Volume 02 No.04 | July - August 2022 | Pages 36 www.industrialautomationreview.com
TRIO MOTION TECHNOLOGY:
Changing the dynamics of
MOTION CONTROL BUSINESS
AN INTERFACE WITH:
SYDNEY QUADROS, VICE PRESIDENT -SALES, TRIO MOTION TECHNOLOGY INDIA PRIVATE LIMITED
PG. 12 - 14
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Automation in manufacturing : Making
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Automation has become known more as using machines to reduce work performed by
Publisher & Director : Shirish Dongre | Shilpa Dongre humans. It has become associated with electromechanical systems that are programmed
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INDUSTRIAL
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CONTENTS 12
COVER STORY
Trio Motion Technology: Changing the
NEW S
dynamics of motion control business
06
ABB launches five axis Delta robot
fastest for lightweight product
picking, packing & re-orientation
08
YASKAWA India opens a brand-
new Robotic Solution Facility
10
Kollmorgen introduces a new
generation of robot-ready
frameless servo motors
TECH INNO V A TIONS
24 Schmersal
Concepts for
communication and
signal evaluation
Machine Safety in
intralogistics - best
when networked
27 Trio Motion
New multi-axis
servo drive provides
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4 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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INDUSTRIAL
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ABB launches five axis Delta • New FlexPicker® IRB 365 picking robot
robot fastest for lightweight fastest-in-class for picking and packing
product picking, packing & applications up to 1.5kg
re-orientation • Flexibility to be used in a range
of applications, from shelf ready
packaging to parcel sorting and bottle
ABB is expanding its handling
FlexPicker Delta robot
®
portfolio with the IRB 365. • Commissioning time reduced from
With five axis and 1.5kg days to hours with ABB PickMaster®
payload, the IRB 365 is both Twin software
flexible and the fastest in
its class for reorientating packaging, to bottle handling, unscrambling, 3D picking,
packaged lightweight feeding and parcel sorting, the IRB 365 meets a wide variety
products such as cookies, of applications. Powered by the OmniCoreTM C30 controller
chocolates, peppers, candies, - the smallest Delta robot controller on the market - the
small bottles, and parcels. system offers best-in-class motion control, built-in digital
Responding to the rise in connectivity, and 1000+ additional software hardware
e-commerce and growing functions ready to meet future demands and requirements.
®
demand for shelf ready packaged goods, the IRB 365 has Through ABB’s PickMaster Twin software, the IRB 365 can
been developed for applications including food and beverage, be integrated into packaging lines in a matter of hours rather
pharmaceuticals and consumer goods, where production line than days, using digital twin technology, which also reduces
speed and adaptability are essential. changeover times from hours to just minutes.
“The IRB 365 can pick, reorientate and place 1kg products As the latest member of ABB’s portfolio of robots for
at 90 picks per minute,” said Roy Fraser, Global Product picking and packing, the IRB 365 can be paired with other
Manager for ABB Robotics. “Our customers saw that the robots including the IRB 390 to pick, handle and pack
growth in online shopping was driving the demand for shelf payloads weighing from a few grammes up to 15kg.
ready packaged goods, so we developed a new Delta robot ABB Robotics & Discrete Automation is a pioneer in
that would rise to the challenge. By handling more products robotics, machine automation and digital services, providing
per minute, the IRB 365 robot increases productivity, while innovative solutions for a diverse range of industries, from
saving time and energy to make production more efficient.” automotive to electronics to logistics. As one of the world’s
From product reorienting, top-loading and secondary leading robotics and machine automation suppliers, we
have shipped more than 500,000 robot
solutions. We help our customers of all
sizes to increase productivity, flexibility and
simplicity and to improve output quality. We
support their transition towards the connected
and collaborative factory of the future. ABB
Robotics & Discrete Automation employs more
than 11,000 people at over 100 locations in
more than 53 countries.
Formore information
https://new.abb.com/products/robotics
6 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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AUTOMATION
REVIEW
YASKAWA India opens a brand-new Robotic
Solution Facility
Yaskawa is a recognized
leader in the industrial
robotics and system
integration and key to our
competitive edge is our ability
to innovate new products
and solutions and enhance
existing ones. We focus on
connecting deeply with our
valued customers across the
various industry segments.
To continue accelerating
innovation in a period of
rising manufacturing complexity and its The experience / demonstration centre of-the-art shop floor to support single
subsequent automation need, we are will showcase the latest technologies in & three axis positioner manufacturing,
pleased to announce the opening of Arc welding, Spot welding, Palletizing, assembly, testing and system integration
our new state-of-the-art robot solution Machine Tending, Painting, and Vision of customized robotic systems and to
facility that aims to take industrial robotic based assembly automation and conduct factory acceptance tests for
automation to a new level. many more suitable for varied industry robots.
Located in the heart of industrial segments.
cluster of Manesar, Haryana, the The live demonstration of Yaskawa About YASKAWA India
state-of-the-art Experience Centre’s cockpit (YCP) which is a part of Yaskawa’ Founded in 1980, YASKAWA India
proximity to customers will enable s i3 mechatronics (intelligent, integrated Pvt. Ltd., is a wholly owned subsidiary
closer collaboration and accelerated and innovative) vision of industry 4.0 of more than 100 years old Yaskawa
development of solutions for the full and IIoT is worth seeing. Electric Corporation- Japan, one of
range of industrial robotic applications Spread over 45,000 sq. ft., the the most advanced and world class
offered by Yaskawa. robotics solutions facility houses a state- manufacturers of Robotics, Drives
& Motion Control and Research &
Development for industrial automation
and OEMs. We, at Yaskawa, are
constantly trying to outperform our
benchmarks with a continuous focus
on R&D supported by robust dynamic
team & strong network worldwide.
Yaskawa delivers high-quality industrial
robots and fully integrated robotic
automation systems incorporated in
various applications like Arc Welding,
Spot Welding, Handling, Pick & Place,
Palletizing, painting etc. that enable
our customers to succeed globally.
Our patents for the world’s fastest
robot are amongst many significant
achievements; showing that we place
quality innovations first.
8 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
INDUSTRIAL
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REVIEW
Kollmorgen
introduces a new
generation of robot-
ready frameless
servo motors
load-carrying capacity, improved energy
efficiency, lower thermal rise, and faster,
smoother movements.
Frameless torque motors typically
deliver their best performance at low
speeds but suffer at higher
speeds. TBM2G motors remove this
limitation through advanced windings
and materials that deliver industry- These motors are designed to perform
leading power, torque and efficiency at high speeds without exceeding the
Kollmorgen, a global leader in motion consistently across a wide speed range. 80°C limit typically needed to safeguard
control systems, recently announced the TBM2G motors also remove the sizing humans working in proximity to cobots
new TBM2G series of frameless servo limitation that engineers often face and to prevent degradation of grease
motors, introducing features that simplify when using off-the-shelf strain wave and electronic components. And they’re
the design of collaborative, surgical, gearing, also known in the robotics available with thermal sensor options
aerospace and defense and other robots market as harmonic gearing. The new to meet the requirements of drives
while delivering optimal performance TBM2G series motors are sized for a and control systems used in the cobot
in a lighter, more compact package. perfect fit with readily available strain market.
These new motors will complement wave systems, eliminating the need Kollmorgen is highly tooled up to
Kollmorgen’s existing TBM and KBM for extensive customizations that can deliver TBM2G motors globally, at any
series of frameless motors. increase engineering time and cost while volume, with fast production times,
Resulting from several years of potentially leading to supply and quality reliable quality and local co-engineering
research, testing and customer issues when robots enter full production. support.
feedback, the TBM2G series offers high- The TBM2G series is available in “We’re excited to introduce new servo
performance torque in an extremely seven frame sizes with three stack motors that significantly increase overall
compact electromagnetics package. lengths each—a total of 21 standard performance while reducing size in a
These nextgeneration motors enable motors that can be integrated directly wide range of frameless applications,”
robots with lower joint weight, higher into robotic joints and similar embedded said Jeff Czarnecki, Vice President,
equipment. Typical applications are Global Marketing at Kollmorgen.
collaborative robots in the 3–15 kg “And we’re particularly excited at the
range, powered at 48 VDC and below. possibilities the TBM2G series opens
up for robotics. TBM2G motors are
a perfect fit for a new generation of
highperformance cobots,” Czarnecki
said. “They are truly robot ready.”
For more information
https://www.kollmorgen.com/en-us/
10 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
INDUSTRIAL
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AUTOMATION COVER STORY
REVIEW
Trio Motion
Technology:
Changing the
dynamics of
motion control
business
Q. Being the key player in automation
technology space, please brief us about
recent initiatives undertaken in the
Motion & Servo product business?
Which are your focus areas?
Trio Motion Technology India is a motion
specialist and has recently worked on
developments with the Internet of Things
(IoT). We’ve used digitalization to control
and manage the movement of servo
drives and motors, as well as integrating
robotics. Alongside partners in IT, we’ve
also involved cloud computing to collect
data from machine processes, enabling
improved operational analysis.
With these developments under the
Make in India initiative, Trio India has
worked cohesively with machine builders
to develop machines that are more efficient,
reliable, and more productive with a faster time
to market. This enables machine builders to have
a competitive edge in the marketplace.
For Trio India, our major focus includes
packaging machines for the FMCG market (fast
moving consumer goods, such as snacks and drinks),
as well as SPM (cutting , textile printing , CNC )
applications. This is supported by a strong portfolio Sydney Quadros
Vice President -Sales
of motion coordinators (also known as motion TRIO Motion Technology
controllers) servo systems, I/O, and robotics. India Private Limited
12 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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COVER STORY AUTOMATION
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REVIEW
Q. Please brief us about company’s global reach Q. Product innovation through R&D is vital to be
& what are the global alliances that has been forrader in the competition. As per your opinion,
made in order to out-front the competition? how does R&D plays the role of catalyst in the
Trio Motion Technology was founded in the UK in 1987, success process?
designing and manufacturing motion control solutions. R&D is crucial to Trio’s strategy, and as a result, we do good
Since then, Trio remains the motion specialist, and its percentage of investment and aggressively pursue new
capability has broadened. Today, Trio provides a complete development opportunities. This is combined with an agile
automation solution for machine builders. approach that achieves a shorter product development time
Trio’s geographical focus is worldwide, with . As a result, we’ve been able to recently launch new servo
manufacturing sites, R&D, applications development, and drives, including the advanced DX4 and the compact, multi-
support, across North America, Europe, and Asia. As part axis DX5, as well as a range of SCARA robots.
of the global expansion, Trio India was established over a Fast time to market in applications development is also a
decade and benefits from extensive support across Trio’s key benefit for the customer. At Trio India, this is achieved
worldwide network. with our methodology of template based programming.
New applications, specific to bespoke requirements, can
Q. What are the market prospects for Trio be developed far more quickly than would otherwise be
Motion Technology products in India? How do possible.
you plan to position these products?
According to forecasts, the Indian motion control market Q. What are the factors affecting to your
is expected to achieve rapid growth in the coming years. business?
Motion solutions have a significant market share, and the Today, increasing numbers of machine builders are
growth is fueled through the thought process of machine developing smart machines to have a cutting edge over
builders shifting from simple to performance to high competition. This means they look for a partner who can
performance machines. This was increasingly driven by the provide economic, reliable and efficient control solutions for
needs of the End User due to the pandemic, and this trend their machines.
of technology driven automation is set to continue. Customer satisfaction is the epi-center for the success of
Trio’s advanced motion solutions are a best fit for the our business. In addition to the technology advancements
present and future , thereby positioning our solutions we continue to bring to market, 24/7 technical support is
for a simple machine with one or two axes, as well as also vital to keep OEM machines up and running. Supply
performance machines with three to six axes, through to chain management plays a vital role, especially to meet
high performance machines with up to 128 axes. today’s increasing electronic component availability
Trio India has a decade of expertise in the Motion Control challenges.
market and Machine Builders prefer us as OEMs partner of
choice . Q. What are the key technological trends that
are driving the industrial automation & motion
Q. What is your marketing strategy for India? control industry?
We focus on marketing activities including brand promotion The Indian manufacturing sector is transforming and
by participating at key exhibitions and forums. For us, face the journey has already started. After the pandemic, the
to face communication with people and our customer base industry has witnessed a shift from manual assistance
is crucial. As a result, we’ve also expanded our presence to automated handling, reinforcing the transfer to smart
by establishing satellite offices across India, alongside industrial automation. In combination with cloud computing,
the appointment of automation partners. We also host data security is also key.
Machine Builders to experience the power of TRIO Motion Alongside these developments, industrial robotics plays
at our Technology Lab in Pune . an increasingly important role to speed up manufacturing
processes and make them more efficient. To achieve
Communicating via digital channels, including networks this, the seamless integration of robots with a machine is
such as LinkedIn (@Trio Motion Technology), complete key. This is where the concept of a single controller for a
information including technical documentation is available machine, motion, and robots, has a unique advantage as
on our website www.triomotion.com it significantly speeds up development time and increases
reliability in the field.
www.industrialautomationreview.com JULY-AUGUST 2022 | IAR 13
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AUTOMATION
REVIEW
Q. How do you perceive the future of the users, with optimized control technology that can increase
automation technology industry? machine throughput and performance.
Indian manufacturing sector is transforming & the journey
has already started. After Pandemic, the industry is Q. Please let us know the issues you need to
witnessing a shift from manual assistance to automated address that are related to automation industry?
handling, thus giving rise to the term “ smart industrial We are witnessing frequent and fast changes happening in
automation”. this modern era. In the Indian context, the use of low-end
This has paved the way for key technologies like technology and a “Chalta Hai” mindset at the bottom of the
Artificial Intelligence , Industrial Robotics , cyber security pyramid must change.
etc . According to me growing demand for industrial robots
in manufacturing processes and ease of use and integration Q. What is your advice to Indian SMEs to achieve
of components within motion control systems are few of global competitiveness?
the primary factor driving the motion control market growth We all have to raise the bar, which calls for choosing and
retaining relationships with technology-oriented partners.
Q. What is your vision for Trio Motion technology Instead of focusing on a passive supplier and those who
India Pvt Ltd for near future? provide ‘commodity’ products, as a machine builder should
We are the motion specialist. Our vision is to breathe life share the vision with a technology partner that can help
into machines, providing innovative technical solutions and achieve goals.
24*7 customer support. This translates into having strong Ultimately, smarter , higher productivity, more reliable
customer intimacy, helping Indian machine builders develop machines, supported by premium-level service, are the
smarter, more reliable machines. This will help Indian value -adds that a Machine builders can provide to End
machine builders achieve the growing demands of End Users .
14 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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5 KEYS TO THE DIGITAL
TRANSFORMATION
ield signal integration, manufacturing processes using
On the path to the smart horizontal and/or vertical sensors. Sensors are already
factory, we are no longer networking, IT security, and contained in production modules for
asking if the digital Fmodularization are the essen- automation; however, for a complete
transformation will occur. tial characteristics of a smart factory. digital transformation of the physical
Rather we are wondering Integration is performed step by step production sequence, components
how it will happen. The fact and according to need. The produc- that were previously considered as
has long been accepted that tion managers know best which utility passive – like storage tanks, transfer
digitally networked production can be expected from digitization. belts, pipelines, or even the product
contains advantages, However, solution providers show itself – must also be digitized. In
particularly in relation to how this transition can occur gradu- addition, objects subject to wear, like
optimized production and ally using certain technologies, includ- bearings in motors and drives, must
increased efficiency. How ing scalable expenses and predictable also be included to complete the
will the digital transformation returns on investments. process. Digital adaptation requires
work? Which technologies play that all production com¬ponents,
key roles? WAGO has outlined 1st Key: Sensor Integration down to the smallest part in the
a plan and now provides the The initial pivot point of the digital manufacturing process, be included.
bases of these ideas.
transformation is to adapt the This is why the sensor system
16 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
INDUSTRIAL
INDUSTRY AUTOMATION
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FOCUS REVIEW
– and its integration – is one of the necessary), without requiring higher- communication characteristics.
most important enablers for a digitized level production control processors. This
factory. “A complete digital process map horizontal networking applies beyond 3rd Key: Vertical Networking
is fundamental for enabling targeted internal production processes to include Cloud networking to servers openly
direction of processes,” states Hempen. external logistics for the manufacturing available online – designated as the
The integration of this new variety of process. The supply of raw materials, “public cloud’ – gener-ates some serious
sensors, in the most cost-efficient way, and their disposal, should also be linked thought, as this could open up access
is a basic pillar for the digitized factory into logistics as needed. to the production process around the
and an enormous challenge, which The multiple communication lines in world under certain circumstances. In
WAGO has addressed. Because the the WAGO PFC Controller meet the the vertical networking of the digitized
WAGO-I/O-SYSTEM 750 offers more requirements for these applications, factory, the distinction between
than 500 I/O modules in a compact size in order to operate multiple clients open cloud applications and vertical
with high scalability, WAGO can offer with different com¬munication networking to external manufacturing
the market’s most diverse system for protocols from one node. Thus, computers belonging to the company
sensor integration. communication with the upstream should be carefully maintained. Through
and downstream manufacturing protected accesses to one’s own severs,
2nd Key: Horizontal Networking islands can be performed from the for example, using VPN, https, and
Production processes are divided controller; in addition, communication other individual encryption methods,
into multiple manufacturing steps. To is possi¬ble with the product itself and encrypted communication in
create an optimal production process, through Bluetooth®, and via Ethernet private client server topologies, the
all participating produc¬tion islands TCP/ IP to the higher-level production Internet structure is merely employed
must be networked. This also enables guidance systems. This all occurs as a network. This architecture,
module-to module communication, through separated communication designated as the ‘‘private cloud’’,
so that production islands agree with paths in the controller. The WAGO differs substantially from the public
one another and with the product (if Controller guarantees these multiple cloud in both its server landscape and in
www.industrialautomationreview.com JULY-AUGUST 2022 | IAR 17
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the server connection to publicly rented TLS1.2 (SSH, FTPS, HTTPS, etc.) and
server landscapes. offer onboard VPN functionality based
Regardless of whether the cloud on the strongSwan package, one of
is ‘‘private’’ or ‘‘public,’’ both cases the secure communication solutions
concern the vertical linkage from the for Linux operating systems. During
®
production model beyond corporate communication with a PFC200, an
boundaries. For B-to-C firms, access encrypted LAN/WLAN connection
to servers can be facilitated for end can be established, and the contents
consumers, for example, enabling of those interchanges can only be
them to place an order directly at the understood by the two endpoints.
production module. WAGO’s controllers
offer integrated remote access which Connections are established only after
converts to an IoT Gateway (Internet Amazon Web Services, or IBM Bluemix. successful authentication.
of Things Gateway). In addition to the With Cloud Data Control, WAGO also
actual controller, parallel communication offers a solution that presents a link Establishing a VPN connection occurs
protocols can be integrated through between the elements of the real and according to the OpenVPN and IPsec
which access can be established. the digital worlds. It manages and standards. While IPsec is encrypted in
Physical access can occur via Ethernet monitors all WAGO PFC Controllers, operating systems in layer-3 (layer-1
or the mobile phone network, while their applications and data. In addition, = physical communication, layer-2 =
logical access takes place via MQTT. connections to third-party solutions data layer link), OpenVPN ensures
As with horizontal networking, can be established, by using the data integrity at the application level
multiple communication access to the MQTT protocol, among others, like a (layer-7). This results in communication
WAGO controller enables access by proprietary customer server with OPC connections between the controllers
different clients to the controller. Status UA communication. and network access points that cannot
information, like run/stop, connection be bugged or manipulated by third
status, device information, and variables 4th Key: IT Security parties. WAGO’s controllers from
defined in the IEC program can thus When production data are detected the PFC100/200 family include an
be transmitted to the cloud and and transmitted, IT security must integrated managed switch that can
visualized. Variables can be defined via play a substantial role. Production be used to implement additional lines
the program that can determine which data are valuable, and require specific or redundant ETHERNET connections.
will be transmit¬ted to the cloud and protection. A great deal of responsibility This also enables the broadband limit
which must be protected. This means is transferred to the WAGO PFC function directly in the switch. In turn,
that sensitive data does not leave the Controllers and Couplers because of it also allows through integration in
company. their multiple communication access ring structures, or redundant coupling
The user determines whether the capabilities. The controllers, with to the network infrastructure. User
®
controller sends the data to major their Linux operating system, have administration and access protocols,
cloud providers, like Microsoft Azure, encryption standards according to like HTTPS, FTPS, SNMPV3, and SSH,
are likewise integrated. Disconnectable
ports, MAC whitelisting, and firewalls
additionally increase security. Finally,
the loggers for all configurations on the
WAGO controllers ensure additional
security.
The PFC100/PFC200 are
characterized by a cross-platform
real-time Linux system, which is
®
available as an open-source operating
system that can be scaled, updated and
supports tools such as Rsync. Basically,
the user should be able to take
18 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
Corrosion free &
maintenance free...
drylin linear guides
®
Fast Lubrication- Quiet
free
Moving on the dry way
Ready to
ship in
hrs
igus India Pvt. Ltd.
®
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Dodda Nekkundi Industrial Area
Phone +91-80-69116900 [email protected] motion plastics
®
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precautions in less critical applications: production control processor. Thanks method for solving the demands
Unsecured protocols, like Telnet, to standardization, manufacturing made by Industry 4.0 for modular
http, FTP, or SNMP can be avoided modules can be replaced without systems that are not merely modularly
for critical applications. These should adaptation in the production control constructed, but also modularly
rely on encrypted protocols instead. processor. This is comparable to automated. This forms an essential
Unnecessary ports (protocols) should exchanging the printer used by a PC, foundation for the autonomous, self-
be de-activated. Default passwords which the user can immediately activate monitoring factory. System modules
should naturally be changed each time, due to standardized printer drivers. can thus be flexibly combined with one
and user roles should be assigned. DIMA MTP likewise uses a software another independent of manufacturer,
driver for the production modules: which then forms the basis for even
5th Key: Modularity The “MTP – Module Type Package”. more flexibility and versatility.
Production must react with flexiblity Like a driver for a printer, the MTP
and versatility to challenges incurred contains a digital description for the Conclusion
by increasingly shorter product life manufacturing module, and thus the Digitization in production is a necessary
cycles, paired with significantly lower virtual description of a system that is development that brings stability
batch numbers down to lot size 1, physically available. The MTP describes and increases added value – it is
without increasing manufacturing costs. the functions of the production also becoming more important with
The necessary versatility can only be module, its visual representation in increasing international competition and
created by modularity in the production the production control processor, rising product customization. The digital
process. This applies to both production diagnostic information, and technical factory – smart factory – is presented
modules, and automation across the data. It is designed in Automation ML, as a reference architectural model of
entire manufacturing process. This is and is generated by the PLC software Industry 4.0 by ZVEI, and describes the
why WAGO introduced the DIMA MTP program in the production module. At essential challenges. WAGO responds
method in 2015, which is currently on WAGO, it is possible to generate the to these challenges with solutions
a path to becoming the international MTP as easily as pressing a button due for sensor integration, horizontal and
standard. to the programming behind the WAGO vertical networking, IT security, and
Content forms the standard for e!COCKPIT Engineering tool. modularity.
interfaces between the manufacturing The MTP is thus an important For more information
modules and a higher-level component, embedded in the DIMA Web:www.wago.com/in
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Industrial Robot
market worth over
$11.8bn in 2021
• Market to grow to $20bn by 2026
• Shipment growth rates saw YoY increase of over 30% in 2021
• Industrial robot market moves from “mature” to an exciting growth phase
fter a 2-year period of worth over $11.8 billion in 2021 forecasted a steady decline in the
contraction, industrial with over three quarters of this value average selling price of industrial
robot shipments saw a YoY represented by articulated robots. robots. But, as a result of global supply
A(year-on-year) increase of By 2026, the market will be worth chain issues, there were dramatic
over 30% in 2021, according to new almost $20 billion, with articulated pricing increases in the industrial robot
research published by Interact Analysis. robots’ ratio slightly decreased but market in 2021. It is likely that price
Pre-pandemic, the industrial robot still accounting for over 70% of this. increases will continue through 2022
sector was considered relatively mature, However, it will be collaborative robots due to ongoing economic uncertainty.
enjoying moderate, stable growth, (cobots) that will see the most success Maya Xiao, Senior Analyst at Interact
but COVID and the extended labor in new markets and applications. Analysis, says, “This new piece of
shortages that followed have caused an However, short-term worries remain. industrial robot research has been
increased enthusiasm for manufacturing These worries include new waves of the largest revision to our forecasts
automation which has turbo-charged COVID causing lockdowns in China, that we’ve had to undertake since we
the robot industry. Additionally, many inflation, and impending recession. started to track the robotics industry
manufacturing companies are investing And the most important, worsening in 2018. The long-term outlook for
in automation as a form of ‘future- supply chain issues have kept industrial robots is bright – significantly
proofing’ to prepare them for future production and demand growth out of brighter than it was pre-pandemic.
emergencies. sync. I think it’s fair to say that COVID
The industrial robot market was Interact Analysis previously has caused the most conservative
of factory managers to consider
the benefits of advanced industrial
automation. However, the short-term
issues are grave. In particular, there
are problems in Europe where the
Ukraine conflict is a real threat to the
industrial automation sector because
the reduction in business confidence is
delaying the sorts of large investment
decisions that are needed to
implement automation projects.”
For more information
Web: www.InteractAnalysis.com
22 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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Concepts for communication
and signal evaluation
Machine Safety in intralogistics -
best when networked
When it comes to machine safety in conveyor and storage technology systems, it’s vital that the topic of
‘networking’ is on the agenda, owing to the extensive nature of the systems, and the numerous and
different safety switchgear devices that they contain. With a sophisticated networking concept, you can
achieve multiple goals in one go – transparency in communication, ‘lean’ wiring and intelligent linking of
different system areas. Here, system engineers can choose from a number of different options.
he fundamental principle of machine safety is no cause of occupational
different in intralogistics than in production or accidents).
assembly: wherever humans and machines work
Ttogether, humans need to be protected. However, in Optoelectronics or
intralogistics, systems are often very extensive, and there are guards?
many and different ‘interfaces’ to staff, such as transfer stations. This kind of concept
Also typical are the high level of automation and, in some also includes a clear
cases, the extremely high product turnover rates. This view of the process
places high requirements on the productivity and failure and indication of the Fig. 2: The components of a
reliability of systems. Moreover, in some task areas – such as operating states of practical safety solution. A
automated palletisation – the components being handled are safety switchgear view of the process, operating
elements close to the door
comparatively heavy. This brings an elevated risk of injury. devices. As guards handle, information about the
often complicate operating state of the safety
Looking for sophisticated concepts workflows (e.g. when switchgear device.
So what does this mean when it comes to ‘designing’ machine packages are moved
safety for conveying and storage systems? Irrespective of into and out of the danger area), the use of optoelectronics
the specific and individual requirements, there should be a may be more suitable. This also applies to area protection
sophisticated concept in place for each and every hazard around packaging machines, for example.
point that ensures the best possible integration into workplace The trend: networking instead of individual wiring As
workflows. intralogistics often involves larger systems with numerous
This will danger areas and corresponding protection needs, it is one
create the sector in which the networking of safety switchgear devices
prerequisite has been fairly well
for high established from the
productivity outset. This has meant
and minimise the replacement of
any incentive traditional individual
there might be wiring of each
to tamper with switchgear device with
the protective efficient, network-like Fig. 3: Widespread intralogistics:
Fig. 1: In intralogistics systems, alternative device (a wiring concepts. There optoelectronic protective devices
wiring concepts for safety switchgear offer frequent is a range of options allow flexibility in safe materials
particular benefits. handling.
24 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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Fig. 4: As many as eight safety switchgear devices can be
connected in the field via the Safety Fieldbox. The data
are captured and forwarded collectively. This saves on
wiring.
available here, one of which is the AS-Interface Safety at Work Fig. 5: Versatile and flexible: the SD 4.0 data bus enables
(AS- i SaW) safety bus. integration of safety switchgear devices into preventive
maintenance concepts.
AS-i SaW: minimal wiring effort signals from connected devices ensures optimum process
The AS-i-Safety standard not only facilitates rapid installation transparency. Plus, increasingly important as an argument
with minimal wiring effort – it often saves on several hundred is the saving that bus systems can achieve on resources like
metres of wire for a single application – it also offers maximum plastic and copper.
flexibility, e.g. in the event of system modifications or new
requirements and safety requirements. Capture and evaluate operational signals via SD 4.0
Another advantage is the comprehensive range of diagnostics If a user only wishes to capture and evaluate operational, i.e.
functions. These make for more rapid identification of the non-safety-related signals, the SD System solution offers a
source of error in the event of irregularities or faults. This third way. This system allows electronic safety sensors and
is particularly beneficial in the case of extensive, complex solenoid interlocks to transmit comprehensive status and
systems, and can help to reduce downtimes significantly. For diagnostic data to a higher-level machine controller.
these reasons, many intralogistics systems that Schmersal A new feature of the SD bus is the significantly expanded
equips with safety systems are networked using AS-i SaW. networking option to include higher levels. A prerequisite for
This networking is also made easier because of the number of this is the connection to OPC UA as a standardised protocol
series of safety switchgear device (including optoelectronics for M2M communication, which has the advantage of better
and operating units) that are available as ‘AS versions’, i.e. with visualisation of diagnostic information collected in the field,
integral AS-i SaW interface. and better access via mobile devices such as tablets and
smartphones. This helps to facilitate predictive maintenance
Alternative – the Safety Fieldbox and additional concepts as part of Industry 4.0.
The ‘Safety Fieldbox’ system can also be used as an alternative
to the AS-Interface Safety at Work. A Safety Fieldbox enables Outlook – alternative wiring concepts are coming
field connection of up to eight safety switchgear devices of The examples and the three bus systems make one thing
different types. Here, safety switchgear devices only occupy a clear – alternatives to traditional wiring in safety circuits are of
single device connection in each case, irrespective of whether particular use in intralogistics systems. There are established
it’s a sensor or interlock. Both the safety-related and the concepts from which to choose, and the appropriate end
operational signals are captured and connected to higher-level devices to pair with them. It is only logical that alternative
control modules via the PROFINET/PROFIsafe protocol. wiring concepts are undergoing further development. New
The flexibility of the system will be further enhanced in versions of the Safety Fieldbox are conceivable, for example,
the future, with the user having a choice of versions with perhaps with additional functions and in combination with
connection to EtherNet/IP CIP Safety and EtherCAT FSoE. switchgear devices. Plus, doing away with hardwired
communication in its entirety in favour of wireless safety
Two solutions, common objectives system would introduce benefits in terms of installation effort
Both solution concepts feature straightforward installation and flexibility, particularly in intralogistics.
and commissioning. What’s more, both alternatives offer Author: Ulrich Bernhardt, Head of Sales for Controls,
potential for cost savings thanks to extensive diagnostics data K.A. Schmersal GmbH & Co. KG, Wuppertal/ Wettenberg
and straightforward installation and wiring. Additionally, both
solutions offer extreme flexibility when it comes to adapting Schmersal India Pvt Ltd.
the individual safety requirements of complex systems and E-mail:[email protected]
machinery. Moreover, additional transmission of all diagnostics Web: www.schmersal.in
www.industrialautomationreview.com JULY-AUGUST 2022 | IAR 25
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NOW WITH NEW ACCESSORIES – SLIM-
LINE AZM150 SOLENOID INTERLOCK
The DHS-150 door handle system is espe-
cially suited to heavy swing doors
ith the new practical DHS-
150 door handle system,
the slimline AZM150
Wsolenoid interlock from
Schmersal is now even easier to use. The
ergonomic DHS-150 avoids the need for
a separate door handle and is suitable for
machine enclosures or fencing and for all
standard aluminium profiles with a width of
40 mm. The robust door bolt is particularly
useful on heavy swing doors and in for use
in harsh environments.
One benefit of the new accessory is that
the actuator is pre-positioned by the bolt in
the DHS system, thus ensuring its optimal
insertion into the device. This gives the
system stability against lateral forces. In
the event of lateral forces on interlocks that
cannot be overcome, the safety door will
not be opened – thus causing delays in the of the interlock is the rotating actuator head which can be
production process. locked with ease by simple placement on the cover, rather
In this regard, the DHS-150 door handle system, in than being bolted into place. The rotating actuator head with
conjunction with the AZM150 solenoid interlock, contributes its two insertion slots enables various installation positions
to improved system availability. and actuating options and makes the interlock particularly
In addition, the DHS-150 door handle system is also versatile in use.
equipped with an integrated locking device (LOTO). This The AZM150 solenoid interlock is electromechanical in
locking tag function protects operating staff from mistakenly design and can be combined with a high safety standard:
being locked inside larger, walk-in systems and machines the interlock is supplied with a low coding level as standard,
while they are performing servicing or optionally with a high coding level in
and repair work. The locking accordance with ISO 14119. The DHS-
device ensures that the door of the 150 door handle system can be used with
protective device cannot be closed the B1 straight actuator for the standard
and unintentional machine start-up version as well as for the individually coded
is prevented. version. The B1 actuator is supplied with
The AZM150 solenoid interlock the high coding level version of the device,
has an interlocking force of 1500 but must be ordered separately for use with
Newtons and is characterised by the standard version.
a slimline, space-saving design. In
Schmersal India Pvt Ltd.
addition, it can be combined with E-mail:[email protected]
three different actuators for different Web: www.schmersal.in
attachment situations. A positive
26 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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REVIEW
New multi-axis servo drive
provides performance control
up to 750W
rio Motion Technology has launched a multi-axis ser- stage. These compact dimensions make DX5 among the
vo drive to provide precision motion coordination for smallest multi-axis servo systems available.
space critical, lower power machines up to 750W.
TThe new DX5 servo drive is designed to be cost Designed for energy and cost savings
effective for machine builders who need multi-axis EtherCAT The DX5 multi-axis servo drive is also highly energy efficient,
performance control, and a zero-stacking gap and compact providing savings for end users across the lifetime of the
dimensions enable a small footprint. machine as a result of the integrated DC Bus regenerative
The DX5 multi-axis servo drive is aimed at OEMs designing energy system. The DC link absorbs motor braking
machines for applications such as laser, plasma, or water energy, reusing it across the machine’s axes. This system
cutting, between two and 16 axes. The multi-axis drive reduces cost for the machine user and contributes to their
is also intended for packaging machines with lower environmental commitment.
power requirements, including form fill seal, and labelling DX5 economically viable solution achieves one of the
applications , says Trio India’s Managing Director ,Upendra lowest cost-per-axis counts between two and eight axes up
Vanarase . to a 750W requirement, or up to 16 axes at 400W.
Motion control performance in a compact Reliable multi-axis synchronisation and fast devel-
footprint opment
Multi-axis synchronisation includes EtherCAT control It’s quick to programme Trio’s controllers for multi-axis
performance down to 250μs, with 350% overload for pulse synchronisation, with a choice of IEC 61131-3 languages,
duty cycles. The DX5 multi-axis servo drive also supports 20- PLCopen, as well as Trio’s intuitive, text-based Motion-iX
bit single turn or 23-bit multi-turn absolute encoders. language.
The compact, multi-axis servo drive is designed as a space- “The DX5 multi-axis servo drive is for machine builders
saving dual axis module in 750W and 400W frame sizes. who need high performance motion synchronisation in a
A zero-stacking gap minimises footprint when adding up to lower power, compact and cost effective package,” says Trio
a maximum of eight axes at 750W, or 16 axes at 400W. A India’s Managing Director, Upendra Vanarase.
single, dual axis module measures 40mm wide x 205mm
high x 203mm deep. A full eight axes at 750W extends
width to just 240mm including power stage, while a full 16 For more information,
axes at 400W only extends width to 400mm including power Web: www.triomotion.com
www.industrialautomationreview.com JULY-AUGUST 2022 | IAR 27
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REVIEW
Available from stock - drylin T - The
®
cost-effective lubrication free alternative
to recirculating ball bearings
ho likes to have greasy hands? You might
know this from your own children. They
quickly eat a few fries and then wipe the
Wgreasy fingers on the T-shirt. Nobody likes
to have greasy fingers or grease stains on their clothes. If
you work with machine elements such as ball bearings,
gears or linear guides, it is almost impossible to avoid this
contamination, isn’t it?
The fact is that all movements of metal on metal must
be provided with a lubricating layer. Oils or greases are
used for this purpose. If these are not present or are not
relubricated regularly, the system will fail.
Grease thus ensures the function of a metallic bearing but
can also be extremely troublesome in many applications.
Have you ever seen bearing getting corroded/getting
failed because of inadequate lubrication or recirculate ball
damaging the rails or shafts?
Isn’t it a big worry for all engineers to find solution for these
problems?
You would love to know that Drylin linear bearing has
already resolved millions of existing conventional bearing Change now to drylin.
problems like corrosion, Noise, Weight reduction and many
more. It is also 1:1 interchangeable with conventional back in the direction opposite to the shaft’s direction of
recirculating bearing. movement. The ball recirculation system and the high level
of stress on the balls due to the load being applied to a
Let’s see the working of drylin linear bearing. small point on each ball are factors that result in potential
weak spots and noise. Recirculating ball systems can be
®
®
drylin T slides instead of roll replaced with igus linear bearings of the drylin series in
®
The drylin linear bearings enable maintenance-free nearly all areas of use. Due to their simple structure, the
®
®
and lubrication-free operation of parts of machines and drylin linear plain bearings have very little susceptibility to
equipment whose function is determined by relative failure. Lubrication-free operation means that the machine
movements in a straight line between components. The parts remain free of dirt, dust and moisture. Another
®
special dry-tech high-performance plastics of the bearing advantage is the very quiet operation of the drylin linear
®
bushings ensure that machine elements can be moved bearings.
along a shaft or profile guide silently and with little friction.
Compared to linear solutions with rolling elements, the
acquisition costs are up to 40% lower and there are no
additional operating costs. In linear ball bearings, one or
several rows of balls support the shaft. To work properly, For more information
they need a ball recirculation system that guides the balls
Web:www.igus.in/drylin
28 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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Fraud Prevention Kit with
DataBridge MS
™
ETTLER TOLEDO offers a number of products to Vehicle Positioning System:
accompany your truck scale that will protect your METTLER
business. Truck scales are convenient targets for TOLEDO
Mfraud. Thieves constantly devise new ways to cheat Help Prevent
businesses that buy or sell truckloads of material by weight. Improper
Protect yourself with the built-in security features of Data- Positioning by
Bridge™ MS software. Photo eyes
i.e. Vehicle
Many software programs rely on password position-
protection alone. DataBridge™ MS software uses ing system,
password protection with defined access levels, but that is which help
just the first layer of fraud prevention. The software provides to prevent
an arsenal of anti-fraud features designed to stop the tactics more than one
that are being used to cheat truck scales. i.e. weight curves, truck driving
stored tare weights, camera capabilities, pre-loading, audit onto the scale. Photo eyes can detect this cheat, as well as
logs etc. improper positioning of a single truck.
The most common way to cheat at the truck scale is
also the simplest–improper positioning of the truck on the Camera Capabilities:
weighbridge. Several scenarios make this possible for a truck DataBridge™ MS software automatically captures still images
driver to accomplish. and attaches them to a permanent record of each weighing
transaction. Images are labeled by event and can be included
• Truck with one set of axles off the front (or the back) of the on the tickets that are given to drivers as receipts. Using the
scale will weigh lighter. software’s built-in camera monitor, scale operators can view
• One truck fully on the scale, while second driver pulls a set activity at a scale.
of axles on the scale, generating a deceptively heavy load. When positioned correctly, cameras can record images that
identify vehicles, drivers, and license plates.
Cameras also protect against cheaters, such as drivers who
position the wheels of their vehicles partially off the scale
to get a lower weight reading. While a busy scale operator
might miss the violation, properly positioned cameras will not.
DataBridge™ MS Scale Management System provides
professional transaction management with METTLER
TOLEDO innovation, offering powerful capabilities for
large and growing organizations with features like Multiple
Work station access, customer user roles & permissions,
notifications, analytics, advance customer data entry and
advance anti-cheating solutions.
This software is also having capability for complete
unattended weighing system, which helps to avoid weighing
attendant, improve data accuracy and faster weighing
throughput.
For more information
Email : [email protected]
Website : www.mt.com/veh-fraud-prevention-ve
www.industrialautomationreview.com JULY-AUGUST 2022 | IAR 29
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How does a digital-platform framework
Help you achieve your objectives?
Industrie 4.0 introduced the concept of automating industrial workflows to reduce errors, increase
shop-floor safety, and increase productivity. The concept behind automating these workflows rests on
developing a framework of digital industrial solutions with the ability to drive interconnectivity, capture
data, and analyze the captured data to empower automated systems with machine vision or machine-
learning capabilities. Integrating the use of a digital platform provides the enabling environment that digital
technologies require for delivering the benefits of Industrie 4.0.
What are digital-platform frameworks?
The traditional concept of digital platforms refers to the
interfaces such as Facebook, Twitter, and Instagram that
dominate the social-media space. However, in the industrial
sector digital platforms refer to service-oriented platforms that
support communication, data collection, and analysis within
a facility. These digital platforms become the framework for
managing an industrial enterprise’s IT and interrelated OT
infrastructure.
Digital platforms leverage a centralized computing resource
framework – the cloud or on-premises infrastructure – to host • Event processing – Identifying and processing important
applications and app development tools. These applications events occurring within a digital platform helps with real-
and tools such as APIs or machine-utilization apps can either time decision-making. A platform with event-processing
be generic to every industry or industry-specific applications. capabilities enables users to automate specific tasks such
For example, using a digital platform built to support as inspections and monitoring actions.
manufacturing digitalization gives manufacturers the tools • External-integration support – Generally, digital-platform
to develop very technical apps from scratch that wouldn’t be frameworks function alongside standalone applications
found in the average Play Store or iTunes Store. or systems such as ERP software. A digital platform must
Focusing on the manufacturing industry, the image below support the integration of external systems that are crucial
highlights the industry-specific nature of a digital-platform to industrial operations.
framework that supports industrial use cases.
The framework provides extensive support for the edge,
near-edge, smart, and automated systems deployed within Leveraging digital platforms to implement
the shop floor. The framework showcases the storage and Industrie 4.0
computing assets needed to power a digital platform, the With approximately 81% of manufacturing enterprises
data-producing devices, and the apps for collecting and adopting increasingly advanced digital-transformation
analyzing captured data. The insight and data captured within solutions, providing answers to the question “Why go the
the framework are accessed using the web and mobile apps, digital route?” is no longer valid. Today, everyone understands
as can be seen from Figure 1. the productivity and operational benefits that come with
embracing digital transformation. A digital-platform
The capabilities of the average digital platform can be framework brings all digitalization tools used within a singular
categorized as offering the following: virtual environment. Thus, a manufacturer gets a singular
environment for managing every digital and physical asset
• Access control – This capability defines the endpoints deployed within the shop floor from a single platform.
that can gain access to platform data and networks. Familiarity with the base goals of the OPC Foundation and its
Access-control management is responsible for securing drive to unify both IT and OT assets highlight the importance
an enterprise’s IT framework through verification and of a unifying digital framework. Using a centralized digital
permission tools. platform, enterprises can:
30 IAR | JULY-AUGUST 2022 www.industrialautomationreview.com
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Build and support industry-specific apps – new IT departments
Manufacturers can leverage digitized frameworks and the to handle the
tools within them to create unique apps that handle machine management
data according to defined goals. The framework can also process.
integrate apps such as capacity-planning software that utilize • Level of
shop-floor data for accurate analysis. Using APIs, the software customization –
automates the collection of related shop-floor data to execute The manufacturing
the requested analyses. industry is known
• Implement remote and condition-monitoring strategies for its industry-
– The centralization of IT resources and digital industrial- specific applications Fig 1. Digital-Platform Framework
solutions support empower manufacturers to test and and platforms.
implement diverse strategies. Examples include leveraging Therefore, instead of IoT, IIoT is the term used within
machine data and web-based interfaces or HMIs to the industrial sector. Deciding to build must account for
remotely monitor asset performance levels or specific the need to customize and configure the platform to
shop-floor operations. The interconnectivity a digital meet industrial requirements. From the purchasing side,
platform supports powers the application of monitoring customization must also be considered because a generic
strategies. digital platform is unlikely to provide the optimization
• Validation and testing – Reducing failure rates when results required from it.
implementing new technologies or strategies within the • Time to market – The time to build a functional digital
shop floor is important to reducing implementation costs. A platform ready for utilization is an important consideration
centralized digital platform provides the tools for assessing for manufacturers interested in competing with their global
the effects of implementations using VR headsets or peers. If the build time for an individual manufacturer is
analytics software to analyze related data sets. extensive, this means the manufacturer ends up playing
catch-up with others already utilizing a digital platform.
Build or buy digital industrial solutions: • Security – Many manufacturing enterprises which choose
Digital-platform frameworks to build point at security challenges as the deciding factor
Manufacturers interested in adopting digital platforms to behind building their platforms. 75% of enterprises name
ease manufacturing operations have two choices before cloud security as their biggest challenge with purchasing
them – build your platform from scratch or buy into an existing digital solutions, and these concerns are legitimate.
platform. Making the right decision involves understanding Although building your platform provides a measure of
some important factors. security; these platforms must be properly configured
because poor configuration accounts for 68% of successful
These considerations include: data breaches. The negative effects of misconfiguration
• Building cost – The infrastructure required to build a once again raise the question of how competent the in-
digital platform from scratch are considerable. These costs house personnel are at building and managing a digital
include hardware purchases such as storage discs capable platform?
of supporting big data sets and supporting computers.
Other costs involved include housing the infrastructure and Conclusion
paying for the labor incurred when building and configuring The decision to buy or build rests on the shoulders of C-level
a digital platform. executives who must consider their industrial enterprise’s
• In-house competency – Building, managing, and key competencies before deciding. The cost and technical
maintaining a digital platform is a task that must be requirements for building digital platforms make purchasing
executed around the clock. There are no days off. A a more attractive option for small and medium-sized
dedicated staff with the ability to respond to security businesses. However, large businesses that choose to build
incidents and downtime triggers is required. For example, generally partner with reputable industrial-solutions providers
the recommended building and management process to meet their building requirements.
involves adopting the CICD tenets of constant development For more information,
and continuous integration to safeguard and build a Email: [email protected],
functioning platform. Manufacturers who lack the technical [email protected]
personnel to implement these processes will have to build Website: www.exorint.com
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