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VOL 07 | DEC’14-JAN’15

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Tips to industrial wireless network planning

A U TO M AT I O N & D R I V E S

FOCUS Food & Beverage P. 34, 38, 42

ROUND-TABLE Revamping the power industry P. 28A&D - InterviewArundhati Bhattacharya General Manager (PE-C&I) & CTF (Muzaffarpur & Darlipali Projects)NTPC (p.26)

BUILDING WIRELESS INFRASTRUCTURE

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ed i tor i al

Wireless in homes was probably a rare concept ten years back. However, today, most of us count on it for not only computers, tablets, and phones, but also for music & television. Similarly, industrial wireless, at one time, was only for “must have” applications such as overhead cranes or automatic guided vehicles, rotating equipment, etc. Today, it’s moving rapidly from those few, critical “point” solutions to a “must-have” ingredient on production floor. Workers can now take the control room with them as they address production needs wherever they are. Though wireless infrastructures provide very good reliability and flexibility, factories and other industrial facilities have long been a challenge for wireless deployments. The Cover Story in this issue provides the tips for a successful execution of wireless infrastructure projects.

Power plant control systems, over the years, have evolved from DCS-centered platforms with proprietary software, to totally integrated plant automation systems with almost unlimited connectivity. In the future, control systems will no longer control the process — they will supervise it! These developments bring in their own set of challenges and requirements when it comes to modernising a power plant, especially for a country like India where the power demand-supply gap is huge. Check out the Round-table to know more about it.

The Industry Focus this time is Food & Beverage, where the articles talk on the latest trends in automation solutions and components that help address the issues related to changing consumer preferences and increasing government regulations.

Hope you will find the contents useful and interesting!

Shekhar JitkarPublisher & Chief [email protected]

Tracking the developments!

3a& d i nd i a | D e c ’ 14 - J a n ’ 15

LASER MICROMETERoptoCONTROL 2520Compact - Smart - Precise Non-contact and wear-free

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Anup WadhwaDirector – AIA (Automation Industry Association)

P V SivaramMD – B&R AutomationMember – AIA

Anant MaheshwariPresident Honeywell India

Ganapathiraman GVice President & GM (South and South-East Asia)ARC Advisory Group

Ravi AgarwalDirector, Pepperl+Fuchs (Factory Automation)

Raj Singh RatheeManaging DirectorKuka Robotics India

Jasbir SinghVice President – Electrical & InstrumentEssar Project Management Consultants

Dr KLS SharmaAdvisor Automation Education & Training

Mandar PhadkeCEO, Abhisam SoftwareFormer Head – Process ControlLanxess India Pvt Ltd

Arcot RajabahadurAutomation Consultant

Thampy MathewChairman, Fieldbus Foundation IndiaRegional Sales Director, Pepperl+Fuchs (Process Automation)

overseas Partner:

China, taiwan, Hong Kong & South-east asia

editorial_Dec14-Jan15.indd 3 12/17/2014 6:09:04 PM

CO N T ENT S

Market Management

26 “BUSINESS ANALYTICS TO PLAY LARGER

ROLE IN BUSINESS OPERATIONS”

Interview with Arundhati Bhattacharya, General Manager (PE-C&I) & CTF (Muzaffarpur & Darlipali Projects), NTPC

ROUND-TABLE

28 REVAMPING THE POWER INDUSTRY

A discussion on the latest developments in industrial automation and IT solutions for the Indian power sector

Food & Beverage 34 PACKAGING BOTTLES THROUGH

3D SENSORS

The article briefs on efector pmd3d vision sensor that detects objects in three dimensions

38 WILL THE FOOD INDUSTRY CRACK UNDER

PRESSURE?

The feature explains how F&B manufacturers can remain competitive by balancing costs & productivity

42 THE FOUR M’S OF FOOD MANUFACTURING

An article on the four M’s of food manufacturing which elaborates on sustainability and line integration in the manufacturing process

Focus

10 NEWS

16 “FOCUS IS ON ENERGY SAVING

TECHNOLOGIES”

Interview with Ajay Bhargava, Managing Director, Rittal India

18 “WE ARE FOCUSSING ON

SLIO TECHNOLOGY”

Interview with Joseph Cherian, Joint MD, Vipa Automation India

EVENT REPORT

72 PLATFORM FOR QUALITY AUTOMATION

SOLUTIONS

A pre-event report on SPS Automation India 2015

74 INTRODUCING FUTURISTIC TECHNOLOGIES

A post event report on the 11th NIDays 2014

Contents_Dec-Jan15.indd 6 12/17/2014 6:15:59 PM

CONTENTS

Technology

New Products

77Noiseless brush motors; Thermocouple terminal blocks; Power & signal connectors; Test & evaluation kit for real-time Ethernet

78Remote management solution; Energy saving LED luminaries; Magneto-inductive displacement sensors; Fieldbus station for control cabinets

79Wireless sensor development kit; Detection scanners for field monitoring applications; Configurable control systems; Compact mechatronic rotary module for flexible rotations

Columns

07 Editorial08 Contents80 Highlights - Next issue80 Company index

Advt

Advt

Cover Image courtesy: SHUTTERSTOCK & FESTO INDIA

Cover Story 20 T IPS TO INDUSTRIAL WIRELESS NETWORK

PLANNING

A feature providing 13 handy tips to ensure planning of a successful industrial wireless network & design

INDUSTRIAL COMPUTERS & PERIPHERIES

46 Facilitating process optimisation The article deals with computer tomography which ensures measuring accuracy and comparability of the optical measurement

MOTORS & DRIVES

52 Adopting high efficiency motorsThe article discusses the importance of energy conservation and the benefits derived with the use of energy efficient motors

IMAGE PROCESSING & MEASURING

60 Tracing the right partThe article discusses the top considerations for implementing Direct Part Mark traceability process into a fully automatic manufacturing line

F IELDBUS & NETWORKING

66 Safety lifecycle management An application story on how AIT has incorporated safety PLCs, motion control, safety and standard I/O on a single PROFINET network for efficient automation

SENSORS & ENCODERS

70 Changing face of Indian sensor marketThe article deals with latest market developments & technologies emerging in the Indian sensor market

TECH TALK

76 Solutions for the machine tool industryAn insight into primary cable requirements of the Indian machine tool industry

Contents_Dec-Jan15.indd 7 12/17/2014 6:16:08 PM

marke t | news

10 a&D I n d i a | D e c ’ 14 - J a n ’ 15

SCHUNK robot competition held in Germany

The SCHUNk robot competition was recently held at Germany, where

14 students of the Hölderlin Gymnasium Lauffen competed at the European

Robotics Week. There were two

mixed teams who had to perform a

series of several tasks with a robot

they designed. Several cylinders had

to be collected, and, in order to win

this competition, had to be converted

into a penalty kick. The competition

was split into two parts—subtasks

had to be solved first and then the

complete sequence without

converting the robot. Both teams

designed different robot models

with impressive creativity, technical

skill, team spirit, and were optimised

in several test series. The Green

Team was declared the winner. “It was our aim that young people should be

inspired by the possibilities of robotics, and to show them the options of

mechatronic solutions. Both teams convinced with great commitment,

curiosity, and smart ideas,” said Martin Aichert, Trainer—Automation

Technology & Mechatronics, SCHUNK.

> MORE@CLICK ADI03597 | www.AandD24.in

Both teams designed different robot

models with impressive creativity,

technical skill, and team spirit

CD-adapco signs agreement with JSOL

CD-adapco™ recently signed a development agreement with JSOL to

jointly develop co-simulation methods in the domain to coupled thermal &

electromagnetic simulations.

The partnership was forged last

year, when establishing a data

transfer process between the

two companies’ simulation

codes, passing electromagnetic

loss distributions and component

temperature distributions. The

performance of components

within the majority of

electromagnetic devices are

temperature dependent, therefore, finding the final 5% of an optimum

design requires the co-simulation of such processes. Doing so will unleash

the final 5% to product designers. A first release is expected in 2015 and

the example problems are now being trialed. “We hope that together we

can provide smooth and reliable multi-physics/multi-disciplinary

simulations with STAR-CCM+ and JMAG for that will benefit our joint

customers,” said Takashi Yamada, Manager—Electromagnetic Engineering

Group, JSOL.


ABB manufactures 1,200 kV circuit breaker

aBB has recently designed, manufactured, installed and commissioned a

1,200-kV circuit breaker. Once the switchgear is fully operational, it will

have a switching capacity of 10,400 MW—a

switch capable of turning on or off the electricity

generated by 10 large power plants. The circuit

breaker is deployed at the 1,200 kV national test

station constructed by Power Grid Corporation of

India Limited (PGCIL), Madhya Pradesh. “PGCIL is

fully engaged in developing a robust and

integrated national grid along with reliable

partners in technology like ABB. This development

takes us a step further in the development of our

ultra high-voltage transmission network,” said

R N Nayak, Chairman & MD, PGCIL. The solution

comprises a gas-insulated disconnector, current

transformers and monitoring & diagnostic

equipment. It requires only half the space that

would be needed for one with conventional

air-insulated designs. The configuration also

protects critical components from environmental

exposure and makes it more resilient against earthquakes.


The solution comprises

a gas-insulated

disconnector,

current transformers

and monitoring &

diagnostic equipment

The performance of components within

the majority of electromagnetic devices

is temperature dependent

Making India global supply centre of valves

The CII Valves National Conference 2014 was recently held in Mumbai, with

the theme—Going Global. I S Malhotra, Chairman - Valves & Actuators

Division, CII & Pentair

Valves and Controls opined

that making India a global

supply centre of valves is a

part of the “Make in India”

programme. “We need to

upgrade our infrastructure

so that India can produce

high-end engineered valves.

China is no threat since

these valves are for the

high end. The Indian valve industry was worth $2 billion, while the global

market was worth $60 billion, which only showed the growth potential,” he

added. According to Anil Gupta, Executive Director (QA&I), National Thermal

Power Corporation (NTPC), the company would be generating `1.28 lakh

megawatt power and would thus, need different valves. “Valves should

have zero defects, which would delight customers and help this sector in

going global. As India is building super critical power plants, the valves

should withstand high temperature and pressure, and exhibit high quality

and total reliability.”


The CII Valves National Conference 2014

was based on the theme ‘Going Global’

Market_news_Dec14-Jan15.indd 10 12/17/2014 6:11:35 PM

marke t | news

12 a&D I n d i a | D e c ’ 14 - J a n ’ 15

Danfoss recognises best practices in cold chain

Danfoss India recently presented the Indian Cold Chain Excellence (ICE)

Award, 2014 in Ahmedabad, recognising cold chain players in the dairy &

food processing sector who follow best practices of energy efficiency in

their facilities. “Recognition of profitable

yet energy efficient facilities like Banas

Dairy is required to encourage stakeholders

in this sector to shift to better technologies

that enable optimum use of energy. With

Gujarat taking the lead in dairy output in

the country, better benefits can be reaped

by milk cooperatives and processing

centres through technology upgradation,”

said Rajesh Premchandran, VP—

Refrigeration & A/C Division, Danfoss

Industries India. Banas Dairy from

Ahmedabad received the best food

processing facility award for using the

most updated technology in bulk milk

coolers and condensing units, such as multi-refrigerant scroll compressors

that help in achieving high energy efficiency levels for milk refrigeration,

processing and storage.


Rajesh Premchandran, VP,

Refrigeration and AC Division,

Danfoss handing over the

Best Food Processing Facility

Award to Banas Diary

Dow Corning opens application development centre

Dow Corning has recently set up a new application development centre in

India to serve the growing demand for silicon materials & services. “The

application development centre provides a

platform for application development and

technical support & expertise. It is staffed by

scientists and engineers who work closely

with sales & marketing professionals to more

effectively collaborate with customers and

meet their needs. This allows the company to

offer better access to customised silicon-

based solutions in key Indian industries like

automotive, beauty and personal care,

construction, household care, packaging and

textile,” said Serge Creutz, Director— Science

& Technology, India & Europe, Dow Corning.

The centre enables state-of-the-art local

support for the company’s global innovation

and sustainability initiatives. “The new centre,

along with our India office and distribution centre, enables us to take better

advantage of the growth opportunities in the Indian silicon market,” said

Peter Cartwright, Regional President — India, Central & Eastern Europe,

Middle East & Africa, Dow Corning.

The centre enables state-

of-the art local support

for the company’s global

innovation


HARTING bags “Factory of the Year” award

HartING Electronics has been felicitated with the “Factory of the Year”

award. “Factory of the Year / Global

Excellence in Operations (GEO)” is the

most well-established benchmark

competition for the manufacturing industry

in Germany since 1992. Torsten Ratzmann,

Senior VP—Production & Logistics,

HARTING Technology Group said, “Our

continual efforts to achieve streamlined

and effective production processes have

been acknowledged with receipt of the

overall winner award.” The jury lauded the

continuous development over the years in

its verdict along with strong focus on

employees. Its reasons also included

HARTING having a clear orientation on

strengths and differentiation in global

competition. The jurors praised the good

production system focused on continuous

improvement and development of in-house

systems, e.g. for electroplating to ensure

technical differentiation.

According to Torsten

Ratzmann, Senior VP—

Production & Logistics,

HARTING Technology

Group, the company’s

efforts to achieve

streamlined and effective

production processes have

been acknowledged with

the receipt of the award


Software for mine planning introduced

Bentley Systems has recently launched BeMineCycle software applications,

which facilitate optioneering to help

mining industry participants address

most pressing challenges, including the

need for a continuous mine planning

cycle. The software products are based

on industry-proven, pacesetting Bentley

software foundations, with MineCycle

Designer extending the company’s

OpenRoadscapabilities, MineCycle Survey

extending Bentley Map capabilities, and

MineCycle Material Handling extending

Bentley OpenPlant and OpenRoads

capabilities. MineCycle Material Handling enables engineering, procurement

and construction (EPC) firms and consultants to accelerate the preliminary

design of bulk material handling (BMH) facilities. Through optioneering, it

helps EPCs optimise cost, footprint, and other key factors by empowering

them to quickly consider multiple scenarios. “The optioneering ability to

quickly assess operational planning and engineering alternatives was one

of the ‘musts’ that our syndicate development sponsors identified,” said

Robert Mankowski, VP - Simulation Product Management, Bentley.

High-quality 3D renderings enable

compelling proposals and improved

stakeholder communication



No compromises: VEGA has the most suitable solution for your application – with Radar, Guided Wave Radar, Ultrasonic, Capacitive, Vibration, Nucleonic and Pressure. With this wide range of measurement techniques, we are the reliable partner of all industries – in technical as well as economic respect. By working closely with our customers, VEGA has continued to produce solutions for almost all products and process conditions.

We’re at your service, ready to provide advice and assistance: Call us on +91 20 4148 4148 to solve your measurement tasks today!

VEGA India Level & Pressure Measurement Pvt. Ltd3-B, 3rd Floor, Mutha Chambers IISenapati Bapat Road, Shivaji NagarPune – 411 016 Phone : +91 20 4148 4148 Fax : +91 20 4148 4149 E-mail : [email protected] www.vega.com/in

“ Instrumentation from the technology leader.”

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marke t | news

14 a&D I n d i a | D e c ’ 14 - J a n ’ 15

Online tool for tracking location from Emerson

emerson’s power transmission solutions has recently introduced the

industry’s first online tool for tracking location, life history and latest

revision drawings & installation instructions for all critical drivetrain

couplings owned by customers,

whether installed or in spares

inventory. Developed by

Emerson’s Kop-Flex business

unit, the web-based tool Asset

Management Program (AMP) for

couplings, accurately identifies

couplings, graphically displays

the location in a specific drive,

identifies parts/couplings at the

site that are interchangeable,

makes assembly drawings a click away and gives a detailed service history

and action to be taken during service intervals. It will be introduced in

Emerson’s booth 1231 in the Turbomachinery Show, to be held on September

22-25, 2015 at Texas. “Plant engineers plan shutdown maintenance with

tight timeframes, yet they struggle to identify couplings by make, model,

serial number, stock code, manufacturer’s part number, etc,” said Parimal

Deshpande, Sr Industry Specialist, Kop-Flex.

AMP identifies couplings & graphically

displays the location in a specific drive


E-commerce portal for cabling by Lapp

Lapp India has recently introduced ‘e-Shop’, its new e-commerce portal for

the cabling industry. The portal offers the widest range of cabling solutions

to customers in

India. With this

venture, the

company takes

the big step

forward to

catapult their

online presence across India. It will ensure speedy delivery of cables/

accessories to customers and will enable customers to quickly locate

relevant products along with detailed information. The user-friendly

interface will enable customers to navigate through the portal and help

them pick & choose products in a simple and efficient way. The company

expects primary demand for the e-Shop from customers across maintenance,

repair, and overhaul (MROs) industry, research institutes (for prototype

creation), engineering companies and institutes, laboratories and SMEs.

“Lapp India has always emphasised on delivering high-end customer buying

experience and through the e-Shop, we will scale up our services to a wide

range of customers and a larger part of the country,” said Marc Jarrault,

MD, Lapp India.


NORD Drivesystems receives F&S award

NOrD Drivesystems has been recently awarded with Customer Value

Leadership Award in the Indian gearboxes & geared motors market in 2014

by Frost & Sullivan. The

award followed a rigorous

methodology by Frost &

Sullivan in 8 to 10

parameters research

process including end

users interviews &

feedback. The awards

were presented to PL

Muthusekkar, MD, NORD

India; Satyen Das, GM—

Finance, NORD India and

Dhanraj Kalbhor, VP—

Operations, NORD India. “We

are the reliable partners in

motion who support our customers globally. We would like to thank Frost &

Sullivan and the jury for awarding us Customer Value Leadership company

of the Year. We would also like to thank our valuable customers for this

award that acknowledges our best practices and excellent team,” said

Muthusekkar.

The awards were presented to

PL Muthusekkar, MD, Satyen Das,

GM—Finance and Dhanraj Kalbhor,

VP—Operations, NORD India

Sameer Gandhi, MD, OMRON

Automation India, speaks

on the initiatives taken by

the company to exploit the

automation needs across

its huge manufacturing

industry base


OMRON to strengthen its business in Tamil Nadu

Omron automation India has recently announced its business in Tamil

Nadu at its Affinity Seminar held in

Coimbatore. These seminars have already

been conducted earlier in Hyderabad, Indore

and Ahmedabad. Attended by more than 200

participants, comprising of OEMs, channel

partners, system integrators and end users,

the symposium was an interactive platform

to make the participants acquainted with the

company’s key offerings such as SYSMAC

platform, vision inspection solution, robotics

solutions and machine safety solutions.

“This year, we are taking our efforts to the

next level by further exploiting the

automation needs across its huge

manufacturing industry base, especially, in

the textile, automotive & engineering sector

through channel expansion in categories of

vision, safety and sysmac. This will also help

us to reach out to more small & medium

OEMs and customers in Kerala,” said Sameer Gandhi, MD, OMRON

Automation India.



n e w s | market

15a& D I nd i a | D e c ’ 14 - J a n ’ 15

HANNOVER MESSE 2015 will provide a boost to India’s manufacturing competence while adding a new leaf to Indo-German bilateral relations. India will be the official Partner Country for this year’s HANNOVER MESSE edition to be held from April 13-17, 2015. “India is an emerging economic giant which is going to open up enormous sales potential for our German and international exhibitors at HANNOVER MESSE,” commented Dr Jochen Köckler, member of the Deutsche Messe Managing Board.

There were three main reasons for India’s selection: fast-growing economy, the many years of good relations between German-Indian enterprises and the positive experience of having India as the Partner Country at HANNOVER MESSE 2006. Together with German Chancellor Angela Merkel, Prime Minister Narendra Modi has confirmed to officially open HANNOVER MESSE 2015 on April 12, 2015. Under the slogan of “Make in India”, Modi will be promoting the modernisation of India’s factories and infrastructure and greater foreign investment in local production.

Highlighting on India as the Partner Country, Marc Siemering, Senior VP, Deutsche Messe AG, said, “Partner Country India is coming at exactly the right moment. India will be showcasing itself to the world as a modern, upwardly mobile economic power, while it simultaneously takes advantage of the opportunities offered by HANNOVER MESSE to invest in modern technology to strengthen its domestic economy.”

“Boasting of an average annual growth rate of 10% over the last 10 years and with current growth running at around 5%, India is one of the world’s fastest-growing economies. The country is brimming with opportunities and manufacturing industry is leading this fresh wave of growth. Through the HANNOVER MESSE show, we aim to catalyse this momentum and highlight the colossal Indian talent pool,” said Mehul Lanvers-Shah, Managing Director, Hannover Milano Fairs India.

Prime Minister Narendra Modi to attend HANNOVER MESSE, Germany in April 2015 to strengthen Indo-German bilateral relations

Partnership for better representation

EEPC, under the aegis of the Ministry of Commerce recently signed up with Deustche Messe as the official partner agency to facilitate India’s participation as partner country for HANNOVER MESSE 2015. Through this partnership, Ministry of Commerce will showcase approx 350 Indian companies under an area of over 3500 sq metres. Along with EEPC, India Brand Equity Foundation (IBEF) and CII will also organise high-level participation from India. Deustche Messe’s Indian subsidiary – Hannover Milano Fairs India (HMFI) will be playing a crucial part in organising participation from all agencies.

Figures say it all

Last year, HANNOVER MESSE attracted 180,000 visitors in 5 days; out of this 57% of visitors were from European Union and 20% from South, East and Central Asia. A total number of 5,000 exhibitors from more than 100 countries showcased their products. The 2015 edition of the fair will comprise ten flagship fairs – Industrial Automation, Motion, Drive & Automation (MDA), Energy, Wind, MobiliTec, Digital Factory, ComVac, Industrial Supply, Surface Technology and Research & Technology. ☐


HANNOVER MESSE 2015 to showcase India’s manufacturing might


16

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a&D I n d i a | D e c ’ 14 - J a n ’ 1516

“Focus is on energy saving technologies”Ajay Bhargava, Managing Director, Rittal India, briefs on the current scenario of power distribution

and climate control in India and the latest trends emerging in this sector, during an interview with Megha Roy

How do you look at the current scenario of power distribution and climate control in India? What are the major challenges faced in this sector? Power distribution is critical and is required across industries & verticals. The standards on power distribution are getting higher every day. Safety and reliability are the key attributes that will shape this business in the future. There are global standards like 61349, increasingly specified by customers. The biggest challenge for the industry is to be aware of the safety issues and implement the right design to ensure environment’s safety.

Industrial climate control is another critical subject in few industries like automotive, steel, textile, O&G, etc. Now, the focus has been on energy saving technologies as cooling is a vital requirement in most of the industries. Our company has already launched high-end products like Blue E, LCP for energy savings.

Please brief us on the RiTherm app. Our company has multiple configurators that are created to help customers size cooling units. RiTherm is one such software that is used to calculate heat load based on a specific customer requirement.

Keeping in mind the technology driven market in India, what are the innovations expected from your company?Our focus is to create multiple cooling solutions. We have launched water based cooling solutions for a very high heat load called industrial LCP. We have also developed new concepts in IT data centre space, where we have preconfigured data centres. This can be implemented in a timeline of 3 to 4 months. Our key focus has been energy efficiency, safety & fast implementation. We are also working to create solutions from engineering to automation & moving towards Industry 4.0. Our recent acquisition of Keisling completes the value chain from Eplan to Rittal to Kiesling.

Are there any plans for further manufacturing expansion in the Indian market? We are continuously working to increase our manufacturing

capacities in India. We have invested in upgrading our machines in the current factory that will increase capacities by 30 to 40%. We will evaluate the need for a second factory in 2016 as markets are expected to show substantial growth in the next 3 to 5 years.

Given that the global economies are on the mend and a new government at the centre brings renewed hope, what are your views on the changing Indian economy?We are optimistic on the economic growth in the next 5 years. Investment climate is changing faster than what we expected. Fortunately, the central government is absolute majority and they can take some tough decision on labour, land & tax reforms that will boost industry confidence.

What are the latest trends witnessed in your sector?We are seeing changes across segments due to

globalisation & many of our customers have global customers. Therefore, customers are increasingly demanding a higher quality, standardisation, products meeting global benchmarks, reduced lead times and high energy efficient products.

What are your global market expectations in 2014-15 term?In process industries like O&G, food, pulp & paper and steel, we see a moderate growth. However, many MNCs are using India as a manufacturing base for global markets and we see excellent business in the export segment. In the energy sector, which includes conventional power and renewable sector, we see a good growth in the coal-based power plants. Wind energy will grow slowly but solar energy will be a big boost to Rittal. The telecom and infrastructure sector is growing at a double digit due to the 3G & 4G roll-out by many leading telco players. For infrastructure, a big growth has been observed in the metro sector. However, in the automotive & ancillaries, we will see a slow growth in 2015. This is likely to speed up from 2016 onwards. Also, we see a good growth in the IT sector, primarily driven out of cloud computing and e-commerce space that will need a high level of IT infrastructure. ☐


Ajay Bhargava_Market Interview.indd 16 12/17/2014 6:12:29 PM

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“We are focussing on SLIO technology”Joseph Cherian, Joint Managing Director, Vipa Automation India, in this interview with

Megha Roy, discusses the benefits of implementing the VIPA motion control concept and the four modules under VIPA Green Solution, that helps reduce costs and optimise the production process

VIPA and Yaskawa together have recently presented the SLIO CPU iMC7 for motor control functions. Can you elaborate on this? iMC7 solution is the first common project for VIPA & Yaskawa. The motion control functionality inside the SLIO CPU with the latest SPEED7 technology offers a completely new market. It expands the already existing SLIO product range with EtherCAT network integration and offers in combination with VIPA SPEED7 studio modern motion control functions. After the activation of the motion control functions with the VIPA set-card-motion, the project engineering and programming can start immediately. The solution offers a new and highly efficient drive configuration.

Moreover, the VIPA motion control concept focuses on the automation tasks. System functions can also be configured without special system knowledge with the motion control library according to PLCopen standards and coupled with the Step7 programming. The advantages are considerably simplified processes and minimised development effort. Special drive, fieldbus and communication programming are not required any longer for the motion control applications. The best of the VIPA PLC and Yaskawa drive world such as Sigma-5, Sigma-7, A 1000, V 1000 and virtual positioning and speed axis are now combined. On EtherCAT, one can easily set up a direct connection to the Yaskawa servo drives or frequency converters in SPEED7 studio. High performance clock synchronisation and multi-axis applications are possible with EtherCAT.

How does your company plan to work towards “Energy management in practice”?Our company started with a new solution called “VIPA Green Solution” in 2012. We offer an energy management system, which functions simply and reliably, with the added value of advice, products and solutions as well as implementation through our company from a single source. This energy management system enables easy certification in accordance with DIN EN ISO 50001 or DIN EN 16247. This will rapidly reduce the energy costs.

The processes will be organised and this allows energy efficient work — efficient, intelligent and tailor made. It also optimises production, increases transparency, becomes economical and sustainable, optimises processes within a closed control circle and connects the machines and plants of the production to the management system.

In this context, the VIPA Green Solution offers four modules. The first module is energy management (according

to DIN EN ISO 50001), which includes energy management, energy monitoring and energy measurement. The second module is load management, which includes energy controlling, intelligent process control, energy adaptation according to the process and intelligent conservation of resources. The next module is plant information system, which includes overall equipment effectiveness / OEE, core error analysis, preventive maintenance, quality management and factory data recording. The last module is ERP/SAP – top floor & shop floor, integration in SAP, structuring a transparent communication between

field, process, installation and enterprise level and complete traceability from raw materials up to end product.

What are the major sectors generating demand?The major sectors currently generating demand are automobile, auto ancillary, food & beverage, water & waste water and power generation.

How are the latest developments helping in creating new value for customers?Currently, we are focusing on the SLIO technology based on the latest SPEED7 technology. In combination with the Yaskawa product portfolio, we are on the right way to come to the market with new solutions, offered by one single hand. Our target is to move from a hardware supplier to a solution provider. With our partners around the world in more than 60 countries, we are well equipped for this challenge. ☐


Vipa Joseph Cherian_Market Interview.indd 18 12/16/2014 7:53:56 PM

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Tips to industrial wireless network planningWith multiple Wi-Fi technologies in the market for industrial applications it becomes difficult for engineers to choose the best-fit. As an engineer looks at the application requirements to make informed decisions regarding which technology to use while moving from a wired to a wireless infrastructure, the handy tips presented in this article help ensure the planning of a successful industrial wireless network and design.

Mike Werning Field Application EngineerMoxa Americas

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This causes latency in the network. If you plan to connect many devices to your industrial wireless network, then you should also plan to add multiple access points to allow different clients to use different access points, and thereby reduce the number of collisions on the wireless network.Tip 3: Know how your application will send and receive data

— Many industrial protocols send small packets of data that are only a couple hundred bytes long. Other applications, such as for video or data storage utilise large blocks of data that require transmitting thousands of bytes. Knowing the characteristics of how your application will use the network allows you to make an informed decision about which Wi-Fi technology is best suited for the intended application. For example, 802.11n is better suited for applications that need to transfer large amounts of data since it contains features that help to optimise large transfers. One such feature supported by 802.11n is called Block Acknowledge. This feature lowers the amount of overhead in the wireless channel by allowing the receiving device to send an acknowledgement after many transfers by the sender. The result is better bandwidth utilisation. By comparison, 802.11a/b/g sends an acknowledgement after every transfer.Tip 4: Know which protocols the application plans to use — Industrial protocols and other networked applications use TCP for control applications or when reliability is critical and message loss is not acceptable. This is because TCP allows the receiver to request that missing or corrupted packets be resent. TCP is known as a reliable protocol. Contrast this with UDP, which is a connectionless protocol. This means the sender will transmit one packet after another without worrying whether or not the packets were transmitted successfully. On wired networks, typically there is little to no packet loss and the low overhead of UDP can be taken advantage of. However, many other factors need to be considered on wireless networks, such as client roaming or RF interference, which can corrupt packets in transit. While 802.11 has the ability to retry transmissions that it does not receive an acknowledgement for, depending on the length of time the interference lasts, packets can still get lost. What this means is that an application’s sensitivity or tolerance to packet loss must be considered. To mitigate this potential loss, highly available transmission features, such as

Wi-Fi is now present everywhere and people have become comfortable using it for just about any application. For example, many systems designers are choosing to move their industrial applications from wired Ethernet to wireless utilising Wi-Fi. The advantages of moving to a wireless design are numerous. Wireless allows for client devices to be located in difficult to reach areas, and it saves on installation and wiring costs in remote locations. The advantage is not to re-wire the plant infrastructure when relocating machines on the plant floor. Thus, it is easy to expand as additional devices are required. There are many different Wi-Fi technologies that can be used in industrial applications. Whether it is an existing application or a new design, an engineer must look at the application requirements to make informed decisions regarding which technology to use. When deciding to move from a wired to a wireless infrastructure, here are the following tips to ensure that the design is successful.

Ensuring successful design Tip 1: Know your application’s throughput requirements — To know the data rate that an application’s client devices will send and receive is critical for planning the network. This information will be used to determine things like which Wi-Fi technology to use, and how many access points will be required to provide the desired throughput. In a Wi-Fi system, the actual throughput that is available to the user’s application is generally about 50 to 60% of the overall bandwidth of the Wi-Fi technology selected. This is due to control and management overhead in Wi-Fi systems. If the application needs more than what is available, then the application will not work.Tip 2: Know how many clients will be accessing the Wi-Fi network — This tip goes hand-in-hand with the application throughput requirement discussed in Tip 1. Wi-Fi works in a manner similar to how Ethernet hubs work. That is, Wi-Fi uses a single collision zone for all the devices connected to the Wi-Fi network. This means that only one device can transmit at a time, and all the other devices must wait until the network is idle to transmit. When multiple devices try to transmit at the same time, there is a higher chance that collisions could occur.

Tips to industrial wireless network planning

Mike Werning Field Application EngineerMoxa Americas


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Moxa’s dual redundant packet solutions, can be employed to avoid this problem. When migrating to a wireless transmission medium for existing applications, application designers may need to tweak the mechanisms used for transmitting data, or make other adjustments.Tip 5: Determine the capabilities of the client devices that will be deployed on your network — Will the client devices all use the same technology or will there be a mix? Decisions regarding which devices will be supported are critical in maintaining application throughput. For example, if both 802.11b and 802.11g devices need to be supported, there will be less overall throughput on the wireless channel. This is due to the fact that the access point will have to slow down to 802.11b speeds when communicating with those clients. The time it takes to perform transfers at the lower rate steals time from the higher performing clients and limits their overall throughput on the network. If mixed mode operation is required, make sure you have enough throughput to support the application. If you can avoid supporting legacy devices, by all means do so, and limit the access point to only support a particular wireless technology to improve performance. For example, limiting the access point to 802.11g only or 802.11n will improve performance by not allowing legacy devices to connect to the access point. Tip 6: Plan for throughput — Knowing how much throughput your client application needs is critical in planning how many access points you need to install. Just because you have selected 802.11n and can support up to 300 Mbps of available bandwidth does not mean that every signal from every access point will transmit at 300 Mbps. The farther a client radio is from the access point the weaker the signal will be, and as the signal gets weaker, it gets closer and closer to the noise floor. The difference between the signal and the noise floor is the signal to noise ratio. A high signal to noise ratio means that a higher performing modulation and coding scheme can be used by the radios. As the signal to noise ratio degrades, the radios must utilise a lower performing modulation and coding scheme to

deal with the interference on the channel. This is called dynamic rate switching. This means that the farther the client is from the access point the lower throughput it can achieve. If your application throughput needs are high, then you must design your wireless network with more access points in closer proximity to the client radio’s location, since doing so will ensure that the radio will be able to sustain higher data rates.Tip 7: Know the application roaming needs — With industrial wireless networks, it is common for clients to move about in a facility. Clients are often used for location tracking or for obtaining the GPS coordinates of an object’s next location. In other cases, the clients are used for machine control on moving conveyors, rail cars, or cranes. The system designer should identify the latency the end application can tolerate while objects move between access points. When a client roams from one access point to another, the time it takes to connect to the new access point introduces a transmission delay. With commonly used Wi-Fi clients such as computers, the delay could be several seconds. If the application requires fast roaming, then plan on using Turbo Roaming in the design. This means that the client must be a Moxa client radio. Turbo Roaming can provide as fast as 100 ms roaming between access points, and if faster roaming is required, then consider a controller based approach such as the Moxa WAC. The wireless controller approach allows for 50 ms roaming for clients.Tip 8: Know the characteristics of the environment — Industrial applications are notorious for using machines that can cause RF interference. In addition, industrial applications are often housed in buildings made of metal, or are full of reflective materials. Utilising 802.11a or 802.11n in the 5 GHz band can help to avoid the interference issues of the overloaded 2.4 GHz band. However, as the frequency increases, the range and penetrating power of the signal decreases. This means that you will need more access points or higher gain antennas to obtain the same coverage as in the 2.4 GHz band. It is a good idea to use two antennas per radio in these environments. Two antennas allow the radio to take advantage of the diversity

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antenna system, which can help manage reflectedTip 9: Know how to handle directly connected vs external antennas — It is common in enterprise or office environments for the access point to utilise built in antennas or directly connected antennas. These are usually low gain solutions in the 2 to 4 dB range. In industrial environments, it is not uncommon to have the radio mounted inside a control cabinet connected to antennas mounted on the outside or on a pole. In these situations, the engineer must pay close attention to the gain of the antennas and account for all the losses due to the cable and connectors used. In short cable runs, using LMR-200 cable provides for acceptable low signal attenuation. For longer cable runs, make sure to use LMR-400 or above to minimise the losses. For example, a 3 metre LMR-200 cable will have a combined cable/connector loss of 1.9 dB at 2.4 GHz and 2.8 dB at 5 GHz. The same solution using LMR-400 cable has less than half the attenuation. For optimum performance, make sure to minimise and match the lengths of the cables to each remote antenna connected to the radio.Tip 10: Design your channel allocation plan — When using more than one access point or when there are other access points in the area, it is important to identify the channels that will be utilised on each adjacent access point. When doing this, it is important to avoid using the same channel as an adjacent access point. In the 2.4 GHz range only three channels do not overlap. These are channels 1, 6, and 11. If at all possible, make sure to stagger the access points in these channels. This will minimize a kind of interference known as co-channel interference. When using the 5 GHz range, each channel is non-overlapping if you are using a 20 MHz channel width. This is known as HT20 mode. If the access point is using 802.11n with 40 MHz channel bonding (known as HT40), then you need to stagger access points every two channels to avoid overlap. Tip 11: Pre-plan your access point placement using a predictive site survey — For applications that must utilise

multiple access points to provide coverage, it is most helpful to use a software tool to provide a preliminary plan for access point locations. Doing so can result in a big time savings later on when visiting the site to perform an actual site survey. These tools typically take in a floor plan of the facility. Using data from the planned access points and clients in use, as well as building materials at the site, the predictive site survey can provide a placement plan for the site as well as the number of access points required to provide the throughput the end application needs.Tip 12: Perform an on-site survey to identify access point locations — Although predictive site surveys can be useful, they do not take in account the obstacles, machinery, equipment, and other radiating devices inside the building, which is why it is essential to do an on-site survey. Once you have a plan for where you want to deploy the access points, visit the site and perform measurements using the actual radios and antennas that will be used in the deployment. Using the preplan as a guide, measure signal levels using the actual devices you plan to use in the deployment to verify coverage. Try to maintain a line of site between the access point and client radios wherever possible. A variety of site survey tools are available on the market for measuring signal levels to create a heat map of the actual coverage in the area and for identifying problem areas. In the absence of advanced site survey tools, plan a 15 to 20 per cent overlap between adjacent AP cells at the minimum data rate required by the application. Tip 13: Check your work and verify throughput— After the radios are deployed verify the throughput in the network at various locations. Use a software utility such as jperf to measure throughput and verify that adequate throughput exists at edge cases in the Wi-Fi cell boundaries.

These tips ensure that the wireless deployment is successful. ☐


Throughput (Mbps) decreases as the client gets farther from the access point

Turbo Roaming provides faster handoff between access points


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“Business Analytics to play larger role in business operations” Arundhati Bhattacharya, General Manager (PE-C&I) & CTF (Muzaffarpur & Darlipali Projects), NTPC – India’s largest power company, in this interview with Sumedha Mahorey, highlights her experience with automation service providers (ASPs), and the various critical aspects of the use of latest automation tools for power generation.

Brief us on the challenges faced by NTPC while executing the automation/modernisation projects. How did you manage to overcome these challenges with the help of NTPC’s own experts as well as automation service providers (ASPs)? C&I in terms of overall project cost is only 3-4%, whereas its impact in the overall operations is quite substantial. This makes the challenges multi-fold – ensuring quality, speedy implementation and easy maintainability while keeping pace with technology. As an example, one such philosophy adopted

for improved site maintenance was single DCS platform for main plant BOP & all offsite areas. But obtaining data of offsite equipment from the OEM and doing in-house engineering for these areas is by no means an easy task, especially with the minimal resources. Similarly, in the project construction phase, C&I has a daunting task of maintaining erection quality while adhering to stringent timelines, as typically it is the last in the execution sequence. This makes accurate engineering and testing a pre-requisite.

Arundati NTPC management_Interview_Dec14-Jan2015.indd 26 12/16/2014 6:59:51 PM

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we have advanced controls for steam temperature, but in other areas, we have a long way to go. Also, training in this niche area needs augmentation.

Please elaborate on the need for business analytics in the power generation business. Can you share any measures implemented or benefits derived by NTPC with the use of business analytics?Considering the challenges of the current scenario of power generation business, especially the new regulatory regime, business analytics is likely to play a larger role in the business operations of power generation companies. Already, Enterprise resource planning (ERP) systems are in place in NTPC where data (including real-time data) is leveraged to optimise several business processes like operations, maintenance, engineering, finance, ultimately increasing the profitability. Of course, scope for further improvements is always there.

What is your definition of information-driven enterprise? How do you predict this enterprise to be in the coming decade?I do not have a formal definition but I think any enterprise which converts data into actionable information for driving its business processes & also bases its business decisions on it, falls in the category of Information-driven enterprise. The main point is how effectively an organisation plans & implements such systems taking into account the changing market dynamics. With the connectivity & IT enablement prevalent today, such enterprises will definitely have a leading edge in the coming decade.

How do you perceive the present level of risk management and safety engineering in the Indian power plants? I can elaborate only about the safety instrumented systems (SIS) which we are engineering for power plant equipment protection. Currently, we are specifying SIL-2 or better level for boiler protection systems. Safety engineering is definitely a very important area in Indian power plants & likely to gain prominence in the future. ☐

Again, modernisation projects (i.e. R&M jobs) have challenges of execution in the brief shutdown period. But thanks to the in-house engineering and meticulous planning of our own experts as well the support provided by automation service providers, C&I R&M jobs have been executed in the given short time span; some as less than 35 days making it a benchmark in project execution. Even in the power project phase, there has been no delay on account of C&I.

How has been your experience with ASPs so far? What are your expectations in terms of making an effective win-win partnership with them?Our experience with automation service providers have been by & large good. Probably, NTPC is one such organisation which got the unique opportunity of working with multiple DCS vendors (more than 8-9). This has helped us to consolidate our operational requirements and implement it in different systems in an optimised way. On the other hand, for automation vendors also, working in NTPC projects is a good learning experience. In this process, some of the functionalities we normally provide in NTPC specifications eventually become part of their standard system, leading to product enhancements & knowledge enrichment of their execution team. However, we expect improvement in areas such as site support which includes process expertise as well as system side expertise, clearer responsibilities for their site personnel, & more project ownership. As far as partnerships are concerned, being a public sector enterprise, tendering is on L1 basis; thus formal long-term strategic partnerships with automation vendors are not done.

How can the potential of advanced controls be fully utilised? How is NTPC’s experience?Advanced controls or APC as it is termed in automation parlance, has a huge potential in terms of operation cost savings; as it directly intervenes with the closed loop controls but it requires equally huge efforts on the part of the APC vendor to realise its benefits. There are three factors affecting the success of such systems, i.e. skilled manpower at the automation vendor’s end, guidance & cooperation of plant equipment supplier and support of site management. In NTPC,

“Advanced controls or APC as it is termed in automation parlance, has a huge potential in terms of operation cost savings; as it directly intervenes with the closed loop controls but it requires equally huge efforts on the part of the APC vendor to realise its benefits”Arundhati Bhattacharya

Arundati NTPC management_Interview_Dec14-Jan2015.indd 27 12/16/2014 6:59:54 PM

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ReVamping the poweR industRyHighlighting the latest developments in industrial automation and IT solutions for the Indian power sector, this feature discusses the views of industry players to help the industry modernise and enable efficient operations in the coming years...

As the global demand for power continues to outstrip supply, expanding the power generation capacity becomes quintessential. This calls for an efficient power generation system to be established and sustained. However, the challenges that confront the Indian power industry, such as, widening demand-supply gap in power generation, low per capita power consumption and poor risk management necessitate greater utilisation of automation and information technologies for its efficient operation & management. As such, it becomes imperative that breakthrough automation and information technologies are leveraged to the maximum towards this objective.

Addressing the major challenges in the Indian power industry and highlighting the latest developments in this arena are industry giants such as G Ganapathiraman, Country Manager, ARC Advisory Group India; Parag Marathe, Engineering Manager, Power Generation Products, GE Power & Water; Sunil Kumar Vuppala, Research Scientist, Infosys and Pradeep Nair, Business Development Manager – Energy, National Instruments.

Indian power sector: Now & then

Over the past decade, power plant control systems have

Megha RoyFeatures [email protected]

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According to Vuppala, such systems will be proactive in predicting the issues much earlier before the problem occurs.

“Early warning system for wide area system stability, real time monitoring for situational awareness are few examples in that direction. With this, operators are playing the role of supervisors rather than controller of the system. We can control the system from anywhere but poses the challenges of security, which needs to be taken care of. Besides, concept of virtual power plants can provide more flexibility and efficiency and it can do load aware power generation with short notice. Micros-grid with small distributed power generation plants and consumers becoming prosumers (producers & consumers) is another trend observed these days,” he said.

Addressing the key challenges

According to Ganapathiraman, the demand supply gap in the Indian power generation necessitates capacity augmentation to be done at a quicker pace compared to developed economies.

“From the present capacity of around 243 GW, India plans to add 76 GW by 2017 and additional 93 GW by 2022,” he said.

However, when compared to developed countries, it has been observed that the cost per unit of power is more in India. As such, it creates enough scope to improve on low cost of operation & maintenance. “For safety and risk management, the major black-out in 2012 indicates lack of coordination in operating the power grid. Various organisations such as TSDSI (Telecommunications Standards Development Society, India) and ISGF (India Smart Grid Forum) are working towards preparing the standards for India as well as participating in international standard bodies. Compared to developed countries, we need smart products at lower cost to support massive rollouts,” asserted Vuppala.

In fact, it is not only the low cost. Much needs to be addressed on maintaining the structure and productivity of the Indian power sector too. Therefore, renovation and modernisation of power plants is critical for efficient running

evolved from DCS-centered platforms (distributed control system) with proprietary software, to open systems using industry standard hardware and software, and then to totally integrated plant automation systems with almost unlimited connectivity and the ability to interrogate field instruments from many different manufacturers. Sharing his thoughts on the changes experienced in the power industry, Ganapathiraman opined that unified architecture is the next big thing. “It is an important step, especially when it comes to the supercritical power plants. In a thermal power plant, DCS with fully integrated turbine and boiler control system provides a common engineering & operator environment. Under such a platform, along with flexibility in operations, accurate process information can be leveraged and delivered at the right time to the right person within an individual plant, and possibly across various geographically dispersed units, further enabling operational excellence and higher reliability.”

On the other hand, Nair focuses on the next phase of change that is quickly catching up, the emergence of software centric hardware platforms, with better computation, control & communication power. “These 3Cs together make the platform turn into a state-of-the-art cyber physical system (CPS). Currently, though the communication protocols between various IEDs are standardised, the IED(intelligent electronic devices) or other computing devices in the power plant is still a black box. A software centric automation platform like National Instrument CompactRIO system is changing the way these IEDs are build, making it more open and flexible. Using such technologies, the same platform with appropriate I/O can be modified into various kinds of power devices like PMUs, DCU, bay controllers, condition monitoring systems, etc.”

Considering the technology driven market in India, it has become imperative to have a technological presence in every sector. As such, when it comes to the power industry, it has been observed that Internet of Things and smart grid concepts will make the industry experience various developments.


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of older power plants and ensuring high availability. In this context, Ganpathiraman further added, “Projects like clean coal technology (CCT) are being implemented to improve the efficiency and environmental standards of conventional power plants.”

How to modernise power plants?

It goes without saying that India is witnessing a modernisation spree. Same applies to the power sector. As such, the power plants can be modernised through automated devices and control systems. “It needs to deploy new M2M devices for real time monitoring of vibration, speed, turbine protection and synchronisation. When these power plants are installed with automated devices and control systems, the plant operators should be trained to respond quickly for the system raised alerts to increase safety and reliability of the plant. Necessary security implementations need to be taken care in the new infrastructure of the plant too. Cyber security is another training element as the modernisation allows access to control the plant remotely,” opined Vuppala.

It is also seen that there has been a continuous need to invest in training and updating skills in India. Emphasising on a strong database for an efficient power plant structure, Ganapathiraman believes that the database needs to include all critical and non-critical/major/minor assets in terms of their procurement & operational phase. “While the main equipment like boiler/turbine have 25-30 years of lifecycle; control systems and HMI have short lifecycle of 3-8 years and need continuous upgrades in terms of OS and hardware obsolescence. So, it is essential that the O&M staffs at project sites are trained adequately prior to systems failures that may lead to major

trips. Further, virtual technology and simulation of control systems can be used in operator training programs to keep the operator aware of dynamic plant scenarios,” he added.

When it comes to infrastructure, Nair opined that the availability of communication networks like FO or GSM will allow the latest IED to be installed in remote locations and be networked to servers, making data accessible at a central location. “Training plays a major role in the modernisation program. There has to be a good hand-holding between academia & industry to train engineers on the latest technologies. We need to have a pool of trained engineers who can analyse the large amount of data that these networked IEDs generate in order to make the whole system work more effectively. National Instruments works with various academic institutes to set up state-of-the-art centre of excellence where power engineers can be trained,” he added.

Facilitating efficient operations

The importance of automation in the power industries has increased dramatically in recent years with the view to the current energy situation and environmental issues. According to Ganapathiraman, power companies are now progressively leaning towards an “information driven” business model. Using concepts like Big Data goes a long way in achieving this.

“As far as Industry 4.0 is concerned; Big Data and cloud computing are its major facilitators. The progress towards a digital enterprise is encouraging. With plant wide network using intelligent automation and open communication protocols, data integration is becoming increasingly easy and enterprises are becoming more agile.”

Speaking on Big Data, Nair said, “If we talk about Big Data,

“Automation solution providers & users can have a mutually beneficial long term partnership” Parag Marathe, Engineering Manager Power Generation Products, GE Power & Water

“Projects like clean coal technology (CCT) are being implemented to improve the efficiency and environmental standards of conventional power plants” G Ganapathiraman, Country Manager ARC Advisory Group India


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the largest or the biggest data is not generated by digital or social media but by equipment’s like turbines and energy meters.

If the data generated by all turbines in the power plants that we have in the country is clubbed with the data generated by PMUs on the transmission grid along with the ones generated by AMR systems on the distribution grid then these analog data generated are much bigger than the ones generated by digital media for an equal timespan.”

In this regard, GE has come up with Predix – the software platform for the Industrial Internet that enables predictive insights from Big Data, business analytics and state-of-the-art user experience. “To put it into perspective, if we are able to offer just 1% of fuel savings for all gas power plants, it would mean saving $ 66 billion over a period of 15 years. The potential is huge,” said Marathe.

Integrating suppliers and users

Automation solution providers can have specific devices to power plant sectors for synchronisation, vibration monitoring, speed control, load control and turbine protection. Underlining this thought, Vuppala opined that there is a role for system integrators in customising automation solution to the need of the users. “Vendor selection has moved beyond the conventional terms of product/service offerings, as customers want a partner who can address more than their technology requirements. Moreover, a differentiated value proposition by the vendor built on a consultative approach helps in bridging the end user-client partnership expectations,” added Ganapathiraman.

Marathe further highlighted that automation solution

providers & users can have a mutually beneficial long term partnership, based on how these solutions are enabling better controls, better utilisation of assets and improving efficiency by connecting deep domain knowledge to automation technology advancements. “Pilot projects, for trying out the latest technologies, are the best way to gain the confidence of the user. By doing this, we can ensure a continuous engagement between users and automation suppliers,” said Nair.

Can intelligent self-controlling power generation become a reality?

Speaking on self-controlling power, Marathe believes that power plants having single pushbutton start-up operations and advancement of control & instrumentation systems already exists. “However, this has still not reached the level of optimum controls and that’s where our company with advanced technology solutions can help power producers.”

On the other hand, Ganpathiraman said, “Self-controlling power generation is unlikely to become a reality, because in a thermal power plant there are more than 20,000 major components and millions of other components to be connected on real time.”

Moreover, in the fluctuating scenario of power supply, generators can adjust the active, reactive power to compensate power fluctuation. Highlighting this thought, Vuppala concluded that M2M devices and actuators coupled with analytics can make the intelligent self-controlling possible for the power generators. ☐


“Necessary security implementations need to be taken care in the new infrastructure of the plant” Sunil Kumar Vupalla, Research Scientist, Infosys

“Pilot projects, for trying out the latest technologies, are the best way to gain the confidence of the user” Pradeep Nair, Business Development Manager – Energy, National Instruments


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To enhance a full crate inspection system in the beverage industry, scrutinising and checking irregularities in the bottles is essential. The article briefs on efector pmd3d vision sensor that detects objects in three dimensions at a glance, thus, ensuring maximum quality and reliability.

PackagIng Bottles through 3d sensors

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In the beverage industry, a lot of glass is handled on a typical bottling line. Every hour up to 60,000 bottles are filled on each line. Numerous different sensors ensure that processes run smoothly. At the end of the production, the “full crate control” checks whether the crates are filled with the correct number of bottles. If a bottle is missing, the crate is rejected and the missing bottle added manually before the crate leaves the plant.

Fault sources

Fortunately, it rarely happens that a bottle is missing in a crate. If this happens, the reason for this is often the bottle packer. With its pneumatic grippers, it takes the bottles from the sorting system and puts them in the empty crates. When doing so, it can happen that a bottle is not correctly gripped. Therefore, a full crate inspection unit is installed on the following conveyor belt. With an optical 3D sensor, it looks at the crates from the top to check them for missing bottles before they are palletised and delivered.

Conventional control for missing bottles

Worldwide conventional bottling processes use diffuse reflection sensors arranged in a matrix to look at the caps of the bottles from the top. If a bottle is missing, no light is reflected back to the sensor. The sensor provides an error signal to the controller.

Control using a 3D sensor

This installation uses the full crate inspection system from the OEM Recop. The heart of the system is efector pmd3d from ifm electronic. This sensor is a 3D camera with integrated evaluation. Its resolution is 64 x 48 pixels. For each of the 3,072 pixels, the sensor supplies a distance value which is

precise to the nearest millimetre, up to 25 times per second. It looks at the crate from the top. The distance between the bottle cap and the sensor is evaluated at defined positions in the camera image. If it is outside the set range, the sensor provides an error signal and the crate is rejected. One sensor alone can reliably detect several missing bottles.

Advantages of the 3D control

Compared to the conventional crate monitoring using diffuse reflection sensors, efector pmd3d can find additional faults in the crate. Due to the distance measurement, which is precise to the nearest millimetre, it detects small differences in height. If, for example, broken pieces of glass are between the bottom of the crate and the bottle, the bottle would be slightly higher. This would be detected by the 3D sensor rejecting the crate. Photoelectric diffuse reflection sensors, however, would not detect this fault.

In addition, the vision sensor can be easily set to different shapes of crates and bottles via software parameter setting. The reference image can be selected later by using a simple switch. This eliminates the need for a mechanical modification of the reading matrix as would be necessary for the diffuse reflection sensor method. This saves time and money when the plant is retrofitted.

The surface characteristics of the bottle caps, e.g. silvery or matt dark print, which again and again lead to faults with the diffuse reflection sensor method, is not a problem for the 3D sensor. Since the 3D image is evaluated in the sensor, an external controller is not needed. The sensor’s switching output can trigger via a switching signal that crates with missing bottles are rejected.

Rejects at a glance

There is also a Ethernet process interface of the sensor to


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visualise the test result on a touch panel display. The machine operator can read the distance values for every bottle in the crate. A statistics function enables to detect the faults over a defined period. Even the information which bottle positions often lead to faults can be evaluated via statistics. Therefore, the machine operator can find and rectify machine parts, which do not function properly. This analysis is useful especially when machines are set up.

Price advantage

Apart from the technical advantages, efector pmd3d provides a clear price advantage of replacing a whole matrix of diffuse reflection sensors. Depending on the size of the crate, 12 to 24 bottles have to be monitored. The costs for cable and controller electronics have to be added. It also provides 3,072 measurement points and costs much less. The evaluation electronics are already integrated into the sensor.

Technology advantage

The efector pmd 3D is the first industrial 3D sensor that can detect objects in three dimensions at a glance. The time-of-flight measurement based on the PMD technology enables the assessment of different applications, for example the detection of volume, distance or level. The sensor chip has 64 x 48 pixels. Each pixel of this chip matrix evaluates its distance to the object. This results in 3,072 distance values at the same

time. The image of the object on the chip matrix and the respective distance values correspond to a 3D image. These values enable the detailed assessment of the object’s or scene’s characteristics up to a range of 6.5 m with an unambiguous range up to 48 m.

The evaluation unit is integrated into the device. The results can be transferred to the controller via two switching or analogue outputs and an Ethernet process interface.

The parameters of the sensor are set via pushbuttons on the device or a PC software. The sensor has an Ethernet interface for parameter setting and communication.

Conclusion

Using the vision sensor, the bottler could enhance their full crate inspection system with additional diagnostic features. An adaptation to different geometrical shapes of the crates is done easily via the software, eliminating the need for a mechanical modification. Therefore, the plant can be retrofitted much more easily and quickly. It has a better performance and costs less than the conventional solution with a diffuse reflection sensor matrix. The sensor can also be integrated easily for quality control in other industrial areas and was another important step to improve their high quality standard. ☐Courtesy: ifm electronic GmbH

Missing bottles are shown in red and statistically evaluated



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In recent years, manufacturers around the world have been under growing pressure to increase production with reduced costs. This article explains how food and beverage manufacturers can remain productive by balancing between increasing raw material prices, energy prices and pressure from retailers.

WIll the Food Industry crack under pressure?

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Jonathan WilkinsMarketing ManagerEuropean [email protected]

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Another way of protecting manufacturers’ interests would be to impose legal restrictions that ensure key obligations for retailers. One example would be guaranteeing that retailers give reasonable notice to change supply arrangements, that they deal fairly and lawfully and don’t constrain manufacturers to obtain goods, services or property from a preferred third party.

When these codes exist, they are often limited by the free market and competition law, which means that reducing manufacturing costs needs to come from somewhere else.

Think ‘lean’

The fastest and most efficient way to reduce costs is by designing and managing a manufacturing process that results in the lowest possible unit cost. This means taking a good look at the operations and identifying how they can be improved. Today, production lines operate at less than 60%, which means there is considerable room for improvement.

Identifying planned losses (cleaning, preventative maintenance or decreasing product demand), operational losses (changeovers, stoppages or shortages) and quality losses (scrap products or defective materials) is the first step in making manufacturing lean.

The next step is utilising existing real-time data collection from the process equipment to improve Overall Equipment Effectiveness (OEE). Intelligent automation solutions help minimise process variability and maximise asset use and productive capacity.

Become flexible

A flexible manufacturing line allows companies to match

According to the 2013 food statistics pocketbook, food prices in the UK have risen in real terms by 12% since 2007. This price increase is emulated internationally and is partly associated with the increasing costs of raw materials and energy. It also reflects the pressure giant retailers have been exercising on food and beverage manufacturers to provide cheaper end products.

Between a rock and a hard place This situation leaves manufacturers stuck between a rock

and a hard place since they need to comply with retailer demands and respond to particularly precarious customer preferences, while finding a way to reduce production expenses and not pass cost increases on to customers.

In a recent industry survey, 83% of the food and beverage manufacturers that responded expressed concerns of pricing pressure from retailers were threatening the quality of own-label products. Around 74% further estimated that this pressure was threatening to cut into new product development budgets. As in any other industry, lack of research and development limits innovation, which in turn, reduces investment, growth and profit. While the food and beverage industry is one of the industries that will not suffer, its potential would be significantly limited should investment in innovation decreases.

How do you reduce costs?

Moving manufacturing operations to a cheaper territory stopped being a viable solution long ago. Cheap labour isn’t strategic in the long run and most industries have already turned their backs on this option.

Jonathan WilkinsMarketing ManagerEuropean [email protected]


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their products to ever-changing consumer behaviour, which is essential in the food and beverage industry.

Batch automation allows the manufacturing of certain products in determinate batches, rather than in a continuous production process. Batch operations in the food and beverage industry include mixing, blending, mashing and fermenting, while continuous operations refer to baking, forming and pasteurisation.

A flexible production line guarantees consistent product quality for all batches, allows a more dynamic product offer and ensures efficient use of the shop floor.

Manage breakdowns

Breakdowns are inevitable, but the way they are managed, it can make or break a business. Lean manufacturing principles state that when a breakdown occurs, the first step is to try all the options that don’t incur additional costs. Whether it’s a simple case of “turn-it-of-and-on-again”, checking the system for blockages or performing an emergency maintenance, internal resources first should be used.

If the breakdown is due to faulty equipment, it’s likely that manufacturers will be able to resolve the situation by getting the part repaired or just purchasing a spare industrial automation component. For an expert business like European

Automation, most parts, including variable speeds drives (VSDs), motors, programmable logic controls (PLCs) and human machine interfaces (HMIs), are easier to find even if these are obsolete. Besides, a specialist like us can deliver them in as little as nine hours, which minimises down time and reduces costs.

If everything else fails, purchasing completely new equipment or refurbishing the production line should be considered.

Busting the myth

One of the myths surrounding the food and beverage industry is that it’s an out-of-date and old fashioned sector, which doesn’t offer exciting professional prospects.

The challenges and external pressures the food and beverage industry is faced with make the rhythm of innovation particularly swift. At European Automation we have definitely sensed a shift towards intelligent automation, reflected in the purchases our clients make. Our food and beverage clients have started purchasing newer generations of PLCs, HMIs, digital sensors and transmitters. This means that despite being under pressure, the food and beverage sectors is still a leader in innovation and has great potential for growth. ☐

A flexible manufacturing line allows companies to match their products to ever-changing consumer behaviour, which is essential in the food and beverage industry



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With high complexity and low margins, it often pays to take a simple approach to food & beverage production, to drill down to a few essentials and ensure that one is performing at optimum levels. While improving operational efficiencies, one should consider the entire production-cycle spectrum, from raw-material receipt to finished goods. At each point during production, there are four key areas that one will be required to evaluate while using the assets in the most productive way. These four categories are all intertwined, so increased efficiency in one area can impact the other three, just as waste in one category can cascade down the rest of the manufacturing process.

The four M’s

Machinery: Innovations in machine-building means that these changes don’t have to hold up productivity, with machines planning ahead for the next batch before finishing the task in hand via visible and automated processes. By implementing end-to-end quality assurance, one can both keep quality high and drive costs down by controlling wastage and process inefficiency. Standardisation helps to maintain consistency of product wherever manufacturing is carried out. Materials: In common with many food and beverage manufacturers today, one will probably be producing more

Improving operational efficiency in manufacturing is a vital element in the process of food & beverage production.To do this, it is important to consider the entire production-cycle spectrum, right from raw material receipt to finished goods. This article briefs on the four M’s essential in food manufacturing, while highlighting sustainability and line integration in the manufacturing process to acheive operational efficiency.

The Four M’s oF Food ManuFacTurIng

Cheryl LangeGlobal Marketing Programs Manager— Consumer Packaged Goods & OEM IndustriesRockwell [email protected]

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unnecessary activities. It could be that operators still carry out tasks manually when there may be a more efficient way of doing them. Can these be automated? How might one make better use of your existing team’s skills, and what one needs to do now to legislate for the skills shortages currently facing the industry?

There will always be unexpected issues that cut into the day. Even more reason to focus on the day-to-day essentials on a regular basis, one’s core assets and how they interrelate, to ensure that one is performing efficiently, competitively, and in line with industry and technological developments.

Sustainable food & beverage manufacturing

As per a survey conducted by Global Food Security, by 2050, the global population is estimated to reach 9 billion.

“Along with the need to feed this growing population is awareness of the impact the necessary increases in production have on the environment. An increase in energy usage required to drive production, increased waste for landfills, and depleting natural resources will all result from higher, more concentrated population levels”, says David Lefebvre, Industry Sales Manager CPG - EMEA, Rockwell Automation

In this scenario, manufacturers have the responsibility of balancing the need to meet increasing demand with operating safely and sustainably at the lowest possible cost. Most manufacturers are starting to track energy consumption in some capacity, whether at a site level or down to specific production lines. By monitoring consumption, these companies can make operational changes to reduce energy consumption & costs.

Access to historical data also permits management personnel to address intermittent or persistent power-quality issues, such as voltage sags or harmonics. By doing so, they can save thousands of dollars in damaged equipment or poor-quality product, and avoid penalties associated with power-factor problems on the energy grid. This type of data monitoring and analysis is critical to make improvements. Though one cannot improve what cannot be measured, but OEMs also can help their customers look ahead to what’s next.

Visible and actionable water, air, gas, electricity and steam data allows managers and operators to constantly see and resolve issues. It’s especially important to secure on-going gains because improved management of energy consumption won’t necessarily deliver substantial improvements immediately.

Energy management is a marathon, rather than a sprint, with savings measured in hour-to-hour and day-to-day increments: When and why did a machine exceed typical energy draw? Why did an equipment changeover cause start-up surges? Why did a component change extend the production cycle into a peak-draw period?

products in more varieties in a greater range of packaging options. For this reason, it’s vital that the machines can move efficiently from batch to batch, while maintaining recipe quality and consistency for each product and minimising waste.Methods: As technology advances, manufacturing methods and capabilities evolve. Is the equipment that one is currently using the most suitable for business needs? How could one make modifications to existing processes to reduce costs or wastage without affecting productivity?Manpower: With proper manpower, it is important to be focused on the task at hand while eliminating time spent on


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Visibility is the only practical way to keep track of progress. While behaviours relying on human observation and intervention – involving managers and team members that perform the activities of plan, do, check, and adjust; the key to accelerated energy-efficiency improvements lies within the streams of data running to, through and from equipment.

Line integration – time on your side

How many times has one heard saying that there are simply aren’t enough hours in the day or time waits for no one. We all know what it feels like being up against the clock, but what if one could get time back on one’s side? We haven’t found a way of getting more hours into a day or having time stand still when we need it to, and despite many successful years of developing retro-encabulator technology, the Rockwell automation R&D department has not perfected a time machine.

So, how can manufacturers get some time back? It is well understood in CPG that flexibility and agility are attributes of superior integration. Those at the forefront of line integration implementation for the CPG industry are getting new products to market in as little as half the time they were able to before integrating their lines and can be benefitting from a huge decrease in downtime attributed to cycle changes and unscheduled downtime due to failures. This also allows them to be more flexible and responsive to consumer demands for variant flavours, special editions, new packaging and all manner of product specifications.

The sheer variety of functions required by packaging machines means that they have been supplied by a vast range of machine builders to perform their various functions; filling, case making, wrapping, labelling, palletising in various flavours of performance vs cost. While the increased adoption of machines onto the ISA-88 and packaging machine language PackML practices has improved the ease of integration, it has not solved the ever present level of disparity even when standards are applied. The game changer is in the use of public

interfaces that can completely normalise these disparities for a specific line integration solution. Now, rather than those machines needing customised integration work and extensive coding for all integration into new lines, the standardised format allow supervisory systems to monitor and control all of the machines regardless of the OEM or specific programmer, in a connected, configurable, and repeatable format. This opens up visibility of the throughput of the individual machines as well as a centralised view of how the overall line is performing.

That saves the OEM or system integrator plant engineering, and management time. It also helps the end user to be more agile and responsive to consu mer needs, again, by being efficient with time. While good integration can be achieved without this type of machine interfacing, reducing the time, cost and variability of line startups and vertical integration is not fully realised without it. Having good line control and performance management capabilities working early in the line startup process has the biggest impact on the return time of capital investment. This, in turn, enables more continuous improvement and capital project investments to happen sooner.

Manufacturing that relies on traditional integration where line control and performance monitoring are completely separate efforts live in the world of lost time. Without having these two capabilities tightly integrated, it is hard to know the root cause of problems in real time. A sophisticated report that is delivered well after the fact is too late. Again, timely information at the fingers of the operators running the line provides the best results. The longer these problems linger, the more the potential costs of spoiled or scrap product resulting from the failures. Many of the associated costs can be avoided with a system that can communicate to the operator where the failure is, as well as communicate directly to other machines in the process to react as needed, whether that is to slow, stop or to continue as normal in order to balance the line. ☐

Many food and beverage manufacturers today are producing more products in more varieties in a greater range of packaging options. For this reason, it‘s vital that machines can move efficiently from batch to batch while maintaining recipe quality and consistency for each product, and minimising waste



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Facilitating process optimisation

Three-dimensional digital models of components can be created with the help of a computer tomograph (CT). The various materials of the component are represented in the digital model by different gray tones. This allows the different materials to be switched in or out of display, as desired. In addition, the digital model may be sectioned in any plane and subsequently analysed both in 2D section as well as in a cut 3D view. This can serve as a replacement for laborious manual grinding.

By means of an analysis of foreign material within the component, the distribution of pores and voids may be visualised. This enables targeted process optimisation of injection moulding and high pressure die-casting processes. The digital model can be used to determine the surface of the component. The surface contour of the component allows its dimensions to be established. Digital cutting of the surface

contour yields contours similar to those from optical measurement of sections. An advantage of using CT for dimensioning is that the measurement programs for determining the dimensions can simply be reused. This is especially useful with highly reentrant tools. A further possible assessment method is the direct comparison of the actual surface contour with the data of the CAD model. Here, deviations are displayed with colour codes, simplifying the recognition of sunk areas and component distortion.

Principles of operation

Computer tomography is an X-ray-based procedure in which the test object is scanned from different angles. The test object is, therefore, positioned on a turntable between X-ray source and detector. The X-radiation from the X-ray source is

The article deals with computer tomograph (CT), a digital model analysed in 2D section and cut 3D view, to ensure measuring accuracy and comparability of the optical measurement

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Dr Stephan MiddelkampHead, Corporate Technology ServicesHarting Technology Group, [email protected]

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partially absorbed by the test object and thus attenuated. The degree of attenuation depends on the irradiated material and the path length. The attenuated radiation is registered by the X-ray detector. This provides the radiograph of the test object from one angle. Then, the test object is rotated slightly and another radiograph is taken. This continues until the test object has completed one turn, where the number of radiographs may be set to reflect the desired accuracy.

All about the 3-dimensional digital model

After the CT scan, a digital model of the test object is calculated from the individual radiographs. In the digital model, the dependency on the path length is eliminated and the different materials of the test object are represented by different gray tones.

The accuracy of the model is a factor of the number of pixels in the detector and also the degree of magnification of the component. Since the component is placed between the X-ray source and the detector (Figure 1), its magnification increases with its closeness to the X-ray source. This magnification determines the size of a pixel of the digital model. Interpolation between the pixels allows accuracy of the model to be increased still further. With 3-dimensional models, the term voxel is used instead of pixel.

The model contains a gray tone for each voxel, which depends on its material. For a test object consisting of only one material, there is, therefore, one gray value everywhere in the test object and another gray value, where there is air. This transition between air and test object allows the surface of the test object to be determined. The analysis of components takes

place on the digital model of the test object. Here, different materials can be displayed or hidden, and digital sections can be performed in any plane. The model can be displayed either in a 3D or 2D section.

As a part of the final checks before release, the contact overlap is checked to ensure the reliability of the connection. This is conventionally performed by making sections. A section must be made to check the overlap of the power contacts. In addition, the deflection of the RJ 45 connector in the various levels of its spring must be checked. Thus, computer tomography allows a considerable simplification of this procedure. The connector is connected up and scanned, and a digital model of it is produced.

Cavities and material defects exhibit different X-ray absorption characteristics than the solid material. This allows cavities and defects to be found by the use of CT analysis of components. These can be then displayed in the digital model or colour coded to reflect their size. A cavity analysis can be performed for both plastic and metal components.

The company has used this possibility for optimising process parameters with regard to the size, number and distribution of cavities.

Determining the dimensions of components

The surface contour may be extracted from the digital model of the test object. This can be used to determine the dimensions of the component. Sections can be placed through the contour, so that dimensioning of a section is possible, analogously to conventional dimensioning. Geometrical elements can be defined in the sectional view, allowing the

Figure 1: Principle of operation of computer tomography (Source: Werth Messtechnik)

X-ray source

Test object X-ray detector

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False colour comparison of a Han housing

dimensions corresponding to the drawing to be determined. The definition of the dimensions proceeds manually by the writing of a measurement program.

However, several advantages result in comparison with conventional dimensioning. Here, sections must be made laboriously and there is the danger of distortion caused by grinding the test object. With CT dimensioning, any number of digital sections can be produced without additional effort. This allows, for example, the shape of a chamber in the vertical direction to be examined by sections at different heights. So, it is only necessary to define the measurement program in a plane. Subsequently, the location of the sectional plane can be shifted in a loop. In addition, the measurement program need only be created once, and can be reused simply by replacing the contour. This is especially useful for the dimensioning of components with several cavities.

Calibration accuracy

The calibration accuracy of the computer tomograph is determined with a pin array and a cube containing spherical caps. To ensure measuring accuracy and comparability of the optical measurement with CT dimensioning, in addition to the calibration of CT with the standard calibration jigs, investigations on HARTING components have been conducted. For instance, a chamber in a male connector was measured optically and with the CT. The optical dimensioning was performed with a plan view, and was carried out several times by several users in order to minimise the influence of the user. For CT dimensioning, the component was scanned several times and was then performed in a defined sectional plane.

While comparing the measurement results, different measurement strategies must be taken into account. With the optical measurement in plan view, a minimal dimension of the chamber breadth is read, since it is always the corresponding outermost contour which appears as the edge. With the CT,

the measurement is determined exactly in a sectional plane. This can be freely defined, which similarly allows the minimal dimension of the chamber width to be determined. Then the optical and the CT measurement results are in good agreement.

Optimised measurement procedure

Since measurement programs, once written, can easily be reused, the possibility of an optimised measurement procedure arises. When the CAD model of a new component is produced, it is used to produce the corresponding tool. But this model can also serve in parallel as the basis for producing the measurement program, using the surface contour defined in the model. When the first samples fall out of the tool, these will be scanned in and the artificial surface contour based on the CAD model will be replaced with the actual surface contour of the sample. Using the previously produced measurement program, the dimensions can then be obtained automatically.

False colour comparison

In addition to the determination of individual measurements, deviations between two contours can also be represented through false color comparison. Here, the deviations between the contours are indicated with colours. On the one hand, this allows a comparison between a real contour and a CAD contour. This enables a good overall impression of a component, which goes beyond the comparison of dimensions. For instance, this allows easy recognition of the distortion of a component or the sinking of individual contours.

Besides, two real contours can be compared with one another. In this way, the condition of a tool can be monitored or individual cavities can be compared with one another. ☐



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K N Hemanth Kumar Chief Manager Energy Efficient Motors & Transformers International Copper Association India

Adopting high efficiency motorsMotors are the workhorses of manufacturing industry offering large potential for energy cost reductions. This article deals with the significance of energy conservation by adoption of energy efficient motors across industries and benefits derived by the users and the environment.

Renewable energy and energy efficiency are said to be the “twin pillars” of sustainable energy policy. Both resources must be developed in order to stabilise and reduce carbon dioxide emissions. Sustainable energy apart from other renewable energy focuses on the ability of an energy source to continue to provide energy is distinct from low-carbon energy, which is sustainable only in the sense that it does not add to the CO2 in the atmosphere.

Moving towards energy sustainability requires changes not


only in the way energy is supplied, but in the way it is used, and reducing the amount of energy required to deliver various goods or services is essential. Efficiency slows down energy demand growth so that rising clean energy supplies can make deep cuts in fossil fuel use. Opportunities for improvement on the demand side of the energy equation are as rich and diverse as those on the supply side, and often offer significant economic benefits. The solution is to find sustainable energy sources and more efficient means of converting and utilising

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technique, and using materials with higher electrical conductivities). Reducing the electrical losses in the rotor coil or casting (e.g. by using materials with higher electrical conductivities), decreasing magnetic losses by using better quality magnetic steel, improving the aerodynamics of motors to reduce mechanical wind age losses and minimising manufacturing tolerances.

In addition to energy savings, other benefits of high efficiency motors over standard motors include cooler operating temperatures due to lower heat generation, which results in lower maintenance and a longer life; improved tolerance to voltage variations and harmonics; extended manufacturers’ warranties and rebates & tax incentives in some regions from utilities and municipalities.

Tools to evaluate motor efficiencies and lifetime costs

As part of its initiative to enhance the efficiency of motors, Motor Energy Saving Calculator, a free tool can help calculate approximate annual savings in choosing IE2 & IE3 versus a lower efficiency model. Older operating motors with low efficiencies can also be evaluated for replacement. These motors cannot be rewound to exceed their original electrical efficiency design standards.

Induction motors

Motors have evolved into a variety of types according to user requirements, design, and production costs. This section will address copper in energy-efficient alternating current (AC) induction motors because these motors are widely used in industrial drives.

The main parts of an AC induction motor are the fixed housing body (stator), a rotating assembly (rotor) and electromagnets consisting of coils of copper or aluminium wire around a core of magnetic steel.

Copper and aluminium can both be used in the stator coils, although copper coils are the standard as they are more flexible and they enhance motor electrical efficiencies due to their higher electrical conductivity. Aluminium die-cast rotors are the standard material but copper die-casting of rotors is an improved new technology that is increasingly used to enhance motor energy efficiency.

energy. There is significant energy conservation potential by adoption of energy efficient motors in the industries. Motors and motor driven systems are huge consumers of electricity, they are estimated to account for 43%-46% of all global electricity consumption as well as 69% of all electricity used by industry.

Electrical motor efficiency

Inefficient electric motors waste electrical energy. Since most electricity is generated from fossil-fueled power plants, motors and motor-driven systems are indirect contributors to greenhouse gases produced by these plants. Hence, there are compelling economic and environmental reasons to increase the use of energy efficient motors.

This is a problem for several reasons like inefficient electric motors waste electrical energy, thereby increasing electrical demand and associated electricity costs required to power motors. When electricity is generated by oil- or coal-fed power plants, the burning of fossil fuels produces carbon footprints from the usage of natural resources and emissions of greenhouse gases. Electrical energy losses from inefficient motors, therefore, waste precious natural resources, cause increased emissions of greenhouse gases, and increase operating costs (i.e. increases utility bills).

Increasing electrical energy efficiencies of motors

There are compelling economic and environmental needs to evaluate the benefits of energy efficient and premium efficiency electric motors versus their standard counterparts.

A well-designed motor can convert over 90% of its input energy into useful power for decades. When the efficiency of a motor is raised by even a few percentage points, the savings, in kilowatt hours (and therefore in cost), are enormous. For example, it has been estimated that if all countries adopted best Minimum Energy Performance Standards (MEPS) for industrial electric motors, by 2030 approximately 322 terawatt-hours of annual electricity demand would be saved.

The electrical energy efficiency of a typical industrial induction motor can be improved by reducing the electrical losses in the stator windings (e.g. by increasing the cross-sectional area of the conductor, improving the winding


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Sustainable technology: Copper die-cast rotors

The electrical efficiency of motors can be improved by replacing the standard aluminium electrical conductor in the rotor with copper, which has a much higher electrical conductivity. Until recently, die-cast motor rotors were produced only from aluminium while researchers worked on solving technological issues with copper pressure die-casting. Today, copper pressure die-casting is a proven technology and thousands of die-cast copper motor rotors are produced annually for motor applications where energy savings are prime design objectives.

The use of copper in place of aluminium for conductor bars and end rings of induction motor rotors results in improvements in motor energy efficiency due to a significant reduction in IR losses. Motor modelling by a number of manufacturers has demonstrated that motors with copper rotors yield overall rotor loss reductions from 15 to 20% compared to aluminium.

The advantages of motors with copper motor rotors on an equivalent basis with aluminium include increased electrical conductivity of the copper rotor material, plus the need for a smaller volume of steel enabling motors to be shorter in length; motors have 1‐5% higher energy efficiency ratings, so consuming less energy and motors have lower overall manufacturing costs.

Scenario of energy efficient motors in India

Bureau of Indian Standards had first introduced an exclusive standard for energy efficiency motors in 1989 (IS 12615), which covered 4-pole motors up to 37 kW. Later, the same standard was revised in 2004 with a proactive approach from the motor manufacturers. This revision covered the scope for all standard continuous duty motors up to 160kW

The use of copper in place of aluminium for conductor bars and end rings of induction motor rotors results in improvements in motor energy efficiency due to a significant reduction in IR losses

(2-pole and 4-pole), 132 kW (6-pole) and up to 110 kW (8-pole). Based on CEMEP, efficiency levels eff2 (improved efficiency) and eff1 (high efficiency) had been defined. Apart from the efficiency class, this standard also specifies other performance parameters like breakaway torque, breakaway current, minimum speed, maximum full load current, etc, for each of the ratings. In other words, this outlines performance specifications for energy efficient motors.

The Bureau of Energy Efficiency also launched its voluntary labelling plan in 2007 based on standard IS 12615:2004. The labelling plan had limited success since it awarded voluntary endorsement labels of eff2 and eff1 to the eligible applicants. The major motor manufacturers had recognised efficiency as a differentiator from the other motor manufacturers and introduced motors with higher efficiency values than the eff1 levels. Hence, the endorsement label failed to encourage such manufacturers to adopt the labels. Upon the introduction of the new IEC standard 60034-30 for the efficiency classification of induction motors and subsequent regulations based on the same adopted by different countries, the Indian manufacturers, Bureau of Indian Standards (BIS), Bureau of Energy Efficiency (BEE) and other stakeholders realised the threat of trade barriers for exports from India and potential influx of inefficient motors into the Indian market. The global harmonisation of efficiency classes, testing methods and access to global markets triggered the Indian motor industry to harmonise its standards with the latest IEC standards. During the annual sectional committee meeting of BIS for rotating machines, the BIS and BEE urged the motor industry to harmonise its standards with IEC with the immediate focus on revising the existing Indian Standard, IS 12615:2004 to make it in line with IEC 60034-30. On the basis of IEC 60034-30 and the performance parameters specified in the existing version of IS 12615: 2004, the draft of the revised standard IS 12615:2011 has been finalised and is published in August 2011.


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The main features of the revised standard are:• The ranges covered are from 0.37 kW to 375 kW for 2, 4

and 6 poles • Intermediate ratings are considered based on the Indian

markets.• The efficiency classes are in line with IEC 60034-30 termed

as IE2 and IE3• The testing method specified is as per IEC 60034-2-1.

Checking and building capacity is the major task in implementation.

• The other performance parameters like starting torque and starting current are considered and specified for all three levels (IE2 and IE3)

Way forward

The standard making body, BIS and the regulatory body BEE have been working towards bringing the supply chain, end users and other stakeholders together to harmonise Indian standards with IEC taking into account the Indian market needs and conditions. The effort of harmonisation of motor standards globally and the regulations introduced in different countries have been a trigger to move in a positive direction. On publishing the new motor standard, BIS and BEE are planning to draw a realistic but firm timeline to introduce minimum Efficiency Performance Standards of IE3.

The following barriers that need to be addressed for smooth implementation of these policies are:• Capacity building of small and medium scale motor

manufacturers to manufacture high and premium efficiency motors

• Adequate test facility establishment as per prescribed testing standards.

• Awareness creation among end users regarding life cycle cost

• Establishment of incentive mechanisms for adopting high and premium efficiency motors and penalties in case of deviations

• Premium efficiency design have an effect on other performance parameters like stating current, starting torque, slip etc, and the barriers from the markets to accept these parameters is important

• Integrate motor driven systems into the process so that the original equipment manufacturers also appreciate benefits of premium efficiencies. In India, the comparative star labeling of pump sets is the best example in this direction.

Conclusion

Motors are the workhorses of manufacturing industry offering large potential for energy cost reductions. Traditionally, capital equipment purchases are based on lowest first cost principles and motor selection is no exception. This needs to change to life-cycle costing based purchase. Purchase specifications for motors need to include efficiency in addition to basic parameters like KW and RPM. Apart from energy savings, EE Motors have a superior built and provide intangible benefits and a longer life.

The penetration of high efficiency motors and premium efficiency motors is low in India. Efforts are being made to address existing barriers. These efforts include regulatory measures, standards making and harmonising Indian standards with global trends. In spite of the regulatory measures and the supply side involvement, it is required to address the end users so as to create a pull for high efficiency motors.

BIS and BEE have been working with all the stakeholders to implement this standard (IS 12615:2011) by addressing the barriers and planning a way forward to move towards premium efficiencies in the next 2 to 3 years and compete in the global market. This combined effort of all the stakeholders will ensure that the goal is achieved. Although there are several barriers, the adoption of energy efficient motors can give immense benefits to the user as well as the country and environment. ☐

The advantages of motors with copper motor rotors on an equivalent basis with aluminium include increased electrical conductivity of the copper rotor material



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Tracing the right mark

Part tracking or traceability is vital for those that make, store or move items through supply chain because the data is used in production output calculations, inventory control, revenue forecasting and other business operations. Traceability also improves quality by ensuring that the appropriate processes are performed in the correct sequence on the right parts. To track a part through its full lifecycle, manufacturers mark it with a permanent two-dimensional (2-D) code known as a Direct Part Mark (DPM). These codes are used due to their small size, error correction and amount of data that can be stored as compared to traditional 1-D barcodes. They also help with anti-counterfeiting measures as they are more difficult to replicate.

Automated image-based ID readers are the only technology capable of decoding such marks as laser scanners are only able to read 1-D linear barcodes. Automatic identification technology eliminates any need to manually enter data during

production, avoiding human error and increasing efficiency. On fully automatic manufacturing lines, parts are handled and moved by conveyor, indexer or robot and the ID reader is mounted in a fixed position where the mark can repeatably be placed in front of the reader. Similarly, a presentation reader operates in a continuous reading cycle, automatically performing the decoding task once the operator places the part in front of the reader. This guide highlights the top considerations for implementing a DPM traceability process onto a fully automatic manufacturing line with fixed-mount code readers.

Code selection

Industry standards groups define codes for a given application like ISO 29158 (formerly known as AIM DPM). The Automotive Industry Action Group (AIAG) has guidelines

The article highlights the top considerations for implementing a Direct Part Mark (DPM) traceability process onto a fully automatic manufacturing line with fixed-mount code readers

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Didier LacroixVice President — International Sales & MarketingCognex [email protected]

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With over 40 years of experience in sensors and control systems we know that quality, reliability and economic efficiency in the manufacture of vehicles and automotive components can only be achieved with innovative automation technology. In addition to proven sensor technology, condition-based maintenance and monitoring of consumables are critical factors for success. The world’s leading manufacturers in the automotive industry rely on solutions from ifm electronic – in over 70 countries worldwide!ifm electronic – close to you!

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as do the Air Transport Association (ATA), the US Department of Defense (DoD), GS1, SEMI and others. When specified, it generally makes sense to follow the industry guidelines because it improves efficiencies throughout product manufacturing and the supply chain. However, if no guidelines are available within the industry, one can use an existing guideline to create their own, noting that Data Matrix ECC200 is strongly recommended and is clearly becoming the choice for most industries involving metal, glass, ceramic or plastic materials. It is very flexible as it offers 24 square formats and six rectangular formats to encode anywhere between six and 3,116 digits in a single code. It also supports Reed Solomon error correction that allows a code to be successfully decoded even though as much as 60% of the code may be damaged. Since this code is in the public domain, marking and reading equipment suppliers have invested significant R&D resources to improve the performance of supporting equipment.

Marking processes & placement

The 2-D DPM codes are marked on the part using several methods depending upon material composition, part application and environmental conditions. Important factors influencing the marking process decision include part life expectancy, material composition, environmental wear & tear and production volume. Dot Peening: It is achieved by striking a carbide or diamond tipped stylus against the surface of the material being marked. Reading solutions must utilise lighting techniques to create contrast between the indentations forming the modules of the symbol and the surface of the part. It is widely used in the automotive & aerospace industries due to demanding lifecycle requirements. Laser marking: It applies heat to the part that causes the

surface to melt, vapourise or change in some way in order to produce a mark. The resulting quality of the mark depends upon the interaction of the laser with the material it is marking. It is most often used in the semiconductor, electronics and medical device industries. Electro-chemical etching (ECE): It is a process whereby a mark is produced from the oxidation of metal from the surface being marked through a stencil impression. ECE is a time-consuming process and has a high cost for on-going consumables. It is used for low volume marking of round surfaces or for stress-sensitive parts of jet engines, automobiles and medical devices.Inkjet printers: It precisely propels ink drops to the part surface creating a permanent pattern of modules. It may require preparation of the part surface, as it is the chemical interaction of the ink to the surface of the part that determines the level of mark permanence and contrast. It provides fast marking of moving parts and offers very good contrast.

The location of the code on a part can directly impact the readability of the code. It should be clearly visible throughout the manufacturing process and, wherever possible, it should provide a “clear zone” free of part features and edges, noise/texture or other interference. Parts that present some of the most difficult reading situations include cylindrical or shiny parts that can create code distortion and specular reflection.

Data encoding & readability

Data encoding refers to the amount of information that is “stored” within the generated data matrix code. Deciding on what information to encode is typically driven by the company specifications and/or the requirements of the traceability project. In selecting what data to encode, one should also consider the amount of available space on the part as code size

If the bumps on the surface of a cast part

are similar in size and/or shape to the dot

peen marks of the code, readability suffers

because the code blends in with the bumps

in the surrounding image


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Laser marking applies heat to the part that causes the surface to melt, vaporise or change in some way in order to produce a mark

can affect readability. Readability defines how easy or difficult it is for a reader to successfully read a code. If a code is not readable, the part is not processed and/or the production line stops. Manufacturers live with varying read rates but should strive to achieve six sigma read rates which equates to only 3.4 defects per one million reads. One factor that contributes significantly to overall readability is the quality of the mark. The process of inspecting the quality of a mark is known as verification. The verification process is defined within the industry’s guidelines and generally takes place offline. Besides mark quality, one must consider other factors that can affect overall read rates. Successful location of the code within the field of view is the first step in successful reading. The next step is for the reader to determine which modules are light and which modules are dark. A code pattern with modules that are consistent in shape and size, but distinctively different from other features on the surface of the part provide the most reliable decoding. However, because of the very nature of DPM applications, this can be challenging due to variations in the surface texture, part presentation during the process, variability of the marking machines and changes that the parts undergo throughout their lifecycle.

Selecting a solution

There are three categories to review during the evaluation process to ensure the highest read rates possible: decoding software, image formation and ease of use. Decoding software: Code reading algorithms form the basis

for any image-based ID reader. There are many variables that impact the readability of the code like distortion due to part material composition and variations in part presentation or variability caused by the manufacturing process. Powerful algorithms can read codes marked on any surface with any form of degradation. One can test a solution with as many sample parts and variations that one can imagine. But even the most advanced algorithms can perform better and faster with the help of resolution, lighting and optics. Image formation: A reading solution should tolerate changes in contrast, focus and degradation to the code without a need to change the underlying parameter settings. One should test the setup by adjusting the aperture or exposure to simulate change in contrast, focus to simulate change in depth of field and position of the light to simulate background problems. When determining the resolution requirements, the most important thing to consider is the number of pixels per module (PPM) one will need within your field of view. Higher resolution readers can maintain a high PPM for a larger field of view, allowing for more positional uncertainty. For very high speed applications, a standard resolution reader will generally provide faster performance. Some high resolution imagers, however, allow the application to use only part of the imager, which can create even faster response times. Lighting is especially important for DPM applications involving metals or other difficult-to-read materials. The proper lighting technique for dot peen applications, for example, can make or break a process. These marks are difficult to read unless lighting adjustments can be made. An intelligent tuning technology


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with controllable lighting is a key for this application. A reader that allows the user to change the lens offers greater adaptability for the reader to be deployed for different working distances based on the machine design requirements. Very often, the machine is designed long before a reader is considered, so having flexible optics in the reader makes retrofitting easier. Ease to use: When readers are deployed, different parameters are set up to optimise the application. A step-by-step process should be intuitive for any floor personnel. In addition, the reader must be able to communicate the results to another device, easily integrating into existing plant networks through whatever communications method is required: Ethernet, RS-232, etc. For establishing a communications link between a reader and a PC at the enterprise level, one has to make sure that the reader supports a broad range of standard network protocols, including: EtherNet/IP, PROFINET, MC Protocol and Modbus/TCP. This connection also gives you a centralised way of managing the readers. Thus, the ID reader selected will allow managing and controlling activity over the network from > MORE@CLICK ADI03618 | www.AandD24.in

remote locations in the plant and beyond. Having an easy to use setup tool minimises the time it takes to integrate the reader and reduces the overall maintenance effort of the system.

Conclusion

DPM reading can be a very challenging application requiring technology and expertise solving difficult image analysis problems. Typically, companies experienced in industrial machine vision have the right expertise and technology for providing the highest DPM read rates. The chosen vendor should also be able to provide the support necessary to thoroughly qualify the application, guide one through to installation success and have the financial stability to maintain their role as your DPM reading solutions provider for the long term. ☐

Courtesy: Cognex


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Integrating control and safety requires a holistic safety mindset built around Safety Lifecycle Management, as specified by major safety standards such as IEC 61508, IEC 62061 and ISO 13849. This is a systematic, phased approach to safety with steps that are well documented and verified, from initial hazard and risk analysis to safety system implementation all the way through to system decommissioning.

Integrating safety

The steps of integrating safety include: • Design and engineering, including risk assessments &

identification, and definition of safety functions needed for a safe manufacturing process;

• Installation and commissioning, including testing of safety functions and training personnel in for safety;

• Operation and servicing, including access to documentation and spare parts for keeping machines functioning safely, periodically testing of operations and fast diagnosis of faults;

• Maintenance, including the inspection and regular

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replacement of safety-relevant components; • Modernisation and upgrading, including the

implementation of functional safety advancements as a machine’s safety design and engineering allows.Following these steps, Advanced Integration Technology

(AIT), a 20-year-old supplier of turnkey industrial automation systems for the leading aerospace suppliers, made major strides in machine safety. As a prime contractor on the Boeing 787 Dreamliner, AIT had responsibility for the final assembly and body join functions, charged with delivering a fully automated positioning and joining system. A comprehensive safety scheme with Safety PLCs is a central element in the system, which communicate using PROFINET. To help plant operators and safety engineers comply with the requirements of IEC 62061 and ISO 13849-1 standards, a TÜV certified online Safety Evaluation Tool (SET) was also available.

Alignment & positioning

For the application, two complete assembly systems and one positioning system were provided. The three main sections

sAFety liFecycle MANAgeMeNtAn application story on how Advanced Integration Technology (AIT)—an aerospace automation provider has incorporated safety PLCs, motion control, safety and standard I/O on a single PROFINET network for more efficient & compliant automation.

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of the fuselage are joined using 14 positioners mounted to transport structures that move either independently or interlocked and indexed to the factory floor for stability. Real-time positioning measurement data are logged with an integrated indoor GPS. AIT designed the alignment and positioning systems that roll under the aircraft dollies, radically reducing auxiliary equipment needs, materials handling requirements, and additional positioning steps.

Onsite at Boeing, the 14 positioning system components were moved into their respective locations near the cradle dollies. Once the system is rigidly joined, a measurement system onboard locates the airplane sections. This information is fed to the system’s software application. From those data points, the system calculates how much each section (nose, tail, left and right wings) needed to move to ensure an exact fit to the adjoining section. This precise alignment ensures a smooth, rapid build of each fuselage. Siemens was tapped to provide equipment for AIT. “We looked for a supplier with an off-the-shelf selection of automation and motion control solutions, who could offer us global support,” says Ed Chalupa, President, AIT. “Our goal was to utilise all current software, integrated safety, and control technology advancements. Both Boeing and AIT were keenly sensitive to lifecycle security issues in this critical area of the project.”

Employing PROFINET

AIT designed the overall layout of the control architecture, programmed the Motion Control system with the PLC, distributed the I/O, and integrated safety and provided support on the Boeing internal structure and lifecycle support requirements. The basic scheme of the motion control system comprises: a motion controller, a Windows-based HMI, the Safety PLC, plus fail-safe and standard I/O modules (linked via PROFIsafe), all running on a PROFINET network. This basic architecture was then multiplied by the number of control nodes for each specific operational system in the overall production line being designed by AIT.

With the addition of a few PROFINET cables and mode

selections, the final body-join assembly tool runs as a single entity. Running together in this configuration, the safety devices work coherently, providing proper response levels to all Emergency-stop situations. Each unit motion controller receives commands to perform uniform group movements with the tool as a whole via network communications from the HMI. The integrated safety concept on this overall system is based on three core principles: increasingly layered safety architectures, greater degrees of integration between the control and safety systems, plus more use of networking, especially PROFINET. In operation, these safety principles manifest themselves in the form of physical barriers and mechanical means such as walls, gates, door interlocks, and more. They all isolate personnel from danger. Meanwhile, the control systems including safety PLCs monitor operating conditions within established parameters. The final protections are safety shutdown systems such as automatic shutdown via PROFIsafe-enabled safety PLC and manual shutdown via E-stops.

Conclusion

With integrated safety and control, the project has a single system for standard and safe automation. Having one PROFINET network and one engineering system for both standard and safety technology, further reduces cost. As a collateral benefit, the software solutions allow easier replication of series machines. Likewise, faster troubleshooting and extensive diagnostics onboard reduces downtimes, with faster restart after issue resolution. Functionally, safety integration in the control system allows uniform user interfaces and data libraries, plus a reduction in the variety of control cabinets. With advanced PLC and PROFINET networking technologies combined, the system safety for AIT and its customer is a production asset that protects the workers from harm and also ensures maximum availability and uptime. Reductions in initial capital expense and field operating expense are also realised. ☐

Courtesy: PROFIBUS PROFINET


The basic scheme of the motion control

system comprises: a motion controller, a

Windows-based HMI, the Safety PLC, plus

fail-safe and standard I/O modules, all

running on a PROFINET network

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Changing face of Indian sensor market

In terms of innovation, sensing technology is moving towards smarter, more compact and more secured solutions. All players are keenly looking into bringing in smart and miniaturisation technology so as to enhance product performance towards minimising human error and improving overall product reliability. The contemporary sensors are a smart ensemble of electronics, integrated intelligence, micro-computers and software. Advanced sensing technologies are being provided and employed for edge, positioning, profile measurement & sensing applications at higher speeds & accuracies which were not possible till date.

Another interesting trend is the advent of industry-specifi c sensors. In terms of demand, the fastest growing segments are image sensors, accelerometers and position sensors (according to India Sensors Market Forecast & Opportunities-2018). Also, optical sensors, laser sensor systems, vision

technology and MEMS (Micro Electro Mechanical Systems) sensors are showing significant growth adding to the overall growth of the sensor market in India.

Growth areas: Applications and geographies

Automotive and consumer electronics industries are contributing substantially to the demand for sensors in India. In addition to these, the boost in the industrial sector led by a surge in the number of process industries is turning out to be a key driver.

Internationally, many players are diverting their core focus from mature markets such as North America and Europe to emerging economies such as China, Thailand, Indonesia and India. These emerging economies hold a significant growth potential for sensor applications. According to a report issued

Sensors are very important components that are installed in products for different applications across varied industries. This article features the latest market developments & technologies emerging in the Indian sensor market, based on rising demands from various sectors.

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Manoj KodakateryBusiness Development ManagerOMRON Electronic Components India

Se n So rS & e n coderS | t e ch n ol og y

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on ‘Sensor market opportunities in BRIC countries 2016 – Brazil, Russia, India, China’, low manufacturing cost, cheap labour, presence of OEMs are some of the factors proving effective in driving the growth of sensors market in BRIC countries. Starting with automotive and industrial applications, the sensors have made their way in other areas too in these countries such as consumer electronics and medical equipment.

Continuous technological innovation and increasing application areas for new-age sensors are pushing their demand in the market. Despite the sluggish growth of the manufacturing sector, the market is likely to remain positive during the 2015-16 period and is expected to grow at the CAGR of 14% till 2018.

Trends in India

Being a fast growing economy, security is one of the key areas to which India is looking into. Aiming to address this issue, Omron is striving to provide high-quality products and services, based on forte in sensing and control technology, so as to contribute towards the social needs pertaining to safety. Omron’s electronic components’ business mantra for this decade is “Shaping our sense of security with sensing technology”. Along with safety, the company also aims to make its presence felt in other emerging areas of Indian market such as energy, building automation, medical and automotive. In fact, MEMS technology has enabled Omron to develop advanced micro component sensors ideal for a wide variety of applications in consumer, commercial and industrial domains. Some of the key sensing solutions which are driving this

endeavour include: HVC (Human vision component) sensor: This sensor

component allows devices to understand people. Just mounting the HVC on the device makes image sensing a reality. This leads to the best matching of machines to people on every device. HVC can be used in varied aspects of building automation such as access control, operations of vending machines, home appliances and automotive. It can also be used for market analysis in retail stores to understand customer preferences even when the shops are closed.

Magnetic, radio wave & shock sensors: These are sensors which are very sensitive, accurate & can be calibrated as per the spec requirement. These are used for protection against tampering of equipment like smart meters, gaming machines and vending machines.

Fence sensors: This sensor uses special wires which can sense very small vibrations in the fence and can be calibrated according to the customer requirement. Mainly used for protecting unauthorised entry to restricted areas.

With many companies introducing the ‘smart’ factor into sensors, they are here to stay although the adoption has been slow due to inherent needs of such platforms. By now, one can ‘sense’ that there is much more in-store than one can imagine in the applications of sensors. The ever increasing and omnipresent need to automate every product so that it can sense, feel and act will never cease to end and so will keep on continuously encouraging innovation in the sensors segment. This continuous technological innovation and increasing application areas will continue to be key drivers pushing demand of sensors in the market. ☐


Fence sensors uses special wires which can sense very small vibrations in the fence and can be

calibrated according to the customer requirement

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Organised by Messe Frankfurt Trade Fairs India, SPS Automation India 2015 will be held on February 5-7, 2015 at the Mahatma Mandir Convention & Exhibition Centre, Gandhinagar, Ahmedabad. Indian Profibus Profinet Association will support SPS Automation India 2015 to showcase innovation in manufacturing, system integration and highlight the benefits of Profibus and Profinet fieldbus systems, while collaborating the best automation technology available for the Indian manufacturing industry.

Showcasing modern automation solutions

Focused on modern automation solutions for the Indian market, SPS Automation India, like the mother event SPS IPC Drives, Nuremberg, Germany, will represent a leading platform for advancements in automation and their cost optimising and

latest technologies in factory & process automation. More than 100 exhibitors from India and abroad are expected to showcase their latest technologies in industrial automation, in the show, underlining its stance as a sophisticated global business platform. With India emerging as a global manufacturing and supply hub in several verticals, Indian manufacturers are recognising the need to invest in intelligent automation and control systems to maintain their competitive edge. Currently, estimated at ` 12,000 crore (USD 2 billion), India’s automation industry is growing at an annual average of 12% which translates to massive untapped potential and huge opportunities for the sector.

Commenting on India’s high-growth path over the next decade, Raj Manek, Managing Director, Messe Frankfurt Trade Fairs India, said, “India has established itself as an economic powerhouse and has the potential to become the world’s 5th

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Platform for quality automation solutionsSPS Automation India, scheduled on February 5-7, 2015, at Ahmedabad, will provide a platform for innovations in automation, through a vast range of products, systems and services. A pre-event report...

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largest consumer market by 2025. With the projected industrial expansion stemmed by stimulation in demand for products & services, automation companies are expected to see a surge of opportunities across all verticals.” He further stated, “With the fair being centred in Gujarat, this will be the perfect opportunity for sector players to establish and strengthen their presence in the Indian market.”

Concurrent shows

Exhibition companies P E Schall GmbH & Co KG and Mesago Messe Frankfurt GmbH are joining forces by collaborating on a trade show project in India to draw attention to dynamically expand the Indian market. The companies want to combine SPS IPC Drives, Motek, and Control – the leading industry trade shows. While SPS IPC Drives is Europe’s premiere event for electrical automation, Motek (International trade show for production and assembly automation) and Control (International trade show for quality assurance) set the global benchmark in their segment.

At the fair, industry professionals will be able to gain a first-hand experience on smart, safe and sustainable automation solutions that will help improve business profitability and optimise manufacturing processes to make operations cleaner, safer, secure and more efficient.

Seminars and demos

A technical conference has also been planned along with the three fairs to provide sector professionals an understanding of new processes and technology trends making a headway in the manufacturing sector.

Day 1 of the SPS Automation India seminar will witness a session on Industry 4.0, briefing on what has been achieved in Europe and the way forward for India. This will highlight Internet of Things and interoperability by Ravi Aggarwal, Director, Pepperl+Fuchs. Besides, there will be presentations on operational & functional safety, advances in sensor technology, control systems, drives and motors – innovations for Indian market for better energy efficiency.

Presentations on manufacturing competitiveness and role

of automation technology by SN Ambardekar, former VP—Manufacturing, Commercial Vehicles Business Unit, Tata Motors; significance of first-step automation for small & medium scale industries & top technical challenges by Vipin Bhogal, Consultant, Steinbeis India and significance of standards in industrial automation by Dr S Rominus Valsalam, Associate Director & Head— Automation Systems Technology Centre (ASTeC) will be discussed on day 2.

Major exhibitors at the fair

Some of the major exhibitors participating in the exhibition include Pepperl+Fuchs, SICK India, Baumer Technologies India, Delta Electronics India, Endress+Hauser India, Geissel India, Harting India, ifm electronic India, Micro-Epsilon, Omron India, Themis Automation (Murr Electronik), Nikon India and Vipa Automation India, among others.

With the “Make in India” campaign in the backdrop, the three-day fair will provide visitors the unique opportunity to witness the latest innovations in industrial automation to suit their emerging market & technology requirements. ☐


“SPS Automation India 2015 will offer the visitors a new & perfect platform to source the right solutions for their automation tasks” Atul Dave, Managing Director, SICK India

“The show will introduce the latest technologies and products for automation, to create the necessary network & community in this domain in India” Ravi Agarwal, Director, Pepperl+Fuchs (Factory Automation)

“The exhibition is important as India is a big growing economy with different industries that need precise sensors for their machines & devices to optimise production processes in the future” Johann Salzberger, Managing Director - Marketing and Sales, Micro-Epsilon

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National Instruments, a world-wide leader in the test and measurement industry, recently hosted the 11th annual NIDays 2014 in Bengaluru. The event, attended by more than 800 engineers, academicians and researchers, witnessed participation from NI customers and alliance partners across a range of industries including healthcare, semiconductor, aerospace, automotive, life sciences, robotics and telecommunication. More than 1000 innovators got the opportunity to learn about the latest technologies to accelerate productivity for software-defined systems in test, measurement and control.

The keynote during the event was delivered by Alex Davern, Chief Operating Officer, National Instruments. Addressing the conference, Davern said, “NIDays is the biggest platform to witness how our Indian customers are solving some interesting challenges with NI tools. Our successes have come from a philosophy of relentless investment in innovation. We

have a team of 170 R&D specialists in Bengaluru and over 2000 people over the world. With the latest technology advancements, we feel like the technologies in the offing can really help redefine how industry works to continue addressing the world’s biggest challenges.”

Significance of NI Days in the Indian market

The conference included technical sessions and dedicated stalls to demonstrate various solutions in sectors like aerospace, life sciences, robotics and telecommunication. “It’s a prime opportunity for our company to launch latest products in the Indian market. We have around 2000 customers including influential professors, engineers and scientists. Since our core application LabView is used in a wide spectrum of industries & academia in India including IIT, TATA & Indian military, our focus is to bring low cost technology in the Indian market”,

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Introducing futuristic technologiesThe 11th annual NIDays2014 was recently held in Bengaluru by National Instruments to showcase new age technologies for software-defined systems in test, measurement & control. A report…

Srimoyee Lahiri Sub-editor & [email protected]

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said Davern. “The Indian market is very open to experimenting the latest hi-tech automation related technologies with better functionality. We believe engineering students need to be given better opportunities for experiential learning and innovative thinking. To make this happen, we are actively working with many universities in India, by developing centres of excellence where students get to work with our technology to prototype their concepts”, he added.

Addressing the conference, Victor Mieres, Vice President, Emerging Markets, Asia / Rest of World, said, “NI’s Indian operations have more than 300 personnel, with around 120 members catering to its R&D activities. NIDays for us is to showcase the newest products, in the Indian market. More specifically, we like to showcase what our customers are doing with our products, i.e. the impact of the technologies in their lives & business. We drive inspiration from our customers and it is a great opportunity to highlight some of the successes of our partners.” He also highlighted how in the area of test, the company has come up with higher frequency RF communication device test product that empowers users to do test in RF devices in a much faster & sophisticated way. “We have also announced the new version of LABVIEW 2014, the flagship software of NI with hundreds of new benefits. Apart from this, we also have a product in the offing dedicated to the market of rotating machinery”.

Display platter

The seminar launched the NI InsightCM Enterprise, a new software solution that helps companies gain insight into the health of their capital equipment for machine maintenance and operations. NI InsightCM Enterprise is an end-to-end software solution that addresses big analog data challenges and builds on the industrial Internet of Things. As the Internet of Things (IoT) evolves to become more mainstream, the company is committed to bridge the gap between vision and implementation. The Internet has undergone various levels in its relatively short life span from consumer IoT to industrial IoT. This evolution will benefit individuals and businesses by removing physical barriers. Internet-powered technology innovation within the industrial operations space adds new dimensions to the technology space.

Davern said, “With the tremendous amount of aging machinery in power plants, steel mills and factories in India, the industrial Internet of Things is a critical element that will ensure the uptime and optimisation of these systems. We believe that NI InsightCM™ Enterprise will enable organisations to monitor critical machinery, analyse vast amounts of data and make meaningful business decisions.”

Key benefits

The key benefits of NI InsightCM Enterprise are:Cost-effectiveness: It lowers the instrumentation cost for monitoring both critical and other plant equipment at a fleet-wide scale; offers open software architecture to access data and gain interoperability with third-party enterprise software packages, such as CMMSs, database historians and prognostics tools.Easily scalable: It scales from one to hundreds of nodes per NI InsightCM Enterprise server and replicates one solution at multiple facilitiesFlexible: It incorporates CompactRIO to adapt to changing sensory needs while maintaining the user’s investment in the platform.

The company is also working on 5G technology which will make the industrial IoT much more accessible and feasible. The event concluded with an award ceremony where the Application of the Year was awarded to the team from National Aerospace Laboratories for their application titled Drishti Transmissometer. ☐


“We drive inspiration from our customers and NIDays is a great opportunity to highlight some of the successes of our partners” Victor Mieres, Vice President, Emerging Markets, Asia / Rest of World, National Instrument

“With the tremendous amount of aging machinery in power plants, steel mills and factories in India, the industrial Internet of Things is a critical element that will ensure the uptime and optimisation of these systems” Alex Davern, Chief Operating Officer, National Instruments

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able to sustain vibrations. The connecting glands must be unaffected by the oil as well. The cables must be ingress protected. IP is a European rating standard for measuring the degree of protection offered by mechanical and electrical equipments against solid and liquid particles. It is mandatory for cables used in the machine tool industry to be IP67 and IP68 certified i.e. the cables should be dust resistant and must be protected against temporary/ continuous immersion in liquids. HFFR (halogen free fire resistant) cables are mandatory accounting for the safety of the staff and surrounding equipments.

Benefits

Depending on the application, Lapp suggests the types of cable from its wide range of power and control cables.

Perfect cable solutions for tight spaces: Since the equipments have space constraints, the cross-sectional size of the cable has to be as small as possible without affecting the nature and the performance of the equipment.

Cables for safe and secure transmission: Control panels and machine automation systems require transmission of signals from one point of the system to another. This is possible through data communication cables, which can transfer large amounts of data in a fast and secure manner. Care is taken to ensure the data cables are adequately protected from the

electromagnetic interference produced by the power and control cables.

Reharnessed cables to keep hazards at bay: The hazards of a loosely connected wire can be avoided by using reharnessed cables whenever possible. These cables are accompanied by their respective cable glands. This arrangement ensures that the cables are securely connected and one does not have to look for other cable gland suppliers.

Finding cables made easy: Since the underside of the control panels and machine automation systems looks like a colourful assortment of noodles, it becomes extremely confusing for the technician to locate faults. To respond to this problem, the company provides cable marking products. ☐Courtesy: Lapp Cables

India stands 16th in production and 11th in the consumption of machine tools in the world as per the 2014 Gardner Business Media survey. The country is set to become a key player in the global machine tools industry and is likely to see substantial high-end machine tools manufacturing. Industry experts say that the phenomenon is linked to the spurt in manufacturing, for which the machine tools sector serves as the mother industry. Since, the manufacturing capacity is stagnating and the growth rate for the machine tools industry is falling in developed economies, shifting machine tools capacity to low-cost high skill geographies like India, has become imperative.

Key trends

The key trends pertaining to India’s Machine Tools Industry are:• Top 20 players in the sector account for over 70%

of its domestic production.• The market is dominated by imports which

account for 67% of the total industry demand.• The machine tool industry is expected to grow at

a healthy growth rate (CAGR) of 20% until 2020.The industry growth drivers include key user

industries like automobile, defence, aerospace and power are set to fuel the growth. The domestic demand is expected to grow at 15% and domestic production between 20-25% and the industry is moving towards increasingly sophisticated CNC machines driven by demand.

Characteristics of cables in the machine tools industry

Machine tool industry is inherently complex and cable requirements of this industry vary from machine to machine depending on the type of equipment. However, some of the common characteristics include all machines require constant oiling and regular maintenance in order to ensure no harm comes to the machines on repeated usage. The cables, however, should be oil resistant. Oil has a tendency to get absorbed into the cable resulting in swelling & softening and eventually degrades the tensile property of the cable. Cables must also be

Care is taken

to ensure the

data cables

are adequately

protected from the

electromagnetic

interference

produced by the

power and control

cables

sOLuTIONs fOr mACHINE TOOL INDusTrYThe article highlights the primary cable requirements in the Indian machine tool industry which enhance substantial high-end machine tools manufacturing


Tech Talk Lapp Dec-Jan 15.indd 76 12/17/2014 5:17:26 PM

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Noisless brush motors

crouzet Motors’ DCmind brush motors are quiet, even under full load, and

offer efficiencies, long service life, and a wide range of gearboxes and

accessories. With virtually noiseless

operation, these motors are particularly

well suited to applications in medical,

biopharmaceutical, laboratory, industrial

machinery and high performance office

equipment and systems. These can also be

used in a variety of other high

performance applications such as pumps

and valves, railway and railcars, as well as

military and aeronautics. These motors have a noise level of only 35 dB,

about the sound of a whispered conversation and 20 dB less than the

current motor standard range. The new product range includes 15, 25 and

55 watt motors with a 42 mm diameter, and 55 and 104 watt motors with

a 63 mm diameter. These motors support 12, 24 and 48 volt power

supplies and are available with seve ral accessories and adaptations,

including rear brake, optical or hall effect encoders (1 or 2 channels),

connectors and wires, voltage, speed and power, etc.

DCmind Brush Motors

Thermocouple terminal blocks

connectwell Industries has released the thermocouple terminal blocks

that are used with thermocouple wires in measurement applications. As

per DIN 43713 & DIN 43714 the current

carrying element of the terminal block is

made of the same material as the

thermocouple wire. These special current

carrying elements ensure that there is no

loss of potential at the connecting points.

There are different types of thermocouple

wires that can be connected using standard

thermocouple terminal blocks. It includes

‘K’ type – chromel (Ni/Cr), alumel (Ni/Al);

‘J’ type – iron (Fe), constantan (Cu/Ni);

‘T’ type – copper (Cu), constantan (Cu/Ni) and ‘E’ type – chromel (Ni/Cr).

The terminal pitch is 43 mm; connection possibility: stranded wire 0.2

– 2.5 sq mm, solid wire 0.2 – 4 sq mm; approvals: IECEE, CE; rated voltage

of 1000 V and rated current: 10 A. These terminal blocks are an ideal

choice for heaters and boiler applications with thermocouples.

Test & evaluation kit for real-time Ethernet

hilscher gmbh has introduced a test and evaluation kit for the six most

common Real-Time-Ethernet

systems. The kit is suitable for

development, test labs, education

& end users. It contains a cifX

master PC card, three NXIO slave

test-devices and a netANALYZER

as Ethernet analysis device with

Gigabit-Ethernet PC-interface.

Furthermore, the kit contains

Ethernet cables, power supply and

master and slave firmwares for

EtherCAT, EtherNet/IP, Modbus TCP,

POWERLINK (slave only), PROFINET and sercos. The comprehensive

documentation helps the user in a step-by-step guide through the

configuration of the network using SYCON.net and explains the

measurement of important network parameters using the netANALYZER

which has no influence on the network, analysis methods supported with

graphic output, captures all process data with name resolution & always

passive with zero delay.

Etanorm SYT pump series

Real-Time-Ethernet

> MORE@CLICK ADI03624 | www.AandD24.in > MORE@CLICK ADI03625 | www.AandD24.in


Power & signal connectors

Fischer connectors has recently launched MiniMax™ series – a high

density miniature solution with a unique combination of power & signal

contacts which enables more

functionality into smaller devices

and lowers the total cost of

ownership. This connector is

ideally suited for hand-held or

body-worn applications, for

instrumentation and for test

equipment where user-

friendliness and easy handling

are a must. The pin socket

version of the series is available as standalone connector, mounted on a

flex or cabled by the users, or as a complete pre-cabled solution. While

the 24-pin configuration is available with 4 power and 20 signal contacts,

the 19-pin configuration of these series features 4 power and 15 signal

contacts as standard, with a unique feature to increase the number of

power contacts depending on the cable used. Within the signal contacts,

there are 2 advanced contacts for USB power connections as an

available option.

Fischer MiniMax™ Series


Email: [email protected] | Tel: +91-080-4113-2204/05Custom Sensors & Technologies | Bangalore

Email: [email protected] | Tel: +91-0124-4255-642/ 45

Fischer Connectors India | Delhi

Email: [email protected] | Tel: +91-251-3980-600/3980-800Connectwell Industries | Mumbai

Email: www.hilscher.in | Tel: +91-8888-750-777

Hilscher India | Pune

Tech_news_NEW rect_Dec-Jan A&D15.indd 77 12/17/2014 7:13:48 PM

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Email: [email protected] | Tel: +91-20-2563/ 0211HMS Industrial Networks India | Pune

Email: [email protected] | Tel: +91-20-2674-1009

MICRO-EPSILON | Pune

Email: [email protected] | Phone: 91-20-2712-2486/85Samudra Electronic System | Pune

Email: [email protected] | Tel: +91-9900-57-344MurrElektronik India | Bangalore

Remote management solution

The Netbiter Remote Management solution from hMS Industrial networks

allows automation devices using EtherNet/IP to be monitored and

controlled via the web. By connecting a Netbiter EasyConnect 300-series

gateway, users of EtherNet/IP-based equipment can

do maintenance from any location. With Netbiter,

users can configure EtherNet/IP devices remotely

using their regular configuration software (RSLogix

for example); log trends and monitor performance

over time. The user connects an EtherNet/IP-based

automation device to a Netbiter gateway via the

LAN port. The gateway sends data via Ethernet or

the cellular network to the cloud-based data

centre called Netbiter Argos. Users can access

Netbiter Argos at www.netbiter.net using a regular

web browser. They can also set up a secure tunnel to the remote machine

or equipment which enables commissioning and debugging just as if they

were on site. Other included features of the new Netbiter release includes

the ability to group and filter alarms and free access to map functionality

showing the exact location of each Netbiter gateway.

Magneto-inductive displacement sensors

Micro-epsilon has offered the mainSENSOR MDS-40-MK and LP series of

sensors — a new generation of cost-effective and flexible magneto-

inductive sensors. Four MDS-40-MK series

predefined sensor variants are available

with different connector, power supply and

output options. These parameters,

including the protection class, can be

individually configured to suit the

customer’s specification for series

production of 200 pieces or more.

Regardless of the order quantity, the

printed circuit board of the MDS-40-LP

sensors can be adapted to suit the

individual application and to other customer requirements. With both

series, the measuring ranges can be defined by selecting the

corresponding magnet type for the respective target and measuring

arrangement. The sensor is based on an innovative measuring principle,

which has been developed to combine the advantages of both inductive

and magnetic sensors. As different strength magnets are applied,

measuring ranges of up to 55 mm can be achieved.

Netbiter Remote Management

mainSENSOR MDS-40-MK

Energy saving LED luminaries

Samudra electronic System has launched Smart series energy saving LED

luminaries — the high mast lights that are

designed for outdoor and indoor

applications. Its multiple applications

include illumination of sea ports / air ports;

municipal roads; outdoor sports arenas; gas

stations; general area; tunnels; shop floor

of auto industry / workshop; warehouse;

petrol pumps at canopy portion and many

other locations which are at heights and not

easy for routine maintenance. Its technical specifications include a lifespan

of 40,000 - 50,000 hrs; colour rendering index (CRI)>80Ra and isolated

power supply with spike protection. Its input voltage range is 85-265 V AC

with 50-60 Hz. It can operate in a wide voltage range and has active power

factor correction of >0.98 with an efficiency of power supply of 84%. It is

available in colour temperatures of 4000 K (warm white), 5700-6500 K

(cool white) and its metal core PCB is used for efficient heat management.

LEDs are mounted on metal core PCB under anti-static environment by

SMT automatic pick-and-place CNC machine.

LED Luminaries

Fieldbus station for control cabinets

Murrelektronik's Cube20S is a compact, efficient fieldbus station for

control cabinets. The new modules

also feature modular designs - a

characteristic for these products.

Cube20S connects slim input and

output modules with a width of only

12.5 mm for base modules with

integrated bus nodes. Digital and

analog modules with two, four or

eight channels are available, as well

as function modules like counters or

potential distributors. Combining the standard output modules with safety

MIRO Safe+ make it possible to safely switch off non-safe outputs up to

category 3 PLd. Modules for active safety applications up to SIL3 and PLe

are also planned. The fieldbus stations can be precisely configured

according to the engineers’ need for their installations. It is available for

the fieldbus systems Profibus, DeviceNet, CANopen, Profinet, Ethernet IP,

Ethercat, and Modbus. This wide variety of models and the short response

times (up to 20 μs) make Cube20S suitable for a large number of

applications.

Cube20S






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Configurable control systems

Pilz has recently introduced PNOZmulti configurator — configurable

control systems that bridge the gap between classic safety relays and

programmable control systems. The configurator guides the programmer

step-by-step. First of all, the user selects the hardware he needs for his

machine via “drag & drop”. This

consists of a base unit and, if

necessary, expansion modules with

safe inputs and outputs, the number

of which is displayed in table form.

The integrated feasibility check

stops the user selecting expansion

modules incorrectly: only the

modules supported by the inserted

base unit are made available for

selection. The PNOZmulti configurator provides assistance if the permitted

number of expansion modules is exceeded or if modules are positioned

incorrectly. Online help is always available during configuration. The

configurator downloads the entire safety program on to a chip card. The

chip card does not necessarily have to be inserted in a base unit. The

program can also be copied via an external read/write device.

Email:[email protected] | Tel: +91-80-43002000Analog Devices India | Bangalore

Email: s.handoo@pilz | Tel: +91-20-2421-3994/95

Pilz India | Pune

Email: [email protected] | Tel: +91-124-3894000Pepperl+Fuchs India | Gurgaon

Email: [email protected] | Tel: +91-80-4058-999

SCHUNK Intec India | Bangalore

Compact mechatronic rotary module for flexible rotations

SchUnK’s ERS rotary modules are developed for rotary movements in the

medium load range. The compact mechatronic rotary module is available

in unit size 170 with a height of 66

mm, achieving a nominal moment of

5 Nm, and a maximum moment of

up to 17 Nm. It is used for

implementing flexible and compact

system concepts. The core piece is

a torque motor with a hollow shaft.

It is light-weight and compact, and

is absolutely wear-free, making it

very reliable. It can endlessly turn

up to 250 rpm to any intermediate

position at a repeat accuracy of 0.01°. In contrast to rotary modules with

a conventional servo motor, the ERS has no additional interfering contours

and no elasticity. In order to feed compressed air or signals without hoses

or cables through the module, the compact module is available in a

version with pneumatic-electric feed-through, by using a slip ring or air

channel of up to eight electric signals (24 V DC / 2 A), and a fluid with a

pressure of up to 8 bar.

Wireless sensor development kit

Analog Devices has introduced a suite of comprehensive development kits

enabling manufacturers of industrial equipment to easily add remote

sensing and monitoring capabilities to their Internet of Things and Big Data

products via a scalable wireless network. The

wireless sensor development kits significantly

reduce the time and effort required to move

designs from proof-of-concept to production

release. The out-of-the-box kits allow

engineers to establish a working wireless

sensor system in 15 minutes to report and

analyse remotely various types of sensor data,

such as temperature, humidity and motion/

vibration. Along with two multi-sensor-node boards, the demo kits include

a base station connector, an emulator platform, and a full-featured

software package that includes a robust communications protocol stack

and rich graphical user interface. The bill-of-materials for the multi-sensor

boards is comprised of an integrated RF transceiver and ARM Cortex M3

microcontroller (ADuCRF101) as well as multiple sensor elements that

include the industry’s lowest power triple-axis accelerometer (ADXL362).

Comprehensive development kits

Detection scanners for field monitoring applications

Pepperl+Fuchs’ powerful Pulse Ranging Technology (PRT), the R2000

detection scanner is the ideal solution for demanding field monitoring

applications and assistance systems. Empty bay detection and gap

recognition are as easily accomplished as the detection of overhanging and

interfering products in high-speed AS/RS applications.

Assistance systems for collision avoidance in both

automatic guided vehicles or manually controlled

forklifts and tuggers are another class of applications

where the PRT-enabled R2000 detection offers

outstanding features and performance. The speed

and performance of the scanner is due to the

revolutionary PRT measurement principle, a true

time-of-flight technology based on ultra-short,

high-intensity light pulses. The scanner offers

exceptional ambient light immunity and unparalleled precision, even at

long distances. Together with all products in the R2000 family it uses a

unique rotating measurement head instead of an complex rotating mirror

design. This approach provides several important functional enhancements

including a wobble-free scan plane and a 360o field of view.

R2000 detection scanner

ERS rotary modules


PNOZmulti configurator



80 A&D I n d i a | D e c ’ 14 - J a n ’ 15

Highlights - (Feb-Mar 2015)

h Igh l Igh t s | compA ny InDex | Impr Int

company IndexName . . . . . . . . . . . . . . . . . . . . . . . . . Page

Ajay Kumar Garg Engineering College . . . . . . 57

Analog Devices . . . . . . . . . . . . . . . . . . . . . 79

ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B&R Industrial Automation . . . . . . . . . Cover,8,9

Bentley Systems . . . . . . . . . . . . . . . . . . . . . 12

Bharat Bijlee . . . . . . . . . . . . . . . . . . . . . . . 25

Connectwell Industries . . . . . . . . . . . . . . 11, 77

Contrinex Automation . . . . . . . . . . . . . . . . . 31

Cognex . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

CST Sensors . . . . . . . . . . . . . . . . . . . . 19, 77

CD-adapco . . . . . . . . . . . . . . . . . . . . . . . . 10

CII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Delta India Electronics . . . . . . . . . . . . . . . . . . 3

Danfoss . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Dow Corning . . . . . . . . . . . . . . . . . . . . . . . 12

Eplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

European Automation . . . . . . . . . . . . . . . . . 38

Emerson . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 2

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Fischer Connectors . . . . . . . . . . . . . . . . . . . 77

Galil Motion Control . . . . . . . . Back Inside Cover

Hannover Milano Fairs India . . . . . . . . . . . . . 17

Hannover Messe . . . . . . . . . . . . . . . . . . . . 15

Harting Technology Group . . . . . . . . . . . 12, 46

Hilscher India . . . . . . . . . . . . . . . . . . . . 37, 77

HMS Industrial Networks . . . . . . . . . . . . 49, 78

Hummel Connector Systems . . . . . . Back Cover

ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 55

IFM Electronic India . . . . . . . . . . . . . . . . 34, 61

ICAI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Igus India . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Janatics . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Kubler Automation . . . . . . . . . . . . . . . . . . . 59

Lapp India . . . . . . . . . . . . . . . . . . . . . . 14, 76

Messe Frankfurt . . . . . . . . . . . . . . . . . . . . . 63

Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . 7, 78

Moxa Americas . . . . . . . . . . . . . . . . . . . . . 20

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 65

Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 53

MurrElektronik India . . . . . . . . . . . . . . . 33, 78

National Instruments . . . . . . . . . . . . . . . . 6, 74

NORD Drivesystems . . . . . . . . . . . . . . . . . . 14

NTPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Omron Automation . . . . . . . . . . . . . . 1, 14, 70

Profibus Profinet . . . . . . . . . . . . . . . . . . . . . 66

Pepperl + Fuchs . . . . . . . . . . . . . . . . . . . . 79

Pilz India . . . . . . . . . . . . . . . . . . . . . . . 51, 79

Rittal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Renu Electronics . . . . . . . . . . . . . . . . . . . . . 45

Rockwell Automation . . . . . . . . . . . . . . . . 5, 42

Samudra Electronic System . . . . . . . . . . . . . 78

Schunk Intec India . . Front Inside Cover, 10, 79

SPS Automation . . . . . . . . . . . . . . . . . . . . . 72

VEGA India Level and Pressure Measurement . . 13

Vipa Automation India . . . . . . . . . . . . . . . . . 18

Hannover Messe 2015

a curtain raiser on the world’s leading show for industrial technology highlighting innovations and groundbreaking solutions in the core sectors i.e. industrial automation and IT, energy and environmental technology, industrial supply, production engineering and services, as well as R&d.

Software & Engg Tools »Software & engineering tools automate project management activities; manage all work products produced throughout the process, and assist engineers in their analysis, design, coding and testing work. The next issue will see how these tools can provide for better productivity and efficiency.

Drives & Components » With a consistent programming structure and common operator interface, drives ease programming and configuration, and reduce set-up time, training, and operation. Today’s drives offer a broad range of control modes, features, options, and packaging, as well as global voltages and many power ratings. The next issue will feature latest drives & components with details on the current developments in this area.

Pharma & Packaging »as per recent reports, the Indian pharmaceutical market is projected to grow at a caGR of 12-14% to become a $ 24 billion market by 2015. With this in the background, the next edition will feature the latest automation case studies and technologies catering to the emerging requirements of this industry. The next issue will also highlight the latest technologies in packaging automation, while discussing latest innovations and R&d in this domain.

ImpRInT

Publisher / Chief Editor Shekhar Jitkar [email protected]

Deputy Editor Sumedha mahorey [email protected]

Sub-editor & Correspondent

Srimoyee Lahiri [email protected]

Features Writer megha Roy [email protected]

Advertising Sales Sagar Tamhane (Regional Head - north & east) contact: +91 9820692293 [email protected]

dhiraj Bhalerao (Regional Head - West & South) contact: +91 9820211816 [email protected]

prabhugouda patil Bengaluru contact: +91 9980432663 [email protected]

Advertising Sales (Germany) caroline Häfner (+49 - 89 - 500 383 - 53) doreen Haugk (+49 - 89 - 500 383 - 27) [email protected]

Overseas Partner Ringier Trade media Ltd china, Taiwan & South-east asia Tel: +852 2369 - 8788 [email protected]

Design & Layout Sovan Lal Tudu (Senior designer) [email protected]

Editorial & Business Office publish-industry India pvt Ltd 302, Sarosh Bhavan, dr ambedkar Road, camp, pune 411 001, maharashtra, India ph: + 91 - 20 - 6451 5752

Board of Directors Kilian müller (ceo - Worldwide) Hanno Hardt (Head - marketing & Business development) Frank Wiegand (coo - Worldwide) Shekhar Jitkar (publisher / chief editor)

Subscription cover price: `100 annual Subscription price: `600 [email protected] ph: +91-20-6451 5754

Printing Kala Jyothi process pvt Ltd, S.no: 185, Kondapur, R R district, ap 500 133, IndIa

Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed w.ith express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted.

Internet http://www.aandd24.in

Highlights_Dec-Jan15.indd 80 12/17/2014 6:19:40 PM

GALIL MOTION CONTROLALL THE RIGHT MOVES FOR ULTIMATE PRECISION

Our cost effective standard

or custom motion controllers

can handle virtually any application.

Select any number of axes and I/O.

Choose internal servo or stepper drives

for one small package, or connect to

external drives. Our products are easy-to-

program, can be up and running in minutes,

and are backed by unparalleled technical support.

galil.com1.800.377.6329

RNI No.: MAHENG/2010/34602

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