The pros and cons of soft starters vs. VFDs by application

Guest contributor: Eaton

Motors often require large amounts of energy when quickly accelerating to full speed. Soft starters and variable frequency drives can both be used to reduce inrush currents and limit torque— protecting your valuable equipment and extending the life of your motor by reducing motor heating caused by frequent starts and stops. Choosing between a soft starter and a variable frequency drive often depends on the application, system requirements, and cost (both for initial startup and over the life cycle of the system).

Soft starters

A soft starter is a solid-state device that protects AC electric motors from damage caused by sudden influxes of power by limiting the large initial inrush of current associated with motor startup. They provide a gentle ramp up to full speed and are used only at startup (and stop, if equipped). Ramping up the initial voltage to the motor produces this gradual start. Soft starters are also known as reduced voltage soft starters (RVSS).

Applications

Soft starters are used in applications where:

• Speed and torque control are required only during startup (and stop if equipped with soft stop)
• Reducing large startup inrush currents associated with a large motor is required
• The mechanical system requires a gentle start to relieve torque spikes and tension associated with normal startup (for example, conveyors, belt-driven systems, gears, and so on)
• Pumps are used to eliminate pressure surges caused in piping systems when fluid changes direction rapidly

How does a soft starter work?

Electrical soft starters temporarily reduce voltage or current input by reducing torque. Some soft starters may use solid-state devices to help control the flow of the current. They can control one to three phases, with three-phase control usually producing better results.

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Most soft starters use a series of thyristors or silicon controlled rectifiers (SCRs) to reduce the voltage. In the normal OFF state, the SCRs restrict current, but in the normal ON state, the SCRs allow current. The SCRs are engaged during ramp up, and bypass contactors are pulled in after maximum speed is achieved. This helps to significantly reduce motor heating.

Benefits of choosing a soft starter

Soft starters are often the more economical choice for applications that require speed and torque control only during motor startup. Additionally, they are often the ideal solution for applications where space is a concern, as they usually take up less space than variable frequency drives.

Variable frequency drives

A variable frequency drive (VFD) is a motor control device that protects and controls the speed of an AC induction motor. A VFD can control the speed of the motor during the start and stop cycle, as well as throughout the run cycle. VFDs are also referred to as adjustable frequency drives (AFDs).

Applications

VFDs are used in applications where:

• Complete speed control is required
• Energy savings is a goal
• Custom control is needed

How do VFDs work?

VFDs convert input power to adjustable frequency and voltage source for controlling speed of AC induction motors. The frequency of the power applied to an AC motor determines the motor speed, based on the following equation:

N = 120 x f x p

N = speed (rpm)
f = frequency (Hz)
p = number of motor poles

For example, a four-pole motor is operating at 60 Hz. These values can be inserted into the formula to calculate the speed:

N = 120 x 60 x 4

N = 1800 (rpm)

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• AC supply: Comes from the facility power network (typically 480V, 60 Hz AC)
• Rectifier: Converts network AC power to DC power
• Filter and DC bus: Work together to smooth the rectified DC power and to provide clean, low ripple DC power to the inverter
• Inverter: Uses DC power from the DC bus and filter to invert an output that resembles sine wave AC power using a pulse width modulation (PWM) technique
•  Pulse width modulation: Switches the inverter semiconductors in varying widths and times that, when averaged, create a sine waveform

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Benefits of using a VFD

• Energy savings
• Reduces peak energy demand
• Reduces power when not required
• Fully adjustable speed (pumps, conveyors, and fans)
• Controlled starting, stopping, and acceleration
• Dynamic torque control
• Provides smooth motion for applications such as elevators and escalators
• Maintains speed of equipment, making drives ideal for manufacturing equipment and industrial equipment such as mixers, grinders, and crushers
• Versatility
• Self-diagnostics and communications
• Advanced overload protection
• PLC-like functionality and software programming
• Digital inputs/outputs (DI/DO)
• Analog inputs/outputs (AI/AO)
• Relay outputs

Energy savings

VFDs offer the greatest energy savings for fans and pumps. The adjustable flow method changes the flow curve and drastically reduces power requirements. Centrifugal equipment (fans, pumps, and compressors) follow a general set of speed affinity laws. The affinity laws define the relationship between speed and a set of variables:

• Flow
• Pressure
• Power

Based on the affinity laws, flow changes linearly with speed while pressure is proportional to the square of speed. The power required is proportional to the cube of the speed. The latter is most important, because if the motor speed drops, the power drops by the cube.

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In this example, the motor is operated at 80 percent of the rated speed. This value can be inserted into the affinity laws formula to calculate the power at this new speed:

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Therefore, the power required to operate the fan at 80 percent speed is half the rated power.ia04003002e-9

Selecting the correct equipment for your needs

Choosing a soft starter or a variable frequency drive often depends on your application. Soft starters are smaller and less expensive when compared with VFDs in larger horsepower applications. Larger VFDs take up more space and are usually more expensive than soft starters.

That being said, while a VFD is often more expensive up front, it can provide energy savings of up to 50 percent, thereby producing more cost savings over the life of the equipment.

Speed control is another advantage of a VFD, because it offers consistent acceleration time throughout the entire operating cycle of the motor, not just during startup. VFDs can also provide more robust functionality than soft starters offer, including digital diagnostic information.

It is important to note that a VFD can initially cost two to three times more than a soft starter. Therefore, if constant acceleration and torque control is not necessary, and your application requires current limiting only during startup, a soft starter may be a better solution from a cost standpoint.

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CMA/Flodyne/Hydradyne is an authorized  Eaton Electrical 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.

Demand the best from your RFID partner

Guest contributor, Wolfgang Kratzenberg, Balluffrfid

That seems like a no-brainer statement, but often I find myself talking to customers who are frustrated with their current vendor for a myriad of reasons. An RFID project can require a pretty decent chunk of capital investment so when something doesn’t go as planned people start looking for answers immediately. This usually presents a great opportunity for us to go in and save the day, but it’s hard for me to ignore the time, money and resources that were wasted. Having witnessed this on several occasions I have concluded that there are a large number of RFID companies who are niche suppliers, but there are very few who can qualify as an RFID Partner. The RFID partner helps ensure success from idea to implementation to future expansion. That said, here is a list of things to consider prior to discussing your application with an RFID company:

  • Does the partner offer hardware that communicates over USB, Serial, TCP/IP, Ethernet/IP, Profinet/Profibus, CC-Link, Ethercat, etc?
  • Does the partner offer a wide range of form factors of readers, tags, and antennae?
  • Does the partner build hardware for multiple frequencies?
  • Is the partner willing to build custom equipment just right for your application?
  • Does the partner offer support before, during and after the project?
  • Does the partner have a core competency in the application?
  • Can the partner meet application specs such as, high temperatures, high speed reading on the fly, storing and reading large amounts of data, high ingress protection rating, etc.?
  • Does the partner develop and design products which are scalable and easily expandable?

If you can answer yes to all of these questions then chances are you are pretty well set. With such a mature technology there are many ways for RFID companies to set themselves apart from one another. However, there are only a few who are willing to do what it takes to be considered a partner.

To learn more about RFID technology visit www.balluff.us/rfid

About 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.

Best Practices: Inconsequential Volume

Guest Contributor: SMC

The advent of manifold mounted, plug-in pneumatic valves has been a boon for machine builders. It allows them to mount complete valve packages in a safe and secure location on a machine. Using a D-sub connector, serial interface module, or similar single-point wiring system, all of the electrical control outputs can feed into one location on the manifold, greatly simplifying the wiring. Plumbing issues are reduced, since a single air pressure line can be used to feed a common pressure gallery. The same advantage applies to the common exhaust gallery. No longer would both a plumber and an electrician be required to replace a valve, since any valve can be replaced without disturbing electrical connections or plumbing lines.ex260_ported

Like most advances, there can be some downsides to this type of arrangement, depending upon the application. One of these revolves around considerations for energy conservation. Most circuits include two air lines extending from the valve to the actuator, one for extend and one for retract. Each time the valve cycles, the actuator is pressurized on one side or the other. Of course, the hose or tube that connects them must also be pressurized. This tubing volume is typically ignored as inconsequential when doing our sizing calculations, but should not always be overlooked.

The tubing volume offers no work at all…only a means of transferring the energy of the compressed air to the actuator. Inconsequential? Maybe. But depending upon the application, those volumes can be significant. Here is an example:

A packaging facility has corrugated boxes being erected at a mezzanine level and dropped down to the main floor where they are filled, sealed and palletized. The box drop-down employs gravity to lower the boxes, but incorporates a series of mechanical stops to sequence them as required. Each of the stops includes a pair of 2 inch bore x 1 inch stroke air cylinders to operate a brake that stops the box and releases it when needed. In all, four stops are included for each drop down, meaning eight actuators in total and four valves to control them.

The directional control valves are located at a central location on a single manifold, presenting a clean and compact package. However, the distance from manifold to actuator varies from 10  feet to 25 feet. In operation, each time a valve shifts, it exhausts one length of tubing and fills another. Given the small volume, we might still think this to be inconsequential, but let’s look at the numbers.

Assume ¼” OD tubing with an ID of approximately .180“. With the first station being 10 feet away from the valve, the volume of tubing going to the actuators is only 3.05 cubic inches. Since there are two lines from the valve to each actuator pair, the total volume is 6.10 cubic inches per complete cycle. To put this in perspective, each of the 2×1” cylinders has a total volume of 5-½ cubic inches. That’s the sum of both the extend and retract sides. Since there are two of them, the total cylinder volume is 11 cubic inches. The volume in the tubing is over half that of the actuators. Much of the energy developed at the compressor is being used to fill the tubing lines.

Let’s leave aside the potential problem with poor response times, and just look at the costs. Let’s also assume the working pressure to be 80 psi. By calculating the compression ratio to be 6.33, and multiplying that by the volume, the normalized volume becomes 38.6 standard cubic inches. If we have the cylinders being actuated five times a minute, we will be consuming 193 standard cubic inches per minute, or using more meaningful terms, 0.11 SCFM. That is just for filling the air tubing to the closest single station on the drop-down. How about the other 3 stops on the drop-down?

The chart below shows the air volume for each of the stations, with a total for all. Please note the total volume of the airlines extending out to the cylinders is 42.8 in³. When we calculate the total volume of all eight cylinders we get 44 in³. The volumes are almost identical. Now we have a situation where half the compressed air is consumed filling all the air lines.

smc-iv

If that single drop down operates 24/7 and the cost for electricity is $.10 per KWh, the annual cost to fill those lines is about $110, the same costs we incur to fill the cylinders. With multiple drop-downs, the costs are multiplied. Staying with our example, the facility has 50 packaging lines, for an annual cost of $5500.

While this may be viewed as an extreme example, think back on all the applications where long air feed lines were employed in order to have a clean valve package. Or consider the oversize tubing that was utilized just because it was handy. Many of us might figure that larger tubing is better anyway, and everything will run more efficiently. However, please take into account that the larger tubing may double the volume to be filled without adding any productive benefit at all.

What happens to the same example when 3/8 inch tubing is used instead of the ¼ inch? The tubing ID increases to .27 inches and the volumes increase by a factor of 2.28, as do the costs. Now the annual price tag has jumped to $250. Again…that is just to fill the tubing for one drop-down.

As a side note, there is also some potential for liquid moisture build-up in those long lines when an excess of air is left between the valve and the actuator, even when good air filtration and drying is in place. Problems can arise due to the adiabatic expansion that occurs with each exhaust cycle. Condensation may occur as the exhausting air temperature falls below that of the atmospheric dew point. With long air lines and many cycles, the moisture may not be completely exhausted and can accumulate in the lines. That accumulation will occur near the actuator ports and will eventually work its way into the actuator, shortening its life.

What’s the solution? Have the valves mounted on or near the actuators so that all or most of the air volume is used to actuate the cylinders. This will require a pressure line running the length of the drop-down with a connection to each valve. However, that pressure line represents energy capacitance that works in our favor. We will also have fewer connections, which will translate into fewer potential leaks. Of course, the downside is that electrical lines will have to be extended independently to each valve. However, with low voltage, low wattage coils, this probably is not that difficult. Another benefit to be gained is that electrical response times remain unaffected, while pneumatic response times improve dramatically.  The dollar savings is the reduction in air consumption by half. In our plant, that could be up to $5500.00 every year.

Reducing the costs for compressed air needs to be an ongoing project for any company that uses substantial amounts of air as part of the manufacturing process. There is a tendency to approach the issue at the compressor room and look for answers there. The resulting recommendations can be expensive as well as require a long ROI. However, dealing with demand side issues, as described here, offers an easy solution that can be incorporated at the OEM level with little additional cost. A case can even be made for modifying these types of applications in the field when machines come due for refurbishment. Addressing these “inconsequential” issues will offer significant savings on the bottom line. “Watch the pennies and the dollars take care of themselves”.

To learn more about Best Practices in Pneumatics, please visit http://www.smcusa.com/

About Us

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CMA/Flodyne/Hydradyne is an authorized  SMC 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 Common IIoT Mistakes and How to Avoid Them

Guest contributor: Pat Millott, Balluff

IIoT is the perfect solution for all your data accessibility needs, right? If you check out my previous blogs, I discussed the many benefits of using the Industrial Internet of Things (IIoT) to remotely access data. However, if not used properly, IIoT can get you into some trouble. Let’s review 5 common mistakes to avoid when building your IIoT application.

1. Excluding your IT department
It’s crucial to make sure your Information Technology group is involved in this project. IIoT applications can be very taxing on your network. It’s easy to forget some key aspects like bandwidth and network traffic when developing your application. But when your application is finished, your IT department is going to want to know what network resources that are being used. Some questions they might ask include:

  • How many potential clients will the server have at any given time?
  • What is the max refresh rate of your application?
  • How frequent do you query the SQL server?
  • How are your queries structured?
  • What might be some vulnerabilities on this application?
  • What measures are you taking to protect these vulnerabilities?

It’s going to be a lot easier if they are included right away so everyone has a good understanding of what resources are available and how to protect them.

2. Excluding OT and Controls Engineers
Similar to the IT department, it’s important to include the controls engineer especially if you plan on hosting data from a PLC. The controls engineer is going to want to determine what data is publicly available and what data should be kept private. Some questions the controls engineer(s) might ask include:

  • What is your application trying to show?
  • What PLC data do you want to use for this?
  • Is your application going to write data to the PLC?
  • Do any modifications need to be made to the PLC code?

Keep in mind that any modifications that need to be made to the PLC will probably have to go through the controls engineer. This is to ensure that no code changes on the PLC will impact the efficiency and safety of production.

3. Running out of date software
Software that you write and the software that your application relies on should always be up to date. In other words, if you use a module or library in your code, it’s important to make sure you have the most up to date version. Also, it’s important to keep updating your application for additional security and functionality. Out of date software can lead to potential application crashes or even vulnerabilities for cyber attacks. Keep in mind, an application that runs on out of date software makes the server host vulnerable as well as its clients.

IIoT_Pyramid4. Unorganized data flow
Data flow is an important concept to consider early on in the development of your application. Say you have a server forwarding PLC data to a SQL database that is then utilized in a web application. The web application acts as a historian and analyzes data change over time. Is it better to calculate the data in the back-end application, the SQL database, the server forwarding the data or the PLC? The answer depends on the situation but typically, it’s best to keep the data calculations as close to the source as possible. For example, say your back-end application calculates percentages based on yesterday’s production compared to today’s. In this situation, if the back-end application crashes, you lose historian calculations. Typically, a SQL database is much more reliable as far as downtime and crashes and it will run whether your back-end application is functional or not. Therefore, it would be better to do these calculations in the SQL database rather than the back-end script. Continuing this concept, what if the PLC could do this calculation? Now the forwarding server, the SQL database, and the back-end script can all crash and you would still have your historian data for when they go back up. For this reason, the closer to the source of data you get, the more reliable your calculations based on that data will be.

5. Unprotected sensitive data
Possibly one of the most important things to remember when developing your application. Even simple applications that just display PLC data can give a hacker enough for an attack. Think about this IoT scenario: Say I have a server that hosts data from my personal home such as whether or not my front door is locked. This information is important to me if I want to check if someone forgot to lock the front door. But to a burglar, this data is just as useful if not more as he/she can now check the status of my door without having to leave their car. If I don’t protect this data, I am openly advertising to the world when my front door is unlocked. This is why encryption is crucial for sensitive data. This is also why it’s important to discuss you project with the controls engineer. Data that seems harmless might actually be detrimental to host publicly.

Data accessibility is evolving from a convenience to a necessity. Everyone’s in a hurry to get their data into the cloud but keeping these ideas in mind early on in the application development process will save everyone a headache later on. That way, IIoT really can be the perfect solution for all you data accessibility needs.

To learn more about IIoT visit www.balluff.us.

About 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.

LED Lighting System Designed Exclusively for Industrial Enclosures

Guest contributor: Steve Sullivan, Rittal

Rittal has set a new standard with the LED compact system light. The innovative LED technology shines into every corner of industrial enclosures, from the roof to the floor. No other enclosure light on the market today provides the lumen power…up to three times the luminous flux of the next closest competitor.

Rittal accomplishes this with intelligent lighting tailored to the geometry of the enclosure. Light is dispersed through a special optical cover with Fresnel structure, in two designs for precise lighting. The cover rotates easily, for adaptive light distribution. With enormous intensity, from 900 to 1200 lumens, the light provides brilliant illumination.

The LED system light matches the footprint of fluorescent lighting on the market, and simplifies specification requirements for the market. It is low maintenance and easy on energy as well.led_light

Rotating connectors support installation, even in the most confined spaces. With a swivel option, the light direction can be changed to spot-illuminate any part of the enclosure. Through-wiring is plug and play, and it can be additionally equipped with a socket for available electricity wherever it’s needed for maintenance work. Daisy chain multiple units, up to 15 direct wire or 10 with socket. Variants with integral motion detectors eliminate the need for installing separate door-operated switches.

The LED Compact lighting is safe, with an extra-low voltage range. As with all Rittal products, the product matches global standards, and the LED system light is suitable for wide range voltage from 100-240 V (AC) and 24 V (DC). It is fully certified by E76083 requirements.

Rittal makes installation simple. It is perfectly integrated to the TS 8. Fast, tool-free assembly on a latching hook system uses a 25 mm pitch pattern of holes to simply latch and secure. Optional screw-fastening is also available, or opt for complete flexibility with magnetic attachment to freely position the light anywhere in the enclosure.

The light may be fitted horizontally or vertically with no loss of space in the enclosure. Existing rails and sections can simply be covered. Lights with motion detectors are equipped with a rotating LED board as standard, allowing the direction of the light to be perfectly adapted to any installation situation.

The newly released LED system light brings optimum illumination of the entire enclosure. It can be attached a variety of ways: with clip, screw or magnet for a configuration to brighten every application. It can be installed in just two minutes, and the cable connection rotates a full 90°, not just in one direction like other lights.

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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.

Improving Arc Flash Prevention and Safety

Guest contributor: Steve Sullivan, Rittal

Working among the electrical components in an enclosure comes with inherent risks. The power in any one enclosure can range from 2kw up to 200kw depending on the power density. One of the most common and dangerous risk is an arc flash (or flashover).

When an explosive release of energy erupts from a phase-to-phase or phase-to-ground arc fault the results range from devastating to deadly. This air to ground electrical explosion is a critical concern for engineers and managers who are charged with the safety of their employees.

The Destructive Force of an Arc Flash

The dangers from an arc flash are all too well known. Five to 10 of these accidents occur every day in the United States. When metal expands and vaporizes at the fault, it causes extreme heating of the air, upwards of 10,000°C/18,032°F. The concussive pressure wave can knock personnel off their feet, the ultraviolet light flash can cause blindness, the sound blast, deafness and the molten metal and heat can cause second and third degree burns. The specific death toll has been estimated to be up to 1-2 people per day worldwide.

An arc flash can be the result of unsafe work procedures, accidental contact or more systemic problems such as corrosion of components and connections or insulation failure. Arc flash prevention should be incorporated into any application from the beginning of the design process.

Minimizing Arc Flash Exposure

Design and retrofit approaches can limit exposure by using components installed outside the enclosure to permit qualified personnel in personal protective equipment (PPE) to service equipment inside without opening the enclosure door. Interface flaps and window kits permit data retrieval, equipment monitoring or routine maintenance to be performed from outside. Collapsible fold down shelves be raised for use with laptops and monitoring equipment. External data pockets can hold wiring diagrams, operation manuals and other documents.

Rittal and Arc Flash Protection

Sometimes components must be accessed from inside the enclosure. Rittal’s arc flash solution is designed to keep high and low voltage equipment within the confines of their own respective enclosures. Low voltage enclosures house equipment that is used for programming, data acquisition and system adjustment.

High voltage components are isolated within their own disconnect enclosure, while line side power is segregated within the power isolation enclosure. A partition wall acts as a barrier to high voltage line side power. Rittal’s interlocking door system ensures that the high voltage enclosure cannot be opened while the disconnect switch is in “ON” position.

For additional safety, all interlocked doors and master door must be closed in order to re-energize the enclosure. This removes potential for accidental contact with the inline power when the disconnect enclosure is put in a safe power-off position, and locked and tagged out.

Minimizing exposure to line side power can help protect personnel from accidents. A qualified person wearing PPE and following appropriate safe work practices can perform visual inspections and tasks, such as diagnosis, testing, troubleshooting and voltage measurement with the door open even when the main enclosure is energized.

Rittal offers an unlimited choice of low-voltage and high-voltage enclosure combinations. More important than saving down time caused by having to power down the whole system to service, the Rittal arc flash solution helps to decrease the risk personnel being exposed to arc flash-related injuries.

Safety is always your priority, so download Rittal’s Arc Flash and How to Prevent it whitepaper for the first step towards arc flash prevention.

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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.

 

Three Things to Know About IO-Link

Guest contributor: Pat Millott, Balluff

IO-Link has become synonymous with the term “distributed modular I/O”. We know it is universal, smart, and easy, but what exactly is IO-Link? In a nutshell, by utilizing a standard sensor cable, the IO-Link slave device speaks point to point with an IO-Link master. The IO-Link master then combines the data with other IO-Link slave devices and communicates over an industrial network or backplane to the controller. In other words, it can be compared to a simple USB connection: for the most part, any USB device will work in any USB port, as long as the manufacturers of both devices have played by the rules when making the devices.

With that being said, here are three things to know about IO-Link:

  • Cable Length Cable Type and Length

Cable runs between master and slave can be up to 20 meters in length and typically utilize standard automation cables. Most cables, but not all, are M12 A-coded, unshielded, 3 or 4-conductor DC sensor cables.

  • Star ArchitectureStar Architecture

Since IO-Link utilizes a point-to-point serial communication, Star Topology is the only device architecture that can be constructed.

  • IO-Link PortsPort Class A vs Port Class B Devices

While most devices utilize IO-Link port Class A, output devices like valves are now being offered as IO-Link port Class B. Be sure to know if the master and/or slaves are Class A or Class B type ports. Most Balluff devices are IO-Link port Class A.

To learn more visit balluff.us/iolink

About 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.

 

A Simple Out Feed Solution for Progressive Stamping

Guest contributor: Dave Bird, Balluff

Applications where sensor contact is unavoidable are some of the most challenging to solve. Metal forming processes involving over travel can also damage or even destroy a sensor causing failure and expensive unplanned downtime. Manufacturers often try to remedy this with in-house manufactured spring loaded out-feed mechanisms but those are expensive to make by experienced tool and die personnel who have more important things to do . Over the years, I’ve seen this as a pervasive problem in the stamping industry. Many of these issues can be solved with the use of a simple yet effective  sensor actuator system known as a Balluff PlungerProx.

PlungerProx solves a few key issues in Progressive stamping:

  • The flexible trigger/actuation point is fully adjustable to meet sensitive or less sensitive activation points, not possible with “fixed” systems with substantial “over travel” built into the design.
  • It is fully self-contained (minimizing any risk of sensor damage and resulting unplanned machine down time).
  • The device can be disassembled and rapidly cleaned, reassembled, and placed back in service in the event that die lube or other industrial fluids enter the M18 body that can potentially congeal during shut down periods.

See me demo this product in the following video:

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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.

To avoid trouble later, consider your application conditions upfront

Guest contributor: Henry Menke, Balluff

Hardly a day passes by where we are not contacted by a desperate end-user or equipment manufacturer seeking assistance with a situation of sensors failing at an unacceptably high rate.  Once we get down to the root cause of the failures, in almost every case it’s a situation where the specific sensors are being applied in a manner which all but guarantees premature failure.

Not all sensors are created equal.  Some are intentionally designed for light-duty applications where the emphasis is more on economical cost rather than the ability to survive in rough service conditions.  Other sensors are specifically designed to meet particular challenges of the application environment and as a result may carry a higher initial price.

Some things to think about when choosing a sensor for a new application:

  • What kind of environmental conditions will the sensor be exposed to?  For example:
    • Very low or very high temperatures
    • Constant exposure to or immersion in liquid water
    • Continuous vibration
    • Extreme shock
    • Disruptive electrical noise (hand-held radios, welding fields, etc.)
    • Chemical contamination
    • Physical abuse or impact
    • Abrasion
    • High pressure wash down procedures
    • Exposure to outdoor conditions of UV sunlight, rain, ice, temperature swings, and condensing humidity
  • Is it possible to relocate the sensor to move it away from the difficult condition?
  • Is the sensor technology the best choice given the kind of application environment that it must operate in?
  • Is there a way to protect the sensor from exposure to the worst of the damaging effects?

When you reach for a catalog or jump on the internet to look for a sensor, it’s a good practice to just stop a moment first and make a list of the environmental challenges that the sensor could face.  Then you will be prepared to make an appropriate selection that best meets your expected application conditions.

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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.

Five trends that support intelligent linear motion technology in practice

Guest contributor; Dr. Steffen Haack, Bosch Rexroth AG

When it comes to progress in linear motion technology, one thing is immediately clear: linear guides and systems move increasingly larger loads more regularly and with increasingly higher positioning accuracy and repeatability. Anyone with an understanding of the interplay between the drive technologies will know the potential resulting from it.

Through a combination of electrics, sensors and software, linear motion technology makes a crucial contribution for integrated factory. Here are the five trends that support intelligent linear motion technology in practice:

Figure 1: Modularization and flexibilityBild1

Ready-to-install electromechanical cylinders combine mechanics with the flexibility of electric drives. A software command to the electric drive and the cylinder move them to any position and carry out complicated movement profiles. Without an additional position measuring system, they can achieve repeatability of up to ± 0.01 mm. Load measuring pins transmit the values analogously to the electric drive or the control and enable a decentralized process management.

Figure 2: Functional integration reduces complexityA006_C010_0101XP

If the precision requirements are high but the environment conditions are rough, conventional measuring systems soon reach their limits. Absolute measuring systems integrated into ball rail and roller rail systems detect the absolute position of the axis with a resolution of 0.025 μm. They immediately recognize the absolute position of the axis when the machine is switched on and report it to the controller without carrying out a reference run. In addition, modern systems do not require buffer batteries that need to be replaced regularly.

Figure 3: Predictive maintenance increases availabilityA008_C023_0101C0

Sensors measure temperature peaks and vibrations. This data forms the basis for future approaches to predictive maintenance. However, it is only significant if it is compared with life cycle models. In load tests, the newly developed runner blocks have demonstrated twice the service life through increased load capacities with the same size. Together with the detected operating conditions and predictive maintenance, they significantly increase the availability of machines and systems.

Figure 4: Digitally supported commissioningBild4

Previously, an experienced technician could easily have spent twenty minutes commissioning a linear axis. With the new mechatronic linear axes and actuators, the commissioning takes only three to five minutes. A digital assistant supports the application engineer with this. The technician only has to enter a few pieces of axis-specific data and can then immediately program or parameterize the drive. In the future, this functionality will automatically be available via the QR code.

Figure 5: Digital engineering for secure and quick dimensioningBild5

More and more engineering departments are changing to integrated digital workflows. With selection guides or sizing tools, design engineers find the correct linear motion technology components and mechatronic systems through intuitive user guidance, which can even be application-specifically configured. The electronically generated data are then integrated directly into the digital construction model and enables the virtual simulation of complex machine movements, for example.

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ABOUT US

cropped-cmafh-logo-with-tagline-caps.png

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.