Industry 4.0 – Industrial Automation Review – Industrial Automation | Automation Magazine | Manufacturing Automation News & Resource https://industrialautomationreview.com Online Portal on Industrial Automation & Instrumentation Fri, 22 Apr 2022 04:50:55 +0000 en-US hourly 1 https://wordpress.org/?v=5.5.14 EmPower Your Control Cabinet With WAGO Power Supply Pro 2 https://industrialautomationreview.com/empower-your-control-cabinet-with-wago-power-supply-pro-2/ https://industrialautomationreview.com/empower-your-control-cabinet-with-wago-power-supply-pro-2/#respond Fri, 22 Apr 2022 04:50:55 +0000 https://industrialautomationreview.com/?p=3309 EmPower Your Control Cabinet With WAGO Power Supply Pro 2

Fast, flexible, as cost-effective as possible – in the face of increasing cost pressure, scarce resources and tight delivery times. The demands on the control cabinet industry are steadily increasing. Production processes are undergoing increasing digitization and automation to reduce costs and save time. That’s where power supplies play a decisive role. But what does […]

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EmPower Your Control Cabinet With WAGO Power Supply Pro 2

Fast, flexible, as cost-effective as possible – in the face of increasing cost pressure, scarce resources and tight delivery times. The demands on the control cabinet industry are steadily increasing. Production processes are undergoing increasing digitization and automation to reduce costs and save time. That’s where power supplies play a decisive role. But what does a modern power supply look like? And what must it be able to do? With the WAGO Power Supply Pro 2, WAGO launches future-ready devices that power your application: Choose the Power of the Possible!

Save Time with Modular Circuit Diagrams

A modern power supply must basically do one thing: Convert alternating current into a safely electrically isolated direct current. It is also necessary to save time and money simultaneously – but how? According to a 2017 study by EPLAN and the Institute for Control Engineering of Machine Tools and Manufacturing Units at the University of Stuttgart, planning and creating the circuit diagram accounts for over 50% of the design time. There is significant potential here for savings potential. This study of Control Cabinet Manufacturing 4.0 shows that switching from project-specific or order-oriented circuit diagrams to modular circuit diagrams can save up to 45 % of the time of the engineering process. There is significant potential for optimization such as this in control cabinet manufacturing and in the power supply, since many work steps are still performed without automation even today. 92 % of the study participants surveyed still rely on two-dimensional engineering. But why? One industry that is facing particular challenges in this regard is the automotive industry.

Automotive Industry: Increasing Demands on Power Supplies

If a production system in automobile manufacturing is idle for even a few minutes, it can quickly cost several thousand Rupees and mean fewer vehicles produced. That’s all the more exasperating if it’s caused by the failure of a power supply whose original price was only a fraction of these costs. To avoid this, it is essential to choose a reliable power supply. Availability plays an important role for automobile manufacturers above all else. An important selection criterion for the power supply is its theoretical life expectancy. It’s worth taking a close look at the datasheets when selecting the power supplies: Comparable devices may differ significantly upon closer inspection. A long life expectancy is usually also associated with low heat generation and low power loss. The example of power loss makes clear that intelligent selection and dimensioning of power supplies can also reduce energy costs.

The Crucial Difference: the Right Control Cabinet Cooling

The higher the power loss is, the more the power supply heats up. That affects the control cabinet air conditioning in particular: The costs for cooling the control cabinet increase. Even a couple degrees of extra heat in the control cabinet mean significantly higher energy consumption. Therefore, manufacturers of air conditioners for control cabinets recommend a temperature of 95 °F (35 °C). However, if a higher temperature is set, as is the case with some automotive industry users, for example 100 °F (38 °C), the delta of five degrees contributes significantly to reducing the energy costs and CO2 emissions. The control cabinet components and the power supplies must however be appropriate for this. The designers need to take the derating curves of individual components into account. But not with the new WAGO Pro 2 Power Supplies, which can operated up to +140 °F (+60 °C) without derating.

Pro 2 – the New Heart of Your Control Cabinet

WAGO’s efficient power supplies always deliver a constant supply voltage – whether for simple applications or automation with greater power requirements. A high-efficiency design permits space-saving dimensions; a uniform housing design and a digital twin make the implementation very easy. Another advantage: Plug-in connections enable pre-assembled cabling and faster installation.

Power with Communication for Industry 4.0

The WAGO Power Supply Pro 2 is structured in such a way that the most important operating status information can be read off the front, or further valuable data can be retrieved through the controller. Real-time status information is essential in order to assess situations in real time and respond deliberately. Therefore, the WAGO Power Supply Pro 2 has various functions and components that keep the user informed. The LED bar chart on the front provides a reliable indication of the current output power, as well as overloads/load reserves. Furthermore, the LEDs indicate the selected operating mode, warnings and errors.

In terms of data collection and read-out of status information, the Pro 2 Power Supply can be connected to a dedicated communication module at any time, allowing selection of the desired protocol for coupling to the automation and control level.

Intelligent Overload Behavior

Applications with high output requirements call for professional power supplies capable of reliably handling power peaks. The WAGO Power Supply Pro 2 gives you the power of the possible for all projects. Its load management features corresponding intelligence – after all, the point is to supply power reliably to your equipment and protect it at the same time. With TopBoost, PowerBoost and further parameterizable overload behavior, the WAGO Power Supply Pro 2 protects your equipment and provides intelligent current and switching modes. 150 % PowerBoost and up to 600 % TopBoost are available for reliable, fail-safe equipment availability.

Resource-Efficient Energy Use

Small but powerful: The difference lies in the details. We can show how with a small example: The typical efficiency of a simple power supply with nominal power of 960 W is 91 %. With the Pro 2 Power Supply, the efficiency is 96 %. At first glance, this five percent doesn’t seem like much, but it makes all the difference: The superior efficiency of the Pro 2 Power Supplies eliminates 55 W of power loss. Calculated with respect to an operating time of five years, this means significant savings of energy costs and one metric ton of CO2 at the same time. For comparison: A 80-year-old beech tree growing 75 feet (23 m) tall can store one metric ton of CO2 – so with several hundred power supplies in a production line, that would already be a whole forest. As you can see, a small difference but a big effect!

Challenging Environmental Conditions

Whether in the arctic or the desert – the WAGO Power Supply Pro 2 can be started and operated from −40 °C to +70 °C. Low derating begins > 60°C and allows 70 % output power even in 70°C applications, and even at an elevation of 5,000 m above sea level. Furthermore, the wiring in the WAGO Power Supply Pro 2 is very robust against transients. Overvoltage category III ensures safe operation in power grids with overvoltage surges or control cabinets with regenerative drive controllers.

For more information, Website: https://www.wago.com/in/power-supply-pro2

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Digitalisation in drive technology: Customer added value from drive data https://industrialautomationreview.com/digitalisation-in-drive-technology-customer-added-value-from-drive-data/ https://industrialautomationreview.com/digitalisation-in-drive-technology-customer-added-value-from-drive-data/#respond Mon, 17 Jan 2022 14:29:53 +0000 https://industrialautomationreview.com/?p=3249 NORD: Condition monitoring for predictive maintenance

Predictive maintenance is the systematic continuation of condition maintenance with the aim of proactively maintaining machinery and equipment and detecting changes, reducing downtimes and increasing the efficiency of the entire plant. A status-oriented maintenance replaces the traditional time-based maintenance. Especially for drive systems in demanding production environments where industrial gear unit installations are usually used […]

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NORD: Condition monitoring for predictive maintenance

Predictive maintenance is the systematic continuation of condition maintenance with the aim of proactively maintaining machinery and equipment and detecting changes, reducing downtimes and increasing the efficiency of the entire plant. A status-oriented maintenance replaces the traditional time-based maintenance.

Especially for drive systems in demanding production environments where industrial gear unit installations are usually used in sensitive applications and their failure can cause severe damage, for example in intralogistics, the food industry or the heavy duty sector, condition monitoring supplements the triad of gear unit, electric motor and frequency inverter with improved safety and reliability. This is where condition monitoring for predictive maintenance comes into play: Based on intelligent algorithms and software in an IIoT environment, the networked drive units can collect their condition data in the inverter’s own PLC and pre-process it together with data of connected sensors and actuators. The result of the pre-processing or the complete data can be optionally transmitted to an edge device. There, data of all subsystems is managed and evaluated. It is then available as pre-selected and edited smart data for further use and clear visualisation.

Data analysis instead of just data reading

A concrete application example is the sensorless determination of the optimum oil change time based on the oil temperature. This is based on the fact that the oil temperature is a key factor for oil ageing in gear units. This information in combination with available gear unit parameters and specific operational parameters make it possible to precisely calculate the oil change time. A physical temperature sensor is not required. The pre-processing of drive data takes place in the NORD frequency inverter’s integrated PLC that is used as an evaluation unit. The customer can access the calculated data via all common interfaces.

The right PLC software architecture for each solution

The drive equipment can be optionally extended and adjusted to the respective automation task. Customers can select what tasks (drive monitoring, drive control, process control) they want to directly shift into the drive. In smaller production areas, this scalability offers the possibility to gain first experiences before reorganising the plant. There are three configuration levels available. At the first level, the drive unit PLC only performs the drive monitoring. The drive parameters are pre-processed in the PLC and communicated to the higher level control system that is responsible for drive and process control. At the medium level, the PLC integrates the drive control and also runs drive-related functions. At the higher configuration level, the inverter PLC completely replaces the higher level control system. Apart from the communication to a control unit, a local data management without internet connection can optionally apply the data.

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Industrial Automation Review July-August 2021 https://industrialautomationreview.com/industrial-automation-review-july-august-2021/ https://industrialautomationreview.com/industrial-automation-review-july-august-2021/#respond Tue, 07 Sep 2021 15:09:56 +0000 https://industrialautomationreview.com/?p=3133 Industrial Automation Review July - August 2021

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Industrial Automation Review July - August 2021


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Industry 4.0 is the primary driver behind wireless technology https://industrialautomationreview.com/industry-4-0-is-the-primary-driver-behind-wireless-technology/ https://industrialautomationreview.com/industry-4-0-is-the-primary-driver-behind-wireless-technology/#respond Mon, 23 Aug 2021 06:04:47 +0000 https://industrialautomationreview.com/?p=3122

Among many other things, Industry 4.0 has also created opportunities for expanded industrial wireless solutions and capabilities. There can be several questions a company should ask itself when headed into the development of its industrial wireless standards. In case you are reading this article, you are most likely a consumer of wireless technology—at least in […]

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Among many other things, Industry 4.0 has also created opportunities for expanded industrial wireless solutions and capabilities. There can be several questions a company should ask itself when headed into the development of its industrial wireless standards. In case you are reading this article, you are most likely a consumer of wireless technology—at least in your personal life. In the industrial space, wireless has been utilised for dozens of years for the transmission of data from personal devices or fixed assets and based upon a specific job functionality or in cases wired communication was not feasible or desirable.

However, the rapid penetration of smartphones, tablets, and Industry 4.0 drivers such as digital twins, augmented reality, gamification, and the Industrial Internet of Things (IIoT) has created opportunities for expanded industrial wireless solutions and capabilities with a much broader range of users and use cases. This includes everyone from shop floor users and geographically dispersed asset management teams to the top floor where executives are realising that wireless isn’t only a technology platform; it also provides technology solutions delivering safety, efficiency, and cost reductions with positive impact to the bottom line.

What is wireless communication? It is the transfer of data or power between two or more points that are not connected by an electrical conductor. Generally, wireless technologies use radio waves. Radio waves cut down distances, such as a few meters for Bluetooth or as far as millions of kilometres for deep-space radio communications. Wireless technologies cover multiple types of fixed line, mobile, and portable applications which include two-way radios, cellular telephones, personal digital assistants (PDAs), and wireless networking.

Wireless devices are used both in process and discrete industries for wide applications, including easy maintenance, control, and monitoring. Such gadgets are expected to be the next big technological breakthrough in industrial automation. Unfortunately, these devices have been moderately so far because of concerns over the robustness, reliability, and security of wireless technology. An increasing demand for automation in industries like oil and gas, automotive, power, and textile has created the need for industrial wireless.

Primarily, Wi-Fi, Bluetooth, Cellular, and Zigbee are the four major wireless platforms in use within the industrial space today. The platforms can be operated individually or in more recent years as hybrid solutions to provide a more comprehensive platform for multiple solution implementations.

The rapid increase in demand for a diverse set of solutions, and perceptible value for industrial wireless applications are driving a sense of urgency for companies to use more wireless solutions. Hence, it is crucial to formulate policies and processes focused on wireless technologies that will become part of the overall corporate information technology (IT)/operational technology (OT) strategy.

However. at the time when wireless starts being considered strategic, a more comprehensive wireless technology plan is required to ensure there are standards for approved platforms, installation guidelines, security, and ongoing management and maintenance.

However, the largest share of the industrial control and factory automation market will be cornered by the industrial sensors segment. The industrial sensors segment is driven by the increasing adoption of Industry 4.0 and IIoT and, of course, the growing wireless sensors market. Apart from that, predictive maintenance is also expected to throw up highly profitable opportunities to the players in the industrial sensors market in the near future. This segment is primarily helped by three major solution enhancements over a traditional maintenance schedule: capturing sensor data, facilitating data communications, and making predictions. Since sensors are an integral part of predictive maintenance solutions, the demand for industrial sensors is expected to rise significantly in the years to come.

According to analysts, the market size of industrial control and factory automation is poised to grow from $133.1 billion in 2021 to $197.8 billion by 2026; going up at a CAGR of 8.2 per cent from 2021 to 2026

We should know that the key factors powering the growth of the market include adoption of cutting-edge technologies such as IoT and AI in industrial environments, emergence of connected enterprises and requirement of mass manufacturing of products. Of course, there are government initiatives to promote industrial automation, emphasis on industrial automation and optimum utilisation of resources are also there. And then there are fiscal policies formulated by regional financial institutions to help manufacturing facilities remain afloat in the midst of the COVID-19 crisis.

The global IoT chip market was valued at $11,980. 8 million in 2020, and it is forecast to reach a value of $27, 627. 9 million by 2026, registering a CAGR of 14. 98 per cent over the period between 2021 and 2026.

The increasing demand for automation and the frequency of application of IoT devices across several end-user verticals, such as healthcare, consumer electronics, automotive, BFSI, and retail, are additionally driving the adoption of IoT devices or in other words wireless technologies.

The number of IoT connected devices, a study by the Internet and Television Association said, had already reached 50.1 billion by 2020 from 34.8 billion in 2018. The growth is, however, primarily attributed to the integration of connectivity competence in a wide range of devices and applications, coupled with the development of different networking protocols that have significantly powered the growth of the wireless technology across multiple end-user industries.

Article by:
Arijit Nag is a freelance journalist who writes on various aspects of the economy and current affairs.
Articles of Arijit Nag

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igus makes 3D printed tribo-components intelligent https://industrialautomationreview.com/igus-makes-3d-printed-tribo-components-intelligent/ https://industrialautomationreview.com/igus-makes-3d-printed-tribo-components-intelligent/#respond Fri, 11 Jun 2021 09:47:23 +0000 https://industrialautomationreview.com/?p=3017 igus makes 3D printed tribo-components intelligent

A world’s first: sensors integrated in printed components indicate maintenance requirements and warn of overload Even today, 3D printed wear-resistant parts from igus often have the same service life as original parts. Now igus goes one step further and makes the printed components intelligent. Manufactured in filament printing, they warn against overload and report their […]

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igus makes 3D printed tribo-components intelligent

A world’s first: sensors integrated in printed components indicate maintenance requirements and warn of overload

Even today, 3D printed wear-resistant parts from igus often have the same service life as original parts. Now igus goes one step further and makes the printed components intelligent. Manufactured in filament printing, they warn against overload and report their maintenance requirements. The special feature: for the first time, the sensors are directly “printed into” the parts. As a result, they not only have extremely short delivery times and low costs but also feature useful Industry 4.0 options.

Additive Manufacturing and Industry 4.0 – two themes that are changing the industry forever. igus engineers have now succeeded in combining both in a single production step: for the first time, sensors are printed into the additively manufactured tribo-component using multi-material printing. “We have now achieved a real breakthrough with the smart 3D printed bearing”, says Tom Krause, Head of Additive Production at igus. “In this way, predictive maintenance is also possible for special parts in a cost-saving manner.” Long before the failure, the intelligent 3D printed component signals that a replacement is imminent. It can also detect overload in order to stop the application immediately and prevent further damage to the bearing position and the entire system.

Wear or load are monitored

igus has been producing intelligent wear-resistant parts for energy chains, plain bearings and linear guides since 2016. At the start, plain bearings were manufactured from iglidur I3 in laser sintering and the intelligence was subsequently introduced in a second processing step. In this case, however, the production of intelligent special parts in small quantities is complex and expensive, as the downstream work steps are very specifically designed for the respective component. Using a new process, igus developers are now able to produce such intelligent wear-resistant parts in just a single work step. No further processing steps are necessary and intelligent special wear parts can be produced cost-effectively from 5 working days. The sensor layer is applied to those parts of the component that will be subjected to load. Wear-resistant components with integrated sensors are created using multi-material printing. The components are manufactured from iglidur I150 or iglidur I180 filaments and a specially developed electrically conductive 3D printing material that bonds well with the tribo-filament.

Currently, two areas of application are possible: if the electrically conductive material is located between the layers subject to wear, it can warn against overloading. Because if the load changes, the electrical resistance also changes. The machine can be stopped and further damage can be prevented. To determine the load limits, the bearing must be calibrated accordingly. If, on the other hand, the conductor track is embedded in the sliding surface, the wear can be measured via the change in resistance. Predictive maintenance is possible with the 3D printed component. The lubrication-free and maintenance-free tribo-component announces when it needs to be replaced, avoiding system downtime and enabling maintenance to be planned in advance. If the 3D printed components are also used in the pre-series stage, the collected wear or load data provide additional information about the service life of the individual component or the planned application in the series. This makes it easier to adapt and optimise the development process.

Interested parties can register for a beta test here: https://content.communication.igus.net/en/3d-isense-beta-tester

This is just one of many 3D printing innovations that igus is presenting this autumn. For all those interested, igus offers individual guided tours at the virtual new products trade show, and also further information at https://www.igus.in/info/3d-printing-fair?L=en

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Industry 4.0 playing huge role in sustainable energy https://industrialautomationreview.com/industry-4-0-playing-huge-role-sustainable-energy/ https://industrialautomationreview.com/industry-4-0-playing-huge-role-sustainable-energy/#respond Wed, 08 Jan 2020 07:08:54 +0000 https://industrialautomationreview.com/?p=1890 interconnectivity, automation, machine learning, and real-time data.

The commonly used term, Industry 4.0, refers to the fourth industrial revolution based on cyber-physical systems, Internet of Things, machine-to-machine communication, big data and analytics, augmented reality, block-chain, and smart manufacturing. Industry 4.0 is a fundamental shift from ‘centralised’ to ‘decentralised’ manufacturing, focussing on highly specialised-and, at times, customisation and low-volume production involving rapid prototyping. […]

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interconnectivity, automation, machine learning, and real-time data.

The commonly used term, Industry 4.0, refers to the fourth industrial revolution based on cyber-physical systems, Internet of Things, machine-to-machine communication, big data and analytics, augmented reality, block-chain, and smart manufacturing. Industry 4.0 is a fundamental shift from ‘centralised’ to ‘decentralised’ manufacturing, focussing on highly specialised-and, at times, customisation and low-volume production involving rapid prototyping. And just like the previous three industrial revolutions, this too would be closely linked with energy.

As Industry 4.0 takes the centre stage in most economies, policy analysts have continued to observe the fate of developing economies and have sought to provide answers to such question as: what will be the role of electricity in this revolution? To what extent will electricity be needed for this revolution to take place? Will this revolution totally replace electricity energy? These questions continue to beg answers among researchers and the academia.

The usage of energy is a close indicator of industrial activity and a significant index of standard of living. In the developing countries, no activity is more basic to the fuller utilisation of their resources than the development of the energy industries.

In order to survive in this competitive market, utilities need to provide uninterrupted power supply with efficient load distribution and minimum downtime and timely maintenance.

As a result, technology innovations such as machine learning algorithms and artificial intelligence are entering the power distribution business at a drastic speed. Among other innovations, battery storage and Internet of Things are showing the promise of transforming the power business in the very near future.

Manufacturers are humongous users of electricity. When they become more sustainable, they make great contributions to a cleaner planet. Additionally, the public also benefits from the drop in electricity prices. At present, very few manufacturers can provide data on their overall energy efficiency.

With digital technologies, they can measure the gains when they introduce new robot systems, and the public can get factual insights into the entire production process.

As per data from the International Energy Agency, the industrial sector accounted for 42 per cent of the world electricity consumption in 2015.

Immediate reaction to changes post incorporating Industry 4.0 in the power sector in energy quality is a good example of how manufacturers can enhance their energy efficiency. Sensors that detect voltage imbalances and trigger changes in the system will prevent damage to the equipment.

Despite the fact that Industry 4.0 has become the buzzword of late, however, it was way back in 2011 that the German federal government announced ‘Industrie 4.0’ as one of the key initiatives under its High-Tech Strategy 2020.

Historically, the first industrial revolution took place in late 18th century with the advent of steam engines. Then, in late 19th century, came the second industrial revolution with the introduction of assembly lines and mass-production techniques. The third industrial revolution pertains to introduction of electronics and ICT in manufacturing in the 1970s.

Post the muted success of the Ujjwal Discom Assurance Yojana (UDAY), the Government of India’s (GoI) big investment support plans for the distribution sector, worth INR 2.5 lakh crore, has not taken off due to the tight fiscal condition existing in the country over the past couple of years. This investment support plan has the potential for transforming utility operations by focusing around smart meters, enterprise resource planning, billing and collection systems, etc.

Another area of the power sector that Industry 4.0 has impacted is the Cross-border Electricity Trade (CBET) . In South Asia CBET is gradually moving from inter-governmental agreement-based trades to market-/commercial-based trading, with both long-term and short-term trades taking place among Bangladesh, Bhutan, India, and Nepal.

The CBET policies and regulations developed in India have created an enabling environment for growth of CBET in the region. At present, several international development agencies are supporting investments in power generation and transmission assets linked to CBET.

Furthermore, the policy and regulatory frameworks and institutions in the neighbouring countries are maturing and such developments are expected to enhance CBET in the region. There have been some positive steps in power trade deals between Nepal and Bhutan with Bangladesh via India, which would set the tone for trilateral trade in this region.

Industry 4.0, along with voluntary commitments from the private sector on platforms such as the Science-Based Targets Initiative and EP100, is expected to drive the agenda in the industrial sector, apart from regulatory frameworks such as perform, achieve and trade. Smart appliances and demand response through grid interactive equipment are the opportunities for domestic industries, buildings, and municipal sectors.

The net-zero concept of energy-friendly buildings, together with digital integration of buildings and implementation of building codes, will drive initiatives in the building sector of the power industry.

The United Nations Industrial Development Organisation (UNIDO) issued a report in 2017: Accelerating Clean Energy through Industry 4.0. The report stated that from that point of view, it’s clear that we had a long way to go. By 2014, 78 per cent of the entire energy consumption of the planet was driven by fossil fuels. But the growth rates are significant, especially for solar photovoltaics, which achieved a growth rate of 46.2 per cent since 1990.

By integrating Industry 4.0 in the sustainable energy industry, we achieve smart energy networks that avoid the development of new path dependency. The technology will enable decentralisation, with energy coming from local solar photovoltaic or wind farms. This, in turn, means that the users will be able to manage and control their energy use.

Built with the help of Industry 4.0 a virtual power plant connects medium-scale, decentralised units that produce power. These can be flexible power consumers and storage systems, as well as solar parks, wind farms, and CHP units. Tesla’s virtual power plant in South Australia is a nice example of theory that works in practice.

This type of system works through a cloud-based centre, which controls IoT devices in the units. Peter Asmus, an expert on new energy models, identified the combination of VPPs and transactive energy as a compelling vision of the future.

A very handy example of the role of Industry 4.0 in the power industry is the SIDRIVE IQ, digital drive system by Siemens, which makes the production process more sustainable, but more intelligent at the same time.

Manufacturers get relevant data from all motors and converters, so they can evaluate their efficiency. The device delivers cloud-based data analytics, which enables the manufacturer to identify and improve affected drive system performance. Data about the machine vibration degree, for example, helps the engineers detect flaws in the systems.

Article by:
Arijit Nag is a freelance journalist who writes on various aspects of the economy and current affairs.
Articles of Arijit Nag

 

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Finalists in Industrial Automation for  2019 LEAP Awards declared https://industrialautomationreview.com/finalists-in-industrial-automation-for-2019-leap-awards-declared/ https://industrialautomationreview.com/finalists-in-industrial-automation-for-2019-leap-awards-declared/#respond Mon, 11 Nov 2019 10:38:17 +0000 https://industrialautomationreview.com/?p=1752 Finalists in Industrial Automation for  2019 LEAP Awards declared

Winners in the second annual LEAP Awards, celebrating the best components and services across the mechanical and electrical engineering design space, were unveiled on November 5, 2019. Across 13 categories, the judging panel awarded Gold, Silver and Bronze recognitions, as well as Honorable Mentions for certain submissions. The awards program is supported by three leading […]

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Finalists in Industrial Automation for  2019 LEAP Awards declared
Winners in the second annual LEAP Awards, celebrating the best components and services across the mechanical and electrical engineering design space, were unveiled on November 5, 2019. Across 13 categories, the judging panel awarded Gold, Silver and Bronze recognitions, as well as Honorable Mentions for certain submissions. The awards program is supported by three leading publications in the design engineering space: Design World, Fluid Power World and EE World.

Paul J. Heney, Vice President, Editorial Director, Design World, said, “Our judges, all of whom are independent engineering industry professionals, did a remarkable job in quickly turning around the scoring this year. We had a combination of judges from last year and several new judges.”

This year, the program changed from having a single declared winner in each category to a medalist concept, with the potentials for a Gold, Silver and Bronze winner in any category, as well as Honorable Mentions. Depending on the scoring ranges, not all categories will necessarily have all medals awarded, and Honorable Mentions are also optional — and tied to how close an entry came to the medalist scores.

The winners will be recognized at a ceremony in Santa Clara, California, in conjunction with the Healthcare Robotics Engineering Forum and DeviceTalks West events, on December 9th. Information on how to register for the ceremony will be posted shortly.

The medalists and honorable mentions for the Industrial Automation category are:

Gold • OnRobot US Inc. • One-System Solution to Simplify Automation

The One-System Solution from OnRobot redefines the end-of-arm-tooling (EoAT) industry. It is a full line of intelligent grippers and sensors that provide a unified mechanical and communications interface that allows for quick plug-and-play tool changes and fast and easy programming across multiple production lines, robot brands, and applications.

With the One System Solution, all OnRobot products now have a unified mechanical and communications interface based on the OnRobot Quick Changer, which is now fully integrated in all OnRobot products. An additional Dual Quick Changer incorporates these same new capabilities while allowing the simultaneous use of two tools in one cycle, mixing and matching to suit application needs and maximizing robot utilization.

With the OnRobot Quick Changer, a single cable provides a universal interface for tools and communications, so there is no need to disconnect cables when changing tools. Extended communications options support a full range of robotic platforms.

Silver • Dunkermotoren GmbH • Integrated DC servo motor BG 95 dPro

The BG 95 dPro from Dunkermotoren is an integrated dc servo motor. It integrates together into one unit the drive, communication interface, controller, encoder, brake and gearbox.

In addition, hardware and software are no longer separate individual components, but networked modules to which further modules are added. Depending on customer requirements, these can supplemented by an additional encoder interface or a customer-specific servo function, for example. This makes the system extremely flexible.

The BG 95 dPro is the first fully integrated low voltage 24-V motor, that will outdo the threshold of 1 kW continuous or 3,900 W peak output power. To minimize heat loss, wires were replaced by punched copper sheets and soldering processes were replaced by welding processes.

Bronze • Advantech • WISE-710

Designed to serve as in-cabinet machine protocol conversion and data collection gateways, Advantech’s WISE-710 series terminals connect legacy equipment to new mesh networks. Ideal applications for the WISE-710 include machine data gateway, protocol converter and asset monitoring.

The WISE-710 works to connect legacy equipment to new mesh networks. With its rich I/O and wide operating temperature design, this gateway plays a role as a PLC-side protocol converter and also a data logger for multiple industrial applications. The WISE-710 industrial IoT gateway has an open platform with Cortex 9 processor, equipped with 3x RS-232/485 serial ports, 2x 10/100/1000 Ethernet ports and 4x DI/DO.

The WISE-710 implements lean manufacturing onto product design, which brings many advantages to the overall engineering process. Due to the consideration that was done in the design and manufacturing during the early stages, excess waste (such as materials, certification process and lead time) was reduced, which allowed for expedited development time.

Honorable Mention • Maxim Integrated • Go-IO

Go-IO is a compact PLC reference design that enables factory subsystems to optimize size and performance based on real-time health and status information. It allows designers striving to bring greater intelligence into Industry 4.0 digital factory equipment while meeting the stringent size and power demands of the programmable logic controllers inside.

Digital factories can dynamically adjust the manufacturing line on the fly based on new or changing requirements. To fully realize industrial convergence, automated equipment must possess self-diagnostic and optimization capabilities. Go-IO pushes intelligence closer to the edge, enabling active monitoring and communication of equipment health and status information as well as higher throughput and productivity.

It meets increasingly stringent size and power requirements of PLCs, providing a 10x smaller solution (packs 17 configurable IOs in a space one-half the size of a credit card) with 50 percent less power consumption compared to its industry-leading predecessor, the Pocket IO. It is ideal for industrial automation, building automation and industrial robotics applications.

Honorable Mention • Universal Robots • The UR16e

The UR16e from Universal Robots expands the e- Series platform and delivers an impressive 16 kg (35.3 lb) of payload for heavy payload applications where cobot automation was previously not possible. The new UR16e combines the high payload with a reach of 900 mm and repeatability of +/- 0.05 mm making it ideal for automating tasks such as heavy-duty material handling, heavy-part handling, and machine tending.

Developed on UR’s innovative e-Series platform, the UR16e offers a number of benefits, capabilities and value for manufacturers. These include fast and frictionless deployment with easy programming and a small footprint. Programming and integration is simple – regardless of the user’s experience or knowledge base.

The UR16e can be unpacked, mounted and programmed to perform a task within less then an hour. Plus, with its 16 kg payload, UR16e eliminates the ergonomic and productivity challenges associated with lifting and moving heavy parts and products, lowering costs, and reducing downtime.
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Robotics can bridge talent gap for multiple industries https://industrialautomationreview.com/robotics-can-bridge-talent-gap-for-multiple-industries/ https://industrialautomationreview.com/robotics-can-bridge-talent-gap-for-multiple-industries/#respond Mon, 11 Nov 2019 09:30:25 +0000 https://industrialautomationreview.com/?p=1749 Robotics can bridge talent gap for multiple industries

Is robotics important to the future of manufacturing? Given the current and future talent gap in the sector, signs point to “Yes.”As of August 2018, as reported by Deloitte and The Manufacturing Institute, the U.S. had 508,000 jobs available in manufacturing. They called this the best jobs gain in the industry in over two decades. […]

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Robotics can bridge talent gap for multiple industries

Is robotics important to the future of manufacturing?

Given the current and future talent gap in the sector, signs point to “Yes.As of August 2018, as reported by Deloitte and The Manufacturing Institute, the U.S. had 508,000 jobs available in manufacturing. They called this the best jobs gain in the industry in over two decades.

However, this opportunity will soon start looking more like a potential crisis for employers. The report predicts 4.6 million jobs — a mix of new positions and exiting retirees — to fill between 2018 and 2028, with only 2.2 million of them “likely” to be successfully filled. The following is a look at six ways advanced robotics are already picking up the slack.

1. Robots eliminate unpopular work and reduce turnover

One of the challenges faced by Hitchiner Manufacturing Co. in Milford, N.H., was that newly hired skilled and semi-skilled machine operators often didn’t make it through their first day. Applying robots saved the company money — around $180,000 per year — and it took people out of the equation for repetitive manufacturing tasks, like placing metal parts in machines for processing or finishing.

Part of the savings Hitchiner enjoys comes from lower rates of employee turnover, which can be costly. In one study of manufacturing companies, 43% of respondents indicated their operations were sitting at 20% turnover per year or even higher. Industrial automation can help cut down on that churn and save jobs.

2. Robots make existing talent more useful

In an industry where skilled workers are both more valuable and scarcer than ever, companies need to find “force multipliers” for existing talent. Doing so helps lift employees into higher-paying and more compelling positions. This, in turn, improves employee engagement.

Waypoint Robotics Inc. is a good example of how robotics developers and suppliers can aid manufacturers with robots. The company recently moved from Merrimack, N.H., to a space three times larger in Nashua, N.H., to have space to meet demand.

“Businesses of all sizes are having trouble attracting and retaining talent,” said CEO Jason Walker. From collaborative robot arms to autonomous mobile robots, automation enables companies of all sizes to repurpose their existing workforce, which is already spread thin.

“I go from a shipping and receiving clerk to also being a robot wrangler,” said Walker, as he described new roles for employees. “I add a new and valuable skill to the company. … I have Industry 4.0 talents.”

Waypoint both exemplifies and serves lean manufacturing by doing as much as possible with as few resources as possible. In this case, the resource is talent.

3. Robots improve safety for human talent

Private industry in the U.S. reported 2.8 million non-fatal illnesses and injuries in 2017. Manufacturing alone contributed 115,500 incidents of days away from work in 2017, or around 93 cases for every 10,000 employees. The perception that working in a factory offers high risks for low rewards is one challenge for staff recruiting and retention.

In addition, people are more likely to be bored and make mistakes with certain tasks. “If a job is repetitive and boring, human workers tend to make a mistake, whereas robots can do these things the same way time after time,” said Frank Hearl, chief of staff at the National Institute for Occupational Safety and Health.

Arla Foods in Götene, Sweden, identified a cheese-packing station as particularly likely to result in productivity-disrupting repetitive strain injuries. It used eliminated potential injuries from that process by using an ABB robot that performs as much work as two employees used to, in the same amount of time.

4. Drones can provide agility at every stage of production

Deloitte last year identified drone data coordinator as one of a handful of new positions opening up as robotics literally take off in manufacturing. Unmanned aerial vehicles can play a role in multiple stages of production:

  • Drones can efficiently and safely locate raw materials out in the field by performing lower flyovers than planes.
  • Drones can transport materials, tools, and other assets within manufacturing plants by using vertical space and keeping out from underfoot.
  • Drones provide considerable opportunities in automated inventory management when combined with bar codes, QR codes or RFID tags.

The agility of drones, whether in the field or within a manufacturing facility, can take manufacturing by storm. For instance, a Spanish car manufacturer called SEAT uses drones to carry automotive parts between production and assembly plants.

This particular fetch-and-carry task once took humans an hour and a half or longer, but drones can do the same work in a quarter of an hour. It’s a perfect example of using robots to provide speed and agility while employees pivot to more cognitively demanding work.

5. Autonomous trucks keep parts moving

The American Trucking Association predicts the U.S. will see its truck driver shortage double in the next 10 years. Demand for freight services has softened slightly amid ongoing global trade tensions, but the talent crunch remains.

Automotive and technology companies are working quickly to solve or at least partially alleviate this problem. Locations throughout the U.S. are actively engaged in on-road testing for self-driving semi trucks.

Daimler’s and Torc Robotics’ on-road testing program in Virginia provides one example of such a collaboration, and Daimler has acquired Torc.

While some estimates predict that fully autonomous trucks could eliminate some 294,000 driving jobs, the American Trucking Association said the industry will fail to fill 160,000 trucking jobs in the coming decade.

The talent shortage in logistics would directly affect manufacturers. Trucking companies transport more than 70% of all manufactured goods in the U.S. Autonomous trucks are very much an extension of robotics in manufacturing.

6. Robots can improve accuracy and error rates

The manufacturing industry relies on precision and generally has a low tolerance for errors. For those reasons, Kay Manufacturing began leveraging collaborative robots at its facility in Calumet City, Ill.

Thanks to improvements in machine vision and pathfinding, cobots have improved awareness of their surroundings in comparison with previous-generation robotics. They’re also capable of carrying out highly detailed and accurate inspections.

Applying just one cobot to a parts inspection process helped Kay Manufacturing repurpose three employees at a time into better-paying roles. Critically, Kay says it hasn’t laid off a single worker since it began incorporating robotics back in 1996, and it bought Universal Robots’ 25,000th robot arm.

Robotics can bridge talent gap for multiple industries

Manufacturing isn’t the only critical sector experiencing a talent shortage. The health care sector is another. People currently employed in these industries might be worried about robots taking over their jobs, but the examples here show their livelihoods are probably safer than they realize.

As robotics spreads into new manufacturing applications, we’ll see new roles for employees emerge even as robots perform many existing functions faster, more safely, and more accurately.

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Safeguarding machine tools from cyberattacks https://industrialautomationreview.com/safeguarding-machine-tools-from-cyberattacks/ https://industrialautomationreview.com/safeguarding-machine-tools-from-cyberattacks/#respond Fri, 08 Nov 2019 09:38:08 +0000 https://industrialautomationreview.com/?p=1736 Safeguarding machine tools from cyberattacks

Data security is gaining in importance as Industry 4.0 takes shape. Automation, cloud applications, and globally networked machines and components play key roles when it comes to shielding systems from external threats. As digitalization becomes more prevalent across industries, there is a growing need for companies to safeguard against cyber risks. An example of this […]

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Safeguarding machine tools from cyberattacks

Data security is gaining in importance as Industry 4.0 takes shape.

Automation, cloud applications, and globally networked machines and components play key roles when it comes to shielding systems from external threats. As digitalization becomes more prevalent across industries, there is a growing need for companies to safeguard against cyber risks.

An example of this can be found in German industry, which has increasingly become a target for cybercriminals. More than eight in 10 industrial companies (84 per cent) have reported an increase in the number of cyberattacks in the past two years, with more than a third (37 per cent) reporting a strong increase.

This data comes from a 2018 survey conducted by the Bitkom digital association, which interviewed 503 managing directors and security officers from all sectors of industry.

“German industry is under constant digital fire from petty digital criminals, organized crime, and even state-backed hackers,” said Bitkom President Achim Berg. “The nature and scale of the cyberattacks is set to increase.”

One thing is certain, however: Cybercrime is a worldwide phenomenon that does not stop at national borders or at locked factory gates. It can happen wherever people use computers, smartphones, and other IT devices.

Security vulnerabilities

“Cybercriminals often use known vulnerabilities or bugs in outdated software to gain access to a system. Promptly installing updates and security patches considerably reduces the risk of cyberattacks,” said Philipp Echteler, IIoT strategy manager at the Balluff Group.

“Using versioned software and firmware and then monitoring them help create greater transparency. Avoidable dangers also emanate from devices that were originally only designed for communication with the controller of isolated networks, and not for connection to the internet. Many of these Ethernet-enabled automation devices have no protection features, which leaves them vulnerable to attack.”

The Balluff Group is a global player in the automation sector. With its workforce of 4,000 employees, the company offers a comprehensive portfolio of sensor, identification, network, and software technology for all areas of automation. Protecting against cybercrime is a key aspect in the development and design of customer products.

Protecting systems

But what are the best ways to protect complex networked systems against manipulation and cybercrime?

“In principle, any networked system represents a possible point of attack. A well-designed security concept is therefore indispensable for safeguarding such systems against manipulation and cybercrime,” said Juliane Schneider, junior product manager at Symmedia.

Symmedia GmbH, Bielefeld, Germany, has been developing services for the mechanical engineering sector since 1997. The company’s digitalization expertise – especially in the field of mechanical and plant engineering – is strengthened by its alliance with Georg Fischer, a mechanical engineering company to which Symmedia has belonged since 2017.

“When it comes to handling sensitive data, any human negligence poses a security risk. An unnoticed cyberattack, the reckless multiple use of passwords, or the deliberate divulgence of confidential data — any human action can have major consequences and cause significant damage,” said Schneider, listing just some of the more obvious risks.

“The risks which arise from internal threats should not be underestimated. Employees unthinkingly open email attachments that can be used to smuggle in viruses unnoticed, or they send critical company information in unencrypted form by email,” added Echteler.

Poorly protected or forgotten maintenance access routines represent back doors that attackers can then use for their own purposes.

Use firewalls

Encryption mechanisms such as SSL and TLS must be deployed as standard to protect complex networked systems from manipulation and cybercrime. These encrypt all data traffic between servers, computers, and applications in a network.

Another common practice is to install a firewall, which checks the trustworthiness of all parties seeking access to a computer to automatically protect it from attacks and unauthorized access.

“Having separate production and office networks offers additional security. Further recommendations include minimizing the number of network accesses and routing the data stream via a central, monitored gateway. Potential threats can often be identified at an early stage if data and network traffic levels and individual nodes are also continuously analyzed,” said Echteler.

Data security in production

Balluff has established its own team of experts to offer comprehensive consulting services to customers all over the world. Some of the Balluff devices now also feature hardware encryption based on the Trusted Platform module. In addition to minimum requirements such as firewall protection, Symmedia also uses HSM and TPM procedures (based on so-called hardware security and Trusted Platform modules) to ensure that only secure software is run.

“We also use a proprietary network protocol to provide very high-level protection against unwanted access. It is virtually impossible to hack into these connections,” said Schneider.The company uses a secure and work flow-based point-to-point link for digital service support.

“The use of common encryption, authentication, and authorization procedures for client applications, servers, and programming interfaces, so-called APIs, is also a matter of course for us. In addition, we offer many other security measures, including a public key infrastructure (PKI)-based individual machine and user certificate structure, password rules, the irreversible storage of access data with up-to-date hash procedures, and multi-factor authentication,” said Schneider.

Clouds play a role

Another major point with regard to data handling is the location of the data storage. Three in 10 companies (29 per cent) use a cloud system that is outsourced to a certified data centre – either to achieve possible cost savings, to relieve the strain on their own IT staff, or to obtain greater security. Another 10 per cent plan to do so, and 28 per cent are discussing this as an option. This is shown by the Digital Office Index 2018, a representative survey of 1,106 Bitkom companies with 20 or more employees.

According to the index, fewer than three in 10 companies (28 per cent) state that cloud hosting is of no concern to them. A comparison of the different industries reveals that the mechanical engineering and plant construction sector is the frontrunner in this field. According to Bitkom, almost half of all companies in this industry (46 per cent) are already using external cloud service providers.For Balluff, too, the public cloud is the first choice.

“Its high availability is attractive because its platforms are replicated in independent, geographically distributed data centres. Other advantages include its easy scalability, its high level of security, its use of state-of-the-art technologies and encryption, and its service continuity. These guarantee that the solutions will work even in the event of negative scenarios,” said Echteler. “From experience we know that it is not possible for a company’s own IT staff also to run a cloud. This is a task for suitably qualified specialists.”

Symmedia, on the other hand, offers its customers hybrid options.

“This gives our customers flexibility combined with outstanding security. And this in turn gives them full data sovereignty,” said Schneider. “They can decide for themselves which data they want to store centrally, for example in a cloud, and which is only to be stored locally. We have found that our customers are open to central solutions, but always want to be able to store specific data locally, depending on how sensitive it is.”

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IO-Link technology sensors for Industry 4.0 https://industrialautomationreview.com/io-link-technology-sensors-for-industry-4-0/ https://industrialautomationreview.com/io-link-technology-sensors-for-industry-4-0/#respond Tue, 15 Oct 2019 12:52:39 +0000 https://industrialautomationreview.com/?p=1686 io-link

Collecting and managing the growing volume of data is integral in today’s age of Industry 4.0. Leveraging IO-Link communication standard provides a powerful infrastructure for collecting the data. IO-Link is a short distance, bi-directional, digital, point-topoint, wired (or wireless), industrial communications networking standard (IEC 61131-9) used for connecting digital sensors and actuators to either a […]

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io-link

Collecting and managing the growing volume of data is integral in today’s age of Industry 4.0. Leveraging IO-Link communication standard provides a powerful infrastructure for collecting the data. IO-Link is a short distance, bi-directional, digital, point-topoint, wired (or wireless), industrial communications networking standard (IEC 61131-9) used for connecting digital sensors and actuators to either a type of industrial fieldbus or a type of industrial Ethernet. IO-Link is the ideal method to obtain status and diagnostic information from proximity sensors.

An IO-Link system consists of an IO-Link master and one or more IO-Link devices, i.e. Sensors or Actuators. The IO-Link master provides the interface to the higherlevel controller (PLC) and controls the communication with the connected IO-Link devices. Leelavati Automation, a provider of automation components, sensor technology, system integration, factory automation, industrial products like sensors, building management systems, etc., provides a complete range of Inductive sensors with IO Link and capacitive sensors with IO link.

Why IO-Link? Benefits

  1. Communication directly to the field devices: Both cyclic and acyclic data exchange with the higher levels is possible.It also allows bidirectional communication.
  2. Consistent communication between devices and controller: It enables continuous communication and monitoring of devices and enables access to all process data, diagnostic data and device information at any time.
  3. Dynamic change of device parameters by the controller, master: It allows change while the device is running. The ability to change parameters or devices without disruptions reduces downtime.
  4.  Simple and Standardized sensor wiring: Fast wiring and re-use of existing wiring is possible.
  5.  Automatic parameter reassignment for device replacement: Device replacement by untrained personnel is possible without additional tools. Plug Play replacement of sensors with reduced downtime for machine changeover.
  6.  Reduces variations and inventory: Flexibility to modify parameters (NO/NC NPN/PNP, time delay, frequency). It reduces inventory and thus reduces cost.

IO Link Functions

The SSC outputs can be set in 3 different modes

• Single Point Mode
• Two Point Mode
• Windows Mode

Logic Function Block

• AND,
• OR,
• XOR,
• Gated Set-reset function or
• Direct

Individually time delays can be added:

• On Delay
• Off Delay
• One-Shot
• Direct
• Timing can be set from 0 to 32’767 units in ”ms”, ”s” or ”min”

Output can be individually configured:

• Normally Open N.O.
• Normally Closed N.C.

The outputs can be configured as:

• NPN,
• PNP,
• Push-Pull

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