the accumulating case - control design

JUL

Y 2

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9

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HOW PRECISE IS PRECISION?

The accumulating case for deterministic control

Time-sensitive networks have many parts under development with some starting to emerge as real products, but the industrial specifi cations will need a few years to mature

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FEATUREScover story

The accumulating case for deterministic controlTime-sensitive networks have many parts under development with some starting to emerge as real

products, but the industrial speci�cations will need a few years to mature

Dave Perkon, technical editor

26

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41

CONTROL DESIGN, (ISSN: 1094-3366) is published 12 times a year by Putman Media, 1501 E. Woodfield Rd., Suite 400N, Schaumburg, Illinois 60173. (Phone 630/467-1300; Fax 630/467-1124.) Periodical postage paid at Schaumburg, IL, and at additional mailing offices. Address all correspondence to Editorial and Executive Offices, same address. Printed in the United States. ©Putman Media 2019. All rights reserved. The contents of this publication should not be reproduced in whole or part without consent of the copyright owner. POSTMASTER: Please send change of address to Putman Media, PO Box 1888, Cedar Rapids IA 52406-1888; SUBSCRIPTIONS: To change or cancel a subscription, email [email protected] or call 1-800-553-8878 ext. 5020. To non-qualified subscribers in the United States and its possessions, subscriptions are $96.00 per year. Single copies are $15. International subscriptions are accepted at $200 (Airmail only.) Putman Media also publishes CHEMICAL PROCESSING, CONTROL, FOOD PROCESSING, PHARMA MANUFACTURING, PLANT SERVICES, SMART INDUSTRY and THE JOURNAL. CONTROL DESIGN assumes no responsibility for validity of claims in items reported. Canada Post International Publications Mail Product Sales Agreement No. 40028661. Canadian Mail Distributor information: World Distribution Services, Inc., Station A, PO Box 54, Windsor, Ontario, Canada N9A 6J5. Printed in the United States.

table of contentsVolume 23, No. 7

ControlDesign.com / July 2019 / 5

motion control

What is the point of precision?How to clarify the meaning

of precision for better

understanding of motion

Bill Hennessey, Alio Industries

38

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9 editor’s page

Grow your own cloud solutionMike Bacidore, editor in chief

11 live wire

How special is a controls engineer?Dave Perkon, technical editor

12 embedded intelligence

How to diagnose network issuesJeremy Pollard, CET

13 technology trends

Collaborative plusRick Rice, contributing editor

15 indiscrete

The birth of an alarm lifecycle

PCB makers

GOP reps call for tari� s against China

43 real answers

How to size motors properly

47 product showcase

50 automation basics

Be gentle and accurate with linear motionDave Perkon, technical editor

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table of contentsVolume 23, No. 7

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SOMETIMES THE BEST ideas are developed internally. By leveraging cloud-based analytic

technologies from Honeywell Connected Plant (HCP), a six-month internal initiative

boosted productivity of machinery and processes running within Honeywell’s own Perfor-

mance Materials and Technologies (PMT) division. The pilot program increased revenue

and capacity by more than 2% at the PMT plant in Orange, Texas, demonstrating the value

that today’s cloud analytics can provide toward recognizing hidden asset performance

degradation and how assets interact with the processes they serve.

“We make low-density polyethylene,” said Will Olp, manufacturing director of the

additives-and-chemicals PMT, in his presentation at Honeywell Users Group Americas in

Dallas. “We were having more unplanned downtime than business could support.”

The plant had experienced several unplanned shutdowns over 24 months, an esti-

mated $20 million negative impact,

explained Olp. Performance analysis

and reporting was lagging, manually

gathered biweekly. Maintenance was

highly reactive, repeatedly �nding

shutdowns were avoidable. And

communication paths between engi-

neering and reliability/maintenance

were inef�cient.

“The plant incurred several costly unplanned shutdowns,” explained Olp. “There were

myriad operational challenges and worn plant infrastructure. We didn’t want to wait for

the engineers to do the analysis. We were able to take the process information and apply

it to the algorithms and data that were being streamed into the cloud. I started this pro-

cess in May 2018, and we had a solution in place in September.”

The project team combined reliability engineers, process engineers and operators.

“Within Asset Sentinel, they’re now putting in what the root cause was,” explained Olp,

“in addition to creating the algorithm from the data in the historian. We have 28 assets

con�gured and 58 measured KPI sentinels. Site knowledge has been captured into it.”

The process and asset monitoring data streams are uni�ed into a single data-processing

scheme. At the same time a duplicate stream is being sent to the cloud.

The plant’s monitored equipment included reciprocating compressors, heat exchang-

ers, boilers, reactors, off-gas spray columns, binary columns and deodorizers. Four areas

of contribution came from the heat exchangers, deodorizers, boilers and an unidenti�ed

trade-secret asset.

While a 2.2% increase in revenue and 2.2% additional capacity were realized in six

months, �nancial projections indicate breakeven in just 1.1 years annualized.

Grow your own cloud solutioneditorial teameditor in chief

Mike [email protected]

technical editor

Dave [email protected]

digital managing editor

Christopher [email protected]

contributing editor

Rick [email protected]

contributing editor

Tom [email protected]

editorial assistant

Lori [email protected]

columnist

Jeremy [email protected]

design/productionsenior production manager

Anetta Gauthier

senior art director

Derek Chamberlain

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SEASONED SENIOR CONTROLS engineers are of great value to

just about any machine builder, system integrator, engineering

� rm or manufacturing facility, and they are harder and harder

to come by lately.

Many of these facilities would be happy to hire controls person-

nel with even basic troubleshooting skills, with the hope that they

can quickly learn what is necessary to support the machines.

With the hardware advancements in automation, the many

industrial protocols and controllers in use and the complexity

of machine applications increasing,

should the controls engineer learn to

support and program everything on

the plant � oor, or should he or she spe-

cialize? The answer is every controls

engineer should master the basics and

then pick a specialty to be ef� cient at

because you cannot know everything.

Of course, some controls engineers will want to know ev-

erything. Your co-workers know who you are—for good and

possibly bad reasons.

In a small operation, an overworked, one-man show is often

all that is available. That’s all good until vacation time. And,

as the size of the operation or system complexity increases,

several specialists, available through both internal and external

sources, may be better.

However, starting at the basics, all controls engineers should

understand the National Electric Code (NEC) and the computer-

aided design (CAD) practices used to implement the NEC as it

relates to industrial automation. The skills to create an electri-

cal design schematic and then use it to build a control panel

and troubleshoot machine power distribution, I/O devices and

related electrical equipment are a must for a controls engineer.

Pneumatic circuit design skills are a must, as well. The selec-

tion, design and integration of a pneumatic air perpetrating

unit, valves, � ttings and actuators are just as important as the

electrical skills in most machine applications.

Basic electrical and pneumatic skills are the cost of admis-

sion to the more advanced controls engineering skills, which

include machine integration and program development.

Unless the same equipment is used every time, and it’s often

not, integration and startup can be time-consuming.

Installation manuals are often needed, and the details cre-

ated during design—the cheat sheets with all the information—

will need to be readily available. Con� guring a PLC on a small

project is easy, but add 20 or more networked devices such as

Ethernet I/P, � eldbus and IO-Link and it becomes complicated.

Why not just have an integration expert do it, so the pro-

grammer can just walk up and download the PLC program with

the I/O and � eld devices all ready to go? Their experience with

con� guring devices and starting up systems will speed things

up. It works great and this expert is just one of many on the

control team.

Other team members may in-

clude PLC, robot and vision-system

programmers. On a large multi-cell

machine with multiple controls engi-

neers working on it, the work is often

divided by cell, but it also should be

divided by specialty.

Again, these specialties make the guru more ef� cient. A

four-hour robot service call doesn’t happen if robots are just one

of the many things a controls engineer works on. Working on

controllers, robots and vision systems from multiple manufac-

turers often dilutes an engineer’s ef� ciency. The work will need

to be � gured out again, or the brain will need to recalibrate for

the new, complicated task.

When wearing many hats, just about the time the program-

mer becomes � uent with a particular manufacturer’s robot or

vision system, that same programmer works on another project

with a different robot.

While there are many similarities, the new system will

require at least a little review time or possibly signi� cant train-

ing time to become � uent with the new system’s software. The

programmer will become � uent with the new software at the

expense of training time and may lose � uency in the other pro-

gramming software when recalibrating the brain.

We controls people are amazing and should be well paid, but

we cannot be experts with everything. It takes time to learn it

or to get back up to speed on a particular product, so consider

specializing or standardizing. Less is more. Learning the secrets

of advanced automation from several 300-page manuals takes

time. You managers and end users out there should consider

that, especially when we work our magic bringing an advanced

automated machine to life.

How special is a controls engineer?

live wire

Every controls engineer should master the basics and then pick a specialty.


Dave Perkontechnical [email protected]

CD1907_11_LiveWire.indd 11 7/9/19 3:25 PM

12 / July 2019 / ControlDesign.com

embedded intelligence

Jeremy [email protected]

IN ANY INDUSTRIAL MAINTENANCE SHOP, you will �nd diagnos-

tic tools such as handheld scopes, multimeters and electrical

test equipment.

Increasingly however the crew is becoming responsible as

the �rst line of defense for OT networks. Software tools are be-

coming more and more prevalent in the maintenance toolbox.

Wired Ethernet networks can be symptomatic in various

ways. Because most are carrier-sense multiple access with

collision detection(CSMA/CD), the devices connected are built

to behave in a certain way. It is when

these devices do not behave properly

that we experience network issues,

and sometimes it is like looking for a

needle in a haystack.

We need tools to diagnose wired

network issues and discover which

device or devices may be causing the

observed anomalies at an affordable price.

There are many options available to the IT guys since most

diagnostic tools are targeted toward that group, but the OT

crew may not know what’s available to them if they are respon-

sible for the OT network.

SolarWinds has a very common toolset for IT peeps. While

comprehensive, the tools are expensive and may take a bit more

base knowledge than an OT person or department has.

I looked after a distribution center in Ontario, Canada of more

than 1.3 million sq ft, and the maintenance network employed

maintenance-owned switches and also borrowed ports on IT

switches and routers.

We had a problem in one of the nine buildings where comput-

er data was not being transferred on time to a PLC-5. I discov-

ered Intravue, now owned by Panduit.

I installed the product and was amazed by how it automati-

cally discovered most of the devices on my network. Now in

real time, and in conversation with Mathew Gier, product man-

ager for Intravue, the software uses multiple options to deter-

mine who is online within a given IP address range. My applica-

tion was simple—75 devices all in the same Class C address.

Gier mentioned that Intravue can support up to 2,048 nodes in a

single install. Multiple installs can support more than that.

I would suggest that if an OT LAN was greater than 150 devic-

es, we may be overwhelmed, but, with the Industrial Internet of

Things (IIoT), that will be probable.

How I discovered my issue was by the ping diagram that

Intravue creates. It largely uses SNMP and LLDP to discover

switches, routers and devices that are attached to each based

on the management-information-base (MIB) tables in the

device. It was determined that the PLC and computer were on

the same switch, and pings to the computer were taking a long

time, relatively speaking.

The packet size was small, and the activity was limited so

it pointed to a chattering Ethernet

card in the computer. The card was

changed with knowledge—nothing

worse than changing something,

and the problem goes away.

There is a cool function that al-

lows you to put a graphic of your

plant into the mix and then place

the devices where they are physically located. I would have

loved that when I was looking after 1.3 million sq ft.

The data logging gives you an overview of the threshold vio-

lations for the system, as well as for each device. You can link

device to �les, such as PDF �les of operating manuals, which

could prove to be valuable in times of panic.

Part of the threshold data is a bandwidth violation, which

will identify problem children such as a chattering network

interface card (NIC).

Intravue is real time, as well as historical. Looking in the rear

view mirror, data logging is a must when trying to �gure out

what happened after the fact. It is real time, as well, but I have

found the historical information invaluable.

This network tool works, and it is in the industrial sphere and

available to be used by non-network people. It is intuitive and

vendor-neutral. It can be installed on any computer that has a

Web browser.

This means that an OT system can be supported by OT

people. Not disrespecting the IT spectrum, but sometimes it’s

best to look after our own backyard.

Inexpensive self-diagnosis maybe isn’t so bad.

How to diagnose network issues

The PLC and computer were on the same switch, and pings to the computer were taking a long time.

JEREMY POLLARD, CET, has been writing about technology and

software issues for many years. Pollard has been involved in control

system programming and training for more than 25 years.

CD1907_12_EmbedIntel.indd 12 7/9/19 3:26 PM


MUCH HAS BEEN said about the emergence of collaborative

robots into the mainstream of manufacturing. Robots have

been around for a very long time, but the development of robots

that could operate in the same workspace as humans has truly

taken the technology to the next level. Not too many years ago,

the very thought that a robot could interact with humans in an

intimate environment would have been the product of a story-

board artist making the next episodes of “The Jetsons.” Now it

is becoming commonplace, and one would be hard-pressed to

imagine an automated assembly line

that didn’t at least consider the pros-

pect of collaborative robots.

Coming out of this rapidly expand-

ing technology, traditional automa-

tion providers have been scrambling

to come up with ways to integrate

collaborative robots into their

product lines. Some of the larger players in the packaging-

machinery business have been �guring out ways to use the

close-proximity workhorses to complement or even replace

their traditional machines for functions such as case-erecting,

packing and case-sealing.

An interesting trend that has recently come to the surface is

the use of collaborative robots to palletize, or unitize, products

that had previously been stacked using manual labor. The typi-

cal machine or full-size robot versions of these take up a lot of

real estate on the plant �oor, and this made them inappropriate

as a replacement operation.

Only those companies with the resources and appropriate

space to plan and build new production lines could consider us-

ing the traditional end-of-line palletizers. There is an old saying

that “necessity is the mother of invention,” and this could not

be truer than when it comes to the implementation of collab-

orative robots. The very possibility that an automated device

could occupy the very same workspace as a person and do as

good of a job or better is too juicy of an opportunity to pass up.

One well-known conveyor company has taken up the chal-

lenge of integrating its products with a collaborative robot by

taking the user interface for the robot and layering its own

user interface on top of it. The base user interface of the robot

was already easy to use, but the value-added interface changes

the multi-tasking nature of the native interface and narrows it

down to speci�cally address the use of the robot functions rela-

tive to the conveyor products that the robot will interact with.

Taking it further, the company has developed a workspace

that allows the user to very easily adapt to various end-of-line

packaging needs by moving the robot into a new workspace

and, scanning a data matrix code attached to the standard

conveyor offerings, quickly con�gure the robot to perform pre-

planned routines.

The possibilities are practically endless, but, given the usual

packaging methods of an end user,

the conveyor vendor has been able

to narrow down the possibilities to

a manageable subset that is very

attractive to the customer. This

approach has enabled the vendor

to launch installations all over the

world that number in the hundreds

in just a couple of years.

The value-added service is becoming more commonplace

across multiple industries. Another long-term provider of con-

veyors has taken a different approach to value-added. Rather

than embracing the collaborative robot by offering solutions

that use the robot, this particular vendor has offered up a

software module written in the operating system of a speci�c

collaborative robot that allows the automation provider an easy

way to integrate the conveyor product into a design that utilizes

the collaborative robot.

This added value suggests two things. One, the particular

collaborative robot is clearly headed for industry dominance as

it would seem imprudent to spend the time and money to de-

velop a software module for a robot that wasn’t going to be used

by many. The other value to this offering is making it inherently

easy for an automation company that might standardize on that

same collaborative robot to have an easy method to add this

particular conveyor product to the automation solution, since

the code is already written.

These two very innovative approaches to value-added machin-

ery manufacturing is an interesting twist in the conventional ap-

proach to control design. I can’t recall another example of two or

more distinct automation providers publicly acknowledging the

market presence of the other in such a direct manner in my 30 or

so years of experience in the automation design business.

Collaborative plus

Rick Ricecontributing [email protected]

technology trends

The value-added service is becoming more commonplace

across multiple industries.

CD1907_13_14_TechTrends.indd 13 7/9/19 3:27 PM

technology trends

Traditionally, it has been the responsibility of an integrator

to pull all the pieces of the puzzle together and perform the

important task of making sure the various parts all � t together

in a seamless fashion. For manufacturers to go to the trouble

of not only acknowledging each other, but sharing enough infor-

mation to provide complementary parts of the solution, shows

a clear change in the direction of automation.

The progression toward an add-on pro� le or instruction or

function block enabled the manufacturer, or a clever end user,

to provide a block of code that automates the process of not

only de� ning the device, but automatically assigns the descrip-

tors to the bits and bytes to make it human-readable.

Newer versions of that same function-block format use struc-

tured text tags that further enhance the programmer’s ability to

easily interface with the device by breaking down the memory

blocks into structures speci� c to the data being exchanged.

Examples of the manufacturer-speci� c function block or

add-on pro� les include digital sensors and valves at the base

level but can be of greater value when used for devices such

as barcode scanners, variable-frequency and servo drives,

linear actuators and a broad base of analog devices. The more

recent IO-Link technology takes that base function further by

transmitting not just the control-speci� c elements of devices,

but includes diagnostic information about the device, such as

temperature or operating parameters.

The latest innovation is to take an entire unit of operation,

such as a code printer or even a case erector or, perhaps, a col-

laborative robot, and provide a manufacturer-developed add-on

instruction—function block—that provides a completely pro-

grammed interface with all contained functions of the unit op.

Collaboration isn’t just about the interaction between man-

kind and a machine. It is also about vendors taking away the

mystery and making it easier for a design to come to fruition.

RICK RICE is a controls engineer at Crest Foods (www.crestfoods.com),

a dry-foods manufacturing and packaging company in Ashton, Illinois.

[email protected]

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WHEN PROCESS-MANUFACTURING facilities started changing

their control rooms from old panels to modern DCS displays,

plants justi�ed the new control systems by reducing the

number of operators by about 75%. “We knew it added a lot of

capability and �exibility,” said Nicholas Sands, senior manu-

facturing technology fellow, global alarm management leader,

and process control engineer, DuPont Safety and Construction.

He is the co-chair of the ISA 18 standard committee and a 2019

inductee in the Control Process Automation Hall of Fame.

“We threw together the new HMI to look like the old panel

control rooms,” Sands explained at Honeywell Users Group

2019 in Dallas. “But we gave the operator more tags and data

points and alarms. It used to be $5,000 to add an alarm on the

panel board. Then, with the new system, it didn’t cost any-

thing to add any alarm.”

Managers, engineers and operators went alarm-crazy.

“If we weren’t using all the alarms, we weren’t getting our

money’s worth out of the DCS,” Sands reminisced. And soon,

HMIs became overrun with so many alarms that operators

couldn’t even see the ones that required immediate correc-

tive action. Eventually, a procedure and a lifecycle map were

needed to streamline the alarms and develop a continuous-

improvement process for review.

Birth of a lifecycle“The reason for alarm management is to improve safety and

business performance,” explained Sands. “When I started with

DuPont, we’d have a high alarm and a low alarm when a pump

turned on or off.” The alarm would go on when the tank hit the

high level, and another would activate when it hit the low lev-

el, which just added to the onslaught of unnecessary alarms.

“Get rid of the alarms you don’t need, so you can see the ones

you do need,” said Sands. This ultimately became part of the

audit function, one of the 10 steps in the alarm-management

lifecycle that is part of ISA 18.2.

“We were polling in 2005 and 2006 for which best practices

we could use for alarm management to build a corporate pro-

gram at DuPont,” explained Sands. “We started with the com-

mon alarm management problems. It was supposed to be the

common solutions to the common problems.”

Standard procedureAccording to ISA 18.2, an alarm is “an audible and/or visible means

of indicating to the operator, an equipment malfunction, process

deviation, or abnormal condition requiring a timely response.”

The alarm must indicate a problem, not a normal process

condition, explained Sands. “There must be a de�ned operator

response to correct the condition, and the action must be for

the short term,” he said, “in minutes, not days.”

As co-chair of the ISA 18 committee, Sands has led a group

that’s developed a lifecycle of the standard for new facilities

and existing plants. This builds on the works of the Abnormal

Situation Management Consortium and the Engineering Equip-

ment and Materials Users Association. The alarm-management

lifecycle is a continuous-improvement process, designed to be a

best practice for control systems.

It comprises 10 steps, three of which can be points of entry.

The philosophy step is a good place to start for new facilities

or systems. However, brown�eld systems can begin with the

monitoring-and-assessment step or the audit step.

The birth of an alarm lifecycleAn explanation of the 10 stages in ISA 18.2

indiscrete

“There must be a defined operator response to correct the condition, and the action must be for the short term.” ISA 18 Co-chair Nicholas Sands explains the alarm-management lifecycle at Honeywell Users Group 2019 in Dallas.

CD1907_15_25_Indiscrete.indd 15 7/9/19 3:28 PM


A. Philosophy

B. Identi� cation

C. Rationalization

D. Detailed design

E. Implementation

F. Operation

G. Maintenance

H. Monitoring and assessment

I. Management of change

J. Audit

A. Alarm-management philosophy is the

guide for all alarm-management activi-

ties at a site. “A written philosophy is

necessary to maintain an alarm system

over time,” explained Sands. “Philosophy

doesn’t have to be your � rst step, but it’s

usually a good place to start.” Philosophy

identi� es what you want to achieve. It

includes de� nitions, performance goals,

roles, responsibilities and methods

for rationalization activities. Sands

recommended eight to 10 pages for the

philosophy document.

B. Identi� cation is the step where you

insert your method for � nding out if and

where you want an alarm, determining

whether it’s a quality, safety, environ-

mental or regulatory reason.

C. Rationalization is when you decide if

it really is going to be an alarm. “In our

results, about 50% of the alarms went

away,” said Sands. “And 80% of our priori-

ties changed.” Rationalization includes

classi� cation, prioritization and docu-

mentation. Sands’ words of advice: Be

careful not to jump ahead and do the de-

tailed design during the rationalization.

D. Detailed design has three parts: basic

alarm design, which includes alarm

types, dead bands and delays; HMI

design, which includes indications and

summaries; and advanced alarm design,

which includes designed suppression.

E. Implementation is the process of

putting the alarm or alarm system into

operation. “Training and testing are key

activities,” said Sands. “Safety systems

are mostly testing and some training.

Alarms are � ipped—mostly training

and some testing.”

F. Operation is where the alarm is in ser-

vice and performing its function. “Shelv-

ing and removal from service are key pro-

cesses to de� ne for operations,” explained

Sands. “You can use shelving to track

out-of-service and in-service. Shelving is

for the operator and by the operator.”

G. Maintenance is when the alarm is

out of service for repair, replacement or

testing. “Testing and return to service are

key activities in maintenance,” he said.

“You can track how long it takes, and you

can return it to service after the repair.”

H. Monitoring and assessment are the

tracking of the alarm system perfor-

mance vs. objectives in the philosophy.

“An unmonitored alarm system is al-

most always broken,” said Sands. “Moni-

toring is a key requirement of ISA 18.2.

That requirement has changed what

every control system supplier offers. The

data tells you what needs to be � xed.”

I. Management of change administers

the authorization for modi� cations to the

alarm system. “Each change is reviewed

and approved prior to implementation.

Changes should follow the steps of the

lifecycle,” he explained. “Once we’ve

done steps A-G, we don’t want to let that

go uncontrolled. The data will drive that

continuous-improvement loop.”

J. Audit is the periodic check that the

alarm system is meeting the objectives

and procedures are followed. “Audit

drives changes to the alarm philosophy,”

said Sands, bringing the lifecycle full cir-

cle. “Compare the performance metrics

to the targets.”

Newark sponsors Women in Electronics communityDEVELOPMENT DISTRIBUTOR NEWARK

has announced its founding sponsorship

of Women in Electronics, a community

of progressive women leaders at all

stages of their careers, dedicated to the

professional and personal leadership

development of women in the electron-

ics industry. According to the company,

it is celebrating women engineers who

drive innovation ahead of International

Women in Engineering Day.

“We’re proud to work with talented

female engineers across our organiza-

tion, each bringing her own unique skills,

interests and backgrounds,” said Louise

Perry, global HR director, Newark. “These

women show strong leadership; they help

keep our company at the forefront of en-

gineering, innovation and technology and

inspire others to grow in their careers.”

Newark has highlighted several com-

munity members including Andreea

Teodorescu, global senior commercial

marketing manager, Marisol Salgado,

technical support manager and Court-

ney Kennedy, technology solutions

marketing manager. Simply easy!

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COCA-COLA HELLENIC BOTTLING COMPANY (HBC), a bottler for

Coca-Cola, now uses vision picking using smart glasses at its

distribution center based in Thessaloniki, Greece.

To optimize processes, Coca-Cola HBC chose to implement

Ubimax solution xPick. The pickers are shown the picking

items, picking locations and quantities in their � eld of view.

To con� rm they picked from the right location, they scan

a QR-Code placed above the pallet with the smart glasses’

camera. This leaves the pickers’ hands free for the actual

task. The orders are displayed in a step-by-step manner as

Coca-Cola HBCs SAP production system and warehouse man-

agement system is connected to the solution. The system is

automatically and simultaneously updated about the status

of all individual orders.

According to Coca-Cola HBC, in its � rst month of vision

picking implementation, the system has recorded a pick-

ing accuracy increase of 99.99% and a picking performance

increase in the range of 6% to 8%. Using the Ubimax solution,

Coca-Cola HBC has been able to save a higher double-digit

percentage in CAPEX compared to the renewal of the former

scanner technology.

Coca-Cola HBC is planning to deploy the vision picking

technology at two further sites instantly with another � ve sites

planned for this year.

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detection range• Available with a

plastic or metal body• See more at www.tesensors.com/XXSonic

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Coca-Cola Hellenic Bottling Company implements smart glasses vision picking



SEVERAL LOCAL PRINTED-CIRCUIT-BOARD (PCB) manufactur-

ers and national Republican of�cials met June 22 in a Chi-

cago suburb to demand sustained, targeted tariffs against

China, which they claim will return thousands of jobs to the

United States.

Staged at the Rana-Reagan Community Center in Carol

Stream, Illinois, the event was attended by about 350 mostly

Indian-American residents, who heard speeches by Steve

Bannon, former Trump Administration strategist; U.S. Air

Force Lieutenant General Steven Kwast; U.S. Rep. Chris

Stewart (R-Utah); Frank Gaffney, founder and president of

the Center for Security Policy; and others. They also viewed

video messages from former U.S. House Speaker Rep. Newt

Gingrich and other analysts and experts.

“It’s important for people to hear that China is not playing

by the rules and destroying jobs by refusing to allow fair com-

petition,” stated Gingrich. “It’s important for businesspeople

to be hard-nosed when foreign governments cut production

costs on technology products to one-third, so others can’t

compete. This is why we’re asking everyone to reach out to

their governmental representatives and insist that China not

be allowed to cheat.”

The event was presented by the Republican Hindu Coali-

tion (www.rhcusa.com) and the National Indian-American

Public Policy Institute (www.niappi.com), both founded and

supported by Shalli Kumar, who is also the founder of the

AVG Group (www.avg.net), including EZAutomation (www.

ezautomation.net).

“The United States lost 3.54 million jobs during 2000-07,

including 50,000 in the nearby Elk Grove Village industrial

park,” said Kumar. “This was the premeditated murder of U.S.

jobs focused on PCB manufacturing and assembly. Part of

AVG’s business was in PCBs as the third-largest U.S. manu-

facturer and a top-20 assembler, employing thousands in our

U.S. facilities. This center used to have 600 staff in 60,000 sq

ft, but there was no business after the Chinese invasion, so

we donated it to the suburban Chicago’s Hindu community.

This is why we need sustained tariffs, but we also need them

on �nished goods, and not just on components. Tariffs could

bring back 80% of the jobs we lost.”

Kumar reported that China sold PCBs at one-third the cost

of boards in the United States, which was less than the cost

of materials. “For 20 years, the strategy of China’s Communist

Party has been de-industrializing our country with the help

of Wall Street and London. Turning this around will be a long

struggle that won’t return jobs immediately, but it will succeed

long-term if we force Wall Street and Washington to do it.”

Vikram Kumar, CEO and chairman of AVG, added, “Lots of

electronics are exported from China to the United States , so if

we had strong tariffs, hundreds of thousands of jobs could be

brought back to the United States. However, we need the right

tariffs, not just on products, but on all components in the as-

sembly process. Of course, AVG makes HMIs, PLCs and controls,

so we know many of these tariffs would negatively affect us

and our components, too. However, we committed long ago to

not move our manufacturing and jobs to China, so even though

our bills of materials (BOM) could go up 25% and it will be even

harder for us to compete, we’re still saying to go ahead with

tariffs because they will bring back 200,000-300,000 jobs.”

indiscrete

PCB makers, GOP reps call for tari�s against China

Dynamic duoShalli Kumar (left), founder of AVG Group, and Steve Bannon, former Trump Administration strategist, headlined a gathering of manufacturers and GOP o�cials to call for sustained, targeting tari�s against China.


TWO SCHOLARSHIPS WORTH NEARLY $10,000 were awarded to

California State Polytechnic University engineering students

during a College of Engineering Scholarship Luncheon. The

students were selected for their academic performance and

� nancial needs. The scholarships were funded by the Beamex

Annual Calibration Exchange.

“As a low-income, female Latina pursuing a STEM career, I

faced an array of challenges in my life. Ironically, one of my

biggest obstacles was in academics,” said Crystal Sandoval, a

Cal Poly Civil Engineering Major. “I started the year with zero

dollars in my bank account and a low GPA, but with a differ-

ent mindset, I worked full time to help out with the family’s

household expenses while attending college full time. I share

my story and tell college students that failure should not be

taken lightly – a person only fails when they give up. Thank you

for taking the time into organizing this scholarship and award-

ing it to me. I feel extremely honored and happy to be part of

the engineering community and I hope to continue being an

exemplary student, person, and future engineer.”

“My parents always encouraged me to go to college because no

one else in our family has gone before,” said Sepehr Ramshini, a

Construction Engineering Management student. “The main rea-

son that we immigrated to the United States was because of my

desire to go to the best universities. I would like to have my own

� rm, after gaining enough experience and � nishing my educa-

tion. I want to achieve happiness and help others to achieve it

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Beamex awards scholarships to California State Polytechnic students



ISO/IEC approves Object Management Group standard for automated function pointsTHE OBJECT MANAGEMENT GROUP (OMG), an interna-

tional, open membership, not-for-pro�t technology stan-

dards consortium, announced that its Automated Func-

tion Points speci�cation has been approved as ISO 19515

by the International Standards Organization (ISO) and

the International Electrotechnical Commission (IEC).

Version 1.0 of Automated Function Points was balloted

through the Joint Technical Committee on Information

Technology (JTC 1) of ISO and given the designation ISO/

IEC 19515. AFP is free for the public to download.

Available as an OMG international standard since

December 2014, Automated Function Points is the 12th

OMG speci�cation to be rati�ed as an ISO standard.

Automated Function Points measure the size of a

software product, according to the counting guidelines

of the International Function Point Users Group (IFPUG).

According to OMG, its standard is detailed enough to be

automatable, making counting consistent and easier.

Along with selected other measures, function points

can be used in the following activities:

• Software quality and productivity analysis

• Estimating the costs and resources required for

software development, enhancement, and mainte-

nance

• Calibrating estimating methods against the results

of past estimates

• Contracting with and managing contracts with sys-

tem integrators and outsourcers

• Normalizing data used in software comparisons

• Determining the size of a purchased application

package (COTS or customized system) by sizing all

the functionality included in the package

• Enabling users to determine the ROI of an applica-

tion by sizing the functionality that speci�cally

matches the requirements of their organization.

indiscrete

Endress+Hauser expands its sensor technology capabilitiesINNOVATIVE SENSOR TECHNOLOGY IST AG, part of the

Endress+Hauser Group, of�cially opened an expansion of a Swit-

zerland plant. The sensor specialist’s facility in Ebnat-Kappel cost

nearly 15 million euros, but now offers double the �oor space.

Mirko Lehmann, CEO of Innovative Sensor Technology IST AG; Mat-

thias Altendorf, CEO of the Endress+Hauser Group; and Klaus Endress,

President of the Supervisory Board at the Endress+Hauser Group, wel-

comed numerous customers, partners, representatives from politics

and business and employees to the dedication ceremony.

“The growing demand for innovative sensors, and the correspond-

ing strong growth at Innovative Sensor Technology IST AG, made

it necessary for us to expand the facility,” said Altendorf. “We’re

con�dent that we have created the space we need to produce even

more innovations.”

The 13,500-square-meter plant includes roughly 3,700 square me-

ters of production space, 1,500 of which is set aside for clean rooms.

The of�ce facilities and cafeteria were expanded as well. According

to Endress+Hauser, the expansion was necessitated by the increas-

ing demands on production and the growing space requirements.

Since moving to Ebnat-Kappel in 2012, Innovative Sensor Technol-

ogy IST AG has doubled the number of employees at the location

to nearly 200. The employees moved into the new facility after the

18-month construction project was completed in early 2019.


Cyber-physical system market to be worth $137,566 million by 2028FUTURE MARKET INSIGHTS (FMI) has published a market re-

search report on cyber-physical systems titled “Cyber-Physical

System Market: Global Industry Analysis (2013-2017) and

Opportunity Assessment (2018-2028).” According to FMI, the

lowering prices of devices such as sensors, several medium and

small scale manufacturers and plant owners are focusing on

the deployment of cyber-physical systems in order to convert

them into smart factories.

According to the report, the global cyber-physical system

market is expected to witness a CAGR of 8.7% during the

period 2018 – 2028. The market was worth $55,075.3 million

in 2017 and is likely to reach a valuation of $137,566.0 million

by the end of 2028.

The principal components of a cyber-physical system are

storage units, sensors, computing unit, software, and actuators.

The declining prices of sensors reduce the overall cost associ-

ated with the system, which makes it achievable for small- and

medium-sized enterprises. This in turn drives the adoption and

application of cyber-physical systems across various industries.

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Global Cyber-Physical System Market Revenueby Region, 2017 (US$ Mn)

North America Western

EuropeChina

JapanEasternEurope

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17,789.3CAGR of 8.7%

(2018-2028)



ABB WAS AWARDED GOLD at the German Innovation Awards in

the category “Excellence in Business to Business – Electronic

Technologies” for its new non-invasive temperature solution.

The award was presented during a gala event held at the Mu-

seum of Technology in Berlin.

The device is the �rst temperature sensor to provide a

simple, non-invasive means of measuring the temperature

of an industrial process without sacri�cing the accuracy and

responsiveness of conventional invasive sensors.

According to ABB, temperature is one of the most critical

process parameters to ensure the safety, quality and energy

ef�ciency of industrial plants. ABB’s non-invasive temperature

sensor offers a safer way of measuring without the need to

shut down, drill a hole or install a thermowell – a thermometer

mounted in a protective shield.

The technology breakthrough of the measurement solu-

tion lies in the double-sensor design of the measurement

probe, combined with a specially developed model-based

algorithm estimating the medium temperature. Two sensor

elements located close to each other record not just the tem-

perature but also its local spatial distribution and dynamics

over a short time scale. This extra information is converted

into a process temperature estimate with unparalleled ac-

curacy and responsiveness.

ABB’s non-invasive temperature sensor was developed

jointly by the Group’s German Corporate Research Center and

its Measurement & Analytics business.

The German Innovation Awards are organized by the Ger-

man Design Council, created in 1953 by the German Federal

Parliament and endowed by the Federation of German Indus-

tries. For 66 years the German Design Council Foundation has

been pursuing its goal of promoting companies.

indiscrete

ABB’s non-invasive sensor wins at German Innovation Awards


Ford honors Siemens at 21st Annual World Excellence AwardsSIEMENS WAS RECOGNIZED as a top-performing global

supplier at the 21st annual Ford World Excellence

Awards. Siemens was presented with a Gold Award by

Hau Thai-Tang, Ford chief product development and

purchasing of� cer and Linda Cash, Ford vice president,

quality and new model programs.

“Siemens is honored to receive this prestigious

award from Ford,” said Reinhold Niesing, head of verti-

cal markets automotive, Siemens Digital Industries US.

“Automation suppliers are not often recognized in this

category so this demonstrates that Siemens is mak-

ing the right strides in innovation and digitalization

Polyester

Die-cast Aluminum

StainlessSteel

IndustrialWall-mount

Polycarbonate



delivering improved quality, increased ef�ciency and shorter

time to market.”

Honorees were recognized for achievement in 10 categories,

including:

• Quality, sustainability, safe and smart categories for suppliers

that demonstrate leadership in Ford’s primary brand pillars

• Aligned business framework for suppliers that most exempli-

fy the framework’s principles, with an emphasis on quality,

value and innovation

• Special recognition for suppliers that delivered results ex-

ceeding expectations

• Diverse supplier of the year and supplier diversity develop-

ment corporation of the year to honor suppliers that excel

in integrating diversity into their organization and business

process

• Gold and silver for supplier manufacturing sites demonstrat-

ing superior quality, delivery and cost performance through-

out the year.

indiscrete

Somic Germany open house attracts 150 industry executivesAPPROXIMATELY 150 packaging indus-

try executives attended the Somic Open

House in Amerang, Germany on May 24.

Several packaging presentations were

followed by a guest appearance and the

unveiling of the new Somic ReadyPack,

an end-of-line packaging machine.

“We were excited about the number of

people who attended this event and the



introduction of the Somic ReadyPack,”

said Somic CEO Patrick Bonetsmüller.

“Our research indicates there is a market

for more simple packaging applications.

The challenge was to produce a machine

to �t industry requirements and meet

speci�c criteria such as speed, ef�ciency

and price points.”

“Seven months ago, we introduced the

Somic FLEXX III at PACK Expo in Chicago

as a �exible solution for one-piece wrap-

around shipping cases, or two-piece tray

and hood for retail ready,” said Peter Fox,

senior vice president of sales for Somic

America. “It is extremely fast at placing

stand-up pouches, �ow packs, rigid con-

tainers, and other units and has generated

a lot of interest. As a customized solution

for shelf-ready packages, we anticipate the

Somic ReadyPack to do the same.”

The event began with messages from

Bonetsmüller, CEO Ralf Kettner, and di-

rector of sales Stefan Julinek, followed

by a presentation on Somic innovation.

Next was the introduction of the Somic

ReadyPack. Thermoformed packages of

cut sausages and soft candy in pillow

pouches were demonstrated in both

single and double rows while standing

upright.

Two presentations about packaged

foodstuffs and packaging materials in

regards to future in�uences to the pack-

aging process, took place directly before

and after lunch.

Somic’s guest speaker of the day was

Italian mountaineer, adventurer and

explorer Reinhold Messner. Known as

the �rst person to make a solo ascent of

Mount Everest, his presentation, “Suc-

cess founded on Strategic Risk Man-

agement,” contained a mix of personal

experiences and advice for those with

business challenges.

DNAF awards $1 million in STEM grantsDENSO has awarded more than $1

million in STEM education grants to

26 colleges and universities across

North America. The grants are made

possible by Denso’s philanthropic di-

vision, Denso North America Founda-

tion (DNAF, www.densofoundation.

org), and are meant to help cultivate

tomorrow’s workforce. These dona-

tions deliver funds to programs that

will help to expose students to the

careers available in automotive and

manufacturing and prepare them for

evolving �elds.

“To achieve our 2030 goal of creat-

ing and inspiring new value for the

future of mobility, we need to be

inspiring our next generation of em-

ployees,” said Jack Helmboldt, presi-

dent of DNAF. “By awarding grants

to these educational institutions,

we’re equipping students, and pos-

sible future Denso employees, with

opportunities, skills, and knowledge

that will help to create a generation

of innovators poised to transform the

mobility industry.”

Grants will be used toward pro-

grams focused on design, materi-

als management, mechanical and

electrical engineering principles,

thermodynamics, robotics and more.

DNAF has supported STEM educa-

tion through grants at colleges and

universities since 2001. Denso educa-

tion grant proposals are invite-only

and evaluated based on technical

merit, student experience and align-

ment with industry needs.


WHAT DO MACHINE builders, system integrators and manufac-

turers need to know about time-sensitive networking (TSN)? In

simplest terms, it is better Ethernet.

What used to be many networks and gateways to meet

performance requirements will be deterministic control and

information on a single cable.

In addition to better performance, it will be easy to use, but the

integrators and end users are happy to support current solutions.

“I don’t think TSN will be complicating things for integrators

involved with advanced manufacturing and robotics,” says Bri-

an D McMorris, president at Futura Automation (www.futura-

automation.com) in Scottsdale, Arizona. “We are a factory-� oor

integrator. We do not know much about the IT world, but our

company structure and vision is focused on Industry 4.0, much

of which is executed on the factory � oor. For example, we are in

the manufacturing-execution-system (MES) world at an appli-

cation level with the Tulip product line of interfaces. We are the

� eld-services capability and help customers to implement the

bene� ts of an MES and a computerized maintenance manage-

ment system (CMMS) and a quality management system (QMS).”

Time-sensitive networks have many parts under development with some starting to emerge as real products, but the industrial specifi cations will need a few years to mature

by Dave Perkon, technical editor


cover story

CD1907_26_31_CoverStory.indd 26 7/9/19 4:49 PM


Futura works with IT mostly on the

security side, in terms of its cloud-based

solution and how the cloud apps are se-

cured. “I am sure it will be good to have

IEEE take a company-sponsored protocol

such as EtherCAT and turn it into a

global open standard under the auspices

of an industry association, but I do not

really see any shortcomings of EtherCAT

today, other than the license cost per

device for its use,” says McMorris.

While McMorris supports develop-

ments in networking technology, with

EtherCAT he has not see many limita-

tions. “We use EtherCAT with our Ser-

votronix drives for multi-axis control on

our open-design robots—cartesian and

delta,” he says. “It’s a very fast propri-

etary network with latency substan-

tially less than 1 microsecond, but it’s

only suitable for certain hard and soft

real-time computing requirements in

automation technology.”

Doug Putnam-Pite, director of soft-

ware development at Owens Design

(www.owensdesign.com) in Fremont,

California, appreciates that proprietary

networks such as EtherCAT and CC-Link

IE provide real-time communications, but

he also acknowledges their limitations.

“The downside to these technologies

is they only work with control devices

that support the protocol,” says Putnam-

Pite. “This means that you cannot have

devices on the same network that do not

support the protocol. These �eldbus net-

works must be separated from any other

Ethernet networks in the tool.”

TSN may allow devices that cannot

currently communicate in real time to

do so. “Time-sensitive networking gives

integrators more options on how to

architect control systems,” says Putnam-

Pite. “A tool with a time-sensitive net-

work may be able to decentralize control,

allowing individual devices to commu-

nicate directly with each other in real

time, allowing some level of control to be

of�oaded from a central tool controller.

Additionally, PCs may be able to com-

municate with time-sensitive network

devices in a semi-real-time manner.”

Progress report“For machine builders, system integra-

tors and manufacturers to deploy TSN, it

needs to be incorporated into industrial-

automation protocols and supported

by a wide enough set of vendors to put

together a system,” says Paul Didier, TSN

testbed coordinator, Industrial Internet

Consortium (IIC, www.iiconsortium.org),

and Internet of Things solution architect

at Cisco (www.cisco.com). “That is not

yet the case, but the industry is working

hard to reach that goal (Figure 1).”

Work is underway to de�ne the set

of approximately 12 IEEE 802 standards

aimed at addressing the determinism

and quality of service required for TSN,

says Dr. Al Beydoun, president of ODVA

(www.odva.org). “In addition, interoper-

ability must be maintained. Completion

of the IEC/IEEE 60802 industrial pro�le

for TSN is key, and this is targeted for

mid-2021,” he says. “In the meantime,

updates to network speci�cations such

as the EtherNet/IP speci�cation will not

be �nalized until the underlying stan-

dard of TSN is �nalized.”

Standard Ethernet is not deterministic

by design, says Michael Bowne, executive

director at PI North America (us.pro�net.

com). “Time-sensitive networking is a

toolkit of roughly two dozen IEEE stan-

dards that create standardized determin-

Time-sensitive network testbed Figure 1: Testing of the numerous parts of TSN is well underway by many of industry’s leaders in net-working, automation and electronics.

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istic Ethernet,” he explains. “Now that

other industries outside of industrial

automation are interested in determinis-

tic Ethernet, there is a larger market for

the hardware. The idea is that eventually

this technology will be available from

commercial off-the-shelf (COTS) chips.

Of the IEEE standards in the TSN toolbox,

we’ve identi�ed roughly half a dozen that

are particularly relevant to industrial

automation. These standards address

determinism with features like synchro-

nization, low latency, high availability,

and robustness.”

It’s important to get the standard

right, and that will take time. “As men-

tioned above, TSN is a toolbox of many

different standards, and not just one

thing,” says Bowne. “Some are relevant

to industrial automation, and some are

not. To ensure that we don’t end up with

different �avors of TSN in industrial

automation, an effort has been started

known as IEC/IEEE 60802. It is currently

staffed by engineers from automation

vendors big and small to ensure harmo-

nization across companies.”

The digital factory demands interop-

erability and simplicity in communica-

tions, says Armando Astarloa Cuéllar,

CEO, system-on-chip engineering, at

Relyum (www.relyum.com). “TSN is the

new-generation Ethernet designed ex-

pressly to meet those requirements,” he

says. Although the introduction of TSN

will be progressive depending on the

sector, some critical ones like railway,

automotive or aerospace, are adopting

TSN as the standard IT/OT network in

their new platforms.

Why should you care about TSN?“From the user’s perspective, at this time,

the status of time-sensitive network-

ing is at a bit of a standstill,” says Paul

Brooks, business development manager,

networks—IIPA, global standards, OPC

and time-sensitive networking, at Rock-

well Automation (www.rockwellautoma-

tion.com). “The TSN standards in IEEE

802 have been published, but they only

provide feature-level interoperability, not

system-level interoperability,” he says.

“Therefore, from the vendors’ perspec-

tive, we as the industrial automation

community are developing IEC/IEEE

60802, which will determine the indus-

trial automation pro�le for TSN to deliver

this system-level interoperability.”

Only when these standards are locked

down will protocol organizations, such as


cover story

Tomorrow’s industrial communicationFigure 2: TSN communication with OPC UA will enable control applications to work on an open, standard network with a large variety of other tra�c and applications—sensor to cloud.

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FactoryControl Level / Cloud

MachineControlLevel

FieldLevel Machine

HMI

Control

VisualizationData Aquisition

Integration

Drives

Control

Machine

Huge customer benefit in standardized control to control communication

IO, sensors, actuators

OPC UA TSNTSN/OPC as widely accepted standard in control to control communication

3 More and more standard communication on field level (motion, safety, and standard I/O)

4

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ODVA, be able to publish that pro�le in speci�cations, continues

Brooks. “Some companies have been releasing pre-standard

products, and, while they will deliver user value, there is no

guarantee that these products will be compatible with the �nal

standard,” he said.

In November 2018, OPC Foundation announced the Field

Level Communication initiative supported by a very broad set

of industrial and IT players: ABB/B&R, Belden, Cisco, Huawei,

Intel, Mitsubishi, Moxa, Rockwell Automation, Schneider Elec-

tric, Siemens, among others, says Cisco’s Didier. “The vision is

to aim for an open, uni�ed, standards-based IIoT communica-

tion solution between sensors, actuators, controllers and cloud

addressing all requirements of industrial automation,” he says.

“The initiative will incorporate the OPC’s work on pub/sub and

TSN communication (Figure 2).”

TSN enables all the control applications to rely on an open,

standard network. “That network can also support a huge vari-

ety of other types of traf�c and applications. This convergence

and the ability to communicate, sensor to cloud are the key

improvements,” says Didier.

“TSN is designed to provide deterministic messaging and

real-time capability over standard Ethernet in order to ensure

communication of information in a �xed and predictable

amount of time,” explains Beydoun. “The key applications of

TSN will be those requiring precision timing control and deter-

ministic network behaviors. However, Ethernet TSN is desired

in any industrial application where higher bandwidth and

faster network response is desired as the case in network ap-

plications conveying audio and video information. TSN’s scal-

ability will allow high-bandwidth streaming of packets with a

guaranteed latency at higher Gigabit transfer rates.”

Why do I need TSN?“Many integrators and machine builders question the need

for TSN and claim the existing industrial Ethernet and related

protocols, such as EtherNet/IP, EtherCAT and Pro�net, meet

their needs, so ‘Why do I need TSN?’ is a common question,”

says Bowne at PI North America. “It’s a valid one, particularly

because many of the techniques employed by TSN—synchro-

nization, bandwidth reservation, scheduling—are ones we’ve

been using in Pro�net for more than 15 years. If TSN had ex-

isted back then, we would have adopted it and saved ourselves

lots of engineering effort. And yet Pro�net has always allowed

high-speed control-related traf�c to coexist plainly with other

information-related traf�c.”

The exact same principle applies to TSN, so, again, why do

you need it? “The answer is subtle and related to the future

of networking,” says Bowne. “As we move into the Industry

4.0/Industrial-Internet-of-Things (IIoT) realm, more and more

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Work is underway to de�ne the set of approximately 12 IEEE 802 standards aimed at addressing the determinism and quality of service required for TSN.


information will be provided to higher-

level systems. Eventually, it appears that

some �attening of the Purdue Model may

occur. While TSN may not be the driver

of this, it certainly can be one of the

tools to help enable it.”

In the future we envision that as more

and more bandwidth gets utilized by

IT protocols, TSN will ensure time-

sensitive—hence, the name—OT traf�c

receives the determinism it requires,

even on networks loaded with other

best-effort IT traf�c, explains Bowne.

“As long as they all share a common TSN

foundation, then manufacturers can

begin implementing converged IT/OT

networks without having to worry about

their OT traf�c being sacri�ced at the

expense of IT traf�c,” he says. “We want

to continue this long-held philosophy

because we believe in using the right

tool for the right task: the Pro�net proto-

col for moving data, other protocols, for

example, OPC UA, for moving informa-

tion, all on a single wire.”

The OT/IT integration roadmap does

not end in an intermediate situation

with a plethora of heterogenous devices

connected through gateways, says

Cuéllar at Relyum. “Instead, it raises the

adoption of a communication technol-

ogy at the link level that is valid for

both worlds,” he says. “In this way, it

would be feasible for an all-to-all data

exchange topology in a homogeneous

plant, similar to a pillar (Figure 3).”

This automation pillar is based on a

blog post titled, “What is TSN? A Look at

Its Role in Future Ethernet Networks,”

(www.controldesign.com/whatistsn) by

René Hummen, senior architect—tech-

nology and innovation, at Belden (www.

belden.com).

In this pillar context, the traditional

layer-based communication and cyber-

security scheme in no longer valid. “The

elements included in the �eld I/O would

communicate directly with applications

and services enabled in remote cloud,”

explains Cuéllar. “Thus, it is critical to

secure communication between the

different devices. The real-time require-

ments of TSN represent one of the great

challenges for securing this kind of

network because traditional cyberse-

curity IT mechanisms can’t guarantee

the transmission of packets with the

required latency.”

TSN is not a protocolTSN is just another better version of

Ethernet; it’s not a protocol. “What’s im-

proving is the infrastructure upon which

all Ethernet-based protocols exist,”


cover story

The data link near the physical layerFigure 4: TSN resides in the Data Link Layer 2 of the IOS/OSI Model and is not a protocol, which resides in Application Layer 7.

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UDP TCP4 Transport layer

IP3 Network layer

RT IRT2 Data Link layer TSN

100 Mbit / 1 GBit / ...1 Physical layer

Automation pillarFigure 3: The automation pillar shows clear, high-speed connections between the plant floor I/O devices and controllers to the factory, enterprise level and to the cloud.

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ERPBI

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CONTROL PLC

FIELD IO

Increased interactionCentralized supervision

Control functions Virtual PCDistributed control

Increase of device numbers

Conn

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Field / IO

Cyber-physical production system’s distributed control unit merges PLC & I/O modules

On-pemises automation cloud

Dat

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Uplink to global cloud

ML /IA

Factory backbone

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ML / IA Microservices

Virtual PLC

Cloud connection

Secure remote access


says PI’s Bowne. “TSN lives at the data

link layer (Layer 2) of the IOS/OSI Model

(Figure 4). Protocols live at the applica-

tion layer (Layer 7) of the ISO/OSI Model.

Gateways translate data between the

different protocols, or languages.”

TSN is designed to be additive to

existing network functionality. “Network

functions that are available today and

delivering reliable operations should be

available in the same way after the in-

troduction of TSN,” says Brooks at Rock-

well. “It should not force any change in

behavior unless there is new value that

justi�es that change (Figure 5).”

Focusing on EtherNet/IP, time-sensitive

networking is completely independent of

the communications protocol, continues

Brooks. “The task for protocol organiza-

tions such as ODVA and OPC Foundation

is simply to de�ne how their protocols

work with TSN and make TSN as trans-

parent to the user as possible,” he says.

“And they need to do this while making

existing quality-of-service mechanisms

such as DSCP (differentiated services

code point) an acronym that most ma-

chine builders and system integrators

will never need to understand!”

How will TSN help an application?“If we all do our jobs correctly, a ma-

chine builder or system integrator won’t

have to interact with TSN very much at

all,” says Bowne at PI North America. “It

will be easy to employ and transparent

to their Pro�net-related tasks of engi-

neering, con�guring and commissioning.

It’s just a better version of the Ethernet

employed today.”

Time-sensitive networking is a tool

that makes �attening of networks easier,

but it is only one of the tools that make

this possible and practical, says Brooks

at Rockwell. “For instance, network

segmentation is the heart of a secure

network architecture,” he explains.

“Time-sensitive networking does not

help with segmentation. For this you

need to use routed protocols, and TSN

does not support routing.”

However, if you have multiple high-

bandwidth streams going through a sin-

gle cable, then TSN can certainly reduce

the engineering efforts required to know

that the network link will operate as

expected, explains Brooks. “Each of the

devices on a network can announce the

volume of traf�c and the periodic rate

at which that traf�c will be sent to the

network infrastructure,” he says. “The

network infrastructure can plan network

loading based on the overall volume of

traf�c �owing through the network. It

also can protect network resources to

help ensure that this volume of traf�c

can �ow through the network.”

TSN enables the various IE protocols

to use a single, interconnected network

for all the industrial control applications,

such as I/O, safety and motion, and to

co-exist with other devices, for example,

video cameras, and applications while

maintaining the deterministic network

requirements control applications rely

upon, says Paul Didier at Cisco. “In this

way, Industrial IoT applications can di-

rectly and securely access end devices to

extract very relevant data and informa-

tion that often cannot be handled by a

gateway,” he says.


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Just add TSNFigure 5: Much of the network

hardware and functional reli-ability will remain the same

after the introduction of TSN, but there will be value added

to justify the change.


MAN OVERBOARD! THERE are times

when rescue boats must be placed over

the deck and into the water to assist

those in distress. However, launching

a boat from a larger vessel is not easy,

and the captain may need to make these

launches and recoveries day or night—

with little or no light. And it will need

to be done in the open ocean, and that’s

not often �at and calm.

To further complicate things, the

rescue boat may be launched while

underway—the boat doesn’t stop. Allied

Systems (www.alliedsystems.com), a

fabricator of material handling equip-

ment, was contacted for these and other

reasons. The marine industry desired

a safer launch and retrieval system for

rescue boats—particularly in adverse

weather conditions. Safer operation was

paramount (Figure 1).

Get the boat in or out of the water safelyMany vessels use a single davit to launch

a boat. A davit system is basically a crane

that’s used to lower and lift boats—rela-

tively small boats—from the deck to the

water and back. Examples include davits

along a line of life boats that would be on

an ocean liner and other large vessels.

The problem is if a 30-ft-long boat is

lowered with one davit during a storm,

the stability of that boat being lifted or

lowered by one cable is very limited. Pic-

ture a severe, windy storm with signi�-

cant wave action and then trying to lift a

life or rescue boat off a large ship—with

people on it—and then into the water. In-

variably, the rescue boat will pitch about

due to the motion of the parent ship from

which it was launched, due to wind veloc-

ity and sea state. Wind velocity could

easily propel the boat back and forth in an

uncontrolled manner. This is dangerous

for the crew and passengers that may be

onboard, and impacting the side of the

parent ship could damage either vessel.

A dual-point davit system uses two

cables—one attaches to the stern of the

boat, the other the bow. This system

reduces the unwanted rescue boat mo-

tion. The dual davit lowers the boat very

uniformly, which is much more stable

and safe for the people in it, even when

launched in a rough sea.

The solutionIn the marine industry, many of the davit

systems for shipboard use are manually

operated using a single hand-driven or

electric winch and a single cable. The

Allied Systems’ dual-point davit is au-

tomated, and it partnered with Systems

Interface to design, manufacturer and

test it. The operator console also provides

more feedback on loading, positions,

maintenance and troubleshooting.

Allied Systems, located in Sherwood,

Oregon, has sold more than a half dozen

of these specially designed dual-point

davit systems. These systems have a

nominal working load limit of 11,000

lb and can handle boats up to 30 ft in

length. They are also designed to operate

any time, day or night, from the North

Pole to the equator, from �at water to Sea

State 5, which is a rough sea with about

8-ft to more than 13-ft waves.

The Rockwell Automation control

system solution was used to control

the automatic operation of the system.

The controller synchronized the two

winch systems, and the operator station

increased safety of both personnel and

equipment.

Becoming shipmatesThe new dual-point davit system was the

�rst time Allied Systems worked with

Systems Interface (www.systems-inter-

face.com), a control system integrator and

Rockwell Automation solution partner.

The scope of work was basically divided

with Allied taking on the mechanical and

hydraulic design and related manufactur-

ing aspects while Systems Interface took

on the electrical design, control panel

build and programming aspects.

Allied Systems began designing and

manufacturing equipment for the wood

product industry more than 40 years ago.

Its success allowed the company to diver-

sify into the marine, coal and agriculture

industries. In the marine market, it serves

a wide host of customers from family-

owned companies to worldwide corpora-

tions and different government agencies.

Systems Interface has worked with

Rockwell Automation for more than three

decades. One of its fortes is the marine

by Tim Rogers, Systems Interface

How to get a boat in the waterWith the proper tension, the dual-point davit system, mounted to large vessels,

can get boats into and out of rough water without making waves


controllers

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Launch the rescue boat

Figure 1: A dual-point davit system uses two cables—one attaches to the stern of the boat, the other the

bow which provides a safe and stable boat launch or

recovery process.

environment and, speci�cally, winch

control systems and marine cranes.

Due to its customer’s needs and

control system requirements, Allied

Systems contacted Systems Interface a

few years ago to use our expertise in the

maritime market to help to develop a

new dual-point davit system.

Calming the hydraulicsOur controls engineers worked with the

Allied Systems’ mechanical engineers

helping to develop the dual-point davit

system. Allied knows a lot about cranes

but discovered there were some me-

chanical elements related to the system

hydraulics that really didn’t accomplish

what needed to be done.

One problem dealt with the limita-

tions of the hydraulic �uid �ow that did

not allow the davit arms that positioned

the rescue boat to move smoothly. And

when you have two pieces of equipment,

in this case with dual davits, it becomes

even more complicated.

Allied came to us with the problem

and asked if we could solve it with the

control system. The hydraulics problem

was described as a pulsation. Similar

to water hammering, when a valve was

closed, a pressure wave is sent backward

up a pipe. This can make controlling the

equipment very dif�cult. Instead of hav-

ing a smooth �owing hydraulic power

source, it �uctuates.

One option was to redesign the hy-

draulics. This would involve changing

the size of the pipes and valves, as well

as the pump. However, this was expen-

sive and would also create a real-estate

problem. There was no room anywhere

to make its system skid larger.

The second options was to solve the

problem by taking advantage of the

diverse instruction set in the Compact-

Logix 5370 L1 programmable automation


controller that Systems Interface speci-

�ed for this system. This solution was

essentially free to use, and its program

could be modi�ed quickly.

Of course we chose to solve the prob-

lem using the controller. Once Allied

Systems advised us of the hydraulic �ow

issue, the Systems Interface engineers

developed code in the CompactLogix to

emulate what resized valves and pump

motors would have achieved, and they

did it while commissioning the system

underway at sea. This mitigated the pres-

sure wave and smoothed operation of the

dual davits, and the time and cost sav-

ings using this approach was signi�cant.

Keeping tension on the tailWhen operating a davit system, the

operator performs a number of dis-

crete steps. The �rst step lifts the boat

straight up off the supports. Once it

reaches proper elevation, it is then

moved toward and over the gunnel, the

upper edge of a ship’s side. When the

boat is away from the ship and at the

proper angle, it is then lowered. During

these steps there is no speed or pressure

control needed. And then things become

more complicated.

Because the vessel may be underway

when the boat is lowered, the water is

moving, causing tension on the line,

and there may be waves, as well. Even

with all these variables, the winch must

maintain a constant tension. If you don’t

maintain constant tension on the winch

lines that are holding this boat in place,

the boat can very easily get out of con-

trol, turn sideways and capsize.

The Allied Systems CT (Constant

Tension) system is critical for the safe

launching and retrieval of the rescue

boat, especially during storm conditions.

The system maintains a constant ten-

sion in each of the two davit cables.

In constant tension mode, the davit

winch pays cable out as the tension

increases and reels cable in when the

tension decreases. This improves safety

by eliminating snap loads on the hook

resulting from the boat rising and fall-

ing on the waves. By keeping the rope

taught, the system also keeps the crew

safe by not allowing a slack cable to

wrap around equipment or personnel.

Key controls and operationSystems Interface designed and manu-

factured the control system. The bulk of

the components are from Rockwell Auto-

mation and are housed in two control

enclosures, a davit operator console and

a remote electrical enclosure.

The davit operator console includes

a CompactLogix 5370 L1 programmable

automation controller combined with

bulletin 1734 Point I/O to save space. Other

control hardware includes Allen-Bradley

1492 terminal blocks, model 1489 circuit

breakers. Operator controls included

series 800F operator devices, such as se-

lector switches, pushbuttons, pilot lights,

potentiometer, contact blocks and LED

power modules. A series 800H emergency-

stop button and model 855P panel mount

alarm is also included (Figure 2).

The remote electrical enclosure was

located on the crane. It included many

of the same components as the console

(Figure 3). Much of the Point I/O in the

remote enclosure controlled the hydrau-


controllers

Space-ef�cient remoteFigure 3: The use of the I/O and other space-e�cient relays and circuit breakers allowed this remote I/O panel to fit in a small area.

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Man the control consoleFigure 2: The davit operator console provided both automatic and manual functions and was usable any time and any place.


lic system. Model 700-HK slim line relays

and model 700-HN sockets are used as

dry contacts to a variety of equipment

outside the enclosure.

The operator controls included auto-

matic mode, manual mode and related

functions. At an operator’s request and

with automatic mode enabled, automat-

ed functions are available at the touch

of a button. These functions are con-

trolled by the CompactLogix PAC and

include move to park, move to embark

and move to water.

In the unlikely event of a controller

failure, manual hardwired functions are

also available. Manually operated buttons

and switches on the console control the

hydraulic pumps and the valves that

move the davits into position and operate

the winches to raise or lower the boat.

Surviving the seaThe davit operator console is typically

located on the main deck where the

deck, rescue/life boat and sea surface

can all be viewed. On the open sea,

protection from the elements—the wind,

waves, rain and snow—is a must, and all

materials and components were speci-

�ed with this in mind.

The operator must to be able to clearly

see the dials, switches, toggle switches

and joysticks. The environment can be

very harsh. At the North Pole, you can

have temperatures to -40 °F, in addition

to the elements, and it can be dark. At

the equator, temperatures can approach

120 °F in bright sun.

Testing at dry dock and at seaSeveral different factory acceptance

tests (FATs) were performed. Preliminary

testing was done at Systems Interface to

con�rm the control system, HMI and PAC

met requirements. The equipment was

then shipped to Allied Systems, along

with two of its engineers. Then our en-

gineers spent about two weeks working

with Allied in the shop where the dual

davit system was set up. Instead of a

30-ft-long boat, metal weights were used

to simulate a boat during testing.

After some optimization of the control

and hydraulic systems, the customer

signed off on a land-based FAT.

Ocean testing was done off the coast of

California and was a lengthy process. The

testing was extensive, as the customer

would only sign off on the equipment if it

was convinced no modi�cations would be

necessary. The equipment needed to be

problem-free, and, to prove it, they really

ran us through the wringer (Figure 4).

The testing showed everything

worked properly. It also con�rmed that

components could be changed out quick-

ly by seaman, if necessary. Additional

testing ensured it worked at night, in the

middle of the day and during rough seas.

The system passed.

This complex equipment was simple

to use and support. Due to its success-

ful maiden voyage, the customer has

ordered �ve more systems. More than 60

identical systems are possible, as there

are many ships on the sea.

Tim Rogers is senior director

of business development at

Systems Interface in Mukilteo,

Washington. He can be reached

at [email protected].


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Ocean testing requiredFigure 4: Extensive testing was performed on the vessel and on the sea as the system needed to be problem-free and easily supportable once operational, when it left port.


KASTO HAS COMPREHENSIVELY re-engi-

neered its tec automatic bandsaws. In do-

ing so, the designers have clearly focused

on the optimum use of carbide metal saw

blades. Further innovations relate to the

saw feed, the main drive and a system

for automatically adjusting the feed

speed (Figure 1).

Kastotec has always been identi�ed

with high machining performance and

low idle times. Shorter cutting times

and higher saw-blade service lives are

possible thanks to a steel mineral casting

compound. This is designed to guaran-

tee a high degree of damping and quiet

running, even with dif�cult-to-machine

materials such as titanium, Hastelloy

and Inconel. In addition, standard pre-

tensioned linear guides, each with two

grease-lubricated guide carriages, extend

the working life (Figure 2).

But there is much more to the new

Kastotec. New is the steplessly adjustable

electromechanical saw feed with two

servo motors and ball screw spindles,

which now provide an ideal basis for ef�-

cient and sensitive working with reduced

tool wear. The saw feed control with

its minimal use of sensors enables the

cutting parameters to be continuously ad-

justed, not only at the beginning and end

of the cut, but also throughout the sawing

process. The user therefore bene�ts from

maximum performance and low tool

wear. The tool service life also bene�ts

from the new double saw blade cleaning

facility. A mechanical system automati-

cally adjusts the brushes over their entire

life, thus ensuring that they are always

optimally positioned relative to the saw

blade (Figure 3). This all contributes to a

further increase in sawing performance.

As well as the technical improve-

ments, the user also has control of the

tool costs and cutting times. All parame-

ters can be optimally adjusted to suit the

type of saw blade used by means of the

intuitive controller (Figure 4). Depending

on the saw blade, this could reduce cut-

ting times by up to 50%.

The frequency-controlled bevel spur

gear saw drive with a power of 15 kW and

a steplessly adjustable cutting speed of

30 to 300 m per minute is also new.

Matthias Eigbrecht is head

of the electrical design

department at Kasto

Maschinenbau based in

Achern, Germany, which specializes in

sawing and storage technology for bar stock

including metal-cutting saws and semi-

automatic and automatic storage systems

for bar stock and sheet metal. Contact him

at [email protected].

by Matthias Eigbrecht, Kasto Maschinenbau

Reduced wear from tensioned linear guidesHigh-performance carbide metal machine makes for shorter cutting times and higher saw-blade

service lives


servos

Rallying cryFigure 1: To improve on the tried-and-tested was Kasto’s motto when re-engineering the tec automatic bandsaws.

CD1907_36_37_Featr1_featr.indd 36 7/9/19 3:34 PM


Brush positionFigure 3: The brushes of the new double saw blade cleaning facility are always optimally positioned relative to the saw blade.

Blade intuitionFigure 4: The user can optimally adjust all parameters to suit the type of saw blade used by means of the intuitive controller.

Larger diametersFigure 2: The new Kastotec AC

5 saws round material up to 530 mm diameter.


THE LANGUAGE USED by suppliers of technology solutions

aimed at precision engineering applications is vague and in

some instances confusing. Words such as “precision” and

“resolution” without any degree of quali�cation are just

meaningless. When looking at motion-control solutions that

provide sub-micron and nanometer-level accuracy, a new

language is necessary, and new standards are required to

indicate the real levels of precision that different motion-

control solutions can achieve.

There are times when technological advancements are such

that they necessitate a root and branch change in the language

and nature of discussion associated with them.

When electricity became available in every

home, it would have been somewhat perverse

if we had all continued to talk in terms of our

preferred candles rather than the relative lumi-

nescence and longevity of various forms of light

bulbs. Likewise, when the car began to emerge,

and eventually replaced the horse and cart as

the most ef�cient form of transportation, the

discussion logically switched from the best hay

to feed the horse to the merits of different forms

of internal combustion.

Without stretching this analogy to the break-

ing point, there is a similar shift in the area of

motion control. A new technology has emerged

that pushes the boundaries of what is deemed possible in

terms of precision to such an extent that the language

surrounding the technology has to change, and the

nature of the conversation needs to shift in order

to differentiate this new technology from standard

industry alternatives.

The technology in question is our Hybrid

Hexapod (Figure 1). We are in blue-ocean territory

here. In the past 20-25 years, there has been more

and more interest in hexapods to cater for the increased de-

mand for micron, and sub-micron level precision in multi-axis

motion applications. Hexapod motion-control technology exists

at the ultra-precision end of motion control, and it has been the

best-in-class motion control solution for exacting industrial ap-

plications for a couple of decades.

The burgeoning area of more and more precise motion

control is driven by industry demand for technologies that

will improve production processes. The emphasis from across

industry is for smarter, smaller and faster precision motion

control and positioning equipment, and demand is especially

by Bill Hennessey, Alio Industries

What is the point of precision?How to clarify the meaning of precision for better understanding of motion


motion control

New stepsFigure 1: The Hybrid Hexapod represents a step forward in motion control and provides the ability to achieve repeatable nano-level accuracy, stimulating innovation and pro-moting manufacturing e�ciency.


high in areas such as laser micro machining, micro assembly

automation, optical inspection, semiconductor metrology and

photonics components test and alignment applications.

The Hybrid Hexapod represents a quantum step forward

in motion control and for the �rst time provides the ability to

achieve repeatable nano-level accuracy, stimulating innovation

and promoting manufacturing ef�ciency.

One key area for focus is how motion control process sup-

pliers describe the level of precision achievable. Standard

industry vernacular talks in terms of micron and sub-micron

precision, but we are now working with the National Institute

of Standards and Technology (NIST) to move to a new and

more effective methodology of measuring and quantifying

motion systems by introducing the concept of Point Precision.

What does precision mean?The very nature of the word “precision” is vague. You might be

used to hearing descriptions using phrases such as “precise”

and “ultra-precise.” Also, you will be used to reading claims of

achievable “resolution.” But what does resolution really mean,

and what does it tell you?

In the area of motion control, the focus should and must be

on much more exacting criteria, by which we mean repeatabil-

ity and accuracy (Figure 2). Precision is actually synonymous

with repeatability and accuracy, but too often suppliers hide

de�ciencies in these areas behind meaningless phrases such

as precision, high accuracy, high precision, or ultra-precision.

When looking at the Hybrid Hexapod, precision means 10

nanometers or less, repeatably.

For standard hexapods, claims of precision are best condi-

tion, unidirectional one-axis numbers, which don’t factor all

six-axis error quotients or the backlash, which is the total error

of all motion in a hexapod due to the compression and ten-

sion of each leg for every move. Claims made for conventional

hexapods may be designed to look like a similar duck to claims

made by real nanometer accurate motion-control solutions, but

from the perspective of Point Precision they do not quack in

nanometers but tens of microns.

Unless the word precision is accompanied by such quanti�-

able and de�nite statements in terms of what is achievable, it is

truly meaningless. While still vague, micron, sub-micron, and

nano precision are better. It at east gives an illusion to the level

of precision that is being claimed.

Point PrecisionThe language used can be seen to be de�cient; it is not being re-

�ned enough and evolving quickly enough to help differentiate

available motion-control solutions. So saying, Alio Industries

has introduced the concept of Point Precision, which has now

been adopted by NIST as the future standard methodology of

measuring and quantifying motion systems.

Point Precision includes all six degrees of freedom of errors

of each axis in motion, guaranteeing the precision point in the

full work envelop. As an example, the Hybrid Hexapod has a 3D

point precision of less than 100 nm repeatability anywhere in

its full work zone. With that information a customer with, for

example, a demanding metrology application can be extremely

con�dent in the uncertainty measurement error quotient.

Point Precision allows for a “precision number” to be quoted

based on an exact point on the wall, as if you used a laser

pointer, whereas today’s standard only gives the measurement


Easy as X, Y, ZFigure 2: In the area of motion control, the focus should and must be on exact-ing criteria, by which we mean repeatability and accuracy.


to the wall as if using a �ood light. As a signi�er of accuracy

and precision today, Point Precision is bene�cial for many ap-

plications from laser processing to metrology.

We have moved the conversation along, and in terms of

speci�cations we have changed the language and now routine-

ly talk about Point Precision, referencing performance speci�-

cations to a point in space, not the planar methodology current

standards use. This is the basis of the new NIST standard for

measuring motion systems.

While there are compensation methods to reduce error

sources in conventional six-link hexapods, they do not improve

performance at the single-digit micron or nanometer level.

Motion systems’ straightness and repeatability performance

must be analyzed and speci�ed using a “point precision”

methodology that accounts for all 6-D spatial errors in order to

provide a true representation of nanometer precision, or what

Alio calls True Nano precision (Figure 3).

There are numerous companies working in the area of micro

and nano manufacturing that exist because of a passion to lead

and to provide industry with solutions that stimulate innova-

tion and advance the chances of achieving success in ever

more exacting precision engineering applications. By their very

nature, they push the boundaries and strive to provide tech-

nology solutions that facilitate greater and greater precision,

which is consistently demanded across industry.

Alio has adopted a new approach to address the lack of

clarity that exists speci�cally in the area of motion-control

solutions. Through the process of education and rede�ning

the language used to explain its technologies, Alio will give

industry the tools and understanding to differentiate between

the alternative levels of accuracy and repeatability that exist in

the market today.

With the creation with NIST of the Point Precision as the

future standard methodology of measuring and quantifying

motion systems, Alio is exemplifying the uniqueness of its

motion-control solutions in the area of nanometer precision.

C. William (Bill) Hennessey founded Alio Industries in 2001. He is

CEO of the company based in Arvada, Colorado. Hennessey has

been a serial entrepreneur, mechanical engineer, robotics sales

leader and marketing professional in the robotics, lasers and

automation �elds with more than 40 years of experience at large

international corporations and small start-ups. He has a bachelor

of science degree in mechanical engineering technology from the

University of Maine. Contact him at [email protected] or

303/339-7500.


motion control

Spherical performance range

Target position

Imperfect real axis

Six ways to precisionFigure 3: 6-D Point Precision incorporates all sources of error at any desired work location into a meaningful three-dimesional value.

Hexapod motion-control technology exists at the ultra-precision end of motion control, and it has been the best-in-class motion control solution for exacting industrial applications for a couple of decades.

– C. William Hennessey



Enclosures for industrial explosion protection This electrical explosion protection equipment (EPE) portfolio

includes enclosure sizes and styles that provide design con�gu-

rations for almost all hazardous area applications. They carry

ATEX, IECEx and North American certi�cations and can be used

as stand-alone terminal boxes or in combination with other

equipment in accordance with Pepperl+Fuchs’ system certi�-

cations. Enclosures are available in aluminum, stainless steel

and glass �ber-reinforced polyester

material. They typically are suitable

for temperatures from -50 to 60 °C but

can be rated for temperatures as high

as 120 °C.

Pepperl+Fuchs / 330-486-0002 /

www.pepperl-fuchs.com

Enclosed and panel-mount switches Motor-reversing switches are available for single- and three-

phase operations. The single phase operates at either 120 or 240

V up to 5 hp. The three-phase motor-reversing switch operates

at 208 or 480 V, reversing up to 20 hp. Enclosed and panel-

mount drum switches are used for maintained or momentary

switching. The panel-mount version includes the motor-revers-

ing switch and handle. The enclosed

version includes an enclosure,

handle, motor-reversing switch and

on/off and forward/reverse labels.

The enclosed drum switches come

with handle on top or on the front of

the enclosure.

ASI / www.asi-ez.com

IP69K metallic enclosuresEngineered specially to withstand high-

pressure, high-temperature sanitary

washdown cleaning procedures, the

HyShed hinge cover enclosures feature a

15° sloped top to prevent �uids or particu-

lates from pooling and to maximize back

panel space. It has an easily replaceable

FDA-grade silicone gasket that helps resist bacteria growth

and chemical absorption while simplifying maintenance and

a streamlined hygienic design that helps wipe out bacteria-

harboring catch points.

Newark / www.newark.com

NEMA 4X cabinet with DIN rail kitThe ARCA–IEC series has been enhanced with a snap-in lock-

able inner front door and easy-to-mount DIN rail frame solution

kit. The lockable door �ts without

the use of tools or hardware. The

DIN rail kit allows users to popu-

late the rail outside the enclosure

and then slide the rail assembly

into the enclosure base and con-

nect any wiring. This watertight,

UV-resistant polycarbonate

enclosure will not dent, rust, crack or bloom. Manufactured in

a Wi-Fi friendly polycarbonate, the NEMA 4X cabinet �exes and

returns to its shape. The formed-in-place PUR gasket makes an

airtight �t, keeping components dust-free and dry.

Fibox / www.fiboxusa.com

Wall-mount polycarbonate enclosures Integra Premium series polycarbonate enclosures include a

lift-off screw cover, hinged screw cover and single-door hinged

cover. The series features a T-rail mounting system for dead-

front panels, swing-out panels,

layering subpanels and in�-

nitely variable subpanel height.

The enclosures weigh less than

comparable steel or �berglass

enclosures and are engineered

for durability, impact resistance,

UV stability and chemical resis-

tance. They have an operating temperature range of -40 to 265

°F. Covers are available in clear or opaque. The enclosures are

NEMA-rated, watertight, noncorrosive and nonconductive and

are UL-listed and CE-, RoHs- and REACH-compliant.

AutomationDirect / 800-633-0405 / www.automationdirect.com

Where the work gets doneEnclosures and workstations protect and enable machinery and operators

product roundupCONTACT US [email protected]

CD1907_41_42_Roundup.indd 41 7/9/19 3:37 PM

Modular diagnostics interface systemThe Modlink MSDD interface system makes it easy to access

controls in the cabinet for in-plant or machinery diagnostics

and servicing. It allows the cabinet to remain closed, and the

components inside can continue

to operate with their required

levels of protection. It is available

in both a single and double frame

size with a transparent, silver or

�berglass-reinforced gray cover.

The cover comes with a choice of

locking mechanism—either a 3-mm

double-bit key or a knob. Both help

the cover and frame to meet IP65 requirements. The two-part

system is based on frames and inserts and offers more than

4,000 combinations.

Murrelektronik / 770-497-9292 / murrinc.com

Enclosure protection for DIN instruments in outdoor locationsThe R-Box �eld-mount enclosure for DIN rail-mount instru-

ments provides an outdoor housing suitable for intrinsically

safe, nonincendive and general location applications. Designed

to meet Type 4X and IP66 ratings, the enclosure is watertight

and resistant to the harmful effects of

heat, UV rays and certain chemicals.

A clear polycarbonate cover allows op-

erators to monitor instruments with-

out opening the enclosure. To prevent

accidental exposure or tampering,

it is equipped with a front-mounted

security lock. Available in four off-

the-shelf sizes (3, 6, 9 and 12 in), it

accommodates isolators and convert-

ers as well as temperature, level and �ow transmitters, meters,

indicators, analyzers and other standard DIN instruments.

Moore Industries / 818-894-7111 / www.miinet.com

Modular industrial enclosuresTS 8 modular industrial enclosures have a frame structure

that creates an inner and an outer mounting level inside the

cabinet, allowing for more gear in the same enclosure space.

Because all external panels can be grounded back to the frame,

there’s no need to run ground straps in the �eld. Every panel is

interchangeable including the

door, which can be switched to

open from the left or right. The

enclosures can handle unique

wiring needs and assembly

challenges as they are avail-

able off the shelf in more than

100 versions.

Rittal North America / rittal.us

IP68 and Industry 4.0 enclosuresThe Industry 4.0 1554 and 1555 sealed enclosure families have

been updated with 36 con�gurations. Available in ABS or poly-

carbonate with styled, opaque,

clear or smoked lids, the six

additional sizes are 4.13 x 4.13

x 2.36 and 3.54 in (105 x 105 x

60 and 90 mm), 5.51 x 5.51 x

2.36 and 3.54 in (140 x 140 x 60

and 90 mm) and 7.10 x 7.10 x

2.36 and 3.54 in (180 x 180 x 60

and 90mm), for a total of 150 sizes and lid options available as

standard. Polycarbonate versions are cUL- and UL 508A-listed

and tested to IP68 (NEMA Types 4, 4X, 6, 6P, 12 and 13).

Hammond Manufacturing / 716-630-7030 / www.hammondmfg.com

Modular design cable entry systemThe Cabtite cable entry system for pre-assembled cables and

cables without plugs replaces an earlier Cabtite version, offer-

ing increased �exibility in the cable management of control

cabinets and OEM equipment in manufacturing environments.

This modular design includes

three basic components– a frame,

snap-in inlays and sealing grom-

mets. The frame is made from

�berglass-reinforced plastic and is

available in four sizes. An optional

internal locking frame is available

for added tamper-proof protection.

The one-piece frame is con�gurable when using the snap-in

inlays, which provide a con�gurable method to generate small

to large entry points with sealing grommets of various sizes

ranging from 0.06 to 1.4 in dia.

Weidmuller / 800-849-9343 / www.weidmuller.com


product roundup

CD1907_41_42_Roundup.indd 42 7/9/19 3:37 PM


This reader questions and responses originally appeared in Control

Design, May 2016, but is being reproduced due to popular demand.

A CONTROL DESIGN reader writes: The multi-station dial index-

ers we build are in multiple diameters and different cycle rates.

We have one basic design that is customized based on the

needs of the application. How can we be sure we’re sizing the

right type of motor correctly? The tables’ motors currently can

vary from induction to servo. We’re also thinking of adding a

gearbox or direct drive. What are the calculations we can use to

determine which motor to use?

ANSWERS

Load inertiaThe number one calculation to make when sizing a motor for

a rotary application is the calculation of the load inertia. The

more accurately this can be calculated, the better. To make this

calculation, it’s generally best to approximate the load as a disc

or cylinder. In the case of a dial indexer, this is fairly straightfor-

ward, since the dial is already essentially a disc shape and the

load is typically evenly distributed around the dial. The basic

load inertia calculation in SI units looks like this—mr2/2—where:

m = the total mass of the dial, with all tooling included, in

units of kg

r = the radius of the dial, in units of m or cm.

In English units the calculation looks like this—Wr2/2g—where:

W = the total weigh of the dial, with all tooling included, in

units of lbf

r = the radius of the dial, in units of in or ft

g = gravity constant, 386 in/sec2.

The result of this calculation will be in units of kg-m2 or kg-

cm2 if using SI units, or units of in-lb-sec2 or ft-lb-sec2 if using

English units.

With this load inertia calculation complete, it is possible to

begin looking for an appropriate motor to rotate the dial. The

most common rules of thumb are to look for a motor whose

rotor inertia is no less than 1/5 or 1/10 the load inertia. If the

dial is large, this may be near impossible, and this is where a

gearbox becomes important.

The advantage of a gearbox is that it reduces the effective

inertia of the load by the square of the gearbox ratio. For ex-

ample a 25:1 gear ratio will reduce the effective load inertia by

252, or 625 times. This reduction in load inertia makes it much

easier to �nd a suitable motor.

The trade-off of a gearbox is that it reduces the output speed

of the motor/gearbox combination, so it is imperative that the

maximum rotational speed and cycle time requirements of the

application are also calculated. In the example above, if the 25:1

gear ratio in combination with the proposed motor’s rated speed

indicate that the required output speed and cycle times are not

achievable, a smaller gear ratio and larger motor, with larger ro-

tor inertia, must be considered.

Another option is to go with a direct drive motor. This can

often eliminate the need for a gearbox and increase overall per-

formance by eliminating mechanical components, such as gear-

boxes, that can introduce backlash or other unwanted mechani-

cal inaccuracies. However, integration of the direct drive motor

is generally more complex than a standard motor and needs

to be considered earlier in the design stage of the machine. It

is also generally a more dif�cult process to retro�t an existing

machine with a direct drive motor than a standard motor.

In conclusion, selecting the best motor and mechanical solu-

tion—gearbox or direct drive—is often an iterative process,

where different approaches must be considered at the same

time and iterations on gear ratio and motor inertia values

must be made and compared to the load inertia and cycle time

requirements of the application. An accurate calculation of the

load inertia is essential to the process and is always the start-

ing point for �nding the best solution.

ERIC RICE

national marketing director / Applied Motion Products / www.applied-motion.com

Determine the technologyThe �rst thing is to determine which technology to use, in-

duction or servo. DC motors and drives are also used in some

of these applications because they are simple and have good

low-end torque, but you don’t mention this as an option. The

technology will be driven by requirements for accuracy and

performance. If the application doesn’t need to index into posi-

tion quickly—rapid cycle positioning—and the accuracy is not so

critical that you can get away with using limit switches to sense

when the indexer is in position, then you could use induction.

How to size motors properly

real answersCONTACT US [email protected]

CD1907_43_46_RealAnswers.indd 43 7/9/19 3:38 PM

However, if the application requires high performance—the

ability to cycle rapidly and/or precisely—then I would use a servo

motor. Servo motors are relatively inexpensive these days, and,

once commissioned, they are very reliable. It will cost a little to

have an integrator install and commission it, if you don’t have

someone in-house who is capable, but, once installed, along with

the improved performance—faster cycles and more accurate

positioning—you also bene�t from the ef�ciency. Since the servo

is typically a synchronous motor, it will be more ef�cient than an

induction motor that would suffer from rotor losses.

Once you have determined the technology, you’ll need to size

and select the motor. Most motor manufacturers offer sizing soft-

ware to help with this process. Enter the application data—load,

technology—along with the move pro�le—speed, distance, accel,

at speed, decel, idle time—and the software will calculate the

required torque, speed and re�ected inertia of the motor. Based on

the results, it recommends a motor that best suits the application.

Whether or not you need a gearbox depends on the torque and

speed required to index the machine. Generally the servo gearbox

is used as a reducer. The output of the gearbox will increase in

torque and reduce in speed by the ratio of the gearbox. Again,

you can use the sizing software to put in a gearbox and change

its ratios to see what that does to your torque and speed require-

ments for the motor. In addition to allowing you to use a smaller

motor, the gearbox will also reduce the re�ected inertia by the

square of the ratio. For example, if you have a 10:1 gearbox, the re-

�ected inertia to the motor will be reduced by a factor of 100. For a

closed-loop servo system, having the right re�ected inertia can be

as critical as having the correct amount of torque. If your load-to-

motor inertia ratio exceeds 10:1, you could have problems trying to

tune the drive. With the introduction of high-resolution feedback

devices, the inertia ratio isn’t as critical as it used to be, but it still

needs to be considered because it can affect the system’s ability to

respond quickly without overshoot. Luckily the sizing software will

take the inertia into consideration, as well as the torque to help you

select the proper motor for the job. I have taught a lot of fundamen-

tal servo-motor classes, and I always had the class do the hand cal-

culations for things such as torque, inertia and friction, and then I

would have them do the same exercise using sizing software.

BOB MERRILL,

product manager – servo motors / ABB Motors and Mechanical / www.baldor.com

Motor factorialChoosing the type of motor technology to drive the indexer is

based on speci�c mechanical factors as moving load weight,

dynamics and position accuracy. System cost is also a selec-

tion factor. Each motor control technology has advantages and

disadvantages; �nding the optimum solutions may require a

compromise between engineering and economics.

AC motors are good for heavy loads, but you will need a vector

drive to control it, to be able to produce positioning functionality.

The ac motor/drive advantage is only ac motor cost; vector drive

cost is similar to servo drive. The typical ac motor runs at 1,750

rpm—1,800 minus slip—so using a gearbox will get just over

half the output torque, compared to using a servo motor with a

nominal speed of 3,000 rpm for the same gearbox output shaft

rpm. You will have to nearly double the torque of the ac motor to

compensate for the lower gearbox input rpm. Also, if you have

high dynamic indexing, the ac motor may not be able to cool

itself properly, and you may have the motor overheating. Another

disadvantage is in lower dynamic capabilities—lower accelera-

tion due to higher rotor inertia.

Closed-loop stepper motors are also to be considered. Stepper

motors can do position control, and closing the feedback loop—

stepper motors with encoder feedback—ensures no skipping

steps, so no positioning error. Using microstepping technol-

ogy in modern drives will increase the resolution and create a

smoother rotor movement. Stepper motors and drives have a

price advantage over servo drives/motors, but with a trade in

application dynamics, missing the capability to produce the

peak torque for fast acceleration. Stepper technology will be the

choice where cost is an issue and dynamics are not critical.

Servo motor/drive technology is the best �t for this applica-

tion. Positioning accuracy, high dynamics and small format

factor are just a few of the advantages. In addition, servo-drive-

technology capability of pre-set indexing positions, synchro-

nization of multiple-axis, triggering events based on position,

changing torque value on the �y based on position and/or

external events are just a few features that helps to simplify

machine control design.

When sizing the servo motor, dynamics and mechanics as-

sociated with the application have to be considered. The most

critical data you have to have is the torque rms required by the

application indexing cycle and re�ected load inertia mismatch.

Servo-motor rated torque rms should not be exceeded by the


real answers

DIAGRAMS and FORMULASFor bonus content, including diagrams, formulas, graphs and more answers to help you size your motors, visit www.controldesign.com/motorsizing.


application indexing cycle required torque rms (TRMS).

Calculation of the TRMS required for the indexing cycle is

based on the formula—(TRMS)2 = (T1

2t1+ T22t2+ T3

2t3+…Tn2tn)/( t1+

t2+ t3+…tn)—where T is torque associated with acquiring/main-

taining desired velocity and t is time duration corresponding

to movement. Please include in the indexing cycle the moving

pro�le and the dwell time until the next cycle is starting.

The servo motor’s main feature is the capability to develop

peak torque for 1-3 seconds, so for an indexing application the

entire move is usually only acceleration/deceleration, with ac-

celeration using the peak torque of the motor.

The servo drive associated with the motor has to be able to

deliver the peak current needed to power the servo motor peak

torque. If the servo motor peak torque requires more current than

the servo drive peak current is rated, the servo drive will protect

itself from going overcurrent; that may either reduce the current

output—current limitation—or trip in overcurrent protection.

Neither of the two situations will provide suf�cient current for

the motor peak torque, so the motor will not be able to reach the

required acceleration. Pay attention to the time associated with

the servo drive peak current; it has to be at least suf�cient to cover

your longest acceleration time at peak torque or the drive may trip

in thermal protection or go in current limitation—3 seconds if the

motor peak torque is 3 seconds.

Inertia mismatch is the re�ected load inertia to servo-motor

rotor. The higher inertia mismatch, the slower the response

time from the motor. Inertia mismatch can be anywhere

between 1:1 and 100:1, or it can be even higher if acceleration/

deceleration times are long and you can live with a sluggish

system response. For a dial indexer where acceleration/decel-

eration and positioning in a 30º-60º range is close to 1 second, a

20:1 inertia mismatch should be suf�cient.

Using a gearbox will decrease the re�ected inertia, divided

by the gearbox ratio and allow for a better usage of the servo

motor. Servo-motor best torque usage is at the maximum speed

before torque is starting to decrease—typically, 3,000 rpm. Us-

ing a 10:1 gearbox, for example, will multiply the motor torque

10 times, decrease inertia mismatch 10 times and allow the

motor to reach higher operation speed. From the cost point of

view, adding the gearbox will be compensated by reduced cost

of smaller-size servo motor, servo drive and probably cables.

On the servo motor torque graph, the peak torque knee is at

3,000 rpm.

Environment vibrations and/or temperature: For high vibra-

tions and temperature variations, a resolver feedback on the

servo motor will be better than an encoder with glass disk.

Backlash associated with the gearbox: It will affect positioning

accuracy. Using a low-backlash planetary will create a typical

positioning error of 3 arcmin (0.05°).

The easiest way to size your servo motor is using the sizing

software of the servo motor/drive manufacturer. The software

can also select additional mechanical components.

Critical data, such as precision accuracy at the end of travel,

can be calculated and documented. One advantage of the

servo software is that it is looking at application vs. capa-

bility of the entire servo system verifying for example that

the servo-drive selection has suf�cient thermal capability

to handle the peak current of the indexing cycle, offering in

the �nal selection different packages with different system

loading capability. This load capacity can be very important in

designing different load/cycle variations of the same machine,

especially when some input data can change in time, such as

friction due to poor machine maintenance.

The technical report on the system selection that the sizing

software provides is a complex document with application-

sizing data and motor, drive, gearbox and actuator technical

data, as well as device loadings for the speci�c application.

The report eliminates the errors in auxiliary components

needed, such as connector size on system cables or adapting

�ange for gearbox/servo motor.

The bill of material (BOM) with all of the correct part num-

bers and quantities can be also provided, making the PO docu-

mentation really easy to process and error-free.

PAUL PLAVICHEANU

EA REGIONAL PRODUCT MANAGER / Region Americas, Festo Americas /

www.festo.com/us

Calculate, calculate, calculateSince there is one design that is customized based on the vari-

ous dial indexers and different cycle rates, calculations will

need to be done for each unique application. However, in a situ-

ation where a single motor is required and the system will be

varied, select the worst-case scenario—largest diameter with

fastest cycle rate—when sizing.

First, calculate for the inertia of all components being used.

The inertia should be calculated �rst as the inertia value will be

used later to calculate for the torque. To calculate inertia of the

dial, use the following equation: JD= (1/8)mD2, where m is the

weight of the dial in ounces and D is the diameter of the dial in

inches. If the weight is unknown, then the inertia can be calcu-

lated by using the dial thickness and material density. The equa-

tion to use is: JD= (π/32) LD4, where = material density in oz-in3,


DIAGRAMS and FORMULASFor bonus content, including diagrams, formulas, graphs and more answers to help you size your motors, visit www.controldesign.com/motorsizing.


real answers

L= dial thickness in inches and D= dial diameter in inches. Either

equation can be used to size for the inertia of the dial, JD.

Next, if the load is not being directly driven, but instead the sys-

tem includes a shaft, then the inertia of the drive shaft, Js will also

need to be calculated. To calculate the inertia of the drive shaft

use the following equation: Js= (1/8) m2D22, where m2 is the weight

of the shaft in ounces and D2 is the diameter of the shaft in inches.

If a gearing system—pulleys and belts—is used to gear the

system, then the inertia of the gearing or transmission will

need to be calculated, as well. To calculate for the inertia of the

transmission pulleys, the following equations are used: JDP1=

(1/8)mp1Dp12 and JDP2= (1/8)mp2Dp2

2. The JDP1 is for the inertia of the

primary pulley and JDP2 is for the inertia of the secondary pulley

where mp1 is the weight of the primary pulley in ounces, mp2 is

the weight of the secondary pulley in ounces, Dp1 is the diam-

eter for the primary pulley in inches and Dp2 is the diameter for

the secondary pulley in inches. If there is no external gearing,

then the inertia calculations for JDP1 and JDP2 can be skipped.

To calculate the total system inertia, JL, use the following

equation: JL= (JD + Js + JDP2) * (Dp1/Dp2) + JDP1.

If no external gearing is being used, then the equation for the

total system inertia, JL, is: JL= JD + Js.

Now that the total system inertia, JL, has been calculated, size

for the speed of the motor. To size for the speed of the motor Vm

in rpm, use the following equation: Vm = ( /360)(60/(t0-t1))(Dp2/ Dp1)

where is the indexing distance in degrees, t0 is the total time for

positioning in seconds, t1 is the acceleration/deceleration time in

seconds, Dp1 is the diameter for the primary pulley in inches and

Dp2 is the diameter for the secondary pulley in inches. If there is

no external gearing, then leave (Dp2/ Dp1) out of the equation.

Last, calculate for the required torque, T, in lb-in. The required

torque is made up of the combination of the acceleration torque,

Ta, and the load torque, TL. Use the following equation: T = (Ta + TL)

(safety factor). When sizing, “2 times safety factor” is used.

Now that the sizing is completed, make note of the � nal val-

ues for JL, Vm and T. Select a product based on those values.

LIZBETH LOPEZ

technical support engineering supervisor / Oriental Motor / www.orientalmotor.com

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Collaborative robotsThis series of power- and force-limiting collaborative robots

can handle 4- to 35-kg payloads and a 550- to 1,813-mm reach.

Easy to use, even for those with little or no experience, the

cobots are equipped with an iHMI intuitive touchscreen user

interface that includes step-by-step programming instructions

right from the

teach pendant.

The hand guid-

ance feature

allows operators

to teach a collab-

orative robot by

leading it through

paths at the press

of a button or use it to lift heavy objects manually. The six co-

bot models combine automation technology and sensitive built-

in sensors that allow them to work safely alongside people in a

variety of industrial jobs.

Fanuc America / 888-326-8287 / www.fanucamerica.com

Voice coil motor with internal shaft and bearingThe GVCM-051-127-01 linear dc voice coil motor has an internal

shaft and bearing. The 3.75-in (95.3-mm) stroke of the preci-

sion-ground 0.236-in- (6-mm-) diameter shaft with an internal

thread is guided by a long-life plain bearing that allow side

loads up to 1 lb (4.4 N). The motor has threaded mounting holes

in the housing and coil ends for easy integration into exist-

ing and future applications. This brushless actuator features

high speed, high acceleration and deceleration, zero

backlash, high accuracy, high repeatability and

a high force-to-size ratio of 5 lb (22.2 N) of

continuous force and 15.8 lb (70.3 N) of

peak force in either direction.

Moticont / 818-785-1800 / http://moticont.com

Pancake cylindersThe DPC family of inch series “pancake” cylinders offer high

force and short stroke for tight spaces. The DPCA for new ma-

chines has an aluminum body and is clear-anodized for corro-

sion resistance. The DPCB is designed for maintenance, repair

and operations (MRO) applications with drop-in compatibility

to other manufacturers. It features a hard chrome-plated

stainless steel piston rod and a nonmetallic composite rod

bushing. Both prelubricated models

feature a choice of eight bore sizes

and variable stroke lengths up

to 4 in. Magnetic piston options

are available for cylinder position

sensing, as are sensors and other

accessories such as clevises. Cus-

tom cylinders also are available.

Festo / www.festo.com

Ultrasonic sensors for object detectionThe RU50 Eco series has been expanded to include analog

variants. The sensors have a plastic threaded barrel made

of durable liquid crystal polymer and a sensing range of 500

mm. They use sonic transducer technology for object detec-

tion. Teachable switching points and sensing distance ensure

users can con�gure the sensors to detect objects between the

sensor and the reference point. Even bad lighting conditions

and glossy or re�ective surfaces have no in�uence on the sen-

sor. PNP and NPN switching versions

as well as analog 4-20 mA and

0-10 V are available. Output

options include an M12 con-

nector or a 2-m cable.

Turck / www.turck.us

Motorized high-resolution pan-tilt stagesThese high-resolution, motorized pan-tilt

stages are available in two sizes. The PT60-1

pan-tilt stage is a combination of two

60-mm (2.362-in) rotary stages, and the

PT100-1 is a combination of two

100-mm (3.937-in) rotary stages

set at a 90° angle to each other.

Each has rotary stages that feature

repeatability of 0.005° (18 arc-sec), a

positional accuracy of 0.005° (18 arc-

sec) and a resolution of 0.001° = 3.6 in

(10 micro-steps per step motor driver in use). These compact,

easily integrated stages weigh 2 kg (4.4 lb) for the PT60-1 and

4.4 kg (9.75 lb) for the PT100-1. Load capacities are 10 kg (22 lb)

and 20 kg (44 lb), respectively).

Optimal Engineering Systems / 818-222-9200 / www.oesincorp.com


product showcaseCONTACT US [email protected]

CD1907_47_49_Showcase.indd 47 7/9/19 3:41 PM

Regenerative low-voltage PWM drives for dc motorsThe DCR300-60 and DCR600-60 series are microprocessor-

based, low-voltage PWM drives for brushed dc motors up to 24

and 48 Vdc, respectively. The microprocessor allows for custom

programming to �t speci�c OEM requirements, potentially

eliminating the need for a PLC and supporting devices. Drives

can be programmed for use in the �eld without trim pots. They

are rated for 30 amps continuous operation or 60 amps for 1

minute. These regenerative controls can brake

or reverse on the �y, without the use

of braking resistors or motor lead

swapping. Two onboard LEDs

are used to communicate run

status and fault conditions.

American Control Electronics /

www.americancontrolelectronics.com

Low-wattage ac/dc power suppliesThe Quint Power family includes ac/dc power supplies with a

12-Vdc output. The devices are available in 2.5-A and 7.5-A op-

tions. Both are UL-listed and Class

I, Div. 2-approved. The 2.5-A version

also is NEC Class 2-rated. These low-

wattage devices include advanced

functionality in a compact form fac-

tor. Designed for critical applications

that may have space limitations, the

power supplies have an adjustable

signal output, which enables LED

and remote digital monitoring to detect critical operating states

before faults occur. The devices have power boost capabilities

and push-in connection technology.

Phoenix Contact / 800-322-3225 / www.phoenixcontact.com

Touchscreen panel metersThe point-of-use, touchscreen digital dis-

plays visualize four types of signals—

analog, incremental counter, start/stop

pulse and synchronous serial SSI—for

easy viewing of information. Built to the

same panel cut-out size, these displays are simple

to install, and their touchscreen operation and plain-text

prompts make it easy to set their parameters, including the

screen color, linearization, hysteresis, totalizer and offset.

They also provide dc sensor supply. The panel meters can be

used for a range of applications, such as manual operations

or automated machine processes that require digital numeric

feedback to operators or when sensors are used to check ma-

chine status and process conditions.

Balluff / www.ballu�.com

IO-Link smart con�guratorThe IO-Link Smart Con�gurator

provides a means to con�gure

any IO-Link sensor with a wire-

less device that, in essence,

replaces the need to program

via a USB IO-Link Master con-

nected to a PC or via a network

connected master device. This device is portable and can be

used anywhere. It is battery-powered and equipped with WiFi

for IODD �les download, eliminating the need for power or a

laptop. It features M12 and M8 connectors and is suitable for

three-, four- or �ve-wire sensors.

Carlo Gavazzi’ / www.gavazzionline.com

Heavy-duty, corrosion-resistant actuatorConstructed of high-strength, corrosion-resistant materials,

the AC-11 actuator features an ergonomic pull handle that is

suitable for actuating a latch remotely in heavy-

duty equipment applications. The actuator

features an oval bezel and a �ush mount

design that minimizes protrusion. The

pull handle can be actuated with a gloved

hand, providing remote actuation of a

latch in challenging environments. Available

in both locking and nonlocking versions, it provides direct,

single or multipoint actuation of a connected latch. When com-

bined with R4 rotary latches and ac cables, the actuators create

a complete rotary latching system that provides secure remote

latching for interior and exterior applications.

Southco / 610-459-4000 / www.southco.com

Industrial panel PCsThe TPC-1551T(B) industrial panel PC has a compact and fanless

universal design and features a true-�at touchscreen with IP66-

rated front panel and an operating temperature range of -20 ~


product showcase


60 °C (-4 ~ 140 °F). It is equipped with an Intel Atom E3845 quad-core pro-

cessor for enhanced computing performance. In addition to the system’s

two serial ports, four USBs and two GbE Intel I210 LANs for enhanced

communication, it includes an iDoor socket, HDD/SDD bay and mPCIE

port with mSATA support for easy system expansion. It is compatible

with a standard VESA arm mount (100 x 100 mm).

Advantech / www.advantech.com

DIN rail mount redundancy moduleThe DRM40 series DIN rail mount redundancy modules are two 20-A

10- to 30-Vdc-rated inputs that can be connected to provide a 20-A re-

dundant con�guration or, using the load-balancing option, to deliver a

40-A output. For capacitive and inductive loads, the module will sup-

port an additional 50% peak load for four seconds. The use of low-loss

MOSFET reverse current protection devices reduces the internal volt-

age drop to just 200 mV. If the input currents are unbalanced, the front panel-mounted LED is off.

When the input voltages are adjusted and the load current is shared equally, the LED is illuminated.

TDK-Lambda Americas / 800-lambda-4 / www.tdk-lambda.com

Cut-to-length bulk sensor/actuator cableFlexible multiconductor sensor/actuator cable is available in 24 AWG

and 22 AWG with three, four or �ve unshielded conductors and

in customer-speci�ed 1-ft-increment lengths. Individual conduc-

tors are stranded bare copper for �exibility, with color-coded PVC

insulation for easy identi�cation. The cable outer jacket is a �exible

PVC available in either gray or yellow, and the jacket is pressure

extruded for optimal roundness. The cable is UL-listed and has CSA approval and is suitable for

both stationary and �exible industrial factory automation applications with limited mechanical

stress and free movement without any tensile stress, loads or forced movements. It is not suit-

able for continuous �exing applications.

AutomationDirect / 800-633-0405 / www.automationdirect.com

Free-core and spring-loaded LVDTThis dc LVDT technology offers expanded output capabilities to

meet the needs of industrial monitoring and feedback applications.

In addition to the 4-20 mA versions of the free-core and spring-

loaded LVDTs, customized 4-20 mA position sensors are available.

The 4-20 mA loop-powered LVDTs are suitable for use in robotic

automation and industrial automation controls. The output signal provided by the sensors in-

tegrates with a variety of PLCs, digital indicators, computer-based data processors and QC data

collection systems. Hermetically sealed versions of the free-core and spring-loaded LVDTs can

withstand dirt, water, steam and other harsh elements.

NewTek Sensor Solutions / www.newteksensors.com


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WHEN DISCUSSING THE physics of linear motion, rotary and

oscillating motion often surface, as well. Linear motion is more

than just displacement; it has a start and a stop point, and

compressed air and rotary motion often drive the physics of the

move and the resulting cycle time.

Fortunately, calculus is not needed to calculate linear motion

as it is simpli� ed by assuming a constant acceleration. The

equations for linear motion and the related variables including

constant acceleration, displacement, velocity and time are eas-

ily accessible.

Linear-motion automation compo-

nents, such as pneumatic actuators

and motor-driven actuators, all oper-

ate within the de� ned physics equa-

tions. All motion starts and stops,

but some are easy to create multiples

of such. Most provide the ability to

adjust positions of the start and stop points, but accuracy and

repeatability vary, and some are programmable.

Linear motion, moving the part or tooling, is initiated and

stopped in many ways. Compressed air and rotary motion are

two of the most common methods used on automated equip-

ment, and each method controls the motion in different ways.

The compressed air controlled through air-preparation units,

solenoids, tubes and � ow controls actuates cylinders and pneu-

matic actuators. This pneumatic actuated linear motion usually

only has two positions, such as advanced/ returned, extended/

retracted, raised/ lowered or open/ closed. The advanced and

returned displacement—the start and stop position—can be

adjusted, and the speed of the move can be varied.

Simple pneumatic linear motion literally runs into hard stops

at each end of travel; the travel is often � xed. These hard stops

can be built internally to the cylinder or actuator or mounted

externally either to the device itself or surrounding support

structure. In any case, it’s good practice to decelerate and even

stop the cylinder piston before impacting the end cap. As the

speed of the motion increases, external shock absorbers or

soft-bump stops are often used to control the stopping of the

actuator at the end of travel.

System air pressure, solenoid valve and hose size, and the

air volume through a � ow control all combine to determine

pneumatic-actuator velocity and acceleration. These actua-

tors often accelerate the whole motion before hitting the hard

stop. Obviously, machine cycle time drives the actuator speed

requirements, but the cylinder speed should only be set as fast

as needed. Adjusting the � ow control to reduce the speed can

greatly soften the abrupt stops at the end of travel.

The repeatability of the hard-stop positioning is well under

0.01 inch, but adjusting it to an accurate position can be dif-

� cult. Moving the advanced or retracted position of an end-of-

travel stop by loosening a nut, turning a bolt and retightening

the nut may require several tries to

get within a few thousandths of an

inch of the desired position.

Better control of the linear motion

speed, acceleration and starting

and stopping positions is possible

by adding rotary motion to an ap-

propriate linear motion actuator

instead of compressed air. Improved precision and gentler op-

eration can be had using rotary motion via a variable-frequency

dive (VFD) and motor, stepper motor and servo motor. And

there are other differences.

To start, these motor-driven linear actuators are not sup-

posed to run into hard stops. That would be a crash condition,

and certainly not a gentle-stop method. It may even damage

the actuator or the carriage and bearings in the device. The

controlling drives and automation controllers are programmed

to move the carriage between the hard stops in this case, with-

out contacting them.

Another difference is that end-of-travel switches on motor-

driven linear actuators are not meant to be actuated during

normal operation such as advanced and returned sensors are

on pneumatic actuators. Activating end-of-travel switches on

a motor-driven actuator will usually cause the motor drive to

perform an immediate stop before reaching a hard stop.

In more precise applications, such as moving between two

or more programmable points, a home switch is part of the

precise and gentle stopping performance of these motor-driven

linear actuators. Open-loop control, such as step and direction

signals to a stepper motor drive or closed-loop control such as

encoder feedback to the servo motor drive, allow programming

of target positions that are then reached via a discrete signal,

analog voltage or controller instruction block.

Be gentle and accurate with linear motion


Dave Perkontechnical editor

[email protected]

automation basics

The linear motion is stopped differently in pneumatic actuators

and motor-driven actuators.

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