Yaskawa is a world-leading manufacturer of inverter drives, servo drives, machine controllers and industrial robots.

Centa Gears

Renold Chain

ABB Drives and Motors


Features 

SPS/IPC/Drives 2009 Show Report

The number of visitors and innovations at the world’s largest automation and motion engineering exhibition – Germany`s  SPS/IPC/Drives show – suggest that the worst effects of the recession may be over for the country’s automation industry. In this report, we look at some of the new devevlopments on display at the show, which took place in Nuremberg in late November, 2009.



Despite the severe downturn in the German automation sector, the 2009 SPS/IPC/Drives exhibition held in Nuremberg in late November, managed to attract slightly more visitors than the 2008 event. The automation and motion engineering show’s organisers say that the rise in visitor numbers – from 48,105 in 2008 to 48,595 in 2009 – “exceeded all expectations” and that it was “a clearly positive sign for the whole automation industry”.

But the number of exhibitors at the show fell from 1,386 in 2008 to 1,237 – the first drop in the 21 times the automation and motion engineering event has been held. The total exhibition space fell from 94,700m2 in 2008, to 89,000m2. And signs of the economic squeeze were also evident at the show’s conference, where the number of delegates dropped from 406 in 2008 to 281.

The German automation sector, which relies on exports for 78% of its business, shrank by 20–25% during 2009, compared to 2008 when it was worth almost €46bn. But, according to Roland Bent, a board member of the industry’s trade body, ZVEI Automation, “the freefall in orders seems to be over”. Speaking on the first day of the show, Bent predicted that the sector would return to growth – albeit small – in 2010.

The proportion of non-German exhibitors at the 2009 SPS/IPC/Drives show was the same (21%) as in 2008. Although the exhibition does not promote itself as an international event, “we have become a marketplace for international suppliers,” says Johann Thoma, president of the show organiser, Mesago. The largest contingents of non-German exhibitors were from Italy (49), Switzerland (38) and China (29). There were just 14 British companies taking part – the same number as in 2008.

Despite the downturn, there was plenty of innovation on show in Nuremberg. Sick, for example, was boasting that it had launched more than 50 new products during 2009 – an average of one every week. Here we report on some of the product announcements made at SPS/IPC/Drives. 


DRIVES AND MOTORS

Baumüller used the show to unveil a new generation of direct-drive synchronous torque motors with higher power densities and wider speed ranges than its previous generations. The DST motors (below) offer rated torques up to 20kNm and maximum torques to 32kNm, opening up new application areas.

Baumüller has also developed water-cooled versions of its DSC and DSD servomotors in frame sizes 71 and 100, roughly doubling the power density of the motors, as well as cutting noise levels and surface temperatures. The company has also released variants on its b maXX 4400 range of drives tailored to the specific needs of peak-load and rated-load applications. The 4600 and 4700 ranges have been optimised for increased peak and rated currents compared to the standard drives, making them more efficient and allowing them to be dimensioned to suit the application.

Beckhoff has added a 40A model to its range of EtherCat servodrives, plugging the gap between its 25A and 60A versions. The new AX5140 drive is said to offer high performance is a compact format (300 x 185 x 232mm).

New from Bonfiglioli is range of sensorless vector inverters spanning the range 0.25–11kW, 230 and 400V. The easy-to-use Agile inverters incorporate PLC functions and guide non-expert users towards ideal configurations. A standby mode disables functions when the motor is not being driven, thus saving energy. Standard features include a 24V back-up power input, an EMI filter, a safe-torque-off function, support for CANopen and Modbus, and digital and analogue I/O. Options include a cold-plate version and a model with long-lasting dielectric capacitors.


B&R introduced a variant of its AcoposMicro drives family that supports servomotors in addition to steppers, allowing users to combine both types of drive. The drive modules (above) support up to two axes from a base surface of less than 50cm2 per axis. They operate from 18–80V DC supplies and have a 24V DC output that can drive external brakes.

Control Techniques unveiled a larger version of the Mentor MP DC drive which it launched at the 2008 SPS show. The new Size 2 (shown below) covers the range 350A–1.85kA, and operates at up to 690V. Several of the drives can be linked together to control armature currents up to 7.4kA in 6-, 12- and 24-pulse configurations. The built-in 20A field controllers are suitable for most DC motors, but a new standalone controller is available for higher field currents and older equipment. The drives accept CT’s SM option modules which support most communications protocols and offer functions such as PLCs and motion engines.

A new German motor-maker CPM (Compact Power Motors) was previewing a new model in its Power Pack range of brushless, permanent magnet synchronous motors that will deliver 200Nm of torque from a package weighing less than 9kg and operating with an efficiency above 96%. CPM was set up in 2008 to develop small, efficient drives, aimed mainly at automotive applications.

Delta Line was showing a 42mm-diameter permanent magnet brushless motor with integrated Hall sensors that can deliver torque levels up to 1.44Nm at speeds up to 3,000 rpm. The 42BLH motors form part of the company’s DPM brushless range.

New from Dunkermotoren is a range of compact, networkable DC servomotors with built-in Profibus DP interfaces. The motors come in three sizes spanning ratings from 40–500W, with continuous torque ratings to 116Ncm and speeds up to 4,000 rpm.

Eaton Moeller was highlighting its M-Max and H-Max families of frequency converters. The sensorless vector M-Max drives now include a 575V (0.55–7.5kW) range, digital I/O with selectable logic, and analogue inputs which can be switched between current and voltage. It is possible to create a second parameter set and to switch between the two via a digital input.

The H-Max family, aimed at HVAC applications, is due to reach the market in March 2010. Users will be able to determine how the drive will respond to a fire or a power failure. The inverters, available with IP21 or 54 protection, will cover ratings from 0.55–90kW (200–240V) and 1.1–160kW (380–480V).

Ebm-Papst displayed several additions to its portfolio, including a range of electronically commutated, mains-powered synchronous motors called VarioDrive C, which cover power ratings from 500W–6kW and torque ratings from 1–20Nm in three frame sizes. The motors are being promoted as an “intelligent” alternative to standard IEC motors with frequency inverters.

Ebm-Papst was also showing a range of modular, electronically commutated, internal rotor motors with outputs to 400W, torque levels to 1Nm, and efficiency levels of around 90%. An initial 63mm model (ECI63) will be followed by others with diameters from 32–80mm, all modular in structure and accommodating options such as gearboxes, brakes, encoders and CANopen interfaces.

Italian drives-maker Gefran unveiled two new families of small inverters: the SIEIDrive ADV20 (above, right), which offers V/f control of motors in the range 0.4–3.7kW; and the ADV50 (above, left) which provides sensorless vector control and incorporates a PLC to allow standalone machine automation without external components. The ADV20 incorporates functions such as automatic acceleration and deceleration, cooling fan control and brake control. The ADV50 is available in single- and three-phase versions spanning power ratings from 0.4–11kW. 

Harmonic Drive was showing a hollow-shaft servomotor covering the torque range 2.9–27Nm and capable of operating at speeds up to 6,500 rpm. The compact CHM motor offers hollow-shaft diameters from 21–49mm and is said to be maintenance-free.  

Drum motor specialist Interroll unveiled what it is hailing as “the world’s first totally-enclosed, single-component, sensorless synchronous drive” and the most efficient conveyor drive available. The synchronous drum motor output is transferred via planetary gears to the conveyor system, resulting in a total efficiency of 82% – much higher than geared motor systems, according to Interroll. The new motors also offer a wide speed range of 0.01–5.9m/s, which could open up new applications. In addition, they: accelerate at 151m/s2, to reach their top speed in milliseconds; deliver up to 1.kN of traction force; and have an operating temperature of less than 45°C, prolonging their lives and allowing them to be used in heat-sensitive applications in the food industry.  

Danish motor-maker JVL demonstrated several developments including a module for wireless control of its integrated servomotors with ratings from 50–750W. Many modules can be controlled wirelessly from a master controller and there is an option of using the self-configuring ZigBee protocol to create a self-healing mesh network. JVL was also showing a new generation of integrated stepper motors with torque ratings from 3–9Nm.

Kollmorgen has expanded its AKM series of brushless servomotors with a new model claimed to be one of the smallest in its segment. The AKM8 motor delivers stall torques up to 150Nm and peak torques up to 375Nm and is claimed to be 30–50% smaller and 10–30% lighter than conventional servomotors of a similar rating. A water-cooled version is planned.

Kollmorgen has also collaborated with Pilz to develop a safety plug-in card for its S700 servo amp drive (above). The card will allow machine-builders to provide the redundancy needed for safety applications using just one encoder. Redundancy is achieved using a patent-pending process that evaluates several internal parameters as well as the feedback signal. The card is said to respond to system deviations in a few milliseconds.

Lenze has developed a decentralised drive system with integrated safety based on its 8400 inverter platform. The IP65-protected 8400 protec drives (shown below) span a power range of 0.75–4kW and can be mounted vertically or horizontally on machines, reducing cable lengths and power losses, while improving EMC performance. Parameters are stored on plug-in memory modules allowing instant commissioning of new or replacement drives.

Leroy Somer was promoting it ability to supply IP55-protected induction motors that meet the new IE2 energy efficiency specification. Its aluminium-frame LSES and cast-iron FLSES motors cover ratings from 0.75–375kW and are available in two- and four-pole versions. 

Mitsubishi Electric was demonstrating a regenerative version of its FR-A700 range of frequency inverters. The FR-A701 model feeds braking energy from the motor back into the grid, thus saving energy and producing less heat than a braking resistor. The regen drive is available with outputs from 5.5–55kW and spans voltages from 323–528V.

Rexroth has produced a slimmed-down servo drive with reduced functions and optional interfaces, for “price-sensitive” applications. The IndraDrive Cs Economy supports open- or closed-loop operation and safe torque-off operation. A 100–230V version handles motors up to 750W, while a 200–500V version spans the range 400W–3.5kW. A multi-encoder interface supports a variety of feedback devices, while comms interfaces include Sercos III, Profinet IO, Ethernet/IP and EtherCat.

Rexroth was also showing a synchronous motor for dynamic positioning applications. The IndraDyn S MSK043 has a low moment of inertia and a high overload capacity, allowing acceleration rates up to 250% faster than for standard machines.

Rockwell Automation unveiled a flexible, general-purpose AC drive that, it claims, offers more control and hardware options than other drives in its class. The PowerFlex 753 (shown below) lets users combine I/O and logic functions to determine its behaviour. The slot-based architecture allows them to choose the I/O, feedback, safety and communications options to suit an application. Safe torque-off and safe-speed monitoring functions are built in. Power ratings are 0.75–250kW at 400–380V AC and 540–650V DC.

Schneider Electric was demonstrating its Lexium 32 family which includes three book-sized servodrives and two servomotor ranges spanning ratings from 0.15–7kW. The drives have a 1.6kHz speed bandwidth and a power density of 548W/l. According to Schneider, they can be replaced in less than three minutes using memory cards and smart connectors.

SEW-Eurodrive was promoting two new variants in its Movigear family of distributed mechatronic drives which combine motors, gearboxes, inverters and communications in a compact housing. The standalone Movigear binary model can be commissioned quickly using just a DIP switch and a potentiometer. Its binary inputs allow it to be controlled locally or by a central PLC. The Movigear AS-i variant provides a simple fieldbus connection. Sensor inputs can be processed locally or sent to a higher-level controller.

SEW’s Movipro SDC decentralised drive and positioning control system allows flexible system architectures to be created in the field and can replace entire inverter control cabinets. It is based on configurable inverters from SEW’s Movidrive system and spans power ratings from 4–15kW. It supports various motors including models from the CMP servomotor family, which has just been extended upwards to include a model that can deliver peak torques up to 179Nm and can reach 3,000 rpm in 7ms.

Among the many new arrivals on Siemens’ vast stand was a range of frequency converters designed to reduce the effects of low-frequency harmonics when driving fans, pumps and compressors. The Sinamics G150 Clean Power converters use a combination of a six-pulse rectifier and a passive line harmonic filter to comply with stringent harmonics standards such as IEEE 519. The compact, efficient drives avoid the need for active components and complex transformer installations.
 

MOTION CONTROL

The Israeli motion control specialist Elmo unveiled a new generation of products, all bearing the Gold name. They include the Maestro multi-axis motion controller, the Trombone (7kW), Guitar (5kW) and Duo (2 x 1.6kW) servo drives, and a network I/O controller. All are designed to be configured, tuned and operated using Elmo’s Application Studio software.

Harmonic Drive has a new universal servo controller called the YukonDrive that generates motion profiles in a master controller or in the axis controller. There are three versions, delivering currents up to 8A.

Jetter has added a high-end controller to its JetWeb series for complex motion applications – such as path control, interpolation and electronic gearing – requiring short cycles and high dynamics. The expandable JetControl 940MC is programmed using Jetter’s multitasking high-level language called JetSym STX.

Mitsubishi has launched a motion controller for up to 16 axes that can be used as a standalone device or integrated into larger systems. The Q170MCPU controller (above) combines motion control, PLC and power supply functions in its 178 x 52 x 135mm housing. It can handle complex sequences with multiple interpolated or synchronised axes. An encoder input can be used to synchronise with upstream drive systems.

SEW-Eurodrive has expanded its decentralised Movi-PLC controller range to include a “standard” version that co-ordinates up to 16 axes using SEW’s internal S-Bus. The controller supports single-axis functions such as positioning and closed-loop speed control.

The Italian controls company Telestar was demonstrating a compact CoDeSys-based controller that combines motion and PLC functions. It supports all of the IEC 1131-3 languages and it is possible to combine functions, programs and function blocks written in different languages. A PLCopen-based SoftMotion library is said to simplify the control of axes.


CONTROLS

ABB is offering a starter kit for its scalable AC500-eCo PLC, including CoDSeSys-based programming software, a 24V DC power pack, cables and even a screwdriver. It is also offering an intelligent communications module (CM574-RS) for the AC500 with two RS-232/485 interfaces that can be used independently of each other.

Beckhoff was showing its first plug-in card in the compact PCI Express (PCIe) format for its panel and cabinet PCs. The module provides two extra Gigabit Ethernet ports for the PCs. Beckhoff has also developed a rail-mounting USB-to-WLAN adapter that allows industrial PCs to be integrated wirelessly into Ethernet networks.

B&R had several new panel PCs and controllers on its expansive stand at SPS/IPC/Drives. The Panel PC 800 offers a choice of processors from the Atom N270 to Core 2 Duo, and 15 or 19 inch touchscreen displays. The “cost-optimised”, IP65-protected Panel PC 725 (shown above) is designed to be installed at a machine on a support arm. The Power Panel 65 integrates control, visualisation and drive technologies and is available with 5.7 or 3.5 inch touchscreens. It is aimed at multi-axis applications.

New arrivals in Gefran’s stand included: the GF_Looper multi-loop controller offering eight or 16 independent control channels; the Gilogik II PLC and remote I/O system that offers a variety of digital and analogue I/O modules; and two new ranges of GF_Vedo operating panels – the ML series of touchscreens from 6.5–15 inches, and the top-of-the-line HL series with 12.1 and 15 inch displays. Gefran has also launched a setpoint programmer/controller called GF-Promer that is said to be easy to use.

Horner APG has demonstrating several extensions to its controls family including two Compact X-Series 5.7 inch touchscreen controllers: the XL6e OCS which supports up to 4,096 digital and 1,024 analogue I/O points, and offers communications options including CANOpen, Profibus DP and quad-band GPRS; and a ruggedised version of the XL6e called the RX371, which has an aluminium housing and metal I/O modules. Most of Horner’s X series is now available with CANopen and J1939 communications. Horner has also added SmartBloc and Smartxtend remote I/O systems to its OCS family, offering communications via CAN, Profibus or Ethernet. Finally, Horner was offering two PC utilities: one, called EnvisionFX, allows data to be captured remotely; the other, EnvisionRV, allows users to visualise and interact with OCS applications remotely from a PC.

Six months after it launched its L-Force 1000 I/O system at the Hannover Fair, Lenze announced several enhancements including: an EtherCat bus coupler that can transfer data between control and I/O systems at 100Mbit/s; digital and analogue I/O modules whose electronic elements can be replaced without changing the wiring; digital output modules with AC outputs up to 5A; modules for connecting resistive temperature sensors and thermocouples; counter modules; power supplies for sensors and actuators; and modules for evaluating encoders with SSI interfaces.

Mitsubishi has introduced versions of its Melsec FX3G compact controllers that operate from 24V DC supplies. It has also added several expansion and special function modules to the controllers, including: a 17.6mm-wide module that adds two 12-bit analogue inputs and one output to the system’s adapter bus; a four-channel temperature control module with four PID circuits that can process signals from resistive and thermocouple sensors; a high-speed counter that counts single- or two-phase pulses at frequencies up to 200kHz; and a datalogging module for applications where fast access to data is important. Mitsubishi has also launched a datalogging module for its modular PLCs that can record data with a resolution down to 1ms.

Phoenix Contact has added ladder logic to the flow chart programming offered by its NanoNavigator 2 programming tool for its Nanoline controls. Both languages can be used in the same project, allowing the best method to be used for each task. A new GSM modem for the Nanoline controllers can send fault and alarm messages automatically and respond to SMS commands to read out and write to registers, timers, counters and I/Os.

New from Rexroth is the IndraControl L25 controller with Sercos III and Ethernet interfaces for its IndraMotion MLC automation system. Other new arrivals on the Rexroth stand included: an IP67-protected modular I/O system for the IndraControl range, which can be mounted near machinery subject to washdowns; bus couplers for Sercos III, Profinet and Ethernet/IP; and a handheld controller with a 8.4-inch touchscreen (VEH30) for its IndraControl VEP family of HMI-style embedded PCs with Atom processors.

Rockwell Automation has introduced a pair of PACs (programmable automation controllers) which support high-performance Ethernet/IP motion control and offer enhanced memory capacities for data-intensive applications such as batch processing. The ControlLogix L73 and L75 PACs include an energy storage module that removes the need for standalone batteries.

At the SPS show, Vipa announced that its Touch Panels with 800MHz processors are now being supplied with pre-installed versions of Invensys’ Wonderware InTouch SCADA/HMI software. The Windows CE-based panels that span display sizes from 6.5–12.1 inches will ship with Compact Edition 10.1 of the software. Vipa has also introduced an analogue I/O module for its system 300s, with four inputs and two outputs.

Wago has developed a new generation of I/O modules which accommodate 16 channels with spring connections in the 12mm width usually occupied by just eight channels. The modules reduce channel prices and save panel space. Initially there are five versions including input-only and output-only models, and combined I/O systems.

Wago has also introduced a new generation of HMIs called Perspecto, consisting of four families: the Perspecto TM touch monitor, which can connect directly to a Wago I/O-IPC via a USB or DVI-D interface; the Perspecto WP Web client panel for controllers with their own Web servers; the Perspecto VP visualisation panel with its own runtime system to accelerate reaction times; and the Perspecto CP control panel which uses a CoDeSys-based runtime system and can operate as an independent PLC.


ELECTRICAL AND SAFETY

B&R has launched a new generation of machinery power supplies with outputs from 2A single-phase to 40A three-phase. The compact supplies handle input voltages from 100–240V AC (single-phase) to 400–500V (three-phase). A buffer module bridges short-term power cuts, and protection is provided against short and open circuits, and overloads.

igus has expanded its range of pre-harnessed drive cables (above) and is now offering a total of 1,335 “ready cables” from stock. In addition to existing cables for Fanuc, Lenze, Rexroth, SEW and Siemens, it is now offering cables for B&R, Baumüller, Beckhoff, Berger Lahr, Danaher, Elau, Fagor, Heidenhain, NUM and Stober products.

Mitsubishi Electric has collaborated with Sick to develop a compact, modular safety controller (shown below) which is certified to meet SIL3/PLe. There are two base modules which support up to 12 22.5mm-wide expansion modules. The Melsec WS processors can handle up to 255 function blocks and connect to up to 144 safety I/O. Response times are said to be better than 8ms. An optional Enhanced Function Interface (EFI) can be used to integrate Sick intelligent sensors and to provide diagnostics. Ethernet and CC-Link interfaces are provided. Installations are configured using drag-and-drop software.

Phoenix Contact has announced a safety system that operates independently of bus systems such as Profisafe and Interbus Safety, and does not need a safety controller. Safety logic operations are processed in intelligent relay output modules which can be distributed around a network in I/O stations that are part of the InLine automation system. A special protocol is used to transfer data from safety input modules, via a network to output modules. A standard controller copies non-safety I/O data between the input and output modules and does not handle any safety-related tasks. The input and output channels and the safety logic of the SafetyBridge system are configured via a software package called SafeConf. Pre-configured function blocks are available for most applications.  

Pilz has developed a device that combines mechanical and electronic functions to monitor safety gates. The 45mm-wide PSENsgate combines safe guard locking with an auxiliary release, an e-stop button, coding and other functions. An optional enable switch allows expansion. The bolt can be padlocked and the device will detect a broken pin or bolt.

Rittal was promoting new installation rails for its AE series compact enclosures (below) which turn them into system enclosures in which accessories such as TS8 chassis can be installed quickly and safely. No drilling is needed, so the corrosion-resistant enclosures’ protection category is not affected.

On its stand, Sick was celebrating nearing the end of a marathon year which had seen it releasing an average of one new product every week. One of the last of these was a safety light curtain designed for use in difficult environments such as woodworking plants where sawdust can affect performance. The C4000 Fusion curtain has three functions to deal with such problems: an “intelligent” multiscanning process which increases the scan rate for better discrimination between body parts and wood shavings; a reduced resolution, down to 300mm; and redundant transmitter-receiver synchronisation.

Siemens has released a 24V single-phase DIN-rail-mounting power supply that is 90mm wide – 40% narrower than its predecessor. The 20A Sitop PSU100M supply has wider input voltages than before (95–275V AC, 88–350V DC) and its efficiency is 4% higher at 93%, saving energy and reducing cabinet heating. An “extra power” function can supply 30A for 5s.

Steute was demonstrating a range of cable-free, radio-based command switchgear devices that can be mounted directly onto a machine. When an operator presses one of the buttons, the movement of the plunger is converted into electrical energy that powers a transmission with a range of 300m outdoors and 30m indoors. The BF 94 series comes in various designs with one enclosure housing up to three command devices.

The German cable gland specialist Wiska was promoting its VentGland system that avoids the need for conventional techniques for tackling enclosure condensation, such as heating, drilling holes or providing external ventilation. The patented VentGland system incorporates a microporous, liquid-tight Gore membrane that allows the enclosure to “breathe’ and compensates for different pressures inside and outside the enclosure. The gland, which is the same size as a conventional cable gland, prevents dirt and water from penetrating the enclosure and provides protection to IP69K.


MECHANICAL AND LINEAR 

Although mechanical systems are not a primary focus of SPS/IPC/Drives, there were several on show including two new series of low-backlash planetary gearboxes from Bonfiglioli. The TQ in-line and TQK right-angle boxes cover a torque range of 30–800Nm in five sizes. The quiet, maintenance-free gearboxes with high overload capacities have been developed in collaboration with an Italian design studio.

Leroy-Somer was showing an extended range of servo gearboxes in a choice of standard or low-backlash versions. The low-noise Dynabloc series (shown above) provides output torques to 5kNm, and spans reduction ratios from 1.25:1 to 1,000:1. The standard range includes helical, helical-bevel and worm boxes with axial, right-angle and parallel outputs, while the low-backlash range includes planetary boxes with axial outputs and worm boxes with right-angle outputs.

The Swiss linear motor specialist Linmot was showing several new ranges, including a family that can deliver forces above 1kN – almost twice as much as the company’s previous motors, allowing higher payloads and high dynamic applications. The P01-48x360 motors use one cable for both power and feedback and have rotatable IP67 connectors.

Linmot has also introduced a range of high-performance linear motors (below) that provide a peak force that is 50% higher, a continuous force that is 70% higher, and speeds that are 20% faster, than its standard machines – but cost just 10% more. The improvements have been achieved using new winding techniques, more powerful magnets and optimising the motors’ magnetic circuits and heat transfer.

Rockwell Automation has announced a pair of electric cylinders that deliver speeds of up to 1m/s and repeatabilities of ±0.02mm. The Allen-Bradley MP and TL series are non-rotating piston rod actuators that operate without external limit or home switches, and hold their position during power cuts. A space-saving version with the motor mounted parallel to the actuator rod will be added soon.

SEW-Eurodrive has launched two ranges of stainless-steel gearboxes for use in hygienic and wet environments. The KES37 helical-bevel and RES337 helical boxes have easy-to-clean corrosion-, alkali- and acid-resistant surfaces with minimal recesses in which dirt or liquid could collect. They deliver up to 200Nm of torque and are available in ratios from 3.98–106.38 (KES37) and 0.12–134.83 (RES37).

Another range of stainless-steel helical-bevel gearboxes for washdown applications could be found on Stober’s stand. The KSS boxes have been redesigned internally to increase their power/volume ratios by about 50% compared to previous models. The low-noise, low-heat gearboxes are claimed to operate with an efficiency of 97%. They are available with solid shafts or hollow bores and can produce up to 350Nm of torque with ratios from 4–70.


SENSORS AND MEASUREMENT

ASM has launched an inclinometer that uses MEMS (microelectromechanical system) technology, resulting in a compact, flat (7mm high) package. The PTAM20 devices are available in single- and dual-axis versions and offer resolutions of 0.05 degrees and a linearity of ±0.5 degrees.

Balluff has developed an inductive coupling system (shown above) that transfers data and power to and from sensors, over a gap of up to 5mm. The BIC coupler, enclosed in an IP67-protected M30 stainless-steel housing, can transfer up to 12W to supply 500mA at 24V DC for powering sensors. Another cable-saving innovation from the company is a limit switch with a battery-powered wireless transceiver in a housing measuring 40 x 20 x 51mm.

Balluff has also developed a tiny sensor that fits in the T-slots of pneumatic cylinders. The 23mm-long BMF 235 sensor incorporates a bright LED function indicator that can be seen 25m away, even in a brightly lit factory.

Eaton Moeller has expanded its range of sensors with a variety of inductive, capacitive, photoelectric and limit switches for AC and DC operation, using two- or three-wire connections. One of the proximity sensors is the programmable iProx device whose switching distance, function and background suppression can be set using Windows software. The sensor can be used to measure speeds or to set customised time delays.

Heidenhain has expanded its range of 35mm-diameter rotary encoders to include models with IP64 protection, absolute position measurement, and functional safety (achieved by providing two independent position values via the bidirectional serial EnDat interface). The EnDat 22 version of the absolute encoders with serial data transfer offers a single-turn resolution of 23 bits and a multi-turn resolution of 12 bits. 

New from ifm electronic is a range of encoders with CANopen interfaces which can be used to program their scaling and direction of rotation. The encoders incorporate switches for setting the bus address, baud rate and zero point. They can detect speeds up to 6,000 rpm and are available in 13-bit single-turn and 12-bit multi-turn versions. Ifm has also developed a range of tiny photoelectric sensors to detect small parts in tight spaces. The O7 sensors are available for ranges from 30–100mm and in various technologies.

Kübler had several new and enhanced ranges at SPS including an incremental magnetic measuring system with a minimal installation depth of just 16mm, and a 30mm-diameter hollow shaft. The non-contact R150/L150 sensors resist vibration and shock and are protected to IP67. Kübler was also showing: SIL3/PLe certified versions of its Sendix SSI/BiSS absolute encoders and incremental encoders with SinCos outputs; multi-turn, non-contact, wear-free absolute encoders with a resolution of up to 41 bits; and single- and multi-turn absolute encoders with ATEX certification.

The Swedish encoder specialist Leine & Linde unveiled several new and enhanced product lines, including a series of programmable encoders with an SSI interface which can be used to scale the resolution and to change the data formats and direction of rotation. The 25-bit resolution encoders (above) are available in solid- or hollow-shaft versions. Other new arrivals included: an encoder with a 1Vpp interface generating sinusoidal signals that can be interpolated for high resolution; a range of rugged absolute encoders with 25-bit resolution, delivering an accuracy of better than 20 arc-seconds; and a series of absolute pulse encoders with a Profibus interface which can be used to transfer position and speed data.

Leuze electronic was demonstrating a laser-based system for measuring distances up to 200m with a tolerance of 3mm. The AMS200 system is set up using easily accessible built-in screws, rather than having to adjust a mounting bracket. An integral display panel shows the distance reading immediately, and can also show speed values. The system supports either RS-232, Profibus and SSI, or RS-232 and Interbus.

Pepperl + Fuchs’ launches at SPS included miniature inductive sensors, rotary encoders and distance sensors. One innovation was a six-beam retro-reflective area sensor for edge-detection applications where irregular edges or changes in material could cause problems for standard single-beam photoelectric sensors. The new RLG28 sensor is interchangeable with standard devices and is said to deliver reliable edge detection with a resolution of 12mm within a 60mm detection field, over a range of 0.2–4m. The six-beam sensor is said to be cheaper and easier to install than alternatives such as light grids.

Sick claims that its new TTK70 absolute linear encoder (above) is the smallest system of its type with a fieldbus interface. The reading head, including the plug connection is barely bigger than a matchbox. The system uses a 10mm-wide coded magnetic tape in lengths up to 4m. It has an SSI/SinCos output and supports Profibus, DeviceNet or CANopen using adapter modules which can be changed without replacing the encoder.

Sick also announced a range of M18 cylindrical photoelectric switches for “price-sensitive” applications. The V180-2 range includes: three versions with ranges from 100–800mm; a reflex switch and polarisation filter with a range of 4m; and a through-beam switch with a range of 20m.


COMMUNICATIONS

Balluff has introduced a range of IP67-protected I/O modules for the CC-Link networking system. The diecast zinc modules with M12 connectors (below) can be used outside control cabinets in distributed automation networks. There are four versions offering different combinations of I/O, including 16 in and eight out, and 16 freely programmable I/O. Baluff has also developed similar rugged IP67 I/O modules for decentralised Profibus and Profinet applications.

Belden had more than a dozen new communications products on show in Nuremberg, mostly under its Hirschmann brand. They included: a three ranges of Gigabit Ethernet switches, one of which boasts IP67 protection; a family of 32 different managed basic Ethernet switches; and a range of copper cabling in more than 30 designs, including two- and four-pair configurations for industrial Ethernet applications. Some of the cables are specifically for Profinet applications; the others are general-purpose.

The German industrial communications specialist Comsoft has developed a Profibus bus monitoring and diagnosis device the size of a Profibus plug. The device, which has a USB interface to connect to a PC, records bus traffic at up to 12Mbit/s with single-bit accuracy. Comsoft was also showing a pair of modules that allow National Instruments’ CompactRIO programmable automation controllers to connect directly to Profibus DP and Profinet IO networks.

On its stand, Harting was showing several new connectors including an M12 cabling system that can be used for Cat 6A Ethernet connections in high-bandwidth industrial applications. The har-speed M12 connectors (above) allow safe data transmission beyond Cat 5. There was also a new generation of Harting’s pioneering tool-free RJ-45 connector for 10Gb Ethernet. A newly developed cable gland holds cables with diameters from 4.5–9mm securely.

The Swedish communications specialist HMS was demonstrating a Sercos III version of its Anybus module that offers an easy way for manufacturers to add Sercos support to their automation products. The module, developed with Bosch Rexroth, contains a complete Sercos III slave interface and is a similar size to a CompactFlash card. It is interchangeable with other Anybus-CC modules that now support 18 different industrial networks. HMS has also been working with Siemens to produce a plug-in module that brings CANopen to Siemens` Simatic ET200S I/O system, allowing CANopen devices to be integrated into Siemens` Profibus and Profinet-based automation architecture.

Molex has introduced an M12 Cat 6 connector that can handle Gigabit Ethernet speeds. The IP68-rated Brad Micro-Change connector is designed to provide secure connections in harsh conditions and to ensure better signal integrity than RJ-45 Cat 6 systems. Molex has also produced an M12 connector that carries four Cat 5e data lines and two 10A power lines in a push/pull design, claimed to cut cabling and installation costs.

Pepper + Fuchs presented a circular AS-i I/O module which is protected to IP68/69k, making it suitable for washdown applications. The G11 module avoids the need for a special AS-i power supply and provides up to 4A of current.

Phoenix Contact was another company offering M12 connectors for Gigabit Ethernet applications. Its M12-Cat 6A connector uses a specially developed system to shield individual data pairs. It supports transmissions at up to 10Gbit/s over distances up to 100m.

The latest product to emerge from Rockwell Automation’s partnership with Cisco is a managed Ethernet switch that provides VLAN and subnet routing functions. The Allen-Bradley Stratix 8300 Layer 3 switch (above) uses Cisco’s Catalyst operating system.

US-based Real Time Automation has added support for Profibus to its 460EDX range of programmable device converter modules which allow users to move data between different protocols, including DeviceNet, Modbus TCP and RTU, CANopen and OPC Server. The new module, which is configured using a built-in Web server, allows data to be moved between these networks and Profibus clients such as Siemens PLCs.

Tyco Electronics is offering an IP65/67 RJ-45 push-pull connector for industrial Ethernet that can be installed in the field without needing tools. The company has also developed a range of hybrid connectors that include eight power contacts that carry up to 10A, and four signal contacts for fast Ethernet.

One of Wago’s launches at the SPS show was a 12mm-wide four-channel IO-Link master module that allows four different IO-Link devices or standard digital sensors and actuators to be integrated simultaneously into an automation system. The 750-657 module uses a three-wire connection and can carry data at up to 340kbd per sensor or actuator.


SOFTWARE

Baumüller has launched a tool called the ProMaster Engineering Framework (below), based on Microsoft’s .Net technology, said to make it easy to create projects and applications using EtherCat or CANopen as the bus system. Templates can be stored in user-structured libraries, allowing sections of applications to be stored individually or in groups for re-use. An integrated environment called ProSafety can be used to add safety functions.

New from Kollmorgen is the Kollmorgen Automation Suite which allows OEMs to move rapidly from concepts to completed machines in a single programming environment. The suite can simulate machine operations, simplifying and shortening design cycles while improving performance. When programming multi-axis synchronised motion, it replaces complex coding with drag-and-drop functions. Functions such as line shafting, gearing and camming can be programmed.

Rexroth has produced a new version of its IndraWorks engineering framework which supports team engineering of machinery and plants, allowing several groups to work simultaneously on large projects. The software, which supports all of the IEC 61131-3 languages, is said to simplify the creation of modular machine software using extensions for object orientation.

Rexroth has also developed a tool, called the IndraDrive Productivity Agent, which monitors the status of axes and gives advanced warning of wear-related damage. The tool uses IndraDrives as “sensors”. Data is recorded and analysed by motion logic in the drive and translated into information on the status of the axis. As well as the diagnostic functions, the tool includes an active vibration damping and counteracting function.

Rittal has released version 6 of its Therm thermal management calculation software for enclosures, with an improved interface and new tools such as a pressure loss program. The company has also produced a new version (4.1) of its Power Engineering planning software which can now be used to configure Ri4Power systems up to 5.5kA and to produce CAD views and sketches that that help to identify which components belong to which sections.

Rockwell Software has announced a new version of its RSLogix 5000 software boasting more than 30 enhancements to simplify programming and configuration and to ease the maintenance of control and information systems. The software, which is used to design and configure Rockwell’s Integrated Architecture system, includes support for the company’s latest drive and control products, and for EtherNet/IP-based CIP motion.

SEW-Eurodrive has equipped its Movitools MotionStudio engineering software with the Tool Calling Interface (TCI) technology which allows tools from different device manufacturers to be called from higher-level engineering systems using one method.

Siemens has enhanced its Simatic WinCC v7 process visualisation software with a calendar option that can be used to plan events and actions for controlling plant processes. Direct connections can be set up in WinCC for the events, and global scripts implemented.

And finally, Wago used SPS/IPC/Drives to launch a development environment called Automation Cockpit for creating visualisation and control applications. The software can be used to manage projects, to configure devices and to create programs using the IEC-61131 languages. The software ensures consistent data storage so data points only need to be input once and are then available for use elsewhere in a project.


The 2010 SPS/IPC/Drives show will take place in Nuremberg from 23–25 November.

 
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