifically approved breaker. In most cases, these are the four basic types you’ll often see.

Supplementary protectors (UL Recognized) interrupt an electrical distribution circuit and are intended to protect equipment.

Branch circuit protectors (UL Listed) open a circuit during overload and short circuit and are intended to protect the circuit conductors.

Completing the outfit

When choosing an outfit, you always want to get the basics down first, before you start accessorizing. Outfitting a cabinet is no different. Once you’ve chosen your breaker, you can add additional bells and whistles to give you a little something extra. Here are just a few options.

To reset or activate/deactivate the breaker remotely, you would use its remote reset/control. Combined with remote status indication, you can easily service and maintain breakers without going to a job site.

But if you’re already on site, the local status indication feature uses color codes that allow you to easily service and maintain breakers.

Busbars reduce wiring by connecting a series of breakers to a common a power source.

And finally, lockout/tagout keeps things safe by attaching to the trip mechanism and preventing unwanted tampering during testing or maintenance.

As you get further into the process, you’ll still have to consider some of the more advanced questions raised above, but this list gives you some of the basic break(er)down that you need to know to get started! To learn more about circuit breakers and overcurrent protection options, visit www.phoenixcontact.com/cbpluggable. 

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CMA/Flodyne/Hydradyne is an authorized Phoenix Contact 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.

Differential Measurement with Ultrasonic Sensors

Guest Contributor: Shawn Day, Balluff

When reviewing or approaching an application we all know that the correct sensor technology plays a key role in reliable detection of production parts or even machine positioning. In many cases, application engineers gravitate to photoelectric sensor Image1offerings as a go-to as they seem more common. Photoelectric sensors are solid performers, however they can run into limitations in certain applications. In these circumstances, considering an ultrasonic sensor could provide a solid solution.

For example, ultrasonic sensor are not affected by color like photoelectric sensors are. Therefore, if the target is black in color or transparent, the ultrasonic sensor will still provide a reliable detection output where the photoelectric technology sensor will not. I was recently approached with an application where a Image2customer needed to detect a few features on a metal angle iron. The customer was currently using a laser photoelectric sensor with analog feedback measurement, however the results were not consistent or repeatable as the laser would simply pick up every imperfection that was present on the angle iron.  This is where the ultrasonic sensors came in as they provide a larger detection range matched with emitting and receiving sound energy. This provided much more stable outputs, allowing the customer to reliably detect and error proof the angle iron. With the customer switching to ultrasonic sensors in this particular application they now have better quality control and less downtime.

So when approaching an application, keep in mindImage3 to think of all sensor technologies as some will provide better results than others. Ultrasonic sensors are indeed an excellent choice when applied correctly. They can measure fill levels, heights, sag, or simply monitor the presence of a target or object. They perform very well in foggy or dusty areas where some other sensor technologies fall short.

For more information on ultrasonic and photoelectric sensors visit www.balluff.com.

Modular Enclosure Accessories Improve Customization and Scalability

Guest Contributor: Rittal Enclosures

5 accessories to enhance TS 8 enclosure functionality  

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With 12 million units sold around the globe, the TS 8 modular enclosure is established as the worldwide-standard. As businesses grow and enclosure needs evolve, many customers are turning to a variety of accessories to scale their solutions. 

These five accessories for lighting, power distribution, viewing and operating, climate control, and assembly are the most popular customizations design engineers and facilities managers are utilizing to maximize their investments. 

1 – For Lighting: LED Compact Lighting System

The Rittal LED Compact Lighting System is a safe, energy-efficient, extra-low-voltage interior lighting solution that delivers full coverage to all corners of the enclosure.  

Enterprise-ready and suitable for voltages ranging from 100–240 V (AC) and 24 V (DC), the LED system can be installed tool-free with clips that connect to a latch-in hook pattern—though optional screw fastening is also available. Magnetic installation is another option, for free positioning within the enclosure. Whichever assembly option you choose, motion detectors or door-operated switches for hands-free illumination are also available.  

2 – For Power Distribution: RiLine Busbar System 

In many regions around the world, busbar systems are the predominant solution for managing power needs now, and in the future. For engineers not familiar with the technology, the RiLine copper busbar system provides reliable power distribution and requires less panel modification, contact points, and wiring work. Busbar systems save space and time for panel builders and offer more contact hazard protection than other cable management options. 

3 – For Viewing Windows and Operating Panels: WKDH Deep Hinged Window Kit 

The Deep-Hinged Window Kit is ideal for installing a viewing window where access to components mounted behind it is required. It is designed to protect HMI displays and components mounted on enclosure panels from wash-downs, rain, snow, sleet, dirt, and dust. The window depth allows for extra-deep pushbuttons (~2”/50mm) and comes with a full-size drill template for easy mounting.  

4 – For Climate Control: TopTherm Filter Fans 

Simply and efficiently manage air flow in your enclosure with filter fans designed for tool-free, snap-in mounting and installation. The TopTherm filter fan’s new diagonal fan technology creates greater pressure stability and constant airflow when installed, even with a contaminated filter mat. This new technology also allows air currents to spread diagonally from the fan, promoting even circulation throughout an enclosure. 

5 – For Base Assembly: Flex-Block Base/Plinth System 

Save assembly time with high-strength plastic corner pieces that clip together base/plinth components. With this system, enclosure transport is uncomplicated, both empty and fully-configured, by removing the base/plinth trim panel. Plus, cable management is straightforward and efficient, saving space for enclosure configuration.

Modular Enclosure Buyers GuideRittal Is Engineered Better 

Whatever your enclosure needs, Rittal has an extensive line of accessories to optimize enclosure functions. Download the Modular Enclosure Buyer’s Guide to see how Rittal products are better than the competition!

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CMA/Flodyne/Hydradyne is an authorized  Rittal 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.

Balancing the Value of Air-to-Air and Air-to-Water Heat Exchangers

Guest contributor: Eric Corzine, Product Manager Climate Control, Rittal

Heat exchangers provide highly efficient cooling for electrical components. As energy costs increase, they are getting more consideration by system designers. Before making a design decision between air-to-air and air-to-water heat exchangers,  it is important to weigh installation considerations and use-cases. Here, we have provided an overview of each technology to help you determine which can best impact your equipment and your bottom line.

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Air-to-air heat exchangers are the most common type of exchangers. They work by utilizing the difference between the hotter internal temperature of an enclosure and the cooler, ambient air temperature. Engineers can implement air-to-air exchangers in a variety of industrial environments, including food and beverage, waste and wastewater, and automotive.

Air-to-air exchangers can utilize existing airflow patterns, through convection or forced air, and do not require additional accessories or equipment. The technology can utilize the airflow within an enclosure or can connect to existing ductwork and HVAC systems.

There are some limitations to air-to-air heat exchangers, particularly in the climates they could be installed. For instance, if the difference between indoor and outdoor temperatures is to great then the effectiveness of the exchangers can be significantly reduced. Recent technology upgrades, however, have made air-to-air exchangers functional even in climates that reach temperatures of -13°F.

These factors make air-to-air heat exchangers useful in applications where plumbing for liquid cooling would be difficult to install, and where existing air flow patterns and equipment layout allow for effective cooling. Often, this means situations with moderate thermal loads. HVAC engineers can install them quickly as well, which reduces setup time and costs. However, they are still less efficient compared to air-to-water exchangers because air is not as effective at transferring heat as water.

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Air-to-water heat exchangers use the same principle of temperature differential to provide heating or cooling, however, they alter the temperature of air by forcing it across water coils.

Because of the efficient heat transfer capabilities of water, they can help reduce energy use and utility costs significantly. This is especially useful in situations with large thermal loads, such as IT mainframe applications or an automotive manufacturing environment where water is already available.

One of the drawbacks of air-to-water heat exchangers is the need to pipe water to the unit. The technology requires plumbing and a reliable water supply or recirculation system, which often means pumps, valves, and other accessories.

These plumbing concerns often mean higher installation costs, so engineers need to balance the initial cost with the expected savings over the lifetime of the exchanger. Overall, air-to-water exchangers are useful for high-demand, energy intensive applications.

Making the Right Choice

It is important to consider the right exchanger for your specific climate control situation. The ultimate decision will balance installation and operational costs, target cooling capacity and thermal loads.

Air-to-air exchangers can get up and running quickly and engineers can integrate them into many different kinds of applications easily. Air-to-water exchangers deliver better efficiency and can suit more energy-demanding applications, but they require plumbing and water supplies, which may not always be available. The ultimate choice, then, should consider these factors and engineers should thoroughly research both types of exchangers to understand which one will best suit their application.

Learn more about climate control at Rittal.com 

About Us

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CMA/Flodyne/Hydradyne is an authorized  Rittal 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.

Predictive Maintenance for Zen State of Manufacturing

Guest contributor: Shishir Rege, Balluff

In a previous entry, Mission Industry 4.0 @ Balluff, I explained that the industry4-0two primary objectives for Balluff’s work in the area of Industry 4.0 are to help customers achieve high production efficiencies in their  automation and achieve  ‘batch size one’ production.

There are several levers that can be adjusted to achieve high levels of manufacturing efficiencies in the realm of IIoT (Industrial Internet of Things). These levers may include selecting quality of production equipment, lean production processes, connectivity and interoperability of devices, and so on. Production efficiency in the short term can be measured by how fast row materials can be processed into the final product – or how fast we deliver goods from the time the order comes in. The later portion depends more on the entire value-chain of the organization. Let’s focus today’s discussion on manufacturing – inside the plant itself.  The long-term definition of production efficiency in the context of manufacturing incorporates the effectiveness of the production system or the automation at hand. What that means is the long-term production efficiency involves the health of the system and its components in harmony with the other levers mentioned above.

The Zen state of manufacturing – nothing important will come up on Google for this as I made this phrase up.  It is the perfect state of the entire manufacturing plant that continues production without hiccups all days, all shifts, every day. Does it mean zero-maintenance? Absolutely not, regular maintenance is necessary. It is one of those ‘non-value added but necessary’ steps in the lean philosophy.  Everyone knows the benefits of maintenance, so what’s new?

Well, all manufacturing facilities have a good, in some cases very strictly followed maintenance schedule, but these plants still face unplanned downtimes ranging from minutes to hours. Of course I don’t need to dwell on the cost associated with unplanned downtime. In most cases, there are minor reasons for the downtime such as a bad sensor connection, or cloudy lens on the vision sensor, etc. What if these components could alert you well in advance so that you could fix it before they go down? This is where Predictive Maintenance (PdM) comes in. In a nutshell, PdM uses actual equipment-performance data to determine the condition of the equipment so that the maintenance can be scheduled, based on the state of the equipment. This approach promises cost savings over “time-based” preventive maintenance.

PowerSuppliesIt is not about choosing predictive maintenance over preventive maintenance. I doubt you could achieve the Zen state with just one or the other. Preventive and predictive maintenance are both important – like diet and exercise. While preventive maintenance focuses on eliminating common scenarios that could have dramatic impact on the production for long time, predictive maintenance focuses on prolonging the life of the system by reducing costs associated with unnecessary maintenance.  For example, it is common practice in manufacturing plants to routinely change power supplies every 10 years, even though the rated life of a power supply under prescribed conditions is 15 years. That means as a preventive measure the plants are throwing away 30% life left on the power supply. In other words, they are throwing away 30% of the money they spent on purchasing these power supplies. If the power supplies can talk, they could probably save you that money indicating that “Hey, I still have 30% life left, I can go until next time you stop the machine for changing oil/grease in that robot!”

In summary, to achieve the zen state of manufacturing, it is important to understand the virtues of predictive maintenance and condition monitoring of your equipment. To learn more visit www.balluff.us.

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CMA/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.

Ensure Optimum Performance In Hostile Welding Cell Environments

Guest contributor: Dave Bird, Balluff

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The image above demonstrates the severity of weld cell hostilities.

Roughly four sensing-related processes occur in a welding cell with regards to parts that are to be joined by MIG, TIG and resistance welding by specialized robotic /automated equipment: 

  1. Nesting…usually, inductive proximity sensors with special Weld Field Resistance properties and hopefully, heavy duty mechanical properties (coatings to resist weld debris accumulation, hardened faces to resist parts loading impact and well-guarded cabling) are used to validate the presence of properly seated or “nested” metal components to ensure perfectly assembled products for end customers.
  2. Poke-Yoke Sensing (Feature Validation)…tabs, holes, flanges and other essential details are generally confirmed by photoelectric, inductive proximity or electromechanical sensing devices.
  3. Pneumatic and Hydraulic cylinder clamping indication is vital for proper positioning before the welding occurs. Improper clamping before welding can lead to finished goods that are out of tolerance and ultimately leads to scrap, a costly item in an already profit-tight, volume dependent business.

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    Several MIB’s covered in weld debris

  4. Connectivity…all peripheral sensing devices mentioned above are ultimately wired back to the controls architecture of the welding apparatus, by means of junction boxes, passive MIB’s (multiport interface boxes) or bus networked systems. It is important to mention that all of these components and more (valve banks, manifolds, etc.) and must be protected to ensure optimum performance against the extremely hostile rigors of the weld process.

Magnetoresistive (MR), and Giant Magnetoresistive (GMR) sensing technologies provide some very positive attributes in welding cell environments in that they provide exceptionally accurate switching points, have form factors that adapt to all popular “C” slot, “T” slot, band mount, tie rod, trapezoid and cylindrical pneumatic cylinder body shapes regardless of manufacturer. One model family combines two separate sensing elements tied to a common connector, eliminating one wire back to the host control. One or two separate cylinders can be controlled from one set if only one sensor is required for position sensing.

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Cylinder and sensor under attack.

Unlike reed switches that are very inexpensive (up front purchase price; these generally come from cylinder manufacturers attached to their products) but are prone to premature failure.  Hall Effect switches are solid state, yet generally have their own set of weaknesses such as a tendency to drift over time and are generally not short circuit protected or reverse polarity protected, something to consider when a performance-oriented cylinder sensing device is desired.  VERY GOOD MR and GMR cylinder position sensors are guaranteed for lifetime performance, something of significance as well when unparalleled performance is expected in high production welding operations.

But!!!!! Yes, there is indeed a caveat in that aluminum bodied cylinders (they must be aluminum in order for its piston-attached magnet must permit magnetic gauss to pass through the non-ferrous cylinder body in order to be detected by the sensor to recognize position) are prone to weld hostility as well. And connection wires on ALL of these devices are prone to welding hostilities such as weld spatter (especially MIG or Resistance welding), heat, over flex, cable cuts made by sharp metal components and impact from direct parts impact. Some inexpensive, effective, off-the-shelf protective silicone cable cover tubing, self-fusing Weld Repel Wrap and silicone sheet material cut to fit particular protective needs go far in protecting all of these components and guarantees positive sensor performance, machine up-time and significantly reduces nuisance maintenance issues.

To learn more about high durability solutions 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.

The 5 automation trends in the packaging industry

Guest contributor: Hans Michael Krause, Bosch Rexroth

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i4.0 in practice: the 5 automation trends in the packaging industry

Next-generation packaging machines are being designed without control cabinets and are increasingly vertically and horizontally connected. Big data analyses, smart maintenance and model-based engineering have unleashed tremendous potential. But even conventional automation tasks can be handled more easily with open interfaces and integrated functions. What are the five major automation trends in detail?

What the packaging lines of tomorrow will be able to do

When I look at the highly dynamic packaging industry, I see four major challenges faced by machine builders: more individuality when it comes to packaging, more flexibility in terms of formats, higher availability and less space required for machines and lines. These challenges lead to five major trends in automation:

(1) Connected – the connectivity trend

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As a user, I need transparency, whether I want to improve system availability through smart maintenance, make my line more flexible, or optimize complex packaging processes. Without knowledge of subprocesses and plant conditions, I can’t analyze anything – neither on premise nor via the cloud. Modern automation technology and sensor systems now provide all the necessary data. I have to retrofit existing systems, but preferably without the need for programming or intervention in the automation. The IoT gateway fulfills this requirement extremely elegantly and can be set up in just five minutes. Machine builders can also opt for Starter Kit, which includes the Software Production Performance Manager (PPM), for a complete analysis platform from a single source.

The sweet side of Industry 4.0

There is also enormous potential in cross-vendor and system-wide networking via IIoT protocols such as MQTT or the open i4.0 standard OPC UA. At interpack, four machine builders and Bosch Rexroth will showcase the “ChoConnect” project as an exciting example of authentic M2M communication: Four locally distributed exhibition machines from LÖSCH Verpackungstechnik, SOLLICH, THEEGARTEN-PACTEC and WINKLER and DÜNNEBIER Süsswaren exchange information as a virtual production line for chocolate products using OPC UA in accordance with the Weihenstephan standard and create an end-to-end transparent value chain at the shopfloor level – without the need for an MES or control system. The individual steps of mass processing, molding, primary and secondary packaging automatically adjust performance according to individual capacities. The production process becomes more flexible; system efficiency increases.

Merging of automation, IT and IIoT

The fact that inflexible line PLCs will soon be obsolete is also a consequence of a merging of automation, IT and IIoT. With open interfaces such as Open Core Interface, ERP systems can be directly linked to machine automation, simplifying inventory management for machine components. Obviously, there must be also be a security strategy for regulating access to the control system.

(2) Simple – Make it simple!

The current trend towards fewer personnel per line has increased the need for intuitive control units such as HMI with multi-touch. Transparent and seamless visualization solutions are required – on the production line itself and at other locations in the company – in order to continuously improve processes and respond quickly when necessary. The ActiveCockpit interactive communication platform shows that such solutions are already available today.

Companies often need the ability to easily integrate new machines or lines into existing systems – this can already be done mechanically using standardized chain conveyor systems such as VarioFlow plus in combination with the MTpro planning tool. In the future, open M2M interfaces will allow for easy electrical integration.

With the growing need to simplify diagnostics and maintenance, we will see even more web-based service tools and innovative LED concepts at machines in the future. Augmented and virtual reality are sure to play a part here, too. It has been repeatedly demonstrated at trade shows how the digital twin integrates itself into the real picture using open interfaces so that complex technical relationships can be visualized and understood more quickly. A product orientation module for beverage packages by WestRock will be showcased at interpack.

(3) Efficient – end-to-end digital engineering

Ever more complex design needs and shorter time-to-market requirements are fueling the demand for model-based engineering with simulations and virtual commissioning. As a technology partner with industry expertise, Open Core Engineering not only ensures seamless integration of the machine control with simulation platforms such as MATLAB/Simulink or 3DEXPERIENCE by Dassault Systèmes. For immediate creation of a digital twin that can be simultaneously used by mechanics, electricians and software programmers, Bosch Rexroth delivers digital behavior models of its automation products as standard.

Bosch Rexroth also provides a comprehensive library of prepared technology functions along with the machine control. By emphasizing parameterizing instead of programming, flow wrappers, secondary packaging systems, fillers or sealing machines can be commissioned more quickly. Integrated standard kinematics and functions for delta, parallel and palletizing robots are also available. Object-oriented PLC programming and high-level languages, such as Java and C++, facilitate creation of the machine control software. The controllers feature a web server for easy integration of Internet technologies such as visualization using HTML5. Of course, standardized programming templates support the creation of machine programs following OMAC/PackML standards as well as the Weihenstephan standard and PLCopen.

(4) Adaptive – the adaptivity trend

What if the packaging line automatically adjusted the product stream in the event of a fault, instead of jamming and displaying a lot of error messages? Prefabricated software functions such as intelligent infeeds or product grouping are already available, even for these trend-setting M2M scenarios. For the use of robots and flexible transport system a separate controller is not needed anymore. These are managed by the standard machine controller, and the number of interfaces and the effort required to use transport systems or robotics are reduced.

In view of increasingly complex packaging processes, there is also a need for machines to automatically adjust to their environment. Machines require Smart Sensor Nodes with MEM technology like XDK in order to “learn” from their current state. Virtual sensors like servo motors and drives, including the intelligent MS2N servo motor, provide useful information.

Last but not least, next-generation packaging machines automatically adjust to the current format and regulate process speed as well as product handling. Adaptive software functions have also been developed for this scenario of the future. The spectrum ranges from flexible electronic cams in the machine control (FlexProfile), drive functions such as auto-tuning and anti-vibration to frequency response measurements and innovative filter functions for minimizing resonance frequencies in mechanical parts.

(5) Cabinet-free – much more than just space saving

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This trend in packaging is not just about saving space in the automation technology, machine footprint and control cabinet space. Instead, it’s about a modular machine configuration that allows machine operators and customers to respond flexibly to different requirements. The individual modules are connected to one another only by a single hybrid cable and can be easily integrated into the machine or retrofitted later. This reduces the installation area and increases servo density in favor of greater flexibility. Installation space, cabling and maintenance costs are also reduced. Such modular approaches are especially useful for secondary packaging and rotary machines such as filling and capping machines as well as retrofit projects.

Solutions for these packaging trends are already available. Use them now!

Manufacturers and users of packaging machines already have numerous options for boosting their competitiveness through intelligent and connected automation solutions. But to achieve this, they need an industry-oriented, expert partner with a broad ecosystem of solutions. At interpack 2017, Bosch Rexroth will give visitors the opportunity to experience the trade show theme of “Connected Automation i4.0 now“ live in all of its facets – including modern networking, simple design, model-based engineering and groundbreaking service. The future of automation has already begun and is ready for “installation” in the latest generation of packaging machines. Now!

 

cropped-cmafh-logo-with-tagline-caps.pngCMA/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.

The Digital Improvement Process in Three Steps

Guest contributor: Marcel Koehler, Bosch Rexroth

Industry 4.0 solutions enable production employees to digitally replicate and implement a continuous improvement process, in order to increase output, improve product quality and reduce costs. But how do I implement a first use-case? How do I ensure the necessary plant transparency? And how do I configure the monitoring and evaluation system? Quite easily – in three steps, with easy to set up tools and tailored support by experienced experts.

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The focus is on people.

There are fundamental principles that were in place long before digitalization. Robert Bosch once said: “People should always strive to improve the existing conditions. No one should merely be content with what they have achieved; instead they should always aspire to do what they do even better.” Today, as in the past, the path to continuous improvement of production processes starts with people. Improving quality, reducing costs or boosting output requires at least one person to design, monitor and readjust the continuous improvement process. This person defines the essential information, keeps track of it, evaluates it, intervenes when necessary and draws conclusions, in order to adapt the process. With the arrival of Industry 4.0 and the Internet of Things (IoT), however, we now have new tools at our disposal. Tools such as IoT Gateway, which collects a variety of data without interfering with the machine logic, as well as the analysis and evaluation solutions associated with it, including the Production Performance Manager, which visualizes and evaluates the data, initiates the required actions to be taken, and simplifies the review and adaptation of the improvement process.

 

Step 1: Workshop in the company

But how do I use these tools? And how do I implement a first exemplary use-case, in order to gradually introduce it? New knowledge is transferred particularly effectively from person to person, just as in Robert Bosch’s time. In line with this principle, an experienced expert comes to the company and demonstrates the typical procedure step by step as part of the Production Performance Starter Kit from Bosch Software Innovations. In the one-day workshop, he explains the digital tools as well as typical use-cases and views the production plant together with the customer. The result of the joint workshop is at least one concrete use-case, including the solution design. The desired benefits will be examined once again and potential hurdles identified. According to the same formula, the customer can later find, develop and implement additional use-cases.

infografik_ENG_16_9_img_w1184_h666The IoT Gateway collects data from various data sources and natively transfers it to the analysis and evaluation software (Production Performance Manager).

Example of a first production performance use-case

A practical example from a concrete workshop: the condition-based monitoring and maintenance of a heat exchanger. If the heat exchanger becomes clogged due to deposits, approximately 1,500 parts become defective and the plant is forced to shut down for two hours for maintenance. An early warning system should be installed, in order to prevent production rejects and unplanned downtimes. A direct measurement of the flow rate in this plant is not possible, however, which is why temperature sensors are installed before and after the heat exchanger. The IoT Gateway, which is also installed in the line, collects the sensor data and transmits it to the Production Performance Manager, where the temperature difference is determined and compared with threshold values in order to indicate contamination. All measured values are visualized centrally for the employees responsible. When the pipes begin to clog, the system transmits a warning signal or assigns a maintenance ticket to the appropriate qualified personnel.

Step 2: Implement yourself with remote support

In the second step of the Production Performance Starter Kit, a senior consultant from Bosch Software Innovations installs the Production Performance Manager via remote access to the customer’s hardware. In doing so, at least one machine is integrated as a prototype, in order to prepare the user for scaling the solution later on. The demo license is valid for three months and up to ten machines are supported. In addition, four days of remote support are included for the Production Performance Manager. Depending on the technical infrastructure, the shopfloor integration can be done in one of three ways: via individual integrators to be programmed, via PPMP-compatible controllers or system-independent integration via the IoT Gateway from Bosch Rexroth, a universal connector that communicates natively in the open source protocol PPMP in addition to other protocols. Via the web-based user interface, the user manages the sensors, defines preprocessing of the collected data if necessary, and configures forwarding to the target system, in this case to the Production Performance Manager.

Industry 4.0 Showcase with IoT Gateway and Production Performance Manager.

Step 3: On-site user training

After configuring the infrastructure, one last step remains, in which the employees learn to successfully apply the software. This takes place as part of a detailed user training course with an experienced trainer who comes to the location for one day. After this training, participants are able to gain quick access to machine data via visualization, set up simple automated analyses and evaluations, and define intelligent, data-driven actions based on the results. Following the idea of continuous improvement, they are, as the key stakeholders of their digital improvement process, also qualified to review the actions for effectiveness and efficiency. Thanks to the transparency this provides, the user now has a valuable Industry 4.0 tool for their daily work.

elemente_eng_16_9_img_w1184_h666.jpgElements of the joint starter kit from Bosch Software Innovations and Bosch Rexroth

Gradual scaling after only three months

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After only three months, employees arrive at the decisive point, from which they scale the prepared solution and repetitively connect additional machines and entire lines. As costs steadily decrease, the benefit increases disproportionately in the long run as the transparency gained gradually extends across all bottlenecks. In this manner, the production management of Bosch’s Pecinci plant (Serbia) succeeded in sustainably improving the stability of a complex coating process for wiper arms. The IoT Gateway collects sensor and controller data, such as humidity or paint consumption, and forwards the data to the Production Performance Manager. The software analyzes this data and compares it with defined threshold values, in order to optimize the plant availability of the coating plant, which consists of ten individual stations. A track & trace function, which allows conclusions to be drawn from the finished product about quality-relevant sub-processes, is planned as a follow-up project to the continuous improvement of product quality.

Do not be afraid of software! Try it out now and get started.

With the Production Performance Starter Kit, the hurdles to implementing digital processes for continuous improvement are greatly reduced. Any fears associated with the digital toolkit are completely unfounded. The IoT Gateway and the Production Performance Manager do not require any programming knowledge for daily application. Together with the methodical knowledge and practical support of our experts, companies acquire the knowledge necessary to implement their first use-case, scale the solution and tackle additional improvement projects in only three months. Robert Bosch surely would have relished the idea!

Learn more about the Production Performance Starter Kit in the webcast.

cropped-cmafh-logo-with-tagline-caps.pngCMA/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.

Absolutely Incremental – Innovations in Magnetic Linear Encoder Technology

Guest contributor: Scott Rosenberger, Balluff

Linear encoders – absolute or incremental?  Incremental encoders are simple, inexpensive, and easy to implement, but they require that the machine be homed or moved to a reference position.  Absolute encoders don’t require homing, but they’re usually more expensive, and implementation is a bit more involved.  What if you could get an incremental encoder that also gave you absolute position?  Would that be great, or what?  Read on.

IncrementalEncodersIncremental encoders are pretty simple and straightforward.  They provide digital pulses, typically in A/B quadrature format, that represent relative position movement.  The number of pulses the encoder sends out correspond to the amount of position movement.  Count the pulses, do some simple math, you know how much movement has occurred from point A to point B.  But, here’s the thing, you don’t actually know where you are exactly.  You only know how far you’ve moved from where you started.  You’ve counted an increment of movement.  If you truly want to know where you are, you have to travel to a defined home or reference position and count continuously from that position.

AbsoluteEncodersAbsolute encoders, on the other hand, provide a unique output value everywhere along the linear travel, usually in the form of a serial data “word”.  Absolute encoders tell you exactly (absolutely) where they are at all times.  There’s no need to go establish a home or reference position.

So absolute is better, yes?  If that’s so, then why doesn’t everyone use them instead of incremental encoders?

It’s because incremental encoders typically cost a lot less, and are much easier to integrate.  In terms of controller hardware, all you need is a counter input to count the pulses.  That counter input could be integral to a PLC, or it could take the form of a dedicated high-speed counter module.  Either way, it’s a fairly inexpensive proposition.  And the programming to interpret the pulse count is pretty simple and straightforward as well.  An absolute encoder will usually require a dedicated motion module with a Synchronous Serial Interface (SSI, BiSS, etc.).  These interfaces are going to be both more expensive and more complex than a simple counter module.  Plus, the programming logic is going to be quite a bit more involved.

So, yes, being able to determine the absolute position of a moving axis is undoubtedly preferable.  But the barriers to entry are sometimes just too high.  An ideal solution would be one that combines the simplicity and lower cost of an incremental encoder with the ability to also provide absolute position.

Fortunately, such solutions do exist.  Magnetic linear encoders with a so-called Absolute Quadrature interface provide familiar A/B quadrature signals PLUS the ability to inform the controller of their exact, absolute position.  Absolute position can be provided either on-demand, or every time the sensor is powered up.

How is this possible?  It’s really quite ingenious. You could say that the Absolute Quadrature encoders are “absolute on the inside, and incremental on the outside”.  These encoders use absolute-coded magnetic tape, and the sensing head reads that position (with resolution as fine as 1 µmeter and at lengths up to 48-meters, by the way).  But, during normal operation, the sensor head outputs standard A/B quadrature signals.  Remember though, it actually knows exactly where it is (absolute inside…remember?), and can tell you if you ask.  When requested (or on power-up, if that’s how you have it configured), the sensor head sends out a string, or burst, of A/B pulses equal to the distance between the home position and the current position.  It’s as if you moved the axis back to home position, zeroed the counter, and then moved instantly back to current position.  But no actual machine movement is necessary.  The absolute burst happens in milliseconds.

So, to sum it up, Absolute Quadrature linear encoders provide a number of advantages:

  • Economical: Compatible with standard A/B incremental interfaces – no absolute controller needed
    • No need to upgrade hardware; can connect to existing control hardware
    • Get the advantages of absolute, but maintain the simplicity of incremental; eliminate the need for homing
  • Easy implementation: Simple setup, no (or very minimal) new programming required
  • Accurate: Resolution down to 1 µm, over lengths up to 48 meters

If you’d like to learn more about linear encoders with Absolute Quadrature, go to: http://www.balluff.com/local/us/news/product-news/bml-absolute-quadrature/

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.