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SPS/IPC/Drives 2008 Show Report
The world’s largest dedicated controls and automation exhibition –Germany’s SPS/IPC/Drives show – managed to attract record numbers of exhibitors and visitors to Nuremberg recently, despite the economic slowdown. On the following pages, we look at some of the technologies on show.
There was little evidence of world’s economic woes at the annual SPS/IPC/Drives show which took place in Nuremberg, Germany, in late November. Despite the global downturn (and a severe cold snap), the automation and motion engineering show managed to maintain its seemingly unstoppable expansion.
The organisers attracted 1,386 exhibitors (65 more than in 2007) and added an extra hall, bring the total number to 11 and the total floorspace to 94,700m2 (7.7% up on the previous year). Non-German exhibitors represented 21% of the total (up from 20% in 2007), although many foreign companies are represented by local subsidiaries or distributors. As in previous years, British exhibitors were few and far between.
Most of the stands would have been booked well before the credit crunch started to bite, so there was speculation that any effect would be seen in visitor numbers. But, in fact, the total number of visitors also increased – to more than 48,100, compared to 45,962 in 2008, possibly boosted by more student visitors than at previous events.
The continued expansion of the SPS/IPC/Drives show reflects the reality that the automation sector in Germany has, so far, been hit less hard than in some other countries. In fact, the president of the electrical and electronic manufacturers’ trade body, ZVEI, predicted at the show that the German automation sector would expand by 2–4% during 2009 – only slightly below the 5% achieved in 2008.
In terms of technologies, the Nuremberg show represented a continuing evolution, rather than many radical breakthroughs. Over the next few pages, we report on some of the new arrivals at the show.
MOTORS & DRIVES
ABB was showing an IP66-protected version of its ACS350 machinery drive in ratings from 0.37–7.5kW. The drive (shown below) has a GRP cover that is free from dirt traps and is said to be suitable for applications in the food industry. An internal fan avoids the need for external cooling.
Baumüller announced a new range of servomotors which, it claims, are up to 30% smaller than conventional servos. In developing the DSC motors (shown below), it focused on boosting torque densities while reducing motor volumes dramatically. The motors operate at up to 4,500 rpm.
Also on the Baumüller stand was a range of easy-to-operate vector control frequency inverters in three frame sizes, covering ratings from 0.2–11kW. The b maXX 1000 inverters offer 15 preset speeds and can achieve a rotating field frequency of 0.1Hz–400Hz, allowing even multi-pole motors to be operated at high speeds.
As well as its new family of inverters, B&R was demonstrating several motor innovations on its vast stand, including a series of permanently excited high-torque motors covering ratings from 0.11–21kW in two sizes. In many cases, the compact, maintenance-free 8LT three-phase synchronous motors can eliminate the need for gears. They offer stall torques in the range 50–900Nm.
B&R also unveiled a range of liquid-cooled three-phase synchronous motors in four sizes with rated speeds from 1,100–2,200 rpm (and top speeds up to 10,000 rpm). The compact 8KS motors do away with the need for noisy fans and are said to have long operating lives with their bearings being the only components that wear.
Finally, B&R was showing a range of compact three-phase synchronous motors in six sizes with stall torques from 0.8–52.5Nm. The 8JS electronically-commutated, permanent-magnet motors are aimed at applications requiring excellent dynamics and positioning precision.
New from Control Techniques Dynamics is an AC synchronous servomotor claimed to offer the highest weight/torque density ratio on the market. The UK-built Unimotor FM has a 250mm frame and can deliver 136Nm continuous (or 408Nm peak) and incorporates an electronic nameplate.
Following its integration into Schneider’s CST group, Crouzet has launched a range of 62 high-performance brushless DC motors with diameters from 28–102mm, power ratings from 1–500W, and capable of speeds up to 18,000 rpm. The motors have been designed to optimise: inertia; detent, starting and ripple torque; noise levels; and power. Crouzet also has a new control card for three-phase brushless motors with Hall effect sensors, rated up to 250W.
Danfoss Bauer was demonstrating a range of IP66-protected permanent-magnet gear-motors for hygienic applications requiring washdowns. The motors have no dirt-trapping fins and no feedback components. Initially they will be available in ratings up to 5.5kW, with extensions to 18.5kW planned. The motors, which are also available in IP65 versions, are powered by standard drives with enhanced software.
On its stand, Delta Line was showing a new range of miniature motors from Portescap that use a patented copper-graphite commutation system, said to deliver high torque and acceleration. The 35mm-diameter 35GLT motors have a nominal output of 180W – claimed to be the largest for any readily available motor of this size. The 67mm-long motors weigh 360g and have a no-load speed of 6,200 rpm and a stall torque of 1,410Nm.
Elau, Schneider’s packaging automation specialist, has developed a 140mm frame size intelligent servo module that can deliver up to 11.5Nm of continuous torque (and peaks up to 50Nm) for high-inertia applications such as conveyors and carousels. The iSH-140 integrated motor-drive (shown above) can power mechanisms that previously required one or conventional servo motors with cabinet-mounted drives.
Elau has also collaborated with the German safety specialist BBH to offer a pair of modules that add Safe Stop 1 and Safely Limited Speed to its MC-4 servo controllers (which already provide Safe Torque Off functions). The single-axis SMX11 and two-axis SMX12 modules have a 4ms reaction time, allowing the controllers to react to a trigger event in less than 20ms.
On its eye-catching stand, the Israeli motion specialist Elmo was showing the latest additions to its musically themed products, including the Bassoon, which it claims is the smallest servo drive controller that can deliver 1.9kW of continuous power (3.8kW peak) for AC, DC and linear motors. The controller, designed to be used with absolute encoders, provides up to 6A of continuous current. Another recent Elmo arrival is the compact Guitar servo control module, designed to be integrated into OEM machines to deliver up to 4.8kW of continuous power (5.4kW peak).
Elmo was also promoting its “next generation” motion control architecture that brings together three layers – intelligent drives, network motion controls, and a software application studio – in a single environment.
The Swedish motor control specialist Emotron was showing several extensions to its FDU/VFX drives, including 690V operation, a liquid cooling option, and support for industrial Ethernet communications. The drives are now available for operation from 380–690V and for motors from 0.18–1,500kW. The liquid cooling option avoids the need for ventilation or air-conditioning and allows the use of IP54-protected cabinets. The Ethernet communications are achieved using a plug-in module from HMS.
Fuji Electric’s Frenic Mega series of inverters previewed at last year’s SPS/IPC/Drives is now in production in ratings up to 630kW. They offer vector, sensorless vector, dynamic torque vector and V/f control. The drives have a ten-year design life and high-duty versions can handle 200% overloads for 3 seconds. In some markets, the Fuji drives are sold under other brand names.
The Swedish specialist motor developer HDD Servo Motors was demonstrating a 90mm-diameter servomotor weighing 2.4kg that can produce 80Nm of torque. The motor – a development from work that HDD has done with clients such as Saab Aerospace and ABB Robotics – uses a patented winding technology and a Harmonic Drive gearbox. It is aimed at applications where weight is critical. HDD was also showing hollow-shaft motors with unusually large bore diameters of up to 40mm.
One of a handful of British exhibitors at the show, the Welsh-drives-maker Invertek was demonstrating an IP55-protected version of its Optidrive Plus 3GV operating under a continuous water spray, as well as its Optidrive Plus 3GV Compact, a “drive-on-a-plate” aimed at OEMs. The company is talking to more than a dozen OEMs about incorporating these 0.75–1.5kW drives into their products.
Denmark’s JVL was showing a 400W version of its MAC integrated brushless servomotor. Like earlier versions, the motor’s driver, controller, encoder and Hall sensor are integrated in a robust, splash-proof housing. New features include: an absolute, multi-turn encoder without a battery; compatibility with Ethernet communications; two RS-422 channels; six I/O; a high-speed serial interface; and fanless operation.
The German drives-maker KEB was previewing its first range of modular multi-axis controllers, prior to their full launch later this year. The Combivert H6 range (shown above) will span ratings from 2.2–150kW and will offer open or closed-loop operation. All modules will be the same height, thus saving cabinet space, and will support cold-plate cooling.
KEB was also showing a range of frequency inverters for motors up to 900kW. There are various versions of the Combivert F5 drives, including: the F5-SCL, which offers sensorless closed-loop control of synchronous motors; the F5-ASCL for asynchronous motors; and the F5-A-Servo, which provides sensorless closed-loop control of servo motors up to 1.5kW.
Lenze is now fitting the StateLine and HighLine versions of its 8400 inverters with a Safe Torque Off function certified to SIL level 3. The PWM switch-off via optocouplers allows axes to start and stop quicker than using contactors, as well as saving cabinet space and wiring.
Lenze has also announced a couple of regenerative power supply modules (rated at 15 and 27kW) for its L-force 9400 servo drives. The modules, which have the same interfaces as the controllers, can also be used as intelligent master stations with central control functions.
At the 2007 SPS show, Leroy Somer launched a range of compact, high-efficiency synchronous permanent magnet motors and drives called Dyneo PM. At the 2008 show, it was showing a variant called Dyneo Varmeca which integrates the motor with its drive and eliminates a considerable amount of cabling.
The Korean manufacturer LS Industrial Systems was promoting its portfolio of drives products including a new family of inverters offering vector, sensorless vector, and V/f control. The iS7 drives span ratings from 0.75–160kW, and are available in IP21 or IP54 (up to 22kW) versions. They have dual constant and variable torque ratings and incorporate automatic torque balancing.
The Swiss miniature motor specialist maxon motor unveiled a range of flat brushless DC motors with integrated control electronics and Hall sensors. The space-spacing motors are almost the same size and the controller-less models on which they are based, and are available in two- and five-wire versions with ratings from 2–50W.
Also new from maxon is a 250W brushed DC motor with a low-inertia ironless rotor, claimed to have twice the power density of existing motors. The 65mm-diameter, 130mm-long RE65 motor delivers 0.5–0.9Nm of torque at 2,400–3,700 rpm.
On the Parker SSD stand, visitors could see a range of Ex “d” servomotors in ratings from 0.4–3.2kW, capable of delivering 0.54–12Nm of torque at speeds of up to 4,300 rpm. The pressure-sealed Parvex motors are available with internal brakes and can operate in temperatures up to 135˚C.
On its stand, SEW Eurodrive was promoting an energy-saving concept called effiDrive which combines its drive modules with energy consulting and application engineering services. SEW has also developed safety modules called Movisafe that offer PL “c” and “e” functions (ISO 13849-1) for its Moviaxis, Movitrac and Movidrive drives. The company has added three new sizes to its CMP range of synchronous servomotors, taking maximum torque levels up to 164Nm.
On its bustling stand, Siemens unveiled a new range of modular, general-purpose motors in ratings from 2.8–1.340kW. The 1PH8 motors (shown above) are available in both synchronous and asynchronous versions, and offer a choice between forced ventilation and water cooling, as well as options such as different types of bearing.
Siemens was also showing a new single-axis drive for simple positioning applications with synchronous or asynchronous motors. The Sinamics S110 is available with Profibus or CANopen interfaces and spans ratings from 0.12–90kW. Also on the Siemens stand was a water-cooled version of its Sinamics S120 converter for applications from 18.5–90kW, especially in dusty or aggressive atmospheres.
The British DC drives specialist Sprint Electric was showing its range of two- and four-quadrant drives recently expanded to include ratings up to 1,850A. The company says that the higher ratings are taking its potential market into large plants such as steel and paper mills, with increased spin-off sales for its lower-rated products.
MOTION CONTROL
The Israeli developer ACS Motion Control was showing a four-axis controller designed for cost-sensitive applications where space is limited. The SPiiPlus-LF controller can be programmed in any of five IEC 61131-3 languages and offers a 20kHz sampling rate on all axes. Another new product, the SPiiPlus-3U controller can handle up to eight axes, as well as managing a CANopen network of up to 64 nodes of axes and I/Os.
Danaher Motion’s stand was dominated by an F1 racing simulator car (shown below), but the company was also showing two new models in its S700 modular digital servo amplifier family, taking the top current ratings from 24A up to 48A and 70A. The new models can be cooled using heatsinks in a cabinet, via a through-hole technology, or using water cooling.
Festo unveiled several new motion control products including the CPX-CM-HPP module that can control up to four electric axes via CANbus. The multi-axis CPX-CMXX interface can execute either simple movements of individual axes or co-ordinate the movement of several axes. The PLC-based CECX-X-M1 motion controller is designed for co-ordinated multi-axis movements with interpolations, while the CMXR-C1 robotic controller is suitable for multi-axis spatial path applications with up to six degrees of freedom.
The second generation of maxon motor’s EPOS intelligent positioning controllers, EPOS2, is designed for applications requiring decentralised drive intelligence. The CANopen-based modular controllers can operate in position, speed and current control modes, and can be configured to work with DC or electronically commutated motors up to 700W.
Pilz was showing a safety card for its PMCprotego D servo amplifiers, which turns them into drives with numerous safety functions, ranging from safe stop and safe motion functions, through to safe braking. The PMCprotego S card will, for example, allow machines to be set up at safely reduced speed with the guards open, thus cutting set-up times and improving machine availability.
Rexroth’s IndraMotion MLC motion controller, based on the company’s new IndraControl L45 and L65 control platforms, expands its motion logic platform into middle and high-end applications. The MLC has an onboard Sercos III interface for communication with I/O and drives and it can also be connected to other Ethernet-based bus systems such as EtherNet/IP and Profinet RT.
Rexroth has also integrated real-time Ethernet interfaces into its HNC100-3X controller, designed to handle up to four electrohydraulic axes. Ethernet/IP communications are also a feature of the HACD-2X module for distributed control of the position, speed, and forces of electrohydraulic axes.
From Siemens comes the C240 PN Simotion controller, capable of handling up to 32 axes. The controller, which has a Profinet interface and 35MB of memory, can be combined with Siemens’ ET 200S high-speed Profinet I/O for tasks such as hydraulic control.
Yaskawa unveiled a new motion controller that combines PLC sequence control with motion control functions ranging from precise positioning and control of speed and torque, to phase control and electronic camming. The MP2300Siec controller (above) uses a control system developed with KW-Software which is PLCopen-compliant and compatible with IEC 61131-3. It is equipped with an OPC server and can control up to 16 servo axes. There are nine option modules covering various analogue and digital I/O as well as master encoders.
CONTROLS
Wireless communication was a widespread theme at this year’s SPS/IPC/Drives show, and ABB’s contribution was an IP65-protected wireless I/O pad that can connect up to eight sensors and actuators. ABB claims that the WIOP208 pad is smallest of its type and expects it to be used on modular production lines and in robotics applications. ABB was also showing an encoder function module for its AC500 automation platform with two independent encoders on board. The CD522 module can be configured for ten different operating modes at input frequencies up to 300kHz.
Bartec has produced modified versions of Moeller’s MFD multifunctional displays and easy 500 controllers that can be used safely in hazardous areas. It has also developed a handheld computer that can be used to scan barcodes and RFID transponders in Ex areas.
Baumüller was showing its bmaXX-safePLC safety control system which has recently won a prestigious red dot industrial design award, voted for by an international jury. The system combines standard and SIL3 safety controls, minimising wiring and testing, and reducing system complexity.
Beckhoff unveiled a DIN-rail-mounting embedded PC which uses Intel’s low-cost, low-energy-consumption Atom processor. The fanless CX5000 (above) is the company’s smallest x86 embedded PC and has a maximum power dissipation of 8W. Beckhoff says the PCs are about 30% less expensive than comparable devices.
The Swedish HMI specialist Beijer Electronics has developed a range of operator panels (called Exter) that can be read under any lighting conditions – including bright sunlight.
Horner APG was demonstrating a new range of all-in-one colour touchscreen controllers which combine 5.7” operator interfaces, I/O and networking. The XL6 controllers support up to 4,096 digital and 1,024 analogue I/O, and provide GPRS or PSTN modems, datalogging using 2Gb MicroSD cards, and networking options including Ethernet, CANbus and Profibus.
Kontron presented a range of compact, fanless embedded box PCs that can be configured easily to suit individual applications and are claimed to reduce the time-to-market for OEM products. The company also announced a second generation of its IP65-protected Micro Client industrial touchscreen HMIs for thin-client applications.
New from Lenze is a 12” version of its L-Force family of Windows CE-based HMIs. The fanless and diskless EL 112 HMI has an integrated touch display and CANopen, USB, Ethernet and RS-232 interfaces. It can be combined with a soft-PLC.
Mitsubishi has added a pair of entry-level HMI control terminals to its GOT1000 series. The GT1050 and GT1055 controllers offer a choice of monochrome or colour 5.7” displays and have built-in USB, RS-232 and RS-422 ports.
Omron was showing a range of 600MHz industrial PCs incorporating boards that operate independently from the rest of the hardware to monitor and log the status of the IPC and to notify the user if unstable hardware or software conditions are detected. The DyaloX PCs, available with 12” or 15” touchscreens, use solid-state storage and up to 1GB of RAM.
Phoenix Contact announced an expandable compact controller for small-scale automation applications. The base unit of the nanoLine control platform has four relay outputs and an input module with four individually configurable input channels with a 12-bit resolution. Expansion Ethernet and RS-485 communications modules allow the base unit to operate as a Modbus TCP or RTU server.
Phoenix was also highlighting a mini controller with an Ethernet interface that can be used to establish linear networks at the machine level without needing extra switches or hubs. The controller (shown above) is part of the Inline modular control family, and has a pluggable parameter memory, making it easy to change applications or recipe data.
Rexroth has added two controllers to its PLC family. The IndraLogic L45 and L65 systems (below) are said to offer improved real-time Ethernet connections and scalable expansion. The L65 can process 1,000 instructions in 15µs. Onboard interfaces are available for Profinet/RT, Ethernet/IP and Profibus.
Rexroth also announced a range of IP67-protected modular I/O, the IndraControl S67 series, that can be mounted near machines without needing cabinets, thus cutting wiring costs and increasing flexibility.
Siemens was promoting several additions to its controls range including its first distributed I/O system to use wireless communications. The ET 200pro IWLAN uses an IP65/66/67-protected interface module that can be mounted directly on machines and connected into a network via a wireless access point such as Siemens’ Scalance W.
Also on the Siemens stand were compact block I/O modules with a Profinet interface supporting star or line topologies. The IP65/67 protected and sealed Simatic ET 200eco PN modules are available in several variants with eight or 16 digital inputs and outputs.
On the display front, Siemens has a new mobile operator panel with a 10.4” colour touchscreen, a stop button and an enabling button. The IP65-protected Simatic Mobile Panel 277 (below) has a resolution of 800 x 600 pixels. There is also a new series of fixed-position operator panels for simple applications with 10” or 15” displays. The IP65-protected Basic Panels have alarm, recipe management and trend curve functions.
The German PLC and HMI supplier Vipa was demonstrating a PLC from its Speed7 family with an update rate on its analogue inputs and outputs that, it says, is 25 times faster than comparable CPUs. The analogue I/Os have a 100kHz sampling rate and the delay for a change in input or output signals to be registered is just 40µs. Like other Vipa PLCs, the CPU 314SX is programmed using Siemens’ Step7 language.
ELECTRICAL & SAFETY
In its stand, Danfoss was previewing a new generation of soft-starts before their launch in the second quarter of 2009. The VLT Soft MC is up to 48% smaller than the earlier 3000 MCD range and covers ratings from 7.5–800kW at 200–690V in five frame sizes. The soft-starts (below) have similar LCD displays to Danfoss’ inverters. There are 23 programmable parameters but a Quick Setup menu option shows only those required for an application. A function called Adaptive Acceleration Control adjusts the acceleration and deceleration ramps dynamically to suit the load.
Jokab Safety was showing several new products including a light curtain with double-beams at each position, both of which must be broken to trigger a stop signal. The Focus curtain is designed to prevent unnecessary stoppages caused by small items such as wood chips. The Swedish safety specialist was also showing a tough, stainless steel safety lock called Knox that operates like a door handle but has a combined resetting and locking function, so does not need a separate reset button or safety switch.
Moeller Electric was showing a sheet steel panel system that can be adapted easily and quickly if application requirements change. The XVTL system is available in 55 sizes with heights from 1.4–2m, widths from 425–1,200mm and depths from 300–600mm. It has standardised internal fittings, reducing the number of components that need to be stocked.
Leuze lumiflex was exhibiting an AS-i-compatible safety monitor with selectable muting (two-sensor parallel or four-sensor sequential). The ASM2E monitor (below) complies with Cat 4 and SIL 3 and can be coupled with a second AS-i network for cross-section emergency-stop applications.
Omron says that its new MS28 (Type 2) and MS48 (Type 4) light curtains are easier to specify and commission than many rival products. They include LED-based alignment aids and a simple switch system, that allows them to be put into operation without needing external programming equipment. The curtains are available in 14mm finger protection models with a 7m range, or 30mm hand protection models with a 20m range.
Phoenix Contact introduced a range of 6.2mm-wide single-function timer relays (below) that, it says, can cut cabinet space requirements by up to 70%. Time settings from 0.1–5s are set using a front-mounted knurled knob.
Rittal has developed a new high-current busbar system for use in its Ri4Power low-voltage switchgear system. The Flat-PLS busbar (below) can withstand rated currents up to 5.5kA. Up to four flat copper rails can be assembled as one- to four-pole systems using single supports. There are two types of support and four sizes of the 10mm-thick bar, in widths from 40–100mm.
Rockwell was showing a safe-speed monitoring relay which, it claims, is the first of its type to allow personnel to enter potentially hazardous areas while safely monitored motion is present. The Guardmaster MSR57P relay supports various safety input devices and can monitor personnel while a machine is in a safe-speed condition. It monitors speeds using one or two sin/cos or TTL encoders. It can be configured so that doors are unlocked automatically when a machine’s speed falls below a safe-speed limit.
Rockwell has also upgraded its SIL3 GuardLogix L63S programmable automation controller by improving its firmware, adding memory, and supporting ten press automation instructions.
Two German safety specialists, Safety Control and Safety Protec, which Schmersal bought in October 2008, are now trading under the name Schmersal Safety Control. At SPS/IPC/Drives, Schmersal was highlighting some of the new company’s products, including a Cat 4 safety light grid, which it says is the world’s smallest. The portfolio also includes IP69K-protected safety guards (below) which can withstand high-pressure water cleaning at 80˚C.
Schmersal was also showing a Cat 4 electromagnetic interlock with an AS-i Safety at Work interface. The MZM interlock needs no mechanical linkages and is fitted with a patented pulse-echo system that allows long switching distances and is tolerant of misalignments between sender and actuator. It monitors both the position of a safety guard and possible actuator “breakage” without needing a second safety switch.
Sick describes its S300 Expert safety laser scanner as the world’s smallest. It can manage up to eight different monitoring tasks. The device, which weighs 1.2kg, has a 2m protective field radius and an 8m warning field radius. It can be used vertically and can distinguish between personnel and materials.
Two more safety laser scanners could be found on the Siemens stand. Its Simatic FS670 motion monitoring scanner calculates positioning distances and speeds. It can monitor six different speeds and eliminates the need for incremental encoders for speed-dependent protection zone monitoring. There are eight protection zones with ranges from 2.5–4m (and soon 6m).
Siemens’ second new laser scanner, the Simatic FS660 SR is aimed at short-range applications up to 2.15m and offers four programmable and switchable protection zones.
Siemens has also developed a series of compact fuseswitch disconnectors which prevent users from touching the conducting parts even when mounted on busbars and accessed from behind. There are five sizes of the Sentron 3NP1 devices with ratings from 160–630A.
Visitors anywhere near Werma’s stand could hear its new 144 multi-tone sounder being put through its paces. The device can produce 32 different alarm tones with an output level of 110 dB. Three different tones can be triggered via separate terminals.
MECHANICAL & LINEAR
Although mechanical systems are not a primary focus at SPS/IPC/Drives, there were several on show, including a low-cost lightweight plastic planetary gear system from IMS Gear aimed at small motor applications where high torque levels and a wide temperature range are not needed.
The Swiss linear motor specialist LinMot was exhibiting several new products, including a family of actuators in a similar form factor to pneumatic cylinders that can deliver forces up to 1.2kN. LinMot also has a new range of high-performance linear motors that deliver a 70% improvement in continuous force and a 20% improvement in speed compared to similar-sized standard designs, but cost only 10% more.
The British motor manufacturer Parvalux launched a new range of planetary gearheads in Nuremberg. The HP gearheads are designed to operate just below servo specifications, offering planetary performance at a fraction of the cost of specialised servo gearheads. They will be available in three frame sizes (42, 60 and 86mm) and 68 ratios in up to four stages, providing output speeds from 0.1–1,000 rpm.
SEW Eurodrive has introduced an “electric cylinder” that combines a ballscrew drive with a planetary rollerscrew drive. The CMS63S can deliver a continuous force of 3.2kN (peak 10.5kN) over a stroke length of up to 200m, at speeds up to 4,500 rpm.
SENSORS & MEASUREMENT
New from ASM is a family of shaftless magnetic angular sensors in various formats including servo flange mounting and MM12 housings. The Posirot sensors are available for angular ranges from 15 to 360 degrees. ASM also has a new range of steel tape extension sensors with measuring distances up to 19m.
Balluff unveiled a vision sensor with a separate configurator and high-resolution 3.5-inch colour display designed for easy retrofitting to existing machines. The IP54-protected BVS-C sensor (above) offers seven different tools such as edge counting, brightness checking, contrast comparisons, pattern detecting and position monitoring. The configurator can be mounted on a DIN rail or in a panel.
Balluff was also demonstrating a new range of diffuse optical sensors with background suppression, designed to detect objects over distances of 0.2–2m. There are six versions of the IP67-protected BOS 50K sensors with different switching possibilities. Another Balluff innovation is a range of space-saving hubs for connecting up to 16 M8 sensors to control systems using IO-Link three-conductor cables.
On its stand, Baumer launched a retro-reflective sensor with a polarisation filter which achieves a 4m sensing range using a reflector measuring just 50 x 50mm. A potentiometer built into the Series 10 sensors allows them to be adjusted to detect objects such as semi-transparent sheets and translucent paper.
Another German sensing specialist ifm electronic had several new arrivals including a non-contact photoelectric sensor which uses a laser beam with a 10m range to sense transparent bulk materials. The O1D300 sensor can handle angles of incidence up to 45 degrees for non-shiny surfaces. Another new range from ifm is a family of stainless-steel inductive sensors in rugged one-piece housings protected against the penetration of oil or coolants. The C series sensors (below) are available in M12, M18 and M30 versions.
Leuze electronic claims that its latest optical distance sensor is the fastest in its class with cyclical measurement intervals of a few milliseconds, allowing them to pick up dynamic processes up to five times faster than rival products. The ODS 96B sensor has a range of 60–2,000mm, a resolution of 0.1mm and a repeat accuracy of 0.5%. It is intended for position monitoring, distance measurements and dynamic product gauging, and allows users to choose the laser light spot size.
Micro-Epsilon was showing a pair of laser micrometers with double the measuring range of previous products, allowing one sensor to be used where previously two would have been needed. The 30mm-high optoControl 1202 micrometers are available with 77 or 100mm ranges and offer a linearity of 0.2%.
Micro-Epsilon has also developed an inline C-clamp system for measuring the thickness of metal sheets using a pair of laser sensors mounted opposite each other. The sensors measure the distance to the surface of the sheet from both sides and, from this, the precise thickness of the sheet can be calculated. The sheet can move within the measuring gap without affecting the results.
Omron claims that its new Xpectia line (below) defines a new class of easy-to-use vision system that can identify objects of any colour and size, at any distance. It is a “true colour” system capable of sensing 16 million colours, thus delivering more accurate and stable results (without needing filters) than conventional vision systems. The 2-megapixel sensors can inspect small and large characteristics of a target at the same time, and find small defects on large objects. 3D inspection is possible, allowing workpieces with complex shapes to be examined.
Omron was also showing a range of photosensors with a novel snap mounting system that, it claims, makes then ten times faster to install than square sensors, and three times faster than standard cylindrical sensors. The M18 format E3FZ sensors simply click into a suitable hole without needing nuts or screws. They are available in through-beam versions with a 15m range, retro-reflective versions with a 4m range, diffuse reflective versions with a 1m range, and background suppression versions with a 20cm range.
Sick asserts that it has set a new standard with an absolute multi-turn encoder with a 30-bit resolution. The AFM60 encoder adds 12 bits of multi-turn resolution to the 18-bit single-turn resolution of its existing AFS60 absolute single-turn encoder. It uses a nickel code disk, said to be more robust than glass disks, and to offer a better resolution and wider temperature range than plastic disks. The same programming tool can be used for Sick’s incremental, and absolute single- or multi-turn encoders.
Sick has also developed a linear motor feedback system with a Hiperface interface that, it claims, is the most compact available. The TTK70 system consists of a matchbox-sized “absolute” reading head containing Hall sensors, and a 10mm-wide magnetic reference tape that can be up to 4,096mm long. The system can generate sin/cos signals at speeds of up to 10m/s and can operate with a resolution of 1µm and an accuracy of better than 10µm.
COMMUNICATIONS
Balluff has produced an instrument for analysing, commissioning, monitoring and maintaining DeviceNet and CANbus installations. The DeviceNet Analyser can perform wiring tests to detect errors and weaknesses such as incorrect cable lengths and types, short circuits and cable breaks, at the installation stage. It can also analyse signal quality and detect gradual deterioration in quality from, for example, worn cables.
Balluff was also showing a compact IO-Link distribution box for Profibus which can be used with IO-Link sensor hubs to connect up to 68 sensors. The IP67-protected box uses M12 connectors and offers two or four IO-Link terminals.
Beckhoff was promoting several EtherCat-based product lines including a terminal that allows cross-factory and cross-site synchronisation in accordance with IEEE 1588. Using the EL6688 terminal, machines, components or production lines can be synchronised with each other or with an external master clock, with a tolerance of better than 100ns. In this way, a precise technology- and vendor-independent global timebase is available for time stamping measured data.
Another new Beckhoff device supports Power over EtherCat, based on IEEE 802.3af, with a standard four-wire EtherCat or Ethernet cable carrying both the fieldbus signal and the power supply. The EK1132 EtherCat junction (above) is said to be particularly suitable for connecting sensors such as shaft encoders or length-measuring devices via a single cable up to 100m long. The maximum current input of the devices is 350mA.
Harting has developed a switching technology that brings Ethernet down to the field level by integrating Ethernet automation protocols with IT communications. It says that technology will allow time-critical automation protocols running on Ethernet to meet the requirements for real-time performance and determinism. The switching technology does not alter Ethernet messages. High-priority automation messages overtake messages that are not relevant to the automation systems. The technology, built into the Ethernet switches, guarantees that the messages are delivered in time.
The Swedish communications specialist HMS Industrial Networks was demonstrating a new range of modules for remotely managing and controlling automation devices. The Anybus RemoteCom connects to any device with a Modbus-RTU interface. The remote connection is made via an Ethernet interface or a GSM/GPRS phone network. A built-in Web server can be used to access the device data remotely for data-logging and trending. An alarm and status handler can send SMS or email messages if pre-defined limits are exceeded.
HMS has also extended its Anybus-IC family to include a module that allows OEMs to add Profinet IO to their products simply and cheaply. The single-chip interface, which includes a fast Ethernet controller and a Profinet IO software stack, is said to cut the effort needed to develop a Profinet IO interface by up to 70%, as well as saving space and power supply requirements.
On its stand at Nuremberg, ifm electronic was showing an AS-i device that combines 4–20mA analogue inputs and outputs with two digital inputs, enabling simultaneous transmission of I/O values to a single AS-i slave address. The AC5230 module avoids the need for extra software and for programming function blocks.
The cable-maker Leoni has developed a range of Cat 6 industrial Ethernet cables that reduce the normal two-stage process of cutting the outer jacket and inner sheath to a single step, performed with a standard stripping tool. The eight-core, twisted-pair Easy-to-Strip cables (shown above in cross-section) are said to allow easy installation using RJ-45 connectors.
Moeller has added a Modbus RTU gateway to its SmartWire system, allowing up to 16 contactors, motor starter combinations, or SmartWire I/O modules to be connected to a Modbus RTU bus. The gateway supports both point-to-point communications via RS-232 and the integration of SmartWire in an existing Modbus network via RS-485. Data rates up to 57.6kbit/s are possible.
Molex is claiming an industry first with a module that embeds PoE+ (Power-over-Ethernet Plus) functions into an RJ-45 connector and supports Ethernet 10/100/100. The HyperJack 1000 PoE+ integrated connector module can manage and deliver 30W of power over Ethernet cables and complies with the IEEE 802.3at standard that doubles the 15W power limit of the first PoE standard, IEEE 802.3af. This boosts the number of devices that can be powered via an Ethernet cable.
Molex was also highlighting a passive diagnostics tool that monitors a DeviceNet network continuously and sends information about its performance via Ethernet to a PLC or PC, or via a DLL interface, an OPC server or Molex’s NetAlytix software. The BradCommunications DeviceNet eNetMeter (below) measures network parameters using high-speed sampling and, by comparing these to a “good” network, can help to predict failures down to individual devices.
The Japanese semiconductor giant NEC has teamed up with Germany’s Elmos Semiconductor to offer the world’s first one-chip IO-Link system for sensors and actuators. The device combines a 16-bit low-power NEC microcontroller with an Elmos IO-Link transceiver circuit, improving performance, saving space, eliminating the need for up to 60 discrete components, and simplifying the design of products that support IO-Link.
Phoenix Contact introduced a rugged Profinet I/O device that can be installed next to machinery. The IP65/67-protected Rugged Line device incorporates diagnostics to help speed start-ups and for later troubleshooting.
New from Rexroth is a pair of IO-Link Master devices – one protected to IP20, the other to IP67 – for connecting sensors and actuators to controllers. Up to four IO-Link subscribers can be connected to each device.
Siemens has developed an industrial wireless local area network (IWLAN) which “guarantees” reliable performance, even when there is radio interference present, by changing automatically the channel on which the access point and its clients are communicating. The channel changing takes place so quickly that applications are not affected. As well as changing channels within the 2.4GHz band, the iHop system can also change to the 5GHz band.
Siemens has also made it easier to commission Profinet systems by allowing users to predefine device cabling as a setpoint topology in Step 7’s Topology Editor. Instead of specifying device designations during commissioning, the Profinet system performs initialisation automatically. This is said to reduce potential sources of errors as well as saving time. It will be a particular advantage when building series machines or in large plants with numerous Profinet IO nodes.
Vipa was showing an AS-I Master that connects to AS-I sensors and actuators via a two-core cable that carries both data and power. The CP 343-2P master includes a diagnostic alarm and is said to reduce commissioning times.
Weidmuller unveiled a range of compact managed switches for decentralised automation networks. The compact IP20-protected WaveLine switches use redundant Rapid Ring connections and are available either in an eight-port RJ-45 version, or with six RJ-45 and two fibre-optic ports.
As part of the same family, Weidmuller is offering an industrial Ethernet router with two digital inputs for remote maintenance and firewall duties. As well as an Ethernet-to-Ethernet version, the WaveLine router is available with analogue, ISDB, GRPRS/Edge, or UMTS/HSDPA modems.
SOFTWARE
Danaher Motion announced a machine automation software package that, it claims, will cut commissioning times by up to 80%. The Danaher Motion Suite combines HMI, PLC and motion control functions in a common environment and can simulate processes involving more than 128 axes. Machine functions and mechanical relationships between components are described with the aid of graphical description blocks. The suite supports a variety of other programming languages in addition to the IEC 61131-3 languages.
Horner APG launched a low-cost software suite called Cscape Envision RV that allows its OCS operator control stations to be accessed remotely from a PC. Service technicians can connect remotely to an installation to check its operation and history, while supervisors can view the operator screens remotely to monitor the process and data.
Phoenix Contact was demonstrating version 6 of its IEC 61131-compliant PC Worx Engineering software that can be used with all of its controllers. Numerous improvements, including new drag-and-drop functions, have been added to make its graphics editors easier to use. A free Express Edition will allow users to acquaint themselves with IEC programming.
Rittal has released version 4 of its Power Engineering software for configuring Ri4Power low-voltage power distribution and switchgear systems. Material and wage cost calculations have been simplified, and the new version allows users to generate design documents quickly for producing copper connection kits to link circuit-breakers.
And finally, Rockwell Automation announced FactoryTalk VantagePoint which allows users to configure Web-based dashboards, trends and reports without costly support resources. The package (shown above) incorporates technology that Rockwell acquired when it bought Incuity Software last year. It will provide automatic access to information from both Rockwell and third-party systems in a cost-effective, easy-to-use manner.
The 2009 SPS/IPC/Drives show will take place in Nuremberg from 24-26 November.
