smartLight

A Smarter SmartLight

Guest contributor: Tom Rosenberg, Balluff

Just when you thought the SmartLight was the most flexible Tower Indicator light ever, it gets even more flexible with the addition of a new mode. This new mode is appropriately named “Flexible Mode”. The new Flexible mode enables two new applications: User defined segments and Point-of-use indication.

User Defined Segments

For traditional tower light applications, it’s now Figure 1possible to define the segments as you see fit. It works by taking control of every LED element. Each SmartLight segment is comprised of four LED elements that can be controlled anyway you want (see Figure 1).  For example, with the 3-segment SmartLight, you actually have 12 LED elements that you can organize any way you want. In Figure 2, we only use three LED elements per SmartLight segment, making it a four segment SmartLight. By using two LED elements we create six segments. Figure 3 is even more interesting, in this example we can see the size of the segments are sized by the intended users. Forklift Drivers need a larger light due to the distance and the fact that they are moving. Operators are closer than the forklift drivers, so their segment can be smaller, and maintenance can use the smallest segments because they are closest to the SmartLight when working on the machine.

Point of Use Indication

In these types of applications, the SmartLight is usedSocket Tray Appin close proximity, usually within the work envelope of the operators. In the example shown, the SmartLight is used in a socket tray application. The SmartLight indicates to the operator which socket is required for a specific task. Inductive proximity sensors connected to an IO-Link Hub verify the correct socket was pulled. The photo is showing an All-Call (all lights lit). Here you can see the unique LED element grouping only available with the new Flexible mode. Other applications for operator guidance are essentially endless. There are no technical limitations to your creativity.

The Flexible mode is available in all SmartLights with firmware version 3.0 or greater. So go have some fun!

Learn more about the SmartLight at www.balluff.com.

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

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

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.

smartlightmodesThe 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.

smartlightgifcroppedUse 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.

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.