The Spring Line is Here!

Guest contributor: Janet Czubek, Balluff

In today’s industrial market, Ethernet cable is in high demand. With words like Ethernet, Ethernet/IP, solid, and stranded, making a decision from the different types of cable can be difficult.

I want to make it easy for you to pick the right cable to go with the network of your choosing. As a network, Ethernet is easy to install and it is easy to connect to other networks – you can probably even have Ethernet network devices connect to your current network.

So, let’s start with the basics…First, what is the difference between Ethernet and Ethernet/IP? They both have teal jackets (hence the title – The “Spring Line”) due to the industrial Ethernet standards in North America. So, the difference between the two is in the application. Ethernet is a good networking cable that transmits data like an internet cable. Ethernet/IP transmits data and also has an industrial protocol application. The Industrial Protocol (IP) allows you to transmit more data if you have a lot devices connected to each other or a lot of machines moving at once. Ethernet/IP resists against UV rays, vibrations, heat, dust, oil, chemical, and other environmental conditions.

Next, there are two kinds of Ethernet IP cables: Solid and Stranded. Solid is great for new applications that require high-speed Ethernet. The solid cables can transmit and receive across long distances and have a higher data rate compared to stranded. The downside is that solid cables can break, and do not bend or flex well. Stranded is a better cable if you have to bend, twist, or flex the cable. It’s also better if you have to run short distances. Stranded is made up of smaller gauge wires stranded together which allows the cable to be flexible and helps protect the cable. They move with the machine and will not break as easily as solid cables.

To recap, remember the four short bullet points below when choosing your next cable:

Ethernet – transmits data
Ethernet/IP – transmits data to many machines/devices
Solid – good for long distance and little flexing
Stranded– good for short distance and flexing

To learn more visit www.balluff.us

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.

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.

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

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

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

How hot is hot? The basics of Infrared Temperature Sensors

Guest Contributor: Jack Moermond, Balluff

Detecting hot objects in industrial applications can be quite challenging. There are a number of technologies available for these applications depending on the temperatures involved and the accuracy required. In this blog we are going to focus on infrared temperature sensors.

Every object with a temperature above absolute zero (-273.15°C or -459.8°F) emits infrared light in proportion to its temperature. The amount and type of radiation enables the temperature of the object to be determined.

In an infrared temperature sensor a lens focuses the thermal radiation emitted by the object on to an infrared detector. The rays are restricted in the IR temperature sensor by a diaphragm, to create a precise measuring spot on the object. Any false radiation is blocked at the lens by a spectral filter. The infrared detector converts radiation into an electrical signal. This is also proportional to the temperature of the target object and is used for signal processing in a digital processor. This electrical signal is the basis for all functions of the temperature sensor.

There are a number of factors that need to be taken into account when selecting an infrared temperature sensor.

What is the temperature range of the application?
- The temperature range can vary. Balluff’s BTS infrared sensor, for example, has a range of 250°C to 1,250°C or for those Fahrenheit fans 482°F to 2,282° This temperature range covers a majority of heat treating, steel processing, and other industrial applications.
What is the size of the object or target?
- The target must completely fill the light spot or viewing area of the sensor completely to ensure an accurate reading. The resolution of the optics is a relationship to the distance and the diameter of the spot.

Is the target moving?
- One of the major advantages of an infrared temperature sensor is its ability to detect high temperatures of moving objects with fast response times without contact and from safe distances.
What type of output is required?
- Infrared temperature sensors can have both an analog output of 4-20mA to correspond to the temperature and is robust enough to survive industrial applications and longer run lengths. In addition, some sensors also have a programmable digital output for alarms or go no go signals.
- Smart infrared temperature sensors also have the ability to communicate on networks such as IO-Link. This network enables full parameterization while providing diagnostics and other valuable process information.

Infrared temperature sensors allow you to monitor temperature ranges without contact and with no feedback effect, detect hot objects, and measure temperatures. A variety of setting options and special processing functions enable use in a wide range of applications. The IO-Link interface allows parameterizing of the sensor remotely, e.g. by the host controller.

For more information visit www.balluff.com

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

How to Calculate RMS Torque

Guest contributor: Hurley Gill, Kollmorgen

Question: How do I calculate RMS (Root Mean Square) Torque for a given axis motion profile in my application?

Answer: Let’s take a look at the Root Mean Square (RMS) Torque and why it is important. Typically an axes’ motion profile is broken up into multiple segments, each segment is found to require a specific torque for a specific amount of time to complete the desired motion. For example, this can include torque required to accelerate, traverse (against an external force and/or friction), decelerate, and dwell. Each of these segments affects the amount of heating the motor experiences and thus the equivalent steady state continuous requirement utilized to select the correct motor. The RMS Torque calculation considers not only the amount of torque, but also the duration of that torque (by segment). Our example below illustrates how to calculate Trms of your motion profile.

The below motion profile would be broken up into eight (8) different segments, each with a required torque T_x and time t_x.

To calculate Trms, use this equation:

Where T₁ = torque required by and during segment 1, and t₁ = time duration (t₁-t₀) of segment 1, etc.. Note the additional torque required by the motor to over come some external/thrust force (greater than friction alone) during segment 2, and the lack of this required torque during the dwell segment 4 and 8.

Going back to the example motion profile above and the chart of that motion profile:

Therefore, if you do the math – and we will spare you writing this into a very long equation, the result is:

Trms = = 2.74 lb-ft or 3.715_Nm (1.35582_Nm/lb-ft.)

Conclusion: We hope that this tutorial has helped you! If you have questions about this or other calculations, or any automation related problem you may be having, please contact the motion control and programming experts at CMA/Flodyne/Hydradyne.

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

IO-Link Hydraulic Cylinder Position Feedback

Guest contributor: Scott Rosenberger, Balluff

Ready for a better mousetrap? Read on…..

Some time ago on Sensortech, we discussed considerations for choosing the right in-cylinder position feedback sensor. In that article, we said:

“…….Analog 0-10 Vdc or 4-20 mA interfaces probably make up 70-80% of all in-cylinder feedback in use…..”

And while that 70-80% analog figure is still not too far off, we’re starting to see those numbers decline, in favor a of newer, more capable interface for linear position feedback: IO-Link. Much has been written, here on Sensortech and elsewhere, about the advantages offered by IO-Link. But until now, those advantages couldn’t necessarily be realized in the world of hydraulic cylinder position feedback. That has all changed with the availability of in-cylinder, rod-style magnetostrictive linear position sensors. Compared to more traditional analog interfaces, IO-Link offers some significant, tangible advantages for absolute position feedback in hydraulic cylinders.

Connectivity

First and foremost, the story of IO-Link is that it offers easy, simple connection of sensors and IO to nearly any industrial network. You can read more about that here.

Simplicity

Another big advantage of IO-Link is the ability to connect sensors to the network using standard, simple, unshielded M12 connectors and cables. Compared to analog systems, which require shielded cabling, and sometimes unusual or proprietary connectors, connecting IO-Link sensors to the network is simpler, and usually less costly.

Visibility

Unlike their traditional analog counterparts, position sensors with IO-Link offer built-in diagnostic capabilities. Sensor status can be monitored over the network, greatly simplifying troubleshooting and fault detection.

Flexibility

This is where IO-Link position sensors really start to shine. Traditional analog position sensors provide one thing: position feedback in the form of an analog signal (obviously). IO-Link position sensors provide position feedback, of course…but wait, there’s more. In addition to position feedback, IO-Link sensors can provide velocity/speed information, temperature, and differential position (the difference between two position magnets). And the best part? All of this functionality can be freely configured over the network. Plus, sensor configurations can be stored and subsequently downloaded to a replacement sensor if necessary.

Suitability

It’s worthwhile to point out that IO-Link linear position sensors are ideal for most positioning or position monitoring applications. Just as with analog sensors though, they’re probably not suitable for high-performance closed-loop servohydraulic motion control applications. In those applications, interfaces that are capable of providing super-fast, deterministic data, such Synchronous Serial Interface (SSI) or even Ethernet/IP are more suitable.

You can learn more in this overview flyer.

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

Basic Color Sensor Overview

Guest contributor: Jack Moermond, Balluff

In the past, color sensors emitted light using red, green and blue LEDs. The sensors were then able to distinguish colors using the RGB components of the reflected light back to the sensor’s receiver. As technology has progressed true color sensors have been developed that not only can compare colors but measure them more accurately than the human eye.

Color sensors are based on diffuse technology and can be compared to a fixed focus or convergent sensor because of the focused light spot. Unlike color contrast sensors that only detect the difference between two colors based on brightness, color sensors can detect a wide range of colors.

True color sensors typically use white LEDs which allow for a greater color spectrum evaluation. Combine this with the CIELAB color system which is one of the most versatile color systems and the result is a color sensor that equals or exceeds the human eye. The CIELAB color system is a three-dimensional independent infinite representation of colors. The L component for lightness and a and b components for color are predefined absolute values. Lightness varies from black (0) to the brightest white (100). Color channel a varies from green negative 100 to red positive 100. Color channel b varies from blue negative 100 to yellow positive 100 with gray values at a=0 and b=0.

Due to the technology, color sensors can check only a small spot of color but can check this spot amazingly fast – up to 1.5 kHz in case of the Balluff’s fiber optic BFS 33M which also has a range of 400mm. Unlike a color sensor camera, which will focus on the object’s surface pattern and may cause false readings the true color sensor will ignore patterns thus providing more accurate color detection. In addition the true color sensor will have more outputs than the color camera.

Smart color cameras are working with RGB but could work also with HSV color models. They could be used to check larger areas for the same color or color codes on a part, but have slower update rate of 50 Hz. Special cameras for faster applications are available in the market but at higher costs. It is important that the light source for the smart color cameras be a white light with a standardized white balance, and that this light must kept constant for all checks to avoid errors.

The sophistication on the front end of the color sensor can be much more advanced and still remain a cost effective option for industrial use due to the fact that a camera requires a much larger processing system. The more sophisticated the sensors are in the camera the more robust the processor must be in order to process or map the data into an image.

To learn more: Request a digital copy of Balluff’s Photoelectric Handbook here.

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

3 Smart Applications for Process Visualization

Guest contributor: Shishir Rege, Balluff

Stack lights used in today’s industrial automation haven’t changed their form or purpose for ages: to visually show the state (not status) of the work-cell. Since the introduction of SmartLight, I have seen customers give new meaning to the term “process visualization”. Almost every month I hear about yet another innovative use of the SmartLight. I thought capturing a few of the use-cases of the SmartLight here may help others to enhance their processes – hopefully in most cost effective manner.

The SmartLight may appear just like another stack-light. The neat thing about it is that it is an IO-Link device and uses simply 3-wire smart communication on the same prox cable that is used for sensors in the field. Being an IO-Link device it can be programmed through the PLC or the controller for change of operation modes on demand, or change of colors, intensity, and beeping sounds as needed. What that means is it can definitely be used as a stack light but has additional modes that can be applied for all sorts of different operation/ process visualization tasks.

Use Case #1: Stack Light Mode for Operation Status – The number of segments can be programmatically changed from 1 to the max segment number provided by the light (up to 5 in a five-segment SmartLight). Colors can be changed to red, blue, green, orange, yellow, white, or any other color of choice. This is the most traditional application of the SmartLight.

Use Case #2: Format Change Indicator – Many of our customers use the level mode to provide feedback to the operators when they are making adjustments to the machine. For example: red might indicate that the machine is out of alignment, yellow might mean the machine is getting closer to the specified alignment, and green might mean the machine is in the zone of alignment. Using the SmartLight in this fashion helped our customers save time in product changeovers because the operators didn’t have to come out of the cell to view the alignment status on a small HMI. When the alignment of the machine is complete, the SmartLight can be programmed to switch back to the status indication mode or whatever mode of operation desired.

Use Case #3: Run Light Mode for Maintenance Indication – In this mode there are two colors – one color for the background and another color for the running segment. Along the assembly line where there are multiple work cells continuously processing raw materials in lock-step operation, downtimes are extremely costly. The standard status indicator will only indicate a problem at the work cell when the system stops, but it will not indicate a lack of raw material, for example. The moment the stack light turns red, the operator or the maintenance person is rushed to the site to first figure out what’s wrong before solving the problem. In Run Light mode, the SmartLight can be programmed to indicate different colors for the running segment and the background to show that attention is required at the cell. For example, as long as the running segment is running the machine is operational, but the background color can be changed to indicate raw material shortage, the need for mechanical adjustment of the machine, or the need for some electrical maintenance. Using a SmartLight, whoever is rushing the cell has a very good idea of what is required of them to get the system back up and running.

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

Industrial Enclosures Protect Components in Harsh Environments

Guest contributor: Steve Sullivan, Rittal Training Manager

Industrial enclosures face harsh conditions. From blazing to frigid temperatures, to dust, oil, dirt, airborne corrosives and liquids. Industrial engineers know that the manufacturing environment poses a multitude of challenges to the integrity of the control panel infrastructure.

Environmental protection of the control panel infrastructure is never simple. Determining factors in the selection of an industrial enclosure can include the most extreme conditions. The key to selecting the superior enclosure is evaluating the harshest environment possible, and specifying an enclosure that can withstand any setting.

Foreign substances

Environment elements that can affect the performance of the control panel include the
penetration of foreign substances (water, dust, dirt, oils, etc.). The delicate electronic equipment housed inside the enclosure can fail with even minimal exposure to external substances.

The Rittal TS 8 combats the ingress of these substances with a four-point latching system and a foamed-in-place gasket system. This forms a continuous barrier around the enclosure skin ensuring a gap-free seal. This creates a superior seal and memory retention to block out the challenges of any environment.

Temperature

The control panel infrastructure faces temperature challenges on two fronts. First, internal temperature is affected by the heat generated from the operation of control panel devices. The external or ambient temperature also affects the enclosure and the operating control panels.

Fully compatible with the TS 8 is Rittal’s line of cooling solutions for both enclosure based and room based thermal management. With 30% to 50% of energy costs attributed to cooling systems, Rittal designs maximum cooling efficiency into each solution: CRAC, in line/in row, chillers, pipe installations, water distribution cabinets or water heat exchangers.

The delicate dew point balance between the load temperature and the ambient temperature is maintained, preventing damaging condensation of the control panels.

Washdown

When washdown of enclosures is required, the control panels must be protected. Exposed to harsh chemical cleansers, high pressure and/or heated water and frequent cleaning can break down some sealing systems. Rittal’s impervious seal guards the vital control panel components from the most stringent cleaning procedures.

Corrosive Elements

Whether an enclosure is in an indoor or outdoor environment, corrosion can be a factor in the breakdown of the enclosure’s durability. Outdoor factors such as sun, snow, salt or chemicals can damage the exterior of some enclosures. Acids, solvents, alkalis, oils and industrial chemicals can threaten an enclosure housed on the factory floor.

Rittal engineers designed a three-step painting process to combat any environmental abuse. Similar to the process used in the automotive industry, an electrophoretic dip-coat primer is applied, followed by a two-part primer nano-coat and final powder coat. This provides a finished external barrier on the TS 8 for any climate, interior or exterior.

Enclosure material construction

A variety of materials have been used for industrial enclosures. The stainless steel 316 construction of the Rittal TS 8 has been proven to be impervious to the most corrosive environments and superior to lesser steel or powder coated materials. Stainless steel 316, combined with the three-step finish has proven durability in the most extreme conditions.

The environmental protection offered by the Rittal TS 8 has been field tested in more than 10 million installations, in industries like oil and gas, mining, pulp and paper, food and beverage and life sciences. For more information on the TS 8 and all of Rittal’s flexible industrial solutions, download our Fact Book today to start your change for the better.

About Us

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

Reliable Part Exit/Part-Out Detection

Guest contributor: Dave Bird, Balluff

Walk into any die shop in the US and nine out of ten times, we discover diffuse reflective sensors being used to detect a large part or a small part exiting a die. Many people have success using this methodology, but lubrication-covered tumbling parts can create challenges for diffuse-reflective photoelectric sensing devices for many reasons:

Tumbling parts with many “openings” on the part itself can cause a miss-detected component.
Overly-reflective parts can false triggering of the output.
Dark segments of the exiting part can cause light absorption. Remember, a diffuse sensors sensing distance is based on reflectivity. Black or dark targets tend to absorb light and not reflect light back to the receiver.
Die lube/misting can often fog over a photoelectric lens requiring maintenance or machine down time.

The solution: Super Long Range Inductive Sensors placed under chutes

Most metal forming personnel are very familiar with smaller versions of inductive proximity sensors in tubular sizes ranging from 3mm through 30mm in diameter and with square or “block style” inductive types (flat packs, “pancake types”, etc.) but it is surprising how many people are just now discovering “Super Long Range Inductive Proximity” types. Super Long Range Inductive Proximity Sensors have been used in metal detection applications for many years including Body-In-White Automotive applications, various segments of steel processing and manufacturing, the canning industry, and conveyance.

Benefits of Using A UHMW Chute + Super Long Range Inductive Proximity Sensor in Part Exit/Part-Out Applications:

It is stronger and quieter than parts flowing over a metal chute, readily available in standard and custom widths, lengths and thicknesses to fit the needs of large and small part stampers everywhere.
UHMW is reported to be 3X stronger than carbon steel.
UHMW is resistant to die lubes.
UHMW allows Super Long Range Inductive Proximity Sensors to be placed underneath and to be “tuned” to fit the exact zone dimension required to detect any part exiting the die (fixed ranges and tunable with a potentiometer). The sensing device is also always out of harm’s way.
Provides an option for part detection in exiting applications that eliminates potential problems experienced in certain metal forming applications where photoelectric sensing solutions aren’t performing optimally.

Not every Part Exit/Part-Out application is the same and not every die, stamping application, vintage of equipment, budget for sensing programs are the same. Butit’s important to remember in the world of stamping, to try as consistently as possible to think application specificity when using sensors. That is, putting the right sensing system in the right place to get the job done and to have as many technical options available as possible to solve application needs in your own “real world” metal forming operation. We believe the UHMW + Super Long Range Inductive System is such an option.

You can learn more in the video below or by visiting www.balluff.us.

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

3 Tips for Reducing Downtime

Guest contributor: Janet Czubek, Balluff:

Whether it’s through preventative maintenance or during planned machine downtime, reducing downtime is a common goal for manufacturers. Difficult environments create challenges for not just machines, but also the components like sensors or cables. Below are three tips to help protect these components and reduce your downtime.

Cables don’t last forever. However, they are important for operations and keeping them functional is vital. An easy way to help reduce downtime and save money is by implementing a “sacrificial cable” in unforgiving environments. A sacrificial cable is any cable less than two meters in length and placed in situations where there is high turnover of cables. This sacrificial cable does not have to be a specialty cable with a custom jacket. It can be a simple 1 meter PVC cable that will get changed out often. The idea is to place a sacrificial cable in a problematic area and connect it to a longer length cable, or a home-run cable. The benefits of this method include: less downtime for maintenance when changing out failures, reduced expenses since shorter cables are less expensive, and there is less travel for the cable around a cell.

A second way to help reduce downtime is consider your application conditions up front. We discussed some of the application conditions to consider in a previous blog post, but how can we address these challenges? Not only is it important to choose the correct sensor for the environment, but remember, cables don’t last forever. Choosing the appropriate cable is also key to reducing downtime. Welding environments demand a cable that weld beads will not stick to and fuse the cable to the sensor. There are a variety of jacket types like silicone, silicone tube, or PTFE that prevent weld debris from accumulating on the cable. I’ve also seen applications where there is a lot of debris cutting through cables. In this case, a stainless steel braid cable would be a better solution than a traditional cable. Fitting the right protection to the right application is crucial..

A third tip to help reduce your machine downtime is to simply add protection to your existing components. Adding protection, whether it is a protective bracket or a silicone product, will help keep components running longer. This type of protection can be added before or after the cell is operational. One example of sensor protection is adding a ceramic cap to protect the face of a sensor. You can also protect the connection by adding tubing to the cable out version of the sensor to shield it from debris. Mounting sensors in a robust bracket helps protect the sensor from being hit, or having debris cover the sensor. There are different degrees of changes that help prolong operations.

Metalforming expert, Dave Bird, explains some of these solutions in the video below. To learn more you can also visit our website at www.balluff.us.

About Us

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

Machine Geeks

CMA/Flodyne/Hydradyne – Your Premier Resource for Automation

The Spring Line is Here!

Tool Identification in Metalworking

How hot is hot? The basics of Infrared Temperature Sensors

How to Calculate RMS Torque

IO-Link Hydraulic Cylinder Position Feedback

Basic Color Sensor Overview

3 Smart Applications for Process Visualization

Industrial Enclosures Protect Components in Harsh Environments

Reliable Part Exit/Part-Out Detection

3 Tips for Reducing Downtime

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