Automation ticks the box!

Cutting-edge automation in box forming machinery.

Amidst the rapidly evolving landscape of the box forming machinery sector, the demand for more efficient, sustainable, and robust machinery is escalating. Delta's innovative automation solutions have played a pivotal role in enhancing the production capabilities of Tecnobox, a box forming machinery company in Spain. This transformation has not only fortified Tecnobox's position in a competitive market, but it has also set new standards in the industry for technological advancement and environmental responsibility.

Nestled in Levante, a bountiful food-producing region, Tecnobox is renowned for its dedication to quality, innovation, and sustainability. With around 40 employees, this medium-sized company has carved a niche in manufacturing robust, low-maintenance cardboard box assembly machinery.

Its products are distinguished by the use of standard components to speed up production and a commitment to replacing metal and plastic containers with biodegradable alternatives.

However, the post-pandemic landscape posed unprecedented challenges for the company. A critical component crisis threatened the continuity of Tecnobox's production, putting its market leadership at risk. This crisis coincided with a period when Delta was seeking to establish a stronger presence in the market.

Tecnobox's need was clear. It required a system that mirrored its current architecture's reliability, while offering enhanced efficiency. The solution had to be complete and incorporate EtherCAT communication while aligning with its ethos of innovation and sustainability. With its AX3 PLC, MS300, ASDA-B3, DOP100, and LITE Power Supply. Delta emerged as the candidate most suited to meeting Tecnobox’s requirements, not just for the completeness of its offering, but also its ability to deliver it promptly.

Operating two distinct machines within the system, Tecnobox required specialized control architectures tailored to each machine's unique tasks and performance metrics. The first machine, TB-Pack, utilizes a servo system with the MS300 drive, achieving a production speed of 3000 pieces per hour. Along with the servo system and MS300 drive, it is also equipped with an HMI, PLC, and I/O, making this machine optimally forms boxes of specific types.

The second machine, TBQ-Pack, shares a similar configuration with TB-Pack but substitutes the MS300 with another servo system, allowing it to operate at a faster pace of up to 10000 pieces per hour. These variations in control architecture stem from the distinct production requirements and speed capabilities of each machine.

A synergy of expertise and innovation.
The journey began with Delta's proactive approach. Collaborating closely with its regional partner, INDA LEVANTE, Delta offered its comprehensive automation solutions to Tecnobox. This collaboration was not just about providing hardware; it involved an intricate process of understanding Tecnobox's needs and tailoring its hardware and software solutions according to Tecnobox’s unique requirements.

Delta’s Project Managers and Field Application Engineers spearheaded the initiative, conducting extensive technical training sessions for Tecnobox and INDA LEVANTE. Within five months, a prototype machine was manufactured which integrated Delta's advanced automation systems. As with all implementations, in the early stages there were challenges to overcome, but they served to prove Delta’s confidence in problem-solving and commitment to complete customer satisfaction.

Enhanced performance and cost-efficiency.
Following the implementation, the results were remarkable. Tecnobox not only overcame the production hurdles, but it did so with a solution that saved approximately 25% in electronic materials costs. Furthermore, the stability and efficiency of Delta’s solutions were not just in line with Tecnobox’s expectations, but also reinforced its market position during a critical period.

This collaboration between Delta, Tecnobox, and INDA LEVANTE transcends a mere business transaction; it exemplifies a synergy where challenges are converted into opportunities. The success story is best encapsulated in the words of Edwin Gomez Rodriguez, Field Application Engineer, Industrial Automation Business Group at Delta EMEA: "This project with Tecnobox not only demonstrates our capabilities in delivering efficient, cost-effective automation solutions but also reinforces Delta’s commitment to customer satisfaction and innovation. We're proud to have played a key role in supporting Tecnobox through a challenging period, and this collaboration signifies a major step in our journey towards becoming a recognised name in the automation industry."

Delta’s commitment to innovative problem-solving and customer satisfaction, coupled with Tecnobox’s strategic market insights and operational excellence, have created a formidable partnership that stands out as a beacon in the manufacturing and automation industry. The resilience and innovation serve as a compelling model for others navigating the complex landscapes of modern industry.

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@DeltaEMEA @mepaxIntPR #PAuto #Manufacturing #Spain

Field power supplies.

DIN-Rail power supplies and Field Power Supplies equipped with a fully integrated EtherCAT interface have been introduced by PULS (at SPS 2023 in November 2023).

The integration of the EtherCAT interface allows users to configure and remotely control the power supplies in an efficient and time-saving manner. In addition, it provides access to a variety of measurement data, which enables reliable monitoring and predictive maintenance of both the power supply and the end system.

Application data in real-time:
PULS power supplies with integrated EtherCAT ports can be directly connected to EtherCAT controllers – without the need for additional gateways, providing easy and rapid access to all application data and power supply functions. The real-time capabilities and high-speed transmission of EtherCAT is ideal for maintenance, logging and remote control in large-scale systems.

The power supply data can also be used within real-time control loops. Based on the data, drives or other high-energy users can be controlled in an optimal way to keep the dynamic power needs within the capabilities of the power supply system. This enables improved system efficiency as power supplies can be used at the optimal operating point.

Three models available: • 240 W or 480 W DIN rail power supplies with EtherCAT • Input: AC 100-240 V, DC 110-150 V • Output: 24 V, 10 A or 20 A; 48 V, 10 A • 2 x RJ45 EtherCAT ports • Rated to IP20 • 600 W FIEPOS Field Power Supply with EtherCAT • Input: AC 380 - 480 V • Output: 24 V, 25 A • 4 eFused outputs • M8 A-Coded • Rated to IP65/67

Key benefits of PULS power supplies with EtherCAT interface include:
Use real application data to improve the utilisation of end system.
Implement preventative maintenance and fix errors before they occur.
Reduce energy costs and speed up fault analysis and troubleshooting.

PULS offers all the documentation and tools required to integrate their smart power supplies with EtherCAT into customer’s automation networks, enabling direct access to the device data from the PLC or embedded controller.

This includes extensive documentation – from datasheets, data- and interface-description to quick start guides, enabling a fast and easy integration even for users with little experience. In addition, PULS also provides the relevant electronic data files such as IODD for IO Link or ESI files for EtherCAT. As part of their quick start quides PULS also provides sample configurations and programs for selected PLCs and control tools.

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@PULSPowerSupply @proactivefleet #PSU 

Next-generation gateways.

The Anybus® Communicator™ EtherCAT Main Device has been launched by HMS. This is a high-performance gateway that provides an easy and reliable way to connect EtherCAT subordinate devices to different industrial networks and control systems.

"We are delighted to add the Anybus Communicator EtherCAT Main Device Gateways to our list of next-generation gateways”, explains Fredrik Brynolf, Product Manager for Anybus gateways at HMS Networks. “With the effortless scanning for EtherCAT devices, the intuitive user interface, and the advanced technology, these EtherCAT gateways offer the easiest and most reliable way to connect EtherCAT subordinate devices to other leading industrial networks and control systems”.

Rapidly growing EtherCAT market

In recent years, EtherCAT has rapidly gained popularity and is now the third most widely installed industrial network in factory automation globally, according to HMS' own research, and the preferred choice in the semiconductor industry. As the number of subordinate devices utilizing EtherCAT continues to increase, there is a growing demand for high-performance gateways that can seamlessly connect these devices to other major industrial networks. The Anybus Communicator EtherCAT Main Device addresses this demand by providing a reliable solution for connecting EtherCAT subordinate devices to PROFIBUS, EtherNet/IP, PROFINET, or Modbus-TCP control systems.

Effortless scan for EtherCAT devices
With the Anybus Communicator, users can quickly and effortlessly scan the EtherCAT network for devices directly from its web user interface. The Communicator automatically identifies each device and maps its data to the control system, eliminating the need to manually search for and import device description files (ESI).

Next-generation technology
Like all Anybus next-generation gateways, the Anybus Communicator EtherCAT Main Device provides reliable, secure, and user-friendly technology:

Proven and fast communication using Anybus NP40 technology
The award-winning Anybus NP40 industrial network processor ensures that the Communicators meet demanding requirements in terms of industrial performance, reliability, and security. Featuring new hardware and software, the gateways enable instant data transfer – up to 10 times faster than their predecessors. Users can also exchange significantly more data between the networks as the gateways transfer up to 1 500 bytes to and from connected PLCs.

Robust and secure communication

Built using carefully selected industrial components and verified against the CE and UL industry standards, the gateways are designed to handle harsh industrial environments.
To protect users from cyberattacks, the gateways have an onboard physical security switch that prevents unauthorized configuration changes and secure boot functionality to resist attacks and infections from malware.

Fast installation and intuitive configuration
Fast installation and smooth configuration procedures are guaranteed thanks to an optimized housing design, an intuitive User Interface, and easy-to-understand documentation.

Installation is simplified thanks to the compact gateway design with forward-facing ports and DIN-rail mounting, which allows gateway installation close to connected devices, reducing the amount of required wiring.

Users can configure the gateways using drag-and-drop functionality in the web-based user interface, which is accessible via a dedicated Ethernet port on the gateways. In the user interface, users can also monitor network traffic and diagnose issues before they become problems.

Hands-on assistance is also available, as a QR code in the user interface provides a step-by-step installation and configuration guide.

Anybus Communicators are available off the shelf as stand-alone ready-to-install units. Users can personalize the Communicators to meet OEM and brand labeling requirements. The gateways can also be pre-configured and locked to be used as tightly integrated communication components of an automation device or a machine.

@hmsnetworks @mepaxIntPR #PAuto  #Communications

Functional safety over EtherCAT.

A new version of the HMS Network Ixxat SafeT100 module allows users to implement safe I/Os for FSoE – Functional Safety over EtherCAT. Previously available for PROFIsafe and CIP Safety, the new version supports Functional Safety over EtherCAT according to ETG 5100 V1.2.0.

Ixxat® Safe T100 is an all-in-one safety solution which allows device manufacturers and machine builders to implement configurable, safe inputs and outputs in applications up to SIL 3 and PLe Cat.4.

The Safe T100 is designed to work hand in hand with Anybus® CompactCom, also from HMS Networks. While Anybus CompactCom handles the standard non-safe communication with the EtherCAT network, the Safe T100 handles the safe communication, in this case over FSoE. Thanks to the full implementation of the safe protocol and application layer in Ixxat Safe T100, device manufacturers and machine builders get a fast track to add functional safety capabilities to their equipment. A typical application for Ixxat Safe T100 is a safe emergency stop function for automation equipment such as drives, robots or process controllers.

Pre-certified and conformance tested solution.
The Ixxat Safe T100 solution is pre-certified by TÜV Rheinland, and its conformity to the FSoE standard ETG 5100 V1.2.0 has been confirmed in the ETG test lab. This enables users to benefit from significantly reduced development time, cost, and risk when realizing safe devices and systems.

Since the Ixxat T100 works together with Anybus CompactCom, the end user will benefit from a device or machine that provides both safe and non-safe functions via just one communication interface. This significantly simplifies configuration and project planning of the overall industrial automation system.

Key technical highlights.
The Ixxat Safe T100 module features three two-channel inputs which can detect external wiring errors, and one two-channel output. The inputs and outputs all operate with 24 V signals.
All service and process data interfaces required for FSoE in the EtherCAT layer are available in the Anybus CompactCom module, such as control of the network and status LED, or transmission of the safe configuration data.
As an additional safety feature, the interface between the Anybus CompactCom module and the Ixxat Safe T100/FSoE is galvanically isolated. Other internal safety features include integrated temperature monitoring and shutdown to a safe state as well as channel-granular error signaling and error handling.

A scalable concept for FSoE, PROFIsafe and CIP Safety.
The internal communication between the non-safe Anybus CompactCom and the safe Ixxat Safe T100 module is done according to the "black-channel" principle. Thanks to this clean separation between the safe and non-safe communication layers, it is possible for customers to support all the three major safety protocols – FSoE, PROFIsafe and CIP Safety – with just one hardware design, adding further to the scalability and efficiency of the solution.

Customized implementation or OEM solutions.
Thanks to the comprehensive implementation guidelines and user documentation, the Safe T100 module can be implemented by device manufacturers and machine builders themselves. However, HMS also supports customers with implementation services, as well as porting and certification services.

For specific requirements regarding e.g., form factor, plugs or number of I/Os, customer-specific versions of the Ixxat Safe T100 can be developed by HMS.

For applications where it is not possible to integrate the Safe T100 – e.g. due to limited space within safety encoders, or when already existing safety hardware limits the design flexibility – HMS also offers protocol stacks for Functional Safety over EtherCAT (FSoE), CIP Safety over EtherNet/IP and CIP Safety over Sercos, all pre-certified by TÜV.

@HMSIxxat @hmsnetworks @mepaxIntPR #PAuto #Safety

I/O remote module with integrated output relays.

32 digital optocoupler inputs and 32 dry contact relay outputs offer easy integration.

The R2-EC0902D0 32 digital input/output remote module has been launched by Delta. Featuring 32 integrated relays on the output, supporting 2 A at 30 VDC/ 250 VAC per channel, and 32 24 VDC digital inputs, the unit greatly simplifies the implementation of digital I/O on EtherCAT networks. The high level of integration reduces system costs by eliminating the need for a separate coupler, digital input/output modules, and external relays.

EtherCAT is predicted to grow above 7% CAGR1 in the coming years, supporting the view that continued innovation around this technology is needed. While advanced automation capabilities are well covered, more straightforward capabilities, such as hardware integrating EtherCAT for digital I/O, are not as refined. Instead, system integrators have relied on couplers, digital input and output modules, and external relays. The R2-EC0902D0 DI/DO mixed remote module removes this complexity and associated cost, integrating digital I/O into a single, EtherCAT-capable unit.

The R2-EC0902D0 features an input and output EtherCAT port, allowing for daisy-chaining. At the front of the 120 mm wide DIN-rail unit, power, communication, and alarm indicators are set into the housing for good visibility. Indicators for each of the 32 inputs and outputs are located in the center of the face plate. All the optical coupler inputs are grouped on one side, with the digital outputs placed on the other. The 32 digital outputs are implemented using normally-open dry contact relays. These operate at up to 1 Hz and have an off/on response time of 10 ms, and on/off response time of 5 ms. On the input side, PNP/NPN configurable sink/source signals of up to 1 kHz can be acquired with a response time of 300 µs.

“The R2-EC0902D0 DI/DO mixed remote module supports the EtherCAT protocol to enable a fast I/O response. The large number of integrated digital inputs and relay-type outputs makes it suitable for a wide range of applications, from the packaging industry and woodworking to assembly lines,” said Simone Orlandi, Product Manager - Motion Control, Delta Electronics EMEA region.

The R2-EC0902D0 is ideal for industrial automation engineers looking for a digital I/O solution with a large number of channels that also supports EtherCAT. Compliant with EN 60068-2-6 for vibration and EN60068-2-27/29 for shock resistance, this IP 20-rated unit can operate over 0°C to 50°C (32°F to 122°F). It requires a 24 V/1 A external power supply and is compatible with all Delta and third-party EtherCAT controllers.

@DeltaEMEA @Delta_Americas @mepaxIntPR #deltaww #PAuto

Multiprotocol support.

PROFINET, EtherNetIP und EtherCAT supported.

The connection of SoM modules (Stack on Module) has been extended by port to the STM32 MCU family from ST Microelectronics. With the firmware extension “µGOAL”, all derivatives of the STM32F, STM32G, STM32L and STM32H families can now be connected to the SoM (Stack on Module) via SPI. The user is now able to offer PROFINET (incl. MRP), EtherNetIP (incl. DLR) and EtherCAT for all named derivatives.

The firmware extension µGOAL describes a software package that enables the integration of the SoM module in applications without using a complete GOAL framework platform. As a result, for example. 8 bit CPUs with 2KB RAM can also be connected via SPI with the multi-protocol support technology SoM (Stack on Module). This makes it possible to enable low-cost or low-performance CPUs to be integrated into PROFINET, EtherNetIP and EtherCAT environments quickly and easily. µGOAL mimics the required functionality from the GOAL framework, which is specifically required by the application controller framework. It is configurable in a number of ways to ensure compatibility with a wide variety of destinations. Most of the CCM-specific examples for fieldbus applications can be reused without modification.

By using the module, no investment costs in the form of licenses are necessary. The module is cUL / CE certified. The PROFINET, EtherNetIP and EtherCAT protocols are “PRE-Certified” and therefore easy to integrate.

An extensive tool chain such as the ICE (Industrial Communication Explorer - is included free of charge) and the ICC (Industrial Communication Creator - optionally available) make integration much easier.

#port #PAuto #fieldbus

World's smallest EtherCAT drive.

High-end positioning applications where space is critical now find an optimal solution in the incredibly small iPOS2401 servo drive from Technosoft, with an EtherCAT interface.

Small and light, 19 x 50 x 10 mm, and weighing only 12 g, the iPOS2401 MX-CAT drive can be used in high precision positioning applications with any motor technology (brushless, stepper, DC/voice coil or linear) that requires no more than 1 A continuous at 24 V.

Users can achieve an optimal mechanical integration, due to the plug-in design of the iPOS2401 that offers full flexibility in terms of motherboard design and connectors choice, for either single or multi-axes applications.

A miniaturized drive, yet with no compromise in performance, the iPOS2401 MX-CAT sup-ports full CoE (CAN application protocol over EtherCAT) protocol, which makes it the ideal solution to medical, robotics, instrumentation or automation projects where a high-end Swiss product can make the difference in terms of quality and performance of the application.

A lighter, CAN version is also available, embedding a motion controller that can execute complex motion sequences programmed in TML (Technosoft Motion Language), stored at drive level and called by specific CANopen commands to reduce the bus traffic in multi-axis applications.

In both EtherCAT and CANopen versions, the iPOS2401 completes the extended Technosoft offer (from 25 W to 1.6 kW) in terms of intelligent drives with embedded motion controller for high-end positioning applications.

@TECHNOSOFT_MT  #Pauto @EtherCAT_Group

EtherCAT connectivity.

Harting has added EtherCAT connectivity to its MICA® (Modular Industrial Computing Architecture) system: an open source platform for industrial applications.

EtherCAT is a real-time Industrial Ethernet technology originally developed by Beckhoff Automation. The EtherCAT protocol which is disclosed in the IEC standard IEC61158 is suitable for hard and soft real-time requirements in automation technology, in test and measurement and many other applications.

The main focus during the development of EtherCAT was on short cycle times (not greater than 100 µs), low jitter for accurate synchronisation (not greater than 1 µs) and low hardware costs.

With the EtherCAT interface, MICA can capture directly from industrial production networks via two M8 connectors, then pre-process it and transmit it to higher-level systems and cloud applications via various standard protocols such as OPC-UA and MQTT.

MICA®s modular Open Source Software Architecture makes it the ideal solution for developing edge and cloud applications in production. Creating the EtherCAT functionality as an internal MICA® function module enables MICA® to deliver further benefits, such as protection class IP67, connectors suitable for industrial use and compliance with major industry standards.

 @Harting #PAuto @EtherCAT_Group

Innovative new servomotor technology expands further.

AMP (Applied Motion Products Inc.) has launched EtherCAT® communications versions of its innovative StepSERVO™ closed loop stepper technology products.

Comprehensive details of AMP’s stepSERVO technology is included in a white paper , available for download from Mclennan’s website which also covers information on the new EtherCAT network drives.

Available with full support from Mclennan, AMP’s European distribution partner, the range covers three EtherCAT network intelligent drives with continuous output current of 3, 5 and 10 Amps together with 14 matched StepSERVO stepper motors from NEMA size 11 to 34. This combination offers automation systems and machine builders an unprecedented range of high performance intelligent drives with greater torque, acceleration, and throughput than traditional step motor systems and also enables highly precise axis synchronisation through EtherCAT – the leading real-time communications network for industrial Ethernet.

AMP’s new SS-EC series drives support CANopen over EtherCAT (CoE) with CiA operating modes that include profile velocity, torque and position as well as profile cyclic synchronous position, and cyclic synchronous velocity. The drives also include AMP’s Q-programming for stored program execution which may be managed over EtherCAT. A complement of digital and analogue IO as well as dual-port Ethernet allows flexible machine control interaction whilst a mini USB port is available for software configuration. The EtherCAT+StepSERVO drives run from 24 to 70 VDC and a full complement of optional interfacing cables and connectors form part of the range.

AMP’s stepSERVO™ technology brings closed-loop servo control to compatible stepper motors. Typical peak-torque performance for the 34 frame version is over 8 Nm - up to 50% more than the equivalent sized motor operating open loop. As well as being quieter and more efficient than open loop steppers, further benefits are stall-free performance and zero lost motion through missed steps. At the other end of the range the diminutive size 11 StepSERVO offers an extremely compact footprint for small machine applications with much enhanced dynamic performance (almost 90 mNm peak torque for the smallest model). Precise positioning is made possible with the larger motors’ encoder resolution of 5,000 counts/rev and 20,000 steps/rev quadrature, whilst the smaller motors offer 1,024 lines and 4,096 counts.

Comprehensive details of AMP’s stepSERVO technology is included in a white paper , available for download from Mclennan’s website which also covers information on the new EtherCAT network drives.

#McLennon #PAuto @ampmotion

Encoder with EtherCAT interface.

Hengstler has extended their ACURO® AC58 product line with the widely-used EtherCAT interface. The number of systems using this open, powerful, Ethernet-based system continues to grow at a rapid pace.

With the availability of the ACURO® AC58, incorporating an EtherCAT interface, users can integrate one of the foremost absolute encoders on the market, into virtually any system that uses EtherCAT technology. This simplifies the design process and guarantees reliable communication. Hengstler's ACURO® AC58 EtherCAT encoder is naturally attested by an official compliance certificate issued by the EtherCAT Technology Group (ETG).

ACURO AC58 EtherCAT delivers reliable communication, extended temperature range, protection rating up to IP67, and extremely high shock and vibration specifications are just some of the outstanding characteristics of the AC58 EtherCAT. This flexibility makes the Hengstler ACURO® AC58 one of the most versatile encoders on the market. Its robustness specifications are particularly impressive. A stainless steel version is also available as an ordering option. This makes it suitable for use even in the harshest environmental conditions.

Values are updated with a cycle time down to 62.5 µs, making it one of the fastest encoders on the market, and allowing customers to implement highly dynamic processes. Device configurations like a residual value function for rotary indexing machines add to the range of application capabilities.

@Hengstler_GmbH #PAuto #Ethetnet 

Complete EtherCAT Solution!

Rugged, intelligent with superior motion function scalability.

Adlink Technology has announced the release of their Adlink EtherCAT solution, consisting of the Talos-3012 IEC 61131-3-compliant automation controller and EPS Series time-deterministic I/O and motion control system.

The combined solution provides time-deterministic control of automatic process, featuring high performance, easy development, rugged construction, intelligent management in ultra-small form factors, and minimal total cost of ownership. Integrated hardware and software elements, fast and easy API configuration, and ADLINK’s Softmotion control kernel, all drive speedy high performance for EtherCAT applications. As well, numerous ready-to-use features speed development for next-generation Smart Factory environments.

High Performance, High Density
Their new Talos-3012 is a palm-size EtherCAT master controller based on the Intel Atom quad-core processor E3845 1.9GHz, with IEC-61131 compliant syntaxes. The Talos master controller allows easy emigration of legacy PLC programming to a PC-based environment and Softmotion function blocks, with a single master controller able to connect up to 64 axes and 10,000 I/O points of control through a daisy-chained slave system. Superior computing power enables the Talos-3012 to flawlessly perform simultaneous multitask processing for HMI, motion control, PLC, and gateway operations in industrial automation applications.

The EPS Series slave system’s modular design empowers flexible channel density in a 110 x 130 x 105 mm package. Incorporating the latest RISC processor and FPGA, Adlink EPS slave systems provide a wide variety of I/O modules, including DI/O, AI/O, thermal measurement, motion control, and EtherCAT communication modules, easily daisy-chained for system expansion with no compatibility issues.

Easy development
Adlink’s EtherCAT solutions further minimize configuration and maintenance burdens on system developers and users. This solution has been verified for interoperability with a variety of EtherCAT servo drives and 3rd party EthercAT products, providing the flexibility to select only the requisite EtherCAT elements. With Adlink’s self-developed EtherCAT configuration utility, LinkMasterPro, the master system is able to automatically detect slave systems and I/O modules of any type and create corresponding XML files to complete configuration without any additional settings.

Their EtherCAT master controllers can easily connect to existing or expanded third-party slave systems for automatic recognition and configuration with no compatibility problems. Moreover, the Softmotion utility provides a complete IEC 61131-3 edition environment supporting application-oriented function and APIs for ease of use and shortened development time.

Intelligent Management and Robust Design
Adlink’s EPS slave systems support a wide variety of I/O, including DI/O, AI/O, thermal measurement and motion control with status monitoring function of EPS modules and systems including overheating detection, low power detection, slave health reporting, error handling, and usage cycle of relay switching, as well as motion control status. All information can be retrieved for review via software or displayed by dedicated indicators, allowing the status of individual modules to be monitored. LinkMasterPro not only assists in EtherCAT configuration but also evaluates the functionality of every single EPS system, and Auto-Slave detection function makes system configuration easier than ever.

The EPS slave system significantly eases system maintenance needs, with each hot-swappable slave module replaceable with no need to power down, for a serious reduction in MTTR (Mean-Time-to-Repair). Additionally, quick-removable connectors minimize rewiring efforts. The EtherCAT products all feature compact construction with fanless design, operable at -20°C to 60°C, with integral IP31-rated metal housing withstanding the rigors of harsh operating conditions.

“Adlink industrial automation and motion control solutions have been widely adopted, to date driving over 500,000 axes industry-wide. As we introduce our completely new EtherCAT solution portfolio, we are confident that our extensive field experience, established one-stop service, comprehensive APIs, and highly integrated portfolio of off-the-shelf I/O modules and industrial computing platforms clearly set us apart from other providers. Adlink’s new EtherCAT Solution helps customers to overcome even the most critical challenges of industrial automation,” said Simon You, Product Director for Adlink’s Automation Product Center.

RFID connectivity via EtherCAT

Many users in the material handling, automobile manufacturing, and intralogistics sector see the IDENTControl concept from Pepperl+Fuchs as the answer to all their needs, because the perfect modularity and general command structure facilitate the use of RFID technology. The wide range of fieldbus solutions makes it possible for users to standardize and use a wide range of programmable logic controllers on a worldwide basis. Because LF, HF, and UHF read/write heads can be connected to the same IDENTControl interface, the system can be perfectly tailored to the relevant applications. Thus, RFID makes it easy to resolve the increasing demands for a large number of variants and short cycle times—through to just-in-time production in the automotive industry. Modularity, flexibility, and investment security are key concerns at Pepperl+Fuchs.

For example, with the new EtherCAT interface, our RFID systems can be connected directly to Beckhoff controllers. Thanks to high-speed communication, a large data range of up to 256 bytes of data per cycle can be transferred to the controller.

A parallel diagnostic interface allows the device properties and component statuses to be queried during operation. The General Station Description data can be stored as an ESI file in the controller for parameterization.

Most RFID applications require one or two readers and IDENTControl Compact is intended for this purpose. Their particular advantage, however, lies in the sophisticated EMC concept employed. However, the metal housing not only benefits EMC, but is also suitable for field mounting in IP67 in its robust version.

The flexible and modular IDENTControl from Pepperl+Fuchs

The RFIDControl Software, which is available free of charge, allows further diagnostics and parameterization functions.This means that today, it is simple to set up a dependable logistics system, an optimized goods process chain, and reliable variant manufacturing. RFID primarily distinguishes itself from barcode and 2-D code solutions through its robust read/write tags and an additionally available write function. Furthermore, RFID readers are durable, as they are based on the inductive principle and contain no moving parts.

EtherCat control

Lenze's Controller 3200 C with EtherCAT to control the ECS servo system

Lenze's ECS servo system can now be ordered with a clock-synchronised EtherCAT interface. Combined with the new L-force Controller 3200 C for central control architectures, even the most demanding motion tasks in terms of number of axes and precision required can be solved effectively and economically.

The ECS servo system provides the compact servo drives with high dynamic performance that are necessary for motion tasks with highest requirements regarding precision and speed. They have been designed specifically for multi-axis applications in central control architectures. The versatile system includes a large selection of axis and power supply modules that can be connected to form a integrated unit. The ECS drives are perfectly matched to the highly dynamic motors in the MCS range, but can also be combined effectively with other synchronous and asynchronous motors.

The L-force Controller 3200 C has been designed for use in the control cabinet and is based on the energy-efficient Intel Atom® processor. The integrated 48 MBit/s backplane bus allows I/O modules from the I/O system 1000 to be directly side-mounted to the controller. A short cycle time and minimum jitter in combination with a time stamp guarantee that the motion system also complies with the strictest speed and synchronism requirements.

"With our combination of Controller 3200 C and ECS servo system, we offer the optimum solution for tasks with a large proportion of motion", explains Sören Mirbach from Control Technology Product Management at Lenze. "And integration of the ECS in the EtherCAT-based control environment rounds off our uniform, end-to-end portfolio for setting up central control architectures."

Distributed motion solution with EtherCAT technology

National Instruments releases new high-performance servo drives and motors

National Instruments has announced new AKD Servo Drives and AKM Servo Motors that make it possible for engineers and scientists to easily build scalable, distributed motion control systems. The new products simplify setup and configuration for deploying custom motion applications to any NI real-time controller supporting NI EtherCAT technology including NI CompactRIO, PXI real-time controllers and NI industrial controllers. Additionally, National Instruments is releasing the NI LabVIEW 2010 NI SoftMotion Module that provides support for NI EtherCAT drives for simplified motion application development.

The new AKM brushless servo motors provide superior dynamic performance, are available in four different frame sizes and feature high torque, density and speed ranges. The motors use low-inertia rotors and feature low-cog, low-harmonic distortion magnetic design. The motors are also perfectly matched with NI servo drives and provide plug-and-play configuration with integrated Smart Feedback Device (SFD) technology and simplified cabling.

The new AKD Servo Drives feature simplified setup and configuration through EtherCAT technology and integration with the LabVIEW project, a feature in LabVIEW software that engineers use to group together LabVIEW and third-party files, create build specifications for executables and deploy or download files to hardware targets. The new drives deliver cutting-edge technology and performance with torque loop updates in 0.67 μs, and velocity and position loops at 62.5 μs and 125 μs. The AKD Servo Drives provide a solution for a wide range of applications, from basic torque-and-velocity applications to indexing to multi-axis programmable motion, using graphical system design.

The new motors and drives provide seamless integration with LabVIEW graphical programming through the LabVIEW NI SoftMotion Module to deliver graphical development for custom motion control applications. With the module, engineers and scientists can use the LabVIEW project to configure motion axis settings, test configuration, tune motors and quickly develop a custom motion application. The new version of the NI SoftMotion Module features an updated interactive configuration and a high-level function block API for increased ease of use and makes the execution of motion applications on a Windows-based system possible. In addition, the new module easily connects to the new drives and motors as well as third-party drives and motors using NI C Series drive interface hardware.

More about EtherCAT.

Industrial networking for automation

Silica is appearing at this year’s Embedded World fair in Nuremberg (March 2nd – 4th, 2010) entirely under the banner of “Networking for automation systems”.

There will be a live demonstration of controlling a high-stack shelving system based on EtherCAT (Ethernet for Control Automation Technology) standards. The high-stack shelving system is used as an example to show how many things industrial Ethernet can do.

The system was designed, built and programmed entirely by SILICA’s applications engineers. All the specialists involved in developing it will be on hand and available to visitors for first-hand information throughout the fair.

The system is controlled via a process control system running as software under Microsoft’s Windows Embedded Standard on an Intel® Atom™ platform which serves both as EtherCAT master and industrial PC. The model’s sensors and actuators are interfaced via a slave module, demonstrating how the EtherCAT standard is realised with an FPGA core on a Xilinx FPGA.
Galvanically separated interfaces linking the 3.3 V and 24 V domains use Infineon and STMicroelectronics modules.

Both the high-stack shelving system’s input and output stations have RFID readers implemented with NFC chips by NXP and barcode readers which analyse camera signals using a Renesas microcontroller. Readout data is sent to the PLC in the industrial PC and processed there. A live image of the demo is sent from a CCTV camera using a Blackfin processor by Analog Devices.

SILICA’s appearance at the fair reflects its total solutions and technical support strategy: its own application developed in-house enables specialists to deal with typical problems and the complex applications involved directly.

SILICA is at Halle 12, Stand 241, and is also represented as co-exhibitor on Microsoft’s Stand 11-318.