ENGINEERING
REVIEW TROUBLE-SHOOTING
Diagnosis and Resolution of
Compressor Vibrations and Cooling
Fan Failure in an Industrial Plant
The issue of fan vibration has been a significant cause behind curtailed operations and shutdowns at various
industrial plants. The article, authored by M.Jeyaselvan, Senior Principal Specialist-Technology who heads the
NVH & CAE Expertise teams at ELGi Equipments Limited, provides a detailed analysis of the causes for these
malfunctions. While probing the root causes for cooling fan vibrations and abnormal noises, the article gauges
the different diagnostics behind these defects, thereby providing a structured approach for sustainable optimal
solutions for safe and smooth operations of the plant.
Fig. a) Illustration of compressor Package b) Cooling system subassembly.
crew compressors form a critical asset in the process a torsional resilient coupling that is dynamically isolated to
industries, wherein most manufacturing processes are minimize the transmission of structural excitation forces to
Saided by compressed air. Being a part of the positive other subsystems of the compressor. The outer rotor axial fans
displacement family, the periodic flow oscillations result in in the parallel configuration are equipped with bell-mouths
fluctuating dynamic forces leading to noise and vibrations in for the efficient and quiet operation of the compressor. In the
a screw air compressor. This article explains an investigation illustrated case, the cooling fan failures led to the shutdown of
where a compressor exhibits high vibrations and noise levels the compressor, thereby stalling the plant operation.
leading to failure of the axial fans in the cooling system, along
with a sustainable, robust solution to assure uptime and Prime causes for the Cooling Fan Vibrations and
reliability for the uninterrupted operation of the plant. Abnormal Noise
The screw air compressor under discussion delivers There are various reasons for possible malfunctioning of a
compressed air at 2500m3/h at a pressure of 7bar as per cooling fan, viz. wear and tear, excessive system resistance,
the requirements of the specific industrial application. The accelerated fouling of coolers from the installation environment,
motor and the compression element (airend) are coupled by surges in supply voltages, improper maintenance of coolers,
46 | JANUARY 2023
ENGINEERING
REVIEW TROUBLE-SHOOTING
Fig. Failure symptoms in Cooling Fan assembly & parts
etc. In this case, the cooling fan exhibits high vibrations and an instrumented impulse generator and piezoelectric
abnormal noises resulting from worn-out failure and anomaly in accelerometers mounted on the stator hub. The fundamental
vibration levels. bouncing and tilting modes were established for possible
excitation from residual unbalance. Detailed analysis
Investigative teardown analysis of the stator-rotor rub pattern indicates that the dynamic behaviour of the subassembly
combined with the bearing bore wear pattern hypothesizes possesses adequate design margins for safe operation.
conical whirling as a possible cause for premature failure.
The stator-rotor rub due to excessive dynamic deflection led • Deep dive diagnostics
to insulation peeling off in the drive end side of the motor The unbalanced excitation frequency of the fan at 22.5Hz
fan, supporting the hypothesis of the conical whirling of the was far from the fundamental structural modes to cause
impeller. dynamic amplification. Hence, it was anticipated that the
residual unbalance might be abnormally higher, resulting in
Investigative diagnostics for excessive vibrations in higher vibration levels. Hence, the fan motor assembly was
Compressor driven by a standalone variable frequency drive to analyse
• Numerical analysis and experimental verification residual unbalance behaviour during the coast up and coast
The dynamic characteristics of the fan subassembly were down operation. Despite having adequate safety margins,
analysed through a numerical simulation of the complete the system resulted in dynamic amplification causing high
cooling system and the subassembly of the fan, motor, vibrations. The bouncing mode remains constant at 12Hz,
suspension and support structure. Experimental verification whereas the tilting frequency increases from 18Hz to 22Hz.
and updating of the numerical model were achieved through While operating on approaching the fan’s rated operating
Fig. a) Fundamental Mode shapes -12Hz & 18Hz b) Measured Mobility
48 | JANUARY 2023
ENGINEERING
REVIEW TROUBLE-SHOOTING
Figure 8 a) Vibration velocity response in coast up b) Time frequency analysis (Contour map)
speed, this resulted in dynamic amplification of the vibration Conclusion
due to the gyroscopic stiffening of the assembly. The stator-rotor rub failure of a fan motor in the cooling
system assembly that led to the shutdown of the 250 kW
Optimal Solution through Structural Dynamic compressor was investigated in detail. The application of
Modification engineering know-how aided by a systemic approach and
Subsequent to the identification of the root cause, solutions tools led to sustainable solutions to the real-world engineering
were sought through dynamic structural modification of the problem. This structured approach resulted in a comprehensive
suspension assembly after detailed evaluations of the strain resolution, thereby reassuring the customers of the promise of
energy and their density distributions. The modified suspension a reliable product and an assured uptime.
assembly with the cooling fan accounted for the gyroscopic
stiffening and was designed and verified through mobility Note:
transfer function measurements for effectiveness. A complete version of this technical content was presented
Verification trials indicated that the vibration response levels at the 28th International Congress on Sound and Vibration
were found to be significantly lesser, ensuring smooth and safe (ICSV28), held in Singapore during July 24-28, 2022.
operation of the fan motor subassembly, eliminating stator-
rotor rub, and leading to the continuous and safe operation of
the plant.
Figure a) Strain energy distribution of tilting mode b) Vibration response comparison (Black - original configuration,
Grey – improved configuration)
50 | JANUARY 2023
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ENGINEERING
REVIEW SOFTWARE SOLUTIONS
owadays engineering efficiency, cost-effectiveness and Based on MRP
manufacturers who are engaged competitive advantage in market • Audit becomes very easy
Nin production of industrial competition. • Real-time insights for better decisions
components, parts, pumps, valves, Here are some features and benefits of • Enhanced Inventory Control
instruments, machines, equipment and having SolutionOne ERP system within • Reduction of Errors and Duplication
tools need an ERP that has features the organization: • Centralized System Access from
and functionalities designed specifically anywhere
to meet their needs. These companies Features • Can host On-site or Cloud
are not always making the same items • Material Requirement Planning • Monitor your cash flow, balance sheet
repeatedly. Although, some of their • Engineering Change Management and profit/loss in real time.
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require a perfect system that not all • Product BOM Costing Analysis
ERP systems can offer. It is therefore • Centralized Alerts & Notification Alerts These essential features of SolutionOne
important to find the right ERP that • Factory-wise Cost/Profit Report ERP system have been developed based
gives satisfaction to engineers for what Complete Procure-To-Pay Tracking on the company’s 20+ years of industrial
they need and how it will improve their • Units/Location Wise Stock experience and best practices and deep
manufacturing processes and get their Management knowledge. The company’s system has
jobs done faster and better. • Financial Auto Posting Accounts covered all the important engineering
SolutionOne ERP company helps • Document Management System fundamentals and complex industrial
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to gain the much needed operational • Planning & Production Scheduling and a lot more.
52 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
Maintenance safeguarding
‘Key in Pocket’ system from Pilz
afeguarding ‘key-in-pocket’ system from Pilz protects
operators from an unauthorised machine restart, allowing
Smaintenance work to be carried out safely. Digital
maintenance safeguarding is based on the access permission
system PITreader and guarantees safety and industrial
security: only authorised persons can access the plant or
machine during the maintenance process – tampering and
misuse are excluded.
Extensive plants often have a large number of danger
zones, which are protected using safety fences. This places
particular demands on safety: for example, it’s important that
only authorised persons have access for maintenance work. At
the same time, it’s essential to ensure that nobody is left in the
danger zone when the plant restarts. With “key in pocket”, Pilz
is presenting a digital maintenance safeguarding system, which
is flexible in meeting the demands of both safety and industrial
security: “key in pocket” ensures that the machine does Simple, safe maintenance
not restart while maintenance work is being carried out Digital maintenance safeguarding is specifically designed
and that unauthorised persons do not gain access. As such, for machines with danger zones that are protected via
the solution offers safety in the face of a hazardous restart safety fences. It offers an economical, efficient alternative
and, at the same time, industrial security, because it’s to mechanical lockout-tagout maintenance safeguarding
impossible to tamper with the maintenance work. systems, which are attached to all safety gates. As it is
possible to enter or leave the plant via various safety
Authentication as the basis gates, ‘key-in-pocket’ offers staff greater flexibility and
‘Key-in-pocket’ is based on the access permission system thus saves time during maintenance.
PITreader and is implemented using the configurable small
controller PNOZmulti 2 or the automation system PSS The Pilz Group : The Pilz Group is a global supplier of
4000. Users are given an RFID key with their individual products, systems and services for automation technology.
permissions, which can be read on the safety gate using Based in Ostfildern, near Stuttgart, the family-run company
PITreader. This way, one or more users who are authorised employs around 2,500 people. With 42 subsidiaries and
for maintenance work can authenticate themselves on the branches around the world, Pilz supplies safe solutions for
plant. At all times, the operator knows who has access for people, machinery and the environment. The technology leader
which task; temporary permissions can also be assigned. offers complete automation solutions comprising sensors
After successful authentication, a personalised security ID as well as control and drive technology – including systems
is stored for the user in the controller, in a safe list. The for industrial communication, diagnostics and visualisation.
machine can now be shut down, the safety gate opened Consulting, engineering and training round off its international
and the machine accessed. During this time, the RFID keys range of services. In addition to mechanical and plant
remain with the respective users – ‘key-in-pocket’. Once engineering, solutions from Pilz are used in many sectors such
maintenance is complete and people have left the danger as wind energy, railway technology and robotics.
zone, everyone signs out. The security IDs are removed
from the safe list on the Pilz controller and the machine For more information,
can be restarted. Website: www.pilz.in
54 | JANUARY 2023
Scan to know more
ENGINEERING
REVIEW TECH INNOVATION
FLIR ONE EDGE PRO
™
Thermal Camera with Wireless Connectivity for iOS and
®
Android Smart Devices
™
he FLIR ONE Edge Pro is an
innovative, rugged thermal
Timager that wirelessly
connects to your smart device so
you can remotely inspect out-of-
reach targets – or clip it onto your
phone or tablet for onehanded
operation. Combining VividIR
™
and FLIR MSX , you can take crisp
®
thermal images from any position
or angle with a natural grip. FLIR
Ignite allows you to easily upload
™
images and videos from your FLIR
ONE Edge Pro to the cloud where
you can edit, organize, store, and
share data. Compatible with iOS
and Android smartphones and
tablets, the FLIR ONE Edge Pro
can be used without limitations,
regardless of carrier, operating system, size, or future smart device
upgrades.
EASILY INSPECT ANYWHERE
Measure targets in difficult-to-reach areas from any angle, and
enhance visibility through remote monitoring
• Remotely inspect hazardous areas up to 30 m (100 ft) away Mobile phone not included www.Flir.com/FLIRONE-EdgePro
• Operate with one hand by clipping the FLIR ONE Edge Pro to
your smart device together to deliver a sharper image
• Conveniently scan out-of-reach or out-of-view targets, holding • Measure temperatures up to 400°C (752°F)
the FLIR ONE Edge Pro in one hand and your smart device in • Rugged design with up to 1.5-hour battery life
the other for a clear view of your screen
• Wireless connectivity eliminates compatibility issues and allows ENHANCE YOUR WAY OF WORKING
you to upgrade your smart device without the need to replace Improve efficiency and large enterprise scalability with the FLIR
your thermal camera ONE Edge Pro and its apps and services
• Effortlessly edit and store images in the cloud, and wirelessly
HIGH-QUALITY IMAGES AND PERFORMANCE transfer files using the included FLIR Ignite cloud service
Inspect areas accurately with FLIR proprietary image • Step-by-step guidance with FLIR-specific smart device apps
enhancement features • Simple integration with FLIR Thermal Studio and FLIR Ignite
• Easily recognize where problems are located and identify software
targets with FLIR MSX (Multi-Spectral Dynamic Imaging) For more information
®
• Take crisp, clear images with 160 × 120 (19,200 pixels) thermal Email: [email protected]
resolution and VividIR, which combines multiple image frames Web:www.teledyneflir.in
56 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
igus e-chain stays at the
highest cleanroom class even
after 60 million double strokes
e-skin flat energy chain: igus proves abrasion resistance with the first industry test of its kind
A unique industry test shows that the modular igus e-skin flat remains at the highest cleanroom class even after 1.5 years of
continuous use and 60 million double strokes. (Source: igus GmbH)
leanroom-compatible energy chains from igus in cooperation with the Fraunhofer Institute
the e-skin flat series still qualify for the for Manufacturing Engineering and Automation
Chighest cleanroom class even after 1.5 (IPA).
years of continuous use and 60 million double Dusting the living room can be annoying.
strokes. A test, unprecedented in the industry, led You scarcely have time to enjoy the spotless
to this result. It was carried out in a cleanroom surfaces before the first specks of dust begin
laboratory set up by motion plastics specialist to collect again. Manufacturers of displays and
58 | JANUARY 2023
MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
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• AC 3-ph brake (no rectifier) or DC brake on request
• Oversized brake disc for higher brake torque, longer life and
• RD helical gearboxes: 50 to 2300 Nm. Two and three stages.
• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • RS-RT worm gearboxes: 28 to 150 mm centres.
reduced maintenance
• AC 3-ph brake (no rectifier) or DC brake on request One stage worm, helical/worm and double worm.
• RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages.
• Oversized brake disc for higher brake torque, longer life and • RD helical gearboxes: 50 to 2300 Nm. Two and three stages.
• Fine and easy brake torque adjustment (as standard)
• RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages.
• Very quick brake r
• RG precision planetary gearboxes: 10 to 230 Nm.
reduced maintenanceeaction time • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages.
• Frequent START/STOP cycle applications
One and two stages.
• Fine and easy brake torque adjustment (as standard) • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages.
• Very quick brake reaction time • RG precision planetary gearboxes: 10 to 230 Nm.
• Manual brake release (as standard)
• VR dry friction speed variators: IEC63 to IEC90
• Frequent START/STOP cycle applications One and two stages.
• Hexagonal hole on non drive end of the shaft for manual rotation
1 to 5 stepless speed range, 300 to 1500 rpm.
• VS planetary speed variators: IEC71 to IEC112
• Manual brake release (as standard) • VR dry friction speed variators: IEC63 to IEC90
• Single speed or two speeds motors
• All motors designed for inverter duty
• Hexagonal hole on non drive end of the shaft for manual rotation 1 to 5 stepless speed range, 300 to 1500 rpm.
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ENGINEERING
REVIEW TECH INNOVATION
semiconductors have the same problem - but with Hermey. “This finding offers cleanroom production
more serious consequences. Any tiny particle, even facility operators additional confidence.”
one invisible to the naked eye, can damage electronic
components. Therefore, the strictest cleanroom class - Modular concept for flexible filling
ISO Class 1 according to DIN 14644-1 - must contain The e-skin flat features not only extreme abrasion
no more than ten 0.1-micrometre (0.0001-millimetre) resistance, but also a modular design. If a profile into
particles per cubic meter of ambient air. To achieve which cables have been fitted is defective, the user
this level of purity, all suppliers of cleanroom can just change that module. Many other solutions
production system components must meet the available on the market would require the entire
strictest requirements. To this end, igus has developed system to be replaced. The module connection also
the e-skin flat, a flat cable guidance system made of allows individual profiles to be interlinked. The cable
abrasion-optimised high-performance plastic that guidance system thus grows in line with requirements
ensures reliable, particle-free guidance of power and and ensures investment security. In combination with
data cables in moving production systems and is thus the specially harmonised chainflex CFCLEAN stranded
suitable for ISO Class 1. structure, the complete system offers an especially
high level of reliability. The complete system also has
Unique test setup: e-chain runs for 1.5 years in a globally recognised certification from the well-known
dirty and dusty environment US Underwriters Laboratories (UL) organisation.
“The e-skin flat cleanroom energy chain is ideal for Finally, the cable guidance systems are 9dB(A) quieter
robots and other automation systems in electronics and cost 20% less than standard ribbon cables.
production in such areas as semiconductors
and display production,” says Andreas Hermey, ABOUT IGUS:
Development Manager for e-chain systems at igus. “It igus GmbH develops and produces motion plastics.
is so abrasion-resistant that contamination by airborne These lubrication-free, high-performance polymers
particles is no longer an issue.” Until now, however, improve technology and reduce costs wherever things
the intensity of the high-performance plastic’s particle move. In energy supplies, highly flexible cables, plain
abrasion after long, intensive use has been unclear. and linear bearings as well as lead screw technology
To determine its details, igus launched a test setup made of tribo-polymers, igus is the worldwide
that is unique in the industry so far. Part one of the market leader. The family-run company based in
experiment was conducted in igus’s own laboratory. Cologne, Germany, is represented in 31 countries and
The energy chain moved in an environment with employs 4,900 people across the globe. In 2021, igus
normal levels of dust and dirt for around 1.5 years, generated a turnover of €961 million. Research in the
during which it performed 60 million double strokes. industry’s largest test laboratories constantly yields
innovations and more security for users. 234,000
igus e-chain stays at the highest cleanroom articles are available from stock and the service life
class even after 60 million double strokes can be calculated online. In recent years, the company
Part two of the experiment took place in the has expanded by creating internal startups, e.g. for
cleanroom laboratory in Cologne, conducted by ball bearings, robot drives, 3D printing, the RBTX
igus in cooperation with the Fraunhofer Institute platform for Lean Robotics and intelligent “smart
for Manufacturing Engineering and Automation plastics” for Industry 4.0. Among the most important
(IPA), igus’s development and certification partner environmental investments are the “chainge”
for more than 17 years. The heart of the setup programme – recycling of used e-chains - and the
was three so-called laminar flow boxes equipped participation in an enterprise that produces oil from
with high-performance filters that enable tests in plastic waste.
uncontaminated air. The worn-out e-chain was in
motion there for over 100 minutes. Sensors detected
particle concentration in the surrounding air. “Even
after 60 million double strokes, our e-skin flat e-chain For more information,
still qualified for the highest cleanroom class,” says https://www.igus.eu/
60 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
How Does a Digital-Platform Framework
Help you Achieve Your Objectives?
ndustrie 4.0 introduced the concept of collection, and analysis within a facility. These
automating industrial workflows to reduce digital platforms become the framework for
Ierrors, increase shop-floor safety, and increase managing an industrial enterprise’s IT and
productivity. The concept behind automating interrelated OT infrastructure.
This article will discuss: these workflows rests on developing a Digital platforms leverage a centralized
framework of digital industrial solutions with computing resource framework – the cloud
• The application of the ability to drive interconnectivity, capture or on-premises infrastructure – to host
digital-platform data, and analyze the captured data to applications and app development tools. These
frameworks as a tool for empower automated systems with machine applications and tools such as APIs or machine-
automating industrial vision or machine-learning capabilities. utilization apps can either be generic to every
processes Integrating the use of a digital platform industry or industry-specific applications.
• Build or buy; provides the enabling environment that digital For example, using a digital platform built to
understanding the technologies require for delivering the benefits support manufacturing digitalization gives
responsibilities that of Industrie 4.0. manufacturers the tools to develop very
come with developing technical apps from scratch that wouldn’t be
or purchasing digital What are digital-platform frameworks? found in the average Play Store or iTunes Store.
industrial solutions The traditional concept of digital platforms Focusing on the manufacturing industry, the
• Leveraging digital refers to the interfaces such as Facebook, image below highlights the industry-specific
platforms to implement Twitter, and Instagram that dominate the nature of a digital-platform framework that
Industrie 4.0 business social-media space. However, in the industrial supports industrial use cases.
models sector digital platforms refer to service-oriented The framework provides extensive support for
platforms that support communication, data the edge, near-edge, smart, and automated
62 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
systems deployed within the shop floor.
The framework showcases the storage
and computing assets needed to power
a digital platform, the data-producing
devices, and the apps for collecting and
analyzing captured data. The insight and
data captured within the framework are
accessed using the web and mobile apps,
as can be seen from Figure 1.
The capabilities of the average
digital platform can be categorized
as offering the following:
• Access control – This capability defines
the endpoints that can gain access to
platform data and networks. Access-
control management is responsible for
securing an enterprise’s IT framework
through verification and permission tools.
• Event processing – Identifying and
processing important events occurring
within a digital platform helps with real-
time decision-making. A platform with Figure 1. Digital-Platform Framework
event-processing capabilities enables every digital and physical asset deployed manufacturers to test and implement
users to automate specific tasks such as within the shop floor from a single diverse strategies. Examples include
inspections and monitoring actions. platform. leveraging machine data and web-
• External-integration support – Familiarity with the base goals of based interfaces or HMIs to remotely
Generally, digital-platform frameworks the OPC Foundation and its drive to monitor asset performance levels or
function alongside standalone unify both IT and OT assets highlight specific shop-floor operations. The
applications or systems such as ERP the importance of a unifying digital interconnectivity a digital platform
software. A digital platform must support framework. Using a centralized digital supports powers the application of
the integration of external systems that platform, enterprises can: monitoring strategies.
are crucial to industrial operations. • Validation and testing – Reducing
• Build and support industry-specific failure rates when implementing
Leveraging digital platforms to apps – Manufacturers can leverage new technologies or strategies
implement Industrie 4.0 digitized frameworks and the tools within the shop floor is important to
With approximately 81% of within them to create unique apps reducing implementation costs. A
manufacturing enterprises adopting that handle machine data according centralized digital platform provides
increasingly advanced digital- to defined goals. The framework can the tools for assessing the effects of
transformation solutions, providing also integrate apps such as capacity- implementations using VR headsets or
answers to the question “Why go the planning software that utilize shop-floor analytics software to analyze related
digital route?” is no longer valid. Today, data for accurate analysis. Using APIs, data sets.
everyone understands the productivity the software automates the collection
and operational benefits that come of related shop-floor data to execute Build or buy digital industrial
with embracing digital transformation. the requested analyses. solutions: digital-platform
A digital-platform framework brings all • Implement remote and condition- frameworks
digitalization tools used within a singular monitoring strategies – The Manufacturers interested in adopting
virtual environment. Thus, a manufacturer centralization of IT resources and digital digital platforms to ease manufacturing
gets a singular environment for managing industrial-solutions support empower operations have two choices before them
64 | JANUARY 2023
The CORVINA digital
framework can help you
digitize your company
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Opp. RTO Office, Vashi, Navi Mumbai - 400705, Maharashtra, India.
ENGINEERING
REVIEW TECH INNOVATION
– build your platform from scratch or buy who lack the technical personnel to point at security challenges as the
into an existing platform. Making the right implement these processes will have to deciding factor behind building their
decision involves understanding some build new IT departments to handle the platforms. 75% of enterprises name
important factors. management process. cloud security as their biggest challenge
• Level of customization – The with purchasing digital solutions, and
These considerations include: manufacturing industry is known for these concerns are legitimate. Although
• Building cost – The infrastructure its industry-specific applications and building your platform provides a
required to build a digital platform from platforms. Therefore, instead of IoT, IIoT measure of security; these platforms
scratch are considerable. These costs is the term used within the industrial must be properly configured because
include hardware purchases such as sector. Deciding to build must account poor configuration accounts for 68% of
storage discs capable of supporting big for the need to customize and configure successful data breaches. The negative
data sets and supporting computers. the platform to meet industrial effects of misconfiguration once again
Other costs involved include housing requirements. From the purchasing side, raise the question of how competent
the infrastructure and paying for the customization must also be considered the in-house personnel are at building
labor incurred when building and because a generic digital platform is and managing a digital platform?
configuring a digital platform. unlikely to provide the optimization
• In-house competency – Building, results required from it. Conclusion
managing, and maintaining a digital • Time to market – The time to build The decision to buy or build rests on the
platform is a task that must be executed a functional digital platform ready for shoulders of C-level executives who must
around the clock. There are no days utilization is an important consideration consider their industrial enterprise’s key
off. A dedicated staff with the ability for manufacturers interested in competencies before deciding. The cost
to respond to security incidents competing with their global peers. and technical requirements for building
and downtime triggers is required. If the build time for an individual digital platforms make purchasing a more
For example, the recommended manufacturer is extensive, this means attractive option for small and medium-
building and management process the manufacturer ends up playing sized businesses. However, large
involves adopting the CICD tenets of catch-up with others already utilizing a businesses that choose to build generally
constant development and continuous digital platform. partner with reputable industrial-
integration to safeguard and build a • Security – Many manufacturing solutions providers to meet their building
functioning platform. Manufacturers enterprises which choose to build requirements.
66 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
SMARTOR
MAINTENANCE 4.0 - IIOT PLATFORM
Artificial Intelligence (AI) and Machine Learning (ML) equipped
CG HIGH POWER MOTORS DEFAULT
• Frame Size 355 & above
• Factory fitted Smartor Kit
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• Warranty from installed date
• Customization with driven equipment with
Machine Learning
• On Premises solution with any make
SMARTOR – SMART MOTOR equipment
MOTORS IN THIS RANGE ARE OFFERED WITH • Extended Warranty with Annual
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PREDICTIVE MAINTENANCE MADE Fans and Gearbox etc. will be monitored • Optional Hardwired Ethernet or
EASY with Machine Learning (ML) feature for RS485 Communication available
Industry 4.0, also known as the fourth overall health of the system.
industrial revolution, is the current trend Get overall equipment’s health • Advanced Role Based Access
of automation and data interconnection performance information on real-time Control (RBAC) and SSL security
in industrial technologies. It includes basis to your Computers, Smartphones implementation
the Internet of Things (IIoT), Wireless and on to your SCADA system.
Sensors, Cloud Computing, Artificial • On premises solution with Large Data
Intelligence (AI), Machine Learning (ML) SMARTOR – total plant equipment’s connectivity
and Big Data. CG Smartor features wireless sensing with Smartor viz. Fan, Pump, Gear
Industry 4.0 is used for manufacturing capabilities by leveraging built in and Box along with Motor.
whereas Maintenance 4.0 uses it for external smart IoT sensors. The featured
predictive maintenance to predict when on board, fully integrated accelerometer • Getting overall plant equipment
equipment failure might occur and take and gyroscope sensors provides high performance data on health
action to avoid it. precision linear acceleration readings for parameters.
CG Smartor i.e. Smart Motors X, Y and Z axis, enabling the analytics
above 355 Frame LT and HT Motors algorithms to accurately monitor the
both are equipped with this facility of mechanical heath of LT and HT motors.
health monitoring and self-diagnostic For more information
information through Artificial SECURE COMMUNICATION CG Power & Industrial Solutions Ltd.
Intelligence (AI). • Secure wireless Wi-Fi based Email: [email protected]
Connected applications like Pumps, connectivity for industrial applications Website: www.cgglobal.com
| OCTOBER 2022
54 | JANUARY 2023
68
ENGINEERING
REVIEW TECH INNOVATION
PM890 IR Series
80000 VA - 500000 VA ( 3:3)
PF 0.9
a890 series UPS 80 - 500 kVA provide maximum ( > 0.99) and low THDi (≤ 3%)
protection and power quality for mission critical • Output isolation transformer using DZn0 winding makes
Eloads, including data centers, industrial processes, strong capability with unbalanced loads.
telecommunications, security and electro-medical systems. It • High MTBF ( > 200,000 h)
is an on-line double conversion UPS with IGBT-based 3-level • High efficiency even at light loads
PWM rectifier technology, featured with high input power • Input and output are completely isolated for great security
factor(> 0.99), low THDi, high efficiency (max.≥ 94%) and • Front accessible maintenance and installation against wall
built-in output isolation transformer. allowed
• Batteries are connected directly to the bus, improving the
Features: impact resistance of UPS output.
• Compact and small footprint
• Low MTTR ( < 0.5 h)
• Onlinetdouble-conversion with DSP control
Simulated modular design makes maintenance easy and
quick
• Intelligent self-diagnosing function, superior failure
protection, large capability of history records storage.
• Unique ventilation design
• Generator compatible
• Strong mixed load capacity and high overload capacity For more information,
• Latest IGBT rectifier technology, high input power factor Website: www.prostarmups.com
70 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
O-Rings / FEP Encapsulated O-Rings
(Silicone / Viton / EPDM / Neoprene / Nitrile)
®
PPL offers its wide range of process which gives joint less O-Rings choice of elastomer core.
O-Rings from 1.0 mm ID to 600 of dimensionally accurate, excellent
Amm ID from its 5000 single workmanship & finish. Why are Encapsulated O-Rings
piece moulds. APPL’s O-Rings are APPL’s Silicone, Viton & EPDM needed?
®
manufactured on a hydraulic press Encapsulated O-Rings with FEP There are certain applications which
with tightly controlled temperature, encapsulation are designed to address prohibit the use of conventional rubber
pressure & time which ensures accurate the growing problem of sealing in the O-Ring seals. The use of hostile
dimensions, glossy finish & invisible most hostile chemical & temperature chemicals or extreme temperature (both
flash line, properly post cured & environments. It combines the best high & low) during various processes can
absolutely defect free articles. These qualities of FEP material on the outside make effective sealing very difficult. The
O-Rings are also manufactured as per with its chemical inertness & an main advantage encapsulated O-Rings
the dimensional tolerance specified by elastomer on the inside for resilience. have over solid P.T.F.E. is that it has
the customers & available from Nitrile, This unique combination forms a highly the chemical inertness whilst with its
Neoprene, Silicone, EPDM, Hapalon, effective, long lasting seal for the most energising core, the O-Ring returns to its
NBR, Viton & Butyl Rubber or in demanding applications. This O-Rings original form.
®
any other rubber as per customer’s are comprised of FEP over Silicone,
specification. It is also available in Viton Viton or EPDM & can be used in For more information,
®
®
O-Rings from 1mm ID - 3000 mm ID temperatures from -75°F to +400°F Email: [email protected]
or in any sizes through step moulding (- 60°C to +205°C) depending upon the Website: www.amipolymer.com
72 | JANUARY 2023
GAS
EMISSION
MONITORING
ONLINE CONTINUOUS EMISSION MONITORING
Gas Emission Monitoring is the process of monitoring the emissions
coming out of the stacks to keep a check on the pollutants thrown out in the air. Usually this
gas emission has to measure on continuous basis.
QAL-1 Testing as per EN 14181 provides Quality Assurance, better Performance of OCEMS &
Creditable Data.
INDUSTRIES WE SERVE
COPPER ZINC PESTICIDE
PROCESS
TANNERY INDUSTRIES
Connect us :
Corporate Office
21, 3rd Floor, Lohana Building, Raopura,
VADODARA – 390001, GUJARAT, INDIA.
+91 7969667000, +91 75748 56749 / 50, +91 82380 37591
[email protected] www.primagroupindia.com
ENGINEERING
REVIEW TECH INNOVATION
Precise sensor
technology for
machine tools
aster, more precise, higher productivity - these are the key requirements when
developing new machine tools. In many cases, improvements can only be
Fachieved using sophisticated sensor technologies. Machine tool manufacturers
and their suppliers benefit from easy sensor integration. Micro-Epsilon demonstrates
Today machine this with a wide range of sensors that are ideally suited to the machine tool industry.
tools can produce In machine building and machine design, sensors are the eyes and ears of machines.
accuracies down to Therefore, the control system is able to process the information provided by the
the micrometer range.
Modern sensors from sensors and to correspondingly control the actuators. Of course, the machine can only
Micro-Epsilon make work as precisely as the sensors measure.
this possible.
For more information
Micro-Epsilon India Private Limited
Office No. 101 A | Delta 1 Giga Space IT Park
Viman Nagar - 411014, Pune | Maharashtra
Tel.: +91 20 4913 1030 |
Fax: +91 20 4913 1001
Email: [email protected] |
Web: www.micro-epsilon.in
74 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
EXLW OCS
Enhanced Screen, Faster Logic, Unprecedented Capabilities
The 7” OCS controller is now faster than ever with improved logic, higher
screenresolution, and proven performance.
Building Automation / Material Handling / Oil and Gas / Renewable Energy / Water/Wastewater
7” Color Touchscreen Online Programming & High-Speed USB 2.0
The new EXLW was engineered to incorporate intuitive The EXLW includes two USB 2.0 ports; host port and an on-
functionalities and innovative features as previous models the-go port. The
of our XL series of OCS controllers. The EXLW LCD TFT Host Port allows connection of removable FLASH drives,
display is full color with VGA resolution and provides virtually supporting drives up to 2TB. EXLW Online Programming
instantaneous updates. Low-temperature options are available allows the logic program to be modified on-thefly without
as an add-on feature. entering stop mode.
Full Ethernet Built into Every Unit Advanced High Speed Counter (>500kHz)
The EXLW model has built-in 100Mbps Ethernet. The EXLW The channel High-Speed Counter accepts frequencies
Ethernet support includes an integrated Web Server, FTP Host, exceeding 500kHz, supporting a variety of modes including
Email, Modbus/TCP Master/Slave, Programming, and much Totalizing, Quadrature, Pulse Measurement, Frequency
more. Counting and Setpoint Controlled Outputs.
High-speed Remote I/O & Advanced Co-Processor
RCC6512 The RCC6512 is a versatile product to handle high speed
applications. This device combines a control co-processor
along with high-speed digital and analog I/O with
integrated networking.
POWERFUL CO-PROCESSOR can be configured as either setpoint controlled outputs or PWM
The RCC6512 is designed as an add-on co-processor to any signals. Analog Outputs (+/- 10V) are provided with motor
application requiring advanced high-speed counting. The speed control in mind.
RCC6512 is programmed in Advanced Ladder using Cscape
FLEXIBLE COMMUNICATIONS
HIGH-SPEED INPUTS, HIGH-SPEED OUTPUTS The RCC6512 supports multiple connectivity options. The on-
The RCC6512 is built around a FPGA chip which provides board Ethernet port (10/100Mbps) supports some of the most
speed and flexibility for its generous complement of high- popular industrial ethernet protocols. These include Modbus
speed I/O. On the input side, up to 8 totalizers or 4 quadrature TCP Server, Ethernet IP I/O Device and Ethernet Global Data
accumulators can be supported at frequencies up to 500kHz. (EGD). Horner’s highly efficient CsCAN network is also onboard
Analog Filtering prevents spurious noise from interfering with its peer-to-peer architecture and superior noise immunity.
with legitimate signals for accurare counting. Digital outputs
#3, Vaishnavi, Domlur 2nd Stage, 3rd Phase, Domlur Main Road, Bangalore - 560071, Karnataka, India.
Mobile: +91-9840213032 (Mr. Kumaraguru. V); +91-9963041484 (Mr. Niladree)
Tel: +91-080-41263460/62/63, Email: [email protected],
[email protected], [email protected],
Website: www.hornerautomation.com
76 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
Test better - Taste better -
Save more.
hile use of cooking oil which is health. Regular measurement of cooking helps to judge the optimal use of the oil.
too old for deep-frying produces oil quality with the testo 270 cooking oil Regularly checking cooking oil quality
Winferior quality of food that may tester prevents the use of oil which is too during ongoing operations, interrupting
also contain substances causing health old along with preventing the wastage of the strict work routine to carry out the
risk, too early replacement of cooking oil cooking oil due to too early replacement measurement, explaining the handling
contrarily causes wastage of resource and thus ensuring the quality of deep-fried of the measuring instrument to the staff,
money. foods and reducing expenditure for and despite all this working according to
cooking oil by up to 20 % and therefore the FSSAI norms, is no easy matter. This
Equipping you to maintain the quality saving cost! makes it more important to use digital and
of cooking oil robust equipment to carry out the precise
Wrapped with German technology and You benefit three-fold when you use the measurement efficiently yet safely. Apart
precision, our cooking oil tester testo cooking oil tester testo 270 for regular from this, every member of staff must be
270 aids you in inspecting the quality of TPM value checks: able to carry out the measurement without
cooking oil for producing healthy food 1. You comply with the legal norms & previous knowledge and intensive training.
even faster. The cooking oil tester testo regulations imposed by FSSAI. Easy cleaning too, is indispensable.
270 measures the Total Polar Material 2. You reduce your cooking oil costs by
(TPM) or the Total Polar Compounds up to 20 %. The solution.
(TPC) content in the cooking oil, which 3. Uniformly high deep-fried food quality Measurement with the cooking oil tester
is a sure indicator of its age and quality. ensures your customers are satisfied. testo 270 could not be any easier. Switch
Cooking oil is healthiest when its TPC on, immerse in hot oil, measure. Done. The
ranges between 10 and 20 % TPM. If the You will learn how this works in the next intuitive measuring instrument is ready for
oil is too old, it shows an increased TPM paragraphs: use immediately after switching on, and
value, and deep-fried goods of inferior The challenge. operable with only four self-explanatory
quality are produced. It can furthermore Time plays a crucial role in determining buttons. Thanks to the ergonomic design,
contain substances which present a risk to the quality of the cooking oil which in turn handling is convenient and safe. The TPM
78 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
is due. simplifies the reading of temperature and
TPM values along with the unmistakeable
Safe to use. Easy to clean. alarm provided by multi-colour
The ergonomic design of the new testo backlighting which makes it even easier
270 offers an added advantage to the to evaluate the quality of the cooking oil;
limit values can be individually defined user by avoiding direct exposure to the Green means that the TPM or the TPC
according to local legislation and are heat from the deep-fryer while taking content is below the set limit value, orange
protected from inadvertent adjustment the measurement, allowing more safety. is close to it, and when the display lights
by a password (PIN). A great help in the The measuring instrument also fulfils the up red, the limit value has been exceeded.
measurements is the large, backlit display. protection class IP65 even without an
For one thing, it flashes if it is a stable additional protective case which makes The advantages.
measurement value has not been reached. cleaning it under running water possible – The testo 270 cooking oil tester
Secondly, the TPM content of the cooking ideal for use in quick-service restaurants. guarantees that the oil and the foods
oil analysed is shown on it not only as a prepared in it are of the highest quality,
percentage, but also by the unambiguous Even more intuitive thanks to traffic ensuring the customers are satisfied.
backlit traffic light system. The staff can light system Regular measurement prevents the oil
thus see the quality of the oil at a glance, The cooking oil tester testo 270 with the from being replaced too early or too
and can act accordingly if a replacement largest display in the market, considerably late – this can reduce your cooking oil
consumption by up to 20 %, thus saving
costs.
Testo India
With more than 60 years of measurement
experience, Testo SE & Co. KGaA is
headquartered in Titisee, Germany. Testo
India Pvt. Ltd., a 100% subsidiary of Testo
SE & Co. KGaA was established in 2006
and has shown phenomenal growth over
the last 15 years with its head office in
Pune, & a PAN India network.
Courtesy: Testo India Pvt. Ltd.
For more information
Email:[email protected]
Web:www.testo.com
80 | JANUARY 2023
ENGINEERING
REVIEW INSIGHT
Is your Boiler Combustion
Efficiency Optimized?
By regular measurement of flue gas parameters, you can minimize fuel consumption and unwanted excess
pollutants in the environment?
ince many decades industries are dependent on
fossil fuels (such as Coal, oil, etc.) for the purpose of
Sproduction of heat/steam or power generation for the
integral part of industries process.
Many medium scales & large-scale industries have their own
heat or power generation unit for the purpose of fulfilling of
process needs of the industry and lower the dependency on
other resources.
During and after the covid situation, many industries are
facing financial crises and facing difficulties in sustaining
their businesses. Unfortunately, day by day Fossil fuels are
degrading and due to lack of availability, the cost of fossil fuels
is increasing. The increasing cost of fossil fuels is disturbing the
budgets of many industries.
Combustion
Combustion has been the cornerstone of industrial
development for nearly two centuries. The burning of fuel to
produce heat or other forms of power is an integral part of
industrial processes. Combustion is a type of chemical process
in which a significant material reacts rapidly with oxygen
and gives off heat. The original material is called the fuel,
and the source of oxygen is called the oxidizer. During the
combustion process, flue gases such as Carbon Monoxide (CO),
Carbon Dioxide (CO2), Sulfur (SO2), Nitrogen Dioxide (NOx),
Nitric Oxide (NO), Volatile organic compounds (VOCs), and
Hydrocarbons (HCs)are generated as a chemical process. efficiency.
Although progress has been made in understanding the Given complete mixing, a precise or stoichiometric amount
fundamental science of combustion over the years, regulatory of air is required to completely react with a given quantity of
and competitive forces are driving the need for combustion fuel. In practice, combustion conditions are never ideal, and
equipment with better performance, lower environmental additional or “excess” air must be supplied to completely burn
impact, and greater flexibility, all at a reasonable cost. the fuel.
The correct amount of excess air is determined from
Boiler’s Combustion Efficiency analysing flue gas oxygen or carbon dioxide concentrations.
Operating your boiler with an optimum amount of excess air Inadequate excess air results in unburned combustibles (fuel,
will minimize heat loss up the stack and improve combustion soot, smoke, and carbon monoxide), while too much results in
efficiency. Combustion efficiency is a measure of how heat lost due to the increased flue gas flow—thus lowering the
effectively the heat content of a fuel is transferred into usable overall boiler fuel-to-steam efficiency.
heat. The stack temperature and flue gas oxygen (or carbon The profile illustrates the relationships between exhaust
dioxide) concentrations are primary indicators of combustion stream oxygen (O2), unburned fuel (hydrocarbons), carbon
82 | JANUARY 2023
More Precision
Precise laser scanners Inductive sensors (eddy current)
for 2D/3D profile measurements for displacement, distance & position
Oil gap Expansion
Radial run-out
Ideal for precise measurement and
evaluation of profiles on any surface
scanCONTROL eddyNCDT
Powerful laser scanners with integrated profile evaluation: Non-contact measurement of displacement, distance & position
no external controller required on all metals
Patented Blue Laser Technology for red-hot glowing metals High frequency response for dynamic measurement tasks
& transparent objects Highest accuracy & stability
Comprehensive software offers easy solution of multiple Robust designs for difficult ambient conditions
measurement tasks (oil, dirt, high temperatures, pressure up to 2000 bar)
+91 20 2674 1009 | [email protected] | www.micro-epsilon.in
HANDWHEELS LOCKING KNOBS HANDLES
ADJUSTABLE CLAMPING LEVERS OIL PLUGS TOOLS THERMOPLASTIC PROTECTIONS HANDLES
INDEXING AND SPRINT PLUNGERS ARTICULTED AND ADJUSTABLE FLEET ANTIVIBRATION, ADJUSTABLE FEET HINGES MEASURING AND
CONTROL INSTRUMENTS
301, 3rd Floor, Mukund House, Commercial Complex,
Azadpur, Delhi - 110 033 Ph: 011-41472715 |
[email protected] | www.acautomation.in
ENGINEERING
REVIEW INSIGHT
by oxygen. When air and fuel are provided to a burner at rates
that create the most efficient combustion, the burner is said to
be operating “on-ratio.”
Controlling combustion ratios to the optimal minimum excess
air reduces fuel consumption, maximizes heat transferred to the
load and reduces toxic CO emissions to safe levels. Measuring
burner exhaust oxygen content and temperature allows for
the assessment of efficiency-improvement potential and fuel
savings.
Fuel Combustion Efficiency Monitor
monoxide (CO), carbon dioxide (CO2) and burner efficiency.
For any particular burner and firing rate, various inputs of
excess air produce predictable and repeatable levels of CO2,
CO, unburned fuel (if any) and combustion efficiency.
Optimum excess air input results in the most desirable
combustion, where CO2 is at its peak, CO is minimized to a
safe level, fuel is completely burned and efficiency is at its peak. To ensure the combustion efficiency of fuel is high and flue gas
The amount of CO, unburned fuel and other harmful emissions are in the restrictedlimit, PRIMA provides a solution
emissions is strongly dependent on how well the burner mixes with the Portable equipment i.e Flue Gas Monitor.
the fuel and air. For a high-performance burner, the maximum Flue Gas Combustion Efficiency Monitor (FEM) is fuel
combustion efficiency typically occurs between 1-2% excess combustion efficiency monitor device. It measures the total
oxygen. combustion efficiency of flue gas which can help in the
Optimum excess oxygen levels are achieved in the field by analysis of combustion of fuel and indirectly saving of fuel.
measuring exhaust components with a multi-gas analyser and These instruments are also used for checking of combustion
making adjustments to the fuel and air control devices. parameters in flue gases which are emitted through stack.
Managing excess air input at optimum levels by measuring The FEM is a microprocessor-based flue gas Analyzer can
and controlling the resulting oxygen output is scientifically store the Average Value of sampled data which can later be
called “closed-loop.” The input and output are linked directly viewed. Besides the thermocouple temperature sensor and
Differential Pressure sensor,the FEM uses electrochemical, non-
dispersive infrared and/or palliators technology-based sensors.
This measuring system has been designed for measurement
of exhaust gases of boilers, furnaces, heaters and kilns in order
to improve combustion efficiency, save fuel and can reduce of
pollutant gases emission.
[Courtesy: Prima Equipment]
For Product Enquiry Contact
PRIMA Group, India
[email protected] | www.primagroupindia.com
84 | JANUARY 2023
ENGINEERING
REVIEW TECH INNOVATION
Bifacial Solar Panels – Best Solar
Panels for Rooftop
Synopsis
In the solar market, another significant
product development is rising. Bifacial
solar panels that can absorb sunlight
from both the front and rear end are an
intriguing new solar alternative for some
types of solar systems.
The traditional solar panels are also
known as mono facial panels that can
absorb light from only one surface, thus
wasting the light energy that does not
get absorbed. On the other hand, the
bifacial solar panels are different from
the conventional panels as they come
with solar cells equipped on both sides.
This mechanism helps the solar panel
absorb the solar energy from both sides
that enhance energy consumption. In this
article, we will primarily focus on bifacial
solar panels.
What is Bifacial Solar Panel? both sides. surface, allowing light to reflect towards
Traditional solar panels have several These bifacial panels are best the panel. Nowadays, bifacial solar
disadvantages that bifacial solar modules employed in industrial or communication panels are on par with traditional solar
do not. A bifacial panel can generate infrastructures where panels are tilted panels as they provide greater efficiency
power from both sides, boosting overall and angled away from a mounting and also use up less space than
electricity production. They are frequently conventional solar panels.
more resilient since both sides are UV When bifacial panels are Also, when used residentially, bifacial
resistant, and when the bifacial solar solar panels are very productive.
panel is structurally sound, the risk of placed on a brightly transparent Especially, the transparent surfaces
potentially induced deterioration (PID) material (such as a white TPO provide extremely clean and efficient
gets diminished. When more electricity ceiling or the ground with light- energy when compared with
is available, the cost of the balance of the coloured boulders), additional conventional panels.
system (BOS) gets reduced as well. electricity is produced from
When bifacial panels are placed on the backside. This additionally Benefits of Bifacial Solar Panel
a brightly transparent material (such Bifacial solar panels may represent
as a white TPO ceiling or the ground generated electricity can further the industry’s future. There are tons
with light-coloured boulders), additional result in a 30 per cent increase in of benefits of bifacial panels over the
electricity is produced from the backside. productivity and more efficient traditional ones. Some of them are
This additionally generated electricity can and clean air. Alas, one thing listed below:
further result in a 30 per cent increase in remains consistent, and that is • Efficiency
productivity and more efficient and clean the power generated from both Being more efficient by 11-12%,
air. Alas, one thing remains consistent, sides. bifacial panels can reduce the
and that is the power generated from LCOE(Levelized Cost of Energy) by
86 | JANUARY 2023
R -
SERIES...
FLAME / EMBER / SPARK / HEAT DETECTORS
ENGINEERING
REVIEW TECH INNOVATION
increasing the total energy generation
of similar-sized projects.
Besides higher performance, bifacial
panels also overcome the limitation
of high temperatures. Their glass
composition channels lower working
temperatures without the heat-
absorbing aluminium backing of mono-
facial panels.
• Durability
The tempered glass strengthens
the light-absorbing capacity of the
panel and provides a sounding edge.
Owners are also entitled to extended
warranties given Potential-induced
Degradation (PID) concerns for bifacial
solar panels by both sides being UV
resistant.
In addition to the durable
manufacturing, the panels are also
equipped for providing a reliable shield
in case of any bad weather conditions.
• Design
Not tampering with the aesthetics of
the facade is an inherent benefit due • Cost-effective Conclusion
to its sleek design that passes sunlight Determined by a study, bifacial panels Showcasing advanced performance
directly. Moreover, the design of the on solar trackers decrease power by maximizing electricity output levels
bifacial panels aids in putting them costs by 16%. Additionally, the glass through clean energy produced while
into service for various purposes such utilized is 20-30% cheaper than the the sun is rising and setting, bifacial
as awnings, barriers, or pergolas, transparent sheets employed in mono- solar panels promise an innovative way
depending on the location. facial panels. Bifacial panel owners of energy harnessing. Before opting
• Accommodativeness also benefit from a proportional for this clean and sustainable energy
Bifacial solar panels’ performance decrease in labor and maintenance source, evaluate your roof, installation
is independent of the angle of their costs. Since more power can be space, budget, and energy consumption
installation as they can even be fixed generated from bifacial modules patterns to make a suitable investment.
at 90°. Furthermore, space utilization in a smaller array footprint, BOS
is also updated since fewer panels are equipment, and related costs are also [Source: Technical Team,
now fulfilling the energy requirements. diminished. Waaree Energies Ltd.]
88 | JANUARY 2023
ENGINEERING
REVIEW CASE STUDY
netTAP 151
Integration of pharmaceutical Process
Skids into a Distributed Control System
netTAP 151 provides a flexible and scalable solution for an easy integration of independent processing systems
into one industrial communication network.
influences the Process Skids and
provides access to the internal data of
the process
One major feature of the DCS is the
accessibility of historian data of the
processes, which enables operators of
chemical plants to automatically generate
signed batch reports, which are crucial
for quality assurance in order to meet the
high demands set in the pharmaceutical
sector. Since this feature requires access
to the process data such as temperature
or pressure during specific stages of the
manufacturing process, the extend and
complexity of the DCS’ integration highly
depends on the customer needs.
Translation between DCS and
The challenge: Access to historian • The controller, which directly process skids
data
The core business of one of Hilscher‘s “netTAP 151 solves the challenge of
customers encompasses products integrating automation components and
and engineering services for a wide systems with heterogeneous communication
range of industrial, commercial and standards into industrial networks in a
customer markets, one of which is unique and flexible way. The product’s
the pharmaceutical and chemical
industry. With its in-house developed capability of converting all relevant Real-
Distributed Control System (DCS), the Time Ethernet protocols into another solves
system integrator offers one of the most various integration challenges and results in
important parts of a pharmaceutical or a significant decrease of efforts and a fast
chemical production plant. time to market for our customer’s solutions.”
Such DCS systems consist out of two Tim Pauls
major components: Group Leader Communication Products
• Software to visualize, monitor and Hilscher Gesellschaft für Systemautomation
operate chemical processes mbH
90 | JANUARY 2023
1 9 4 6 - 2 0 2 1
Largest Machine Tool
and Manufacturing
Technology Show
in South and
South-East Asia
19 - 25 January 2023, Bengaluru
Highlights
• 5 Exhibition Halls with 77,000 Sq.mts. space Scan to Register Now
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Exhibition Timings: 10:00 hrs to 18:00 hrs | Visitors below 18 years of age are not allowed
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International Seminar on Manufacturing Technologies, 18th January 2023, Bengaluru.
For more details, log on to www.imtma.in/ismt
ENGINEERING
REVIEW CASE STUDY
netTAP 151 - at a glance
netTAP 151 is Hilscher’s
flexible solution for an easy
integration of processing
systems from different
manufacturers into one
industrial communication
network.
• Provides fast and simple
conversion of numerous
different
Real-Time Ethernet
protocols: Conversion rate
in typical use
netX communication controller: Every protocol at your hands cases under 5ms
within one hardware
• Reduced commissioning time due to generic process data
In a specific use case, a biopharmaceutical company from mapping
India wanted such a DCS to control various independent • Less engineering costs
process skids from different manufacturers. However, the
process skids were using PROFINET IO as communication netTAP 151 is facilitating the integration of various
protocol, while the DCS of Hilscher‘s customer was relying independent process skids into a distributed control
on Ethernet/IP, setting the task of combining these two types system (DCS) by seamlessly converting different
of devices. industrial communication protocols, for example in the
biopharmaceutical sector.
Reduction of cost and complexity
Typically, the biopharmaceutical company would have to
integrate the process skids via separate IO cards for the DCS, conversions with a single hardware.
causing high engineering costs and posing the risk of long netTAP 151 is the ideal solution for installations with
commissioning times. At this point, the netTAP 151 comes into heterogeneous
play as it offers one of the easiest, fastest and most flexible networks in order to exchange data across certain network
solutions to convert various Real-Time Ethernet protocols. boundaries. The gateway maps the process data of
Providing a generic conversion from any common the process skids, regardless of the manufacturer, exactly
industrial communication protocol to Ethernet/IP, the DCS can according to the requirements of the DCS. This makes it
be easily integrated in different process skid, facilitating the especially easy for Hilscher‘s customer to scale his production
setup of complex chemical production processes. systems with the DCS and netTAP 151. With this solution, the
system integrator can offer his customers more flexibility and a
Flexible protocol conversion with netTAP high degree of freedom in supported automation components
netTAP 151 helps to remedy the complex integration of third with minimum effort.
party process skids into the manufacturing process. Although
the conversion of the industrial communication protocols
in this case only applies to PROFINET IO and Ethernet/ IP,
customer options do not end there. Profiting from Hilscher’s
multiprotocol approach, the automation solutions provider
is able to easily integrate different devices and solutions as
netTAP 151 offers connectivity from Ethernet/IP to EtherCAT,
Open Modbus/TCP, PROFINET IO, POWERLINK, Sercos III For more information,
and even to Ethernet/IP. In total, the device supports up to 45 Website: www.hilscher.com
92 | JANUARY 2023
Concurrent with
Ushering Next Generation Manufacturing
Industry 4.O CAD / CAM / CAE
IoT Digital Twins
/ Simulation
Networking
& Connectivity ERP
Machine Robotics
Learning / Cobots
Cloud Computing 3D Printers
Big Data Analytics 3D Materials
& Processes
5G AR/VR
AI
Highlights
• 5 Exhibition Halls with 77,000 Sq.mts. space Scan to Register Now
• Over 950 Exhibitors from 23 Countries
•
• Live Technologies on Display i2 Academia Pavilion
Organiser Venue
Exhibition Timings: 10:00 hrs to 18:00 hrs | Visitors below 18 years of age are not allowed
www.imtex.in Follow IMTEX on #imtex #imtex2023
International Seminar on Manufacturing Technologies, 18th January 2023, Bengaluru.
For more details, log on to www.imtma.in/ismt
ENGINEERING
REVIEW CASE STUDY
NASA Takes the
Teledyne FLIR Boson
Thermal Camera Module
Out of this World
Thanks to the efforts of engineers at the NASA Marshall Space Flight Center, the Teledyne FLIR Boson
thermal camera module is ready to venture beyond the atmosphere.
he miniature Boson thermal lightweight, passively cooled infrared harshest of terrestrial conditions as well,
imaging system sees thermal camera with 640x480 thermal resolution. including for aerospace and unmanned
Tenergy and provides accurate The platform also lends itself well to industrial machinery.
stand-off temperature measurements. customization and repackaging for
NASA’s packaging features clever surviving the rigors of space travel. Inflatable Re-Entry Heat Shield Test
modifications that enable it to survive in The Boson and package assembly For its first mission, the space-grade
the most extreme conditions imaginable, developed by NASA has been fully tested Boson will be used as part of the NASA
from the intense vibrations at liftoff, and qualified at technology readiness Low Earth Orbit Flight Test of an Inflatable
to the vacuum of space, and then the level (TRL) 8 for operation in conditions Decelerator (LOFTID/IHAD), essentially a
temperatures reached during re-entry into including high vibration, shock, vacuum, test of the effectiveness of an inflatable
Earth’s atmosphere. high radiation, and temperature cycling heat shield during re-entry into Earth’s
NASA chose the Boson as it fits many from extreme cold to extreme heat. The atmosphere.
of its stringent engineering requirements modified Boson packaging could also The Boson will rest behind the heat
already, including the need for a small, serve as a potential option for use in the shield, with the goal of monitoring the
heat generated in the infrared spectrum
as the shield descends back to Earth.
An inflatable, lighter-weight heat shield
could provide significant benefits for
future missions, whether that’s returning
to Earth or entering the atmosphere of
neighboring celestial objects within the
solar system. The modified Boson could
also be used as part of imaging systems
for future low-Earth orbit satellites and
spacecraft.
The initial test is expected to commence
November 2022. Successful testing will
increase the TRL to level 9 for the Boson
94 | JANUARY 2023