Precise dip coating.

With its own in-house motion system design and integration service, and distribution partnerships with globally leading motion control component suppliers, Heason Technology has the capability and a strong reputation for application customised motion control solutions. Typically including precision-grade positioning mechanics and advanced motion control hardware and software, these bespoke systems often provide an important part of the enabling technology for innovative manufacturing or research processes. With the positioning system requirements fulfilled by Heason, the customer can apply its own technological expertise, safe in the knowledge that motion control will not be a limiting factor to project success.

Schematic of the dip coating process components

A recent example where Heason’s motion expertise played a significant role in a manufacturing project involved the design and supply of a single-axis servo motor driven actuator and control system for a novel thin-film dip coating process. The positioning system required ultra-precise speed control for the withdrawal cycle of a large, heavy and irregular shaped component to ensure a highly uniform and precise coating thickness. The components’ asymmetrically distributed mass and dimensions combined with the buoyancy effect of the coating fluid caused a load variation that would result in a significant series of stepped fluctuations in the reflected inertia seen at the motor as the product was vertically retracted from the coating bath. This load variation was a challenging factor for the low-speed control required for the process.

The customer specified a stand-alone system where an operator could simply program the actuator to a load position and adjust the dipping and retraction speed with recordable values to maintain a consistent and repeatable coating thickness over the process. Heason delivered a 700 mm stroke length actuator driven by a servo motor fitted with an absolute encoder for precise closed loop speed and position control from a servo drive. The speed control parameters were programmed between the servo drive and an HMI to complete the autonomous system. The servo drive chain included a planetary reduction gearbox to achieve the low speed required and a holding brake ensured safety for the vertically mounted system.

The specific choice of components for the stand-alone system fell to a PC32 series actuator from Thomson, a leading linear motion component manufacturer and a valued partner for Heason over several years. Its PC32 series features a smooth IP65 rated aluminium housing protecting a precision ball screw whilst a stainless-steel extension tube and rod adapter perfectly suit the environment and load mounting arrangement for the dip-coating process. A 7:1 ratio precision grade planetary gearbox, also from Thomson, is included to reduce the linear speed within the set range as well as help smooth speed fluctuations by reducing the effect of reflected motor inertia due to the irregular load distribution of the component during the process.

The actuator assembly is driven by a Kollmorgen AKM21E servo motor complete with integral holding brake and absolute multi-turn encoder. Heason enjoys a long-term distribution partnership and several years’ experience with Kollmorgen, as a British certified partner and silver-status supplier for its industrial automation systems, servo motors and drives. With precise servo control from the AKD BASIC series servo drive through its built-in BASIC programmable motion and machine software, the digital drives’ ultra-fast 62.5 microsecond servo update rate constantly maintains the exact desired motor speed despite the torque variation due to the irregular load. The AK12G series 7” HMI touchscreen, programmed with Kollmorgen Visualization Builder software allows full stand-alone operator control of the coating process. As an absolute encoder is used for servo feedback, homing the actuator to a loading position is a simple command. The operator then enters a retraction speed value into the graphic panel and a sequence is called from the intelligent servo drive delivering and retracting the component at the desired speed.

Heason provided the complete system pre-programmed and fully operational based on the speed range and speed tolerance specifications supplied for the dip coated component following extensive in-house testing before delivery to the customer. The motion system was supplied with operation manuals and servicing information.

@mepaxIntPR @heasonmotion @AboutKollmorgen #PAuto #Motion

Wine, Spirits in paper bottles!

A collaboration between Festo and PCE Automation has helped recyclable packaging experts Frugalpac Limited to achieve the high throughputs and precision assembly necessary to meet increased demand for its innovative paperboard Frugal Bottle.

Frugal Bottle is the world’s first paper wine and spirits bottle. Its innovative design comprises an outer made from 94% recycled paperboard with an inner food grade pouch. The bottle is fully recyclable, is five times lighter than glass and has a much lower carbon footprint than traditional wine bottles. It also offers 360-degree branding for better impact on the shelf.

Frugal Bottles are manufactured from two paperboard blanks that are precision cut, glued and then wetted front and back, before being stacked ready for feeding into the bottle forming machine. Achieving the desired throughputs is a major challenge because the glue pathway is complex and must be tailored to the profile of the bottle. In addition, the correct amount of glue has to be applied to prevent malformation or unsightly glue excess on the finished bottle.

They had approached an adhesive systems company for a solution, but they were unable to achieve the desired cycle times. Working closely together, PCE Automation and Festo developed a fully automated gluing and wetting line to meet the tight tolerances and complex gluing patterns necessary to deliver throughputs of 630 bottles per hour.

Ronan Quinn, project manager for PCE, says: “The gluing process was more complex than anything we’d encountered before. Tight tolerances on the gluing pattern combined with a short cycle time and critical bead thicknesses were a real challenge. We would usually undertake the entire design and assembly inhouse, but on this occasion Festo supplied the handling gantries to us fully assembled which added real value in terms of component compatibility and commissioning.”

The automation cell provided by PCE Automation requires minimal human intervention. An operator loads the blanks for the front and back of the bottles at the front end. The machine then picks, loads, transfers, glues, transfers again, wets and conveys the prepared blanks into a container at the end of process. The prepared blanks are then transferred to the bottle forming machine.

PCE Automation used the Festo Handling Guide Online (HGO) to design the automation cell. This free online tool dramatically reduces design, assembly and delivery time and enables customers to create a ready-to-install handling system: whether for a single-axis system, a 2D linear and planar surface gantry or a 3D gantry. With just a few clicks, the HGO delivers the right standard handling system, including CAD model, animation, and complete EPLAN schematic documentation. The individual steps (including RFQ, layout, quotation and CAD design), which previously could take 10 to 15 days, can be completed in a matter of minutes. The reduction in design and documentation time enabled PCE to meet Frugalpac’s delivery expectations.

The unique gluing and wetting solution was tested and sized at Festo’s British Application Centre to prove that the desired cycle times could be achieved. It uses the Festo CPX-E-CEC Controller as the PLC to deliver interpolated soft motion, controlling multiple axes at the same time to achieve the complex curves on the glue paths. Festo CMMT servo controllers feature in the three handling systems for precise and repeatable loading, gluing and unloading. Festo core pneumatics products, valve terminals and process valves are also used extensively throughout the gluing and wetting system.

Bottling success
The PCE automation cell needed to achieve a cycle time of just 19 seconds to meet Frugalpac’s requirements. The gluing and wetting solution delivers a gluing time that is 50% faster than specified, enabling the entire machine to meet the overall cycle times required. It achieves this by batch-gluing eight bottles simultaneously, with different glue patterns being applied to the front and back blanks.

John-Paul Grogan, Product Director at Frugalpac, says: “Frugalpac is committed to the development of more sustainable packaging. The application of automation in the production of Frugal Bottle will help us to achieve our aim of reducing the carbon of wine and spirits packaging.”

Festo and PCE are now working with Frugalpac to develop an automated method for the forming of the Frugal Bottle itself.

@festo_global @FestoIE_NIE @frugalpac #PCEAutomation #PAuto #Food_Drink

Workstation memory enhancement.

Innodisk has announced the debut of their new industrial-grade DDR5 memory in workstations, which are powerful computers intended for specialized technical and scientific use cases. This new technology gives early adopters the chance to demonstrate the real-world speed, and performance gains that were promised during the hype surrounding the announcement of DDR5 in 2021.

Now, as Innodisk begins mass production, the new technologies that DDR5 introduced, such as double bank groups, same bank refresh, on-die ECC, and dual subchannels are being utilized in workstations that push the limits of speed, capacity, and reliability in professional environments.

Innodisk is already leading the industry in the implementation of DDR5 memory in workstation computers. One of their clients, who has already put DDR5 to the test in a meaningful way, is a global company that designs and manufactures workstations for engineering, product design, architecture, data science, and VFX. They decided to use Innodisk’s 4800MT/s 32GB DDR5 UDIMM for their workstation computers. These workstations provide the ideal match for early DDR5 adoption as they offer server-grade performance, with high-end processors, and lots of memory, in a standard PC form factor for CPU and RAM-intensive applications like graphics, 3D design, and video editing.

The client, whose end customers cover multiple industries including science and medical, film, mission critical applications, as well as manufacturing and design, was able to benefit from DDR5’s increased bandwidth, better power efficiency, and higher memory efficiency, while also future proofing the workstations they built with the latest and greatest standard in DRAM technology. The aforementioned improvements over DDR4 will allow customers to work faster, and more efficiently, while not having to worry about data loss, due to the extra layer of protection through IC level checking that DDR5’s on-die ECC provides.

@Innodisk_Corp @mepaxIntPR #Automation 

Is there an object on the conveyer belt?

The new ODT 3C sensor from Leuze transmits both switching and measuring information to the machine control system via IO-Link – an efficient and economical 2-in-1 solution. It can handle both measuring and switching tasks and thus is suitable for a wide range of automated industrial applications

Is there an object on the conveyor belt? If yes: What is its position or distance to the machine? These are typical issues that need to be addressed in a wide range of industrial applications and processes. In the past, to solve this problem required the use of multiple sensors. With the new ODT 3C from Leuze, only a single device is needed: The innovative sensor can transmit both switching and measuring information to the machine control system, which makes it an efficient and economical 2-in-1 solution.

The ODT 3C transmits measurement values and extensive diagnostic data via IO-Link. The data includes temperature values, warnings, and signal quality. It features impressive black-and-white behavior (< ± 3 millimeter at 150 millimeter). The operating range can be easily adjusted via the teach button, remote signal or IO-Link. 

The new  sensor also offers impressive functional reliability: Active ambient light suppression prevents faulty switching, even when exposed to direct light from LED building lighting systems. LEDs that are easily visible from all sides allow you to quickly read the status of the ODT 3C. Two independent switching outputs and sensor models with warning output or a small light spot (pinpoint) round of the sensor’s functions. This enables plant operators to use the ODT 3C flexibly in a wide range of applications.

@TheSensorPeople @LeuzeUK @mepaxIntPR #PAuto #Manufacturing

Long reach Ethernet extenders.

Advantech’s IMC-150LPC series hardened PoE long-reach Ethernet extenders are available for order now. This innovative device uses extant coaxial cables to deliver both power and data to locations up to 300m away. These capabilities are buttressed by an LFPT mechanism that augments transmission quality. This combination of attributes and features make the IMC-150LPC an excellent choice for industrial and rail network infrastructure upgrade projects with limited power and network resources.

The IMC-150LPC series enables users to increase performance over earlier 100m Ethernet transmission ranges and deliver power and data, via a single coaxial cable, to distances as far as 300m away at speeds of 100Mbps. This empowers peripheral devices, such as IP cameras, while saving cabling costs, reducing installation complexity, and expanding power coverage and network services.

Upgrading network infrastructure usually necessitates costly rewiring and reconstruction. The IMC-150LPC supports both Ethernet and coaxial transmission, enabling network communication via extant underground coaxial cables. These features help users avoid downtime in manufacturing and surveillance when upgrading network infrastructure.

Link Fault Pass Through (LFPT), a troubleshooting feature designed for media converters, is used on both the local and remote IMC-150LPC extenders when they are used as a pair. When enabled, this feature will pass a link fault through the device at each segment. LFPT serves to prevent data loss by taking action during link failure incidents. For, example if the link fails on one IMC-150PLC, the other IMC-150LPC will force the link down on its link partner and avoid data loss.

The IMC-150LPC series is EN50121-4 EMC certified and designed with an industrial grade housing that supports broad temperature operation from -40 to 75oC. This advanced durability makes IMC-150LPC suitable for applications in harsh environments such as trackside surveillance.

Key specifications of the EKI-150LPC-M (master) and EKI-150LPC-R (remote) include, transmits data up to 300 m (984 ft) at 100Mbps via power over coaxial cable, extends power >15.4Watt power with 300m-long coaxial cable, railway Trackside EN 50121-4 EMC certified, features Link Fault Pass Through (LFPT), supports remote PD power ON/OFF by disabling/enabling port via management switch.

@AdvantechEurope  @proactivefleet #Pauto #Communications

Monitoring tyre tread depth.

A new collaboration with between Sensata Technologies with NIRA Dynamics AB delivers an accurate and robust tyre Tread Depth Monitoring (TDM) ‘virtual sensor’ system for automotive OEMs that optimizes tyre health and improves vehicle safety, efficiency and uptime. The TDM solution, powered by NIRA Dynamics’ tread wear estimation software, is designed to give vehicle OEMs, drivers and fleets timely alerts when tyres have worn to unsafe levels and need servicing.

“We’re excited to collaborate with NIRA Dynamics on new technology for the automotive industry." said Eric Sorret, VP Automotive at Sensata. "Sensata has developed tire technologies for more than 20 years, and we believe that this new virtual sensor builds on this experience and takes it to the next level. Using and analyzing data already being captured by other sensors, this solution provides accurate and useful information to our customers.”

Combining Sensata Technologies’ expertise in automotive sensors with NIRA Dynamics’ proficiency in developing embedded software and cloud services, the TDM solution adds new safety and maintenance capabilities to Sensata’s existing market-leading tyre safety products.

The virtual sensor system is a new, innovative technology that gathers and combines data from multiple existing sensors on a vehicle, including Sensata’s tyre pressure sensors, to provide accurate information about tyre wear and tear.

This software-based system uses a complex algorithm that monitors the tyre tread’s decreasing depth, while compensating for a wide range of real-world environmental challenges. The system tracks tyres through changes and rotations and provides a more comprehensive solution than just measuring the distance travelled.

The virtual TDM can be integrated into existing Electronic Control Units (ECU) and is designed to work with many combinations of tyre and vehicle designs. Vehicle manufacturers can quickly introduce and implement the solution across vehicle platforms without the need for custom software development.

Lisa Åbom, CEO at NIRA Dynamics said, “The cooperation between NIRA and Sensata is a perfect match. By combining our decades of experience in vehicle data cloud services with Sensata’s Tire Pressure Monitoring System, infrastructure, and extensive customer base, we can offer vehicle manufacturers additional insights and information for customers without the need to fit additional hardware on the vehicle. This solution will improve safety, creating more driver awareness about the quality of their tires to decrease the number of tire-related accidents.”

@Sensata @niradynamics #Automotive 

Networking to help futureproof industrial automation.

The EDS-4000/G4000 Series Ethernet Switches from Moxa, includes 68 models that will help Moxa’s customers build futureproof industrial networks to strengthen operational resilience in industrial spaces such as power, transportation, maritime, and factory automation.

According to IDC’s Worldwide IT/OT Convergence 2022 Predictions, by 2024, 75% of new operational applications deployed at the edge will leverage containerization to enable a more open and composable architecture that is necessary for resilient operations. As industrial automation applications continue to evolve, OT architectures require enhanced networking capabilities and network security.

"Recently, we observed that our customers find it more challenging to connect their devices while fulfilling a variety of requirements for critical infrastructure," said Gary Chang, Product Manager at Moxa Networking Co. Ltd. "Critical infrastructure requires advanced networking solutions that strengthen operational resilience and futureproof networks. Our EDS-4000/G4000 Series portfolio of switches transforms the networking-evolved concept into tangible networking capabilities in order to empower our customers to build secure, reliable, and high-bandwidth industrial networks with ease."

Evolved Networking Solutions That Strengthen Operational Resilience
While OT/IT convergence is accelerating, enhanced network security, high performance, strong reliability, and advanced usability become paramount to building next-generation industrial networks that strengthen operational resilience.

• Industry-leading Network Security: The EDS-4000/G4000 Series is the world's first IEC 62443-4-2 certified Ethernet switches to be certified by IECEE due to the built-in hardened security that was developed by following the stringent software development lifecycle described in the standard. Along with Moxa’s extensive network security portfolio, Moxa helps create a secure network foundation to safeguard and futureproof industrial operations.
• Unprecedented Performance for Mass Deployments: As the number of connected devices in industrial operations grows exponentially, the EDS-4000/G4000 Series provides multiple interface combinations with up to 14 ports and a range of options including fast Ethernet, Gigabit, 2.5GbE uplinks, SFP, and IEEE 802.3bt PoE connectivity. This enables customers to connect more devices especially in applications such as intelligent transportation systems that require high-power and high-bandwidth networking.
• Multiple Industrial Certifications: The EDS-4000/G4000 Series is certified for NEMA TS2, EN 50121-4, IEC 61850-3/IEEE 1613, DNV, ATEX Zone 2, Class I Division 2, to fulfill the needs of a wide variety of industrial applications. The EDS-4000/G4000 Series also features Turbo Ring and Turbo Chain fast network recovery to ensure smooth operations. Advanced Usability: The improved web GUI provides a more intuitive way for users to perform configurations and network management. The rotatable power module offers flexibility to field engineers when they are installing devices and maintaining the network. In addition, the LED indicators on two sides of the device help engineers easily identify the status of networking devices, making their job easier.

Customer Testimonial "We particularly appreciated the intuitive user interface, the innovative mechanical design with the rotatable power supply module, and the robust DIN-rail mounting kit. The EDS-4000/G4000 Series gives us more confidence to provide futureproof, robust, and secure industrial automation and navigation solutions to our customers on their digital transformation journeys," said Christian M. Skytte, Head of Product Management, Automation, at Wärtsilä Lyngsø Marine A/S.

@MoxaInc @OConnell_PR #PAuto #Communications