INDUSTRIAL AUTOMATION REVIEW MARCH-APRIL 2022

Volume 02 No. 02 | March - April 2022 | Pages 44 www.industrialautomationreview.com

















TECH INNOVATION IN FOCUS
INTEGRATED OR SEPARATE? BETTINELLI at the cutting-
SAFE CONTROL TECHNOLOGY edge of motion control
ON SMALLER MACHINERY and automation technologies
pg. 21 pg. 06

New Digital Tool Management “The future of Injection molding
System for High Productivity is the complete basket of
pg. 23 automation, communication
and energy saving.”
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4 TECHNOLOGY TRENDS



THAT WILL DEFINE MODERN



MANUFACTURING IN 2022






AN INTERFACE WITH:
RAJESH KHOSLA, PRESIDENT & CEO, AGI GLASPAC
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HEAD OFFICE
Phoenix Contact (India) Pvt.Ltd. SOUTHERN INDIA OFFICE WESTERN INDIA OFFICES
sr
th
F-26/2, Okhla Industrial Area, Phase-II, No. 10/7 - 8, 2 Floor, 30, Shaswat Bungalow, 1 Floor, 5 Floor, Devi House,
nd
New Delhi - 110 020 INDIA Umiya Landmark, Lavelle Road, Ceaser Road, Amboli, 37, Shivaji Nagar,
Tel.: +91-11-71810700 / 800 Bangalore - 560 001 Andheri [W], Mumbai - 400 058 Pune - 411 005
Fax: +91-11-41611071 Tel.: +91-80-33235400 Tel.: +91-8377004752 / 4753 Tel.: +91-20-71395000-031
E-mail: [email protected]
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From the CEO





Industry 4.0: Changing the

dynamics of manufacturing





Publisher : Shilpa Dongre
CEO : Shekhar Dongre Industry 4.0 provides real-time information regarding the whole manufacturing process. The user
Editor : Rajeev lyer can see through the value chain of the organization. The materials used in production, the supply of
Editorial Head : P.K. Balasubbramaniian
CMO: Shirish Dongre the materials through different stages, the origin of the materials, and different activities associated
with the productions. By keeping track of the total value chain and the production activities, it
Marketing Team : Ladoji Pendurkar, Amol Powle,
Bhavin Shah, Bharat Shah, Sandeep Shetye, becomes easier for the manufacturing organization to develop strategies for managing the supply
Hiren Shah, Reshma Mandal, Rinki Pundir chain and improving the production rate of the organization (Ghobakhloo and Fathi, 2019). The
Digital Marketing : Kailash P. distribution of resources and goods can be controlled effectively to manage the production activities
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Print & Online Division :
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Ganesh B. Mahale, Dinesh S. Gawade productivity can also help an organization to fulfill the orders of the customers in different market
Circulation Executive : segments.
Jyoti Fegade, Satish Kadam, Amol Ranshur
Centered around advanced robotics and automation, new ways of human-machine interaction and
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vast troves of data, and boosted connectivity, Industry 4.0 is poised to modernize manufacturing and
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Head Office : Divya Media Publications Pvt. Ltd., of IT and manufacturing operations – the maturation of digital technology in the manufacturing
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2 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

Digitized Automation for A Changing World

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100
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25

www.deltaelectronicsindia.com 5
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0






Engineering Review Magazine 25.02.2022
Friday, February 25, 2022 5:29:42 PM

INDUSTRIAL
AUTOMATION
REVIEW


CONTENTS 14


COVER STORY


INTER VIEW 4 TECHNOLOGY trends that will define
modern manufacturing in 2022
06

BETTINELLI at the cutting-edge of motion control and
automation technologies






























TECH INNO V A TIONS
16
23 ELGI
“The future of Injection New Digital Tool
molding is the complete Management System
basket of automation, for High Productivity
communication and
energy saving.”

24 EXOR
The Automated
Predictive
Maintenancep
INDUS TR Y FOCUS
32 WAGO
18 ABB predicts key emPower Your Control
trends that will Cabinet with WAGO
Power Supply Pro 2
change ROBOTIC
AUTOMATION in
2022 PRODUC T S - 38

4 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

E-mail: [email protected]
Fax: +91-11-41611071
Tel.: +91-8377004752 / 4753
Tel.: +91-80-33235400
Tel.: +91-20-71395000-031
Tel.: +91-11-71810700 / 800
Pune - 411 005
Bangalore - 560 001
Andheri [W], Mumbai - 400 058
Andheri [W], Mumbai - 400 058
Pune - 411 005
Bangalore - 560 001
New Delhi - 110 020 INDIA
Umiya Landmark, Lavelle Road,
Ceaser Road, Amboli,
Umiya Landmark, Lavelle Road,
Ceaser Road, Amboli,
37, Shivaji Nagar,
37, Shivaji Nagar,
No. 10/7 - 8, 2 Floor,
th
th
5 Floor, Devi House,
5 Floor, Devi House,
nd
F-26/2, Okhla Industrial Area, Phase-II,
30, Shaswat Bungalow, 1 Floor,
No. 10/7 - 8, 2 Floor,
nd
sr
sr
30, Shaswat Bungalow, 1 Floor,
SOUTHERN INDIA OFFICE
WESTERN INDIA OFFICES
WESTERN INDIA OFFICES
SOUTHERN INDIA OFFICE
Phoenix Contact (India) Pvt.Ltd.
HEAD OFFICE














































HEAD OFFICE Website : www.phoenixcontact.co.in E-mail: [email protected] Fax: +91-11-41611071 Tel.: +91-11-71810700 / 800 New Delhi - 110 020 INDIA F-26/2, Okhla Industrial Area, Phase-II, Phoenix Contact (India) Pvt.Ltd. HEAD OFFICE Website : www.phoenixcontact.co.in Tel.: +91-80-33235400 Tel.: +91-8377004752 / 4753 Tel.: +91-20-71395000-031 th Tel.: +91-20-71395000-031 Pune - 411 005 37, Shivaji Nagar, 5 Floor, Devi House, sr Tel.: +91-8377004752 /
HEAD OFFICE
WESTERN INDIA OFFICES SOUTHERN INDIA OFFICE Phoenix Contact (India) Pvt.Ltd. Phoenix Contact (India) Pvt.Ltd. SOUTHERN INDIA OFFICE WESTERN INDIA OFFICES WESTERN INDIA OFFICES SOUTHERN INDIA OFFICE Phoenix Contact (India) Pvt.Ltd.
th sr nd nd sr th th sr nd
5 Floor, Devi House, 30, Shaswat Bungalow, 1 Floor, No. 10/7 - 8, 2 Floor, F-26/2, Okhla Industrial Area, Phase-II, F-26/2, Okhla Industrial Area, Phase-II, No. 10/7 - 8, 2 Floor, 30, Shaswat Bungalow, 1 Floor, 5 Floor, Devi House, 5 Floor, Devi House, 30, Shaswat Bungalow, 1 Floor, No. 10/7 - 8, 2 Floor, F-26/2, Okhla Industrial Area, Phase-II,
37, Shivaji Nagar, Ceaser Road, Amboli, Umiya Landmark, Lavelle Road, New Delhi - 110 020 INDIA New Delhi - 110 020 INDIA Umiya Landmark, Lavelle Road, Ceaser Road, Amboli, 37, Shivaji Nagar, 37, Shivaji Nagar, Ceaser Road, Amboli, Umiya Landmark, Lavelle Road, New Delhi - 110 020 INDIA
Pune - 411 005 Andheri [W], Mumbai - 400 058 Bangalore - 560 001 Tel.: +91-11-71810700 / 800 Tel.: +91-11-71810700 / 800 Bangalore - 560 001 Andheri [W], Mumbai - 400 058 Pune - 411 005 Pune - 411 005 Andheri [W], Mumbai - 400 058 Bangalore - 560 001 Tel.: +91-11-71810700 / 800
Tel.: +91-20-71395000-031 Tel.: +91-8377004752 / 4753 Tel.: +91-80-33235400 Fax: +91-11-41611071 Fax: +91-11-41611071 Tel.: +91-80-33235400 Tel.: +91-8377004752 / 4753 Tel.: +91-20-71395000-031 Tel.: +91-20-71395000-031 Tel.: +91-8377004752 / 4753 Tel.: +91-80-33235400 Fax: +91-11-41611071
E-mail: [email protected] E-mail: [email protected] E-mail: [email protected]
Website : www.phoenixcontact.co.in Website : www.phoenixcontact.co.in Website : www.phoenixcontact.co.in

INDUSTRIAL
AUTOMATION IN
AUTOMATION
REVIEW FOCUS

BETTINELLI at the cutting-edge


of motion control and automation


technologies





In the industrial world, Bettinelli is a renowned brand synonymous with quality, operational efficiency and
productivity in motion control and automation. The brand has a reputation for versatility, precision and
reliability spanning over seven decades. Bettinelli is a conglomerate headquartered in Italy. Its Indian
arm, Bettinelli Automation Components Pvt. Ltd. has been serving the Indian industry for over a decade,
providing world-class products and matching technical and service support.




CDS Cam Driven Systems transfer systems, and epicycloidal servo
Bettinelli S.p.A, established in 1953, reducers.
specializes in the development and
manufacturing of precision motion control Broad Product Spectrum
components and systems. In 1996 a The broad product spectrum covers IP
separate division named CDS Cam Driven parallel shaft indexers, IT roller dial indexing
Systems was created for engineering tables, TR roller dial indexing tables, HP
solutions in automation and motion roller dial indexing tables, IG/IGA roller
technology. gear indexer, TL precision link conveyors,
CDS produces the widest range of MHP/LHP part handlers, FT-HT open
mechanical Cam Driven Units, commonly center ring tables and packages of rotary
known as rotary / indexing tables indexing tables. Bettinelli has a wide range
for precision motion of standard products. These are delivered
control applications, in 3 weeks. When it comes to customized
requiring rotary products, these are designed, manufactured
or linear transfer, and shipped in 6-8 weeks.
positioning and The manufacturing takes place centrally
handling. The in Italy. The regimen starts with design &
products range engineering, CNC induction hardening,
includes cam CNC milling, grinding, quality check and
indexing and then assembly, painting and shipment. In
servo-driven order to ensure quality, all components
tables, ring are machined internally, including the cam
positioning hardening by a proprietary CNC controlled
drives, induction hardening equipment. For better
intermittent finish, the products are also subjected
and oscillating to chemical nickel plating, blasting and
drives with painting. The manufacturing process
parallel or is constantly controlled to conform to
right angle international standards. The company’s
Rupesh Paparaju, configuration, quality systems are ISO-9001-2008
Managing Director, rotary & linear certified.
Bettinelli Automation Components Pvt. Ltd. part handlers, The company has its own subsidiaries
precision link to look after sales and service in Germany,


6 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

INDUSTRIAL
IN AUTOMATION
AUTOMATION
FOCUS REVIEW




























































Bettinelli’s CPC Series Chain Pallet Conveyors

France, United States, India, and China and representative a symbiotic relationship with our customers. Our design
companies in other countries such as Spain, Denmark and the and manufacturing systems have afforded competitive and
Netherlands. strategic advantage to numerous industries in pharmaceutical,
Over the years, Bettinelli Group and CDS Indexers have automobile, manufacturing, packaging and a plethora of
become synonymous with high quality automation products other sectors and for automation functions. Our solutions are
and technologies. The Indian subsidiary, headquartered in invariably preferred by companies,” says Rupesh Paparaju,
Pune, serves its customers in India by providing installation, Managing Director, Bettinelli Automation Components, India.
commissioning, and after-sales support. It also offers technical “It helps us to match our world-class products with our
consultation. eminent customer support,” underlines Paparaju, who has
Bettinelli Automation Components Pvt. Ltd. is highly built up a team to improve Bettinelli’s response time. “CDS
customer-centric. are high-tech products which lend themselves to enhance the
“Our presence in India means quite something in fostering operational efficiency and productivity at the customer’s end.


www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 7

TURNING WORKPLACES



INTO SAFER PLACES








Safety light grid SLC440 / COM with Bluetooth interface
(Bluetooth Low Energy)
SLC440COM-R-0330-14
Device Data 2018229000
Type 14 mm
Serial Number 330 mm
Field Resolution
Protection Field Height ■ Shows status and diagnostic data on smartphones or tablets
Automatic
Device Status
Operating Mode ■ Status data in real time
Protective Field FREE
Field Status ON ■ Faster troubleshooting – higher machine availability
Beam Signal Level 185
OSSD Status 24.0 V
OSSD Switching Counter 48 h.
Supply Voltage ■ Long range / can be used worldwide
Operating Time



www.schmersal.in













Device Data
Type SLC440COM-R-0490-14
Serial Number 2018118002
Field Resolution 14 mm
Protection Field Height 490 mm
Number of Beams 48
Firmware Version v1.6.07
Device Configuration
Floating Blanking 1 beam
Product video "SLC Assist" "SLC Assist" Fixed Blanking
for iOS for Android Fixed Blanking with edges
Contactor Control (EDM)
Beam Coding
Turned Display
Device Status
Automatic
Operating Mode








Contact Details:
Phone: +91 9607800255
Mail: [email protected]
Schmersal India Pvt Ltd
www.schmersal.in






27.09.2021 17:47:51
ad_industrial-automation-review_opro-ble_431x279_in.indd 1 27.09.2021 17:47:51
ad_industrial-automation-review_opro-ble_431x279_in.indd 1

TURNING WORKPLACES



INTO SAFER PLACES








Safety light grid SLC440 / COM with Bluetooth interface
(Bluetooth Low Energy)
SLC440COM-R-0330-14
Device Data 2018229000
Type 14 mm
Serial Number 330 mm
Field Resolution
Protection Field Height ■ Shows status and diagnostic data on smartphones or tablets
Automatic
Device Status
Operating Mode ■ Status data in real time
Protective Field FREE
Field Status ON ■ Faster troubleshooting – higher machine availability
Beam Signal Level 185
OSSD Status 24.0 V
OSSD Switching Counter 48 h.
Supply Voltage ■ Long range / can be used worldwide
Operating Time



www.schmersal.in













Device Data
Type SLC440COM-R-0490-14
Serial Number 2018118002
Field Resolution 14 mm
Protection Field Height 490 mm
Number of Beams 48
Firmware Version v1.6.07
Device Configuration
Floating Blanking 1 beam
Product video "SLC Assist" "SLC Assist" Fixed Blanking
for iOS for Android Fixed Blanking with edges
Contactor Control (EDM)
Beam Coding
Turned Display
Device Status
Automatic
Operating Mode








Contact Details:
Phone: +91 9607800255
Mail: [email protected]
Schmersal India Pvt Ltd
www.schmersal.in






27.09.2021 17:47:51
ad_industrial-automation-review_opro-ble_431x279_in.indd 1 27.09.2021 17:47:51
ad_industrial-automation-review_opro-ble_431x279_in.indd 1

INDUSTRIAL
AUTOMATION IN
AUTOMATION
REVIEW FOCUS






































MCR Series Pick & Place Systems









































Team Bettinelli India


10 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

More than


60 years


of
quality


and
innovation





Made in Italy
since 1959
















Safety Light Curtains

Safety Controllers and Relays

Magnetic and RFID Safety Switches

Inductive Safety Switches

Safety Photocells


Measurement Light Curtains






Please enquire at
[email protected]

Country Manager
ReeR SpA Mr Zavier Paul Antony
Via Carcano, 32 [email protected]
10153 Turin, Italy
+91 99408 77677
Local Address
Flat No S1, Plot No A-3
Mithra Apartment www.reersafety.in
Thirumagal Nagar Main Road
Rajakilpakkam
Chennai 600 073, Tamil Nadu
ReeR is ISO 9001, ISO 14001
and ISO 45001 certified

INDUSTRIAL
AUTOMATION IN
AUTOMATION
REVIEW FOCUS
We stay close to the customer to understand his needs and CDS Indexers are known for durability. Thanks to the friction
offer bespoke solutions within the shortest possible time to followers, they do not break or need to be replaced. They
ensure peak uptime of his equipment and operations,” he adds. can bear higher loads compared to needle-based followers.
Compact cast aluminium alloy housing, double extended cam-
Wide Ranging Applications shaft, CNC case hardened cam-profiles, etc. are the salient
CDS find wide ranging applications in the industry. features lending to high productivity.
In the pharmaceutical industry, cam driven systems are used CDS underlines precision in operations. Repeatability of
in filling, blister pack, tablet making and packaging machines. +/- 0.02 mm at cam follower, Airtight special aluminium alloy
In automobile industry, they are used in pallet transfer tables, housing, Flanged through-hole input and out-put shafts
assembly machines, painting applications and test rigs, just supported by large preloaded tapered roller bearings, and
to mention a few. In machining industry, they are used in Oscillating and customized cam motion are some of the
deburring, lapping and pressing machines and in transfer elements facilitating this.
lines. In SPM & robotics, they find applications in transfer lines, CDS customization leads to adaptability. Customized
station loading, sequential operations and so on. In welding, size, stops, input shaft, threads & tooling on output flange,
these indexers are inevitable in positioners, synchronous bores on the housing and a number of other features like
welding, robotic welding and component transfer. Packaging prearrangement for gearbox connection, etc. contribute to this
too is a major application area. Cam systems are used in attribute.
box filling machines, wrapping machines and cartoning and “Our engineers are involved throughout in the design and
capping machines. Indexers are also used in casting, printing manufacturing process of our products to ensure that all our
and cosmetics industries. customer requirements are fulfilled throughout the different
phases of production. Our erudite team works in tandem with
Built to Last our customers’ engineering departments to evolve customized
The Bettinelli products are easy to install, they can run at a solutions to meet their unique specifications”, remarks
speed of 800 cycles per minute; there is no wear & tear and Paparaju.
hence they entail zero maintenance. Designed to give high
accuracy (+-20 microns), these systems also feature zero
backlash.


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12 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com



INDUSTRIAL
AUTOMATION COVER STORY
AUTOMATION
REVIEW

















































RAJESH KHOSLA,
PRESIDENT & CEO,
AGI GLASPAC








4 TECHNOLOGY trends



that will define modern




manufacturing in 2022










14 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

INDUSTRIAL
AUTOMATION
COVER STORY AUTOMATION
REVIEW

ndustry 4.0 has received a lot of attention because it from travelling to job locations to install equipment
allows manufacturers to use cutting-edge tools and or perform repairs. Assistive technologies, such as
technologies at every stage of the product lifecycle. augmented reality (AR) and virtual reality (VR) allow
I Increasing operational visibility, reducing costs and technicians to provide remote support via AR and
manufacturing time and providing excellent customer VR-enabled devices to guide consumers through
service are made possible by Industry 4.0. simple diagnostics and repairs, so that site visits are
It’s time to move from Industry 4.0 and focus on restricted.
what’s coming next in the industry, Industry 5.0. It opens up numerous possibilities for businesses.
Human-machine collaboration is at the heart of the A customer’s preference for having a technician do a
fifth industrial revolution, which builds on the fourth repair on-site rather than exploring touchless service
by emphasising technology to improve manufacturing solutions was common in the past. COVID-19 has
methods. The commencement of the COVID-19 made it easier for manufacturers to test new processes
pandemic may have hastened the arrival of Industry and procedures to incorporate them in product design.
5.0. Reducing exposure risks benefits both customers and
There is little doubt that manufacturers must field service specialists, while manufacturers gain from
continue to embrace change to stay ahead of their improving the reliability of their products.
competition and gain market share. One must take
advantage of the most current technologies and trends 3D printing speeds up and
to thrive. lowers the cost of production.
Additive manufacturing has relied on 3D printing for
The Internet of Things (IoT) is still the most nearly four decades. Prototyping is a cost-effective
significant thing globally. approach for product designers to test and debug new
This year, the Internet of Things (IoT) is again at the goods. Manufacturers rely on 3D printing to generate
top of trend lists in the industrial business because of items on demand rather than keep stocks.
its adaptability and innovation. Tools can now be made in 3D printing, a procedure
Manufacturers may now use real-time data from the that was previously prohibitively expensive and
Internet of Things (IoT) to make data-driven strategic time-consuming. It took months for manufacturers
decisions and achieve a wide range of objectives, such to make the moulds, jig and fixtures essential for
as lowering costs, increasing efficiency, enhancing the mass manufacturing of heavy equipment, and
safety and creating new products. As per reports from many manufacturers relied on the support of tooling
the MPI Group, more than 30 per cent of manufacturing businesses based overseas. In recent years, 3D
processes now include smart devices and embedded printing has become an integral part of the automotive
intelligence. According to the manufacturers surveyed, and aerospace manufacturing industries because of its
IoT will be integrated into 34 per cent of manufacturing ability to produce tooling on-site in a matter of days.
processes and 32 per cent of goods.
Remote monitoring and predictive maintenance Ways to improve the customer experience
have re-ignited interest in the Internet of Things(IoT) in In today’s marketplace, businesses must be prepared
the wake of COVID-19. For manufacturers, the Internet to interact with customers online and offline. The
of Things (IoT) allows the remote monitoring of pandemic has forced manufacturers to reconsider their
equipment performance and identification of potential omnichannel strategy and communicate with their
issues before a malfunction even occurs; for field customers in new ways.
service personnel, it means a better understanding of Manufacturers are rapidly implementing customer
the problem and possible solutions before they even experience optimisation technology, such as product
arrive at the site, allowing them to get in and out faster digitisation and customer master data management
than before with improved efficiency and safety. solutions. . Manufacturers will be able to cultivate
long-term connections with customers using these
Touchless Service Model customer-centric technologies throughout the product
Supported by VR and AR lifecycle. They can get significant consumer insight
For field service departments, COVID-19 has proven that will help them sustain their customers’ loyalties
to be a severe roadblock that prevents technicians and generate income in the long run.


www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 15

INDUSTRIAL
AUTOMATION
AUTOMATION IN
REVIEW FOCUS

“The future of


Injection molding is


the complete basket


of automation,


communication and


energy saving.”




















Mr Chiranjeevi Raj,
Senior Product Manager for Servo Hydraulic Automation solutions,
Delta Electronics India



Q. There seems to be heavy world, the consumption of plastic in
investment in Injection molding India is still low yet, it is a high potential
across the world. What is caus- market. The per capita usage of plastic
ing this high demand? is ever increasing and even across
The consumption of plastic has industry, plastic is in demand. Most
grown atleast twenty times since sectors require plastic components but
the nineties. If you need plastic the automobile, packaging, consumer
products or components you have to goods, appliances and electronics
manufacture them and the process is industries are amongst the biggest
Injection molding and Blow molding. drivers behind this growth.
It is a simple equation and this is the
reason for the rise in Injection molding Q. What are the issues that crop
machines and installed capacity. The up in the Injection molding seg-
rubber industry also uses the Injection ment?
molding machinery but the usage and Currently, Indian manufacturers are
production does not equate to plastic. exporting plastic products to more
Because of its simplicity and diverse than 50 countries. Yet, if they use the
use, Injection molding has become the mechanical hydraulic process it uses
most popular process in plastic. a lot of energy and turns out to be
In comparison to the rest of the expensive. There are also factors of


16 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

INDUSTRIAL
AUTOMATION
IN AUTOMATION
FOCUS REVIEW

control regarding flow and pressure constant torque to the system. With into a dedicated controller system. We
which require consistency especially if precise control of pressure and flow will be bringing IoT to the system in a
one needs to scale up. the HES eliminates the energy waste complete package with Industry 4.0.
and improves the control system for This will not include the plastic
Q. How has Automation im- Injection molding machinery which in processing but an entire system to
proved the Injection molding turn enhances market competitiveness. monitor the plastic process including
process? the heat control system and Direct
Well, first and foremost it improved Q. What more does Delta bring Drive torque motors which are a crucial
the efficiency of the whole process. to the table? part of the refilling process, Door
The control system in an Injection We are the only company in India Control Drives via communication and
molding process is the conventional who can actually take ownership of more. This integrated solution simplifies
hydraulic pump driven by a normal electronics, electrical and hydraulic the system structure. Production Data
motor. This has been replaced with a together because we have a dedicated can then be monitored and managed
Servo hydraulic pump governed with inhouse team and an inhouse testing on our Delta Manufacturing Execution
a Servo motor and Drive. At Delta we facility. A testing facility for hydraulics System or the MES for the Injection
have the Hybrid Energy Saving or the in manufacturing companies is still molding machine. It will connect the
HES System which is a combination rare. The testing helps us enhance master controller, Servo and motor
of hydraulic and electric. HES features performance and check the reliability of Drive through CANopen communication
high power density, excellent pressure our products. for real time communication. We
and flow control, long service life will also support standard Ethernet
design and ease of maintenance. The Q. What new innovations is this communication to connect peripheral
system uses CANopen communication. sector likely to see? equipment to achieve equipment
A hydraulic system with an AC Servo There are exciting times ahead for IoT. The future of Injection molding is
motor with a Servo pump provides Injection molding. Delta started with the the complete basket of automation,
a high response rate. There is also hydraulic control system for Injection communication and energy saving.
a higher duplication accuracy and molding and now we are venturing



INDIA’S LEADING

BI-MONTHLY
MAGAZINE ON
AUTOMATION

INDUSTRY


Connect with the
industry

For advertising opportunity
contact:
[email protected]







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www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 17

INDUSTRIAL
AUTOMATION INDUSTRY
AUTOMATION
REVIEW FOCUS
ABB predicts key trends that



will change ROBOTIC



AUTOMATION in 2022






• Post-pandemic acceleration continues for robots in new sectors like logistics and retail, and speeds up for
EV production
• Adoption of robots driving demand for new skills that require education and training
• Marc Segura, ABB’s new Robotics Division President, outlines the key 2022 ro-botic trends


ith demand for robots race towards electric cars has accelerated.
growing as companies Manufacturers and their supply chains
in multiple sectors look must tackle the complexity of diversifying
Wfor new ways to enhance into EVs alongside combustion-engine
their productivity and competitiveness vehicles, to meet varying regulatory
post-pandemic, ABB has compiled a set of frameworks governing EV adoption across
growth predictions, looking at key trends the globe. The speed and added flexibility
driving demand for robots in the coming needed will see new and established
year. manufacturers move away from traditional
“The pandemic accelerated far-reaching linear manufacturing, towards modular,
global mega trends – from labor shortages flexible production.
and supply chain uncertainty, to the Segura said: “EV is not about a change
individualized consumer and growing only in the powertrain, but a larger
pressure to operate sustainably and transformation to a digitized car. This
resiliently – leading new businesses to transition will also see the growing
look to robotic automation,” says Marc uptake of robots in combination with
Segura, ABB’s newly appointed Robotics other technologies, including Autonomous
Division President. “As technology opens Mobile Robots (AMR’s). This will enable
new opportunities for meeting customer manufacturers to optimize the delivery of
demands, new trends will continue to components across facilities and enable
emerge that will further drive demand in integrated scalable, modular production
areas where robots have traditionally not cells – methods traditionally associated
been used.” with e-commerce and consumer goods, but
Based on customer conversations, now required in automotive to ensure the
market research and a global survey of 250 necessary flexibility to meet varying levels
companies across multiple industries, ABB of demand.”
has identified three key trends that will Another major shift will see battery
shape the demand for robots in 2022. manufacturing brought closer to vehicle
assembly, to meet sustainability and
Trend 1 – The EV revolution is regional requirements, which in most cases
bringing wholesale changes for requires all-new facilities.
automotive manufacturing
With many countries restricting and Trend 2 – The E-commerce boom
phasing out the production of combustion will accelerate
engine vehicles over the next decade, the Consumer behavior and expectations

18 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

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INDUSTRIAL
AUTOMATION INDUSTRY
AUTOMATION
REVIEW FOCUS

are driving companies to find new time, more advanced and responsive machine automation, supported
ways to satisfy demand, developing simulation and programming software by the digital services and training
new channels through omnichannel tools, such as those in ABB’s they need to get the most from their
retailing and adapting their production RobotStudio®, will cover the entire investment.”
lines and distribution processes life cycle of robotic applications – ABB (ABBN: SIX Swiss Ex) is a
to enable personalization of both from commissioning to onstream leading global technology company
products and delivery. Fulfilling these productivity – using AR and VR tools that energizes the transformation
requirements has seen thousands to simplify automation for customers.” of society and industry to achieve
of robots installed worldwide where The enhanced ability of robots to a more productive, sustainable
they were not used just five years work directly alongside humans, future. By connecting software to its
ago, and this rapid rate of automation share tasks and learn through AI is electrification, robotics, automation
will continue in 2022 driven by a also making it easier for companies to and motion portfolio, ABB pushes
combination of consumer trends and a adopt intelligent automation in new the boundaries of technology to drive
growing shortage of labor. environments, such as construction, performance to new levels. With a
“This trend will see the growth of healthcare laboratories and history of excellence stretching back
lighter, smaller robotic applications, restaurants and retail. more than 130 years, ABB’s success
enabling the expansion of automation In a future with a high prevalence is driven by about 105,000 talented
into new areas of warehousing of robots in workplaces, engineers employees in over 100 countries.
and distribution operations. As and staff will need to be retrained ABB Robotics & Discrete
Artificial Intelligence in robotics and more robotic training will be Automation is a pioneer in robotics,
matures and learning robots become demanded in schools, colleges and machine automation and digital
mainstream, expect to see these universities, for the skills to program, services, providing innovative
technologies deployed alongside operate and maintain robots for an solutions for a diverse range of
AMR technologies, orchestrated and automated future. industries, from automotive to
managed by intelligent software to electronics to logistics. As one of the
provide enhanced flexibility, speed A decade of change world’s leading robotics and machine
and efficiency,” Segura continued. The trends outlined for 2022 are automation suppliers, we have
the latest chapter in the ongoing shipped more than 500,000 robot
Trend 3 – More robots will transformation of robotic automation solutions. We help our customers
appear in more places – and which is seeing a rapid acceleration of all sizes to increase productivity,
workers will need new skills and adoption of robots across flexibility and simplicity and to
Smaller, more affordable, and easy- industry. improve output quality. We support
to-use robots, such as ABB’s YuMi®, “While automation has always their transition towards the connected
GoFa™ and SWIFTI™ cobots, are been about productivity and quality and collaborative factory of the future.
helping to remove many of the – scaling up, doing more – the shifts ABB Robotics & Discrete Automation
barriers previously preventing we’re witnessing today (the greatest employs more than 11,000 people at
companies from investing in robots. in a generation) mean that flexibility over 100 locations in more than 53
This is seeing an acceleration of and simplicity are key to success,” countries.
robots in general industry and small concludes Marc Segura. “Today,
and medium-sized enterprises flexibility is essential – it is a strategic
as companies seek new ways to need, essential across the entire
automate different tasks. value chain: from manufacturing
Segura continued: “As we look and logistics through to the point of
beyond 2022, we see an ever-greater consumption. Robotic automation is a
emphasis on connectivity and data vital enabler of this flexibility.
acquisition as key enablers of future “ABB’s goal is to help our customers
manufacturing. Data collected from achieve this flexibility and add
intelligently automated processes will value to their businesses by driving For more information
be analyzed by producers to make innovation to create new possibilities go.abb/robotics
more informed decisions. At the same with robotics, mobile robotics and Web: www.abb.com


20 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

INDUSTRIAL
TECH INNOVATION AUTOMATION
AUTOMATION
REVIEW
INTEGRATED OR SEPARATE?



SAFE CONTROL TECHNOLOGY



ON SMALLER MACHINERY




Safety controllers are becoming increasingly popular as an alternative to relay modules, even on smaller
machinery. The designer can opt for one of two concepts: some designers favour integration of safety into the
automation PLC, but a separate (small) safety controller offers clear benefits.


‘Safety integrated’ or ‘safety separated’: should machine
safety be integrated into the PLC or implemented separately
using separate hardware and software? This is the question
that every machinery designer needs to ask today.


Replacing relay modules
The question is especially important in the case of smaller
machinery with a manageable number of safety functions
and switchgear devices. There is a noticeable trend favouring
replacing multiple safety relay modules with one small safety
controller or with a PLC with integrated safety functions.
There is good reasoning behind this trend. In the first
instance, machinery is becoming increasingly complex. It
features additional and differentiated safety functions, in
some cases offering interaction with the operator. Examples Fig. 1: Developed for applications with a manageable
include setup with touch mode or troubleshooting. This does, number of safety switchgear devices – the parametrisable
however, presuppose that these options can be mapped and compact safety controller Protect Select.
monitored in the safety-focused control system. Additionally, certain complexity. With safety control systems, the wiring
the requirements on the safety of machinery are becoming effort is reduced. The configuration is also simpler and enables
increasingly stringent, partly due to growing awareness of better adaptation to the individual application as it can be
hazards and partly due to increasing differentiation of general realised in wide- ranging areas through parametrisation and
and machinery-specific standards. programming.

Productivity and availability Integrated or separate?
Equally important is the fact that differentiated, needs-based To return to the original question: should the machinery
implementation of safety requirements can also enhance user builder accomplish these benefits with an integrated or
operability and machinery productivity. With a safety-focused separated solution for the safety of machinery?
control system, machinery builders can create the prerequisite At first glance, there is more than one argument in favour of
for bringing only part of a machine to a halt in the event of integration – the fact, for example, that modern PLCs cover
irregularities. Additionally, safety functions can be linked safety of machinery tasks and that users can save on costs as
together, which can also lead to increased productivity and well as space in the control cabinet. Plus, it’s for good reason
avoidance of unscheduled downtime. The enhanced diagnosis that integration has become a popular concept in automation
options when compared to safety relay modules enable more and digitisation.
rapid localisation of fault causes in the event of malfunctions. In theory at least, integrated solutions promise robust
With traditional relay modules, the effort required for wiring, coordination of functions and simple infrastructure with
documentation and validation of the module solution becomes reduced hardware effort. In practice, there are clear benefits
disproportionately large when the safety functions reach a of a separated solution One of the positives of standalone


www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 21

INDUSTRIAL
AUTOMATION
AUTOMATION TECH INNOVATION
REVIEW

safety infrastructure is the fact that a safety concept can be
accomplished independently of the automation solution and,
therefore, independently of the manufacturer of the functional
control system that may
be specified by the machinery builder. Consequently, even
when customer-specific automation PLCs are used, a
standardised safety concept can be accomplished on an
always identical component and hardware basis.
Another benefit is that you do not need to be a PLC
specialist to program the safety functions – the range of
language is manageable when compared to automation
control systems.


Integration option Fig. 2: The Protect PSC1 safety controller enables the
Opting for separate safety does not mean that integration is realisation of ‘safety separated’ solutions. It also enables
impossible. Quite the opposite in fact. Bus protocols enable integration into higher-level infrastructure.
integration into higher-level control systems, something which as free allocation of feedback circuits (EDM), start-up tests,
might be required when production systems comprising cyclical testing and auto-start with every program. Additional
multiple subsystems from different providers need to be functions and operating modes (setup mode, process
integrated. In that case, the safety solutions of the individual monitoring) can also be accomplished.
system must be connected in order to implement a higher-
level emergency-stop function, for example. Modular compact safety controller
If the higher-level safety concept is based on a safety If a higher level of customisation and adaptability is required,
integrated solution, machinery and subsystems that operate in the Protect PSC1 safety PLC could be an option. Thanks to
standalone mode can often only be operated in a rudimental its modular design, it is easy to adapt to user requirements,
manner. On the other hand, a compact safety controller like irrespective of whether the signals from emergency-stop
the Protect PSC1 from Schmersal offers a simple and flexible control devices, electromechanical safety switchgear, tactile
option by means of integrated safety protocols (Profisafe protective devices, safety sensors or optical protective devices
and FSoE) to operate such machinery encapsulated and, if need to be evaluated. A number of modules are available for
required, to integrate them into fail-safe fieldbus architectures fail-safe drive monitoring, which reliably monitor parameters
without having to make changes to the safety application. including position, speed and increment.
Additionally, the controller can also be supplemented with
Compact and complete a universal communication interface, where the user simply
Manufacturers of smaller machines in particular are selects and sets various bus protocols such as Profinet,
increasingly having to confront more stringent safety Ethercat, Ethernet/IP, Profibus or CANopen using software.
requirements. In addition, the expectations of end customers The interface also allows safety remote I/O communication
in terms of diagnosis options and ease of maintenance are and the simultaneous connection of up to four systems via
also on the increase in this segment. This requirements profile safety cross communication via Ethernet. An OPC UA server
can be mapped easily and cost-effectively with a small safety can also be integrated. In summary, a safety separated
controller. Depending on the application, standard automation safety concept can offer significant benefits in terms of
can also be realised with the small controller, and integration standardisation, operating convenience and flexibility.
can be achieved ‘in the opposite direction’.
The Schmersal Group offers two options to help achieve a Authors:
safety separated concept on smaller machinery. The Protect Christian Lumpe and Tobias Thiesmann,
Select small safety controller has been specially developed Product Manager for Control Systems, Schmersal Group
Schmersal India Pvt Ltd.
for this very application. The user does not have to program Plot No. G-7/1, Ranjangaon MIDC,
the controller but can choose from pre-configured programs Tal. Shirur, Dist. Pune – 412220 India.
and only has to enter the corresponding parameters. These Phone: +912138614700
applications cover a wide range of possible use cases. E-mail: [email protected]
Additionally, the user can also activate special features such Web: www.schmersal.in


22 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

INDUSTRIAL
TECH INNOVATION AUTOMATION
AUTOMATION
REVIEW
New Digital Tool Management



System for High Productivity





















Subash Ramdoss
The author is DGM-Special Projects, Machining and Engineering,
ELGi Equipments Limited



LGi’s Tools Management System (TMS) is a digital Benefits Galore
platform developed in-house and deployed to man- • This system ensures that all the tools and equipment
age manufacturing facilities. This platform makes it used in the production lines are maintained and kept in
Eeasy to track, maintain and manage the lifecycle of prime condition to assure the build quality in the assembly
all the tools, facilities, and equipment used in the production process.
assembly line. • The quality and life cycle costs of the tools, facilities,
annual maintenance contracts are monitored, and
Cutting-edge TMS Platform decisions on future purchase choices can be well informed
In a single assembly line of approximately 8000 square based on actual performance data.
feet, about 500 tools and equipment are required to ensure • The activities are well planned; ownership matrix
consistent build quality. With ELGi’s new TMS platform, the and responsibilities are maintained between different
facilities manager can digitally map the range of hand tools, stakeholders, such as production, maintenance, quality,
including spanners, torque tools, testing systems, gauges, stores, suppliers, and machining and engineering teams.
material-handling trolleys, fixtures to specialized expensive Elimination of frequent follow-up and firefighting improves
Digital SPMs and testing facilities. The platform also white-collar productivity and higher morale of blue-collar
successfully maps information related to critical subsystem employees.
parts, asset owners, maintenance in charge, vendor • This digital tool management system ensures proactive
information, item price, warranty, maintenance frequency, maintenance of all the assets that are essential to the
visual checkpoints, and expected life necessary to monitor products build quality and creates a complete asset
and maintain the performance of the assets. register for assembly lines.
This cutting-edge digital platform allows manufacturing
facilities to map out a matrix of responsibilities and workflows Based on this pilot project’s success, this Digital Tool
to maintain specific assets, automated alerts for asset Management System will be deployed across our other
replacement, maintenance, and performance monitoring assembly lines systematically.
without manual intervention. Recognition, after-service
performance feedback, and replacement processes are
incorporated into the workflow. While designing the platform,
a workflow for defect replacement requests for assembly For more information
tools with an approval process is also included. https://www.elgi.com/in/


www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 23

INDUSTRIAL
AUTOMATION TECH INNOVATION
AUTOMATION
REVIEW #PREDICTIVE MAINTENANCE

The Automated


Predictive Maintenance





Everyone in the industrial manufacturing community has heard stories about downtime. But for those who
have lived it, statistics such as one hour of downtime cost manufacturers up to $260,000 per hour or two
million dollars in 4 hours do not tell the entire story. Aside from monetary losses, the actual cost of downtime
includes a disillusioned workforce which becomes more difficult to motivate when persistent equipment
failures occur. These are some of the reasons why the automation of predictive maintenance is fast becoming
an industrial concept that enterprises integrate into everyday business operations.











































Predictive maintenance as an data a shop floor asset produces downtime by approximately 20%
Industrie 4.0 business model is the foundation for automating while the option of automating the
Predictive maintenance involves taking maintenance tasks at both component process can further increase this
a preemptive approach to discovering and assembly level. percentage and reduce unplanned
faults in, maintaining, and repairing Although predictive maintenance downtime. The choice to integrate the
factory equipment before it fails. As is an Industrie 4.0 concept, it still automation of predictive maintenance
with every Industrie 4.0 concept, this applies to both legacy and relatively across the shop floor also comes with
approach also relies on data capture new assets. According to The Plant many benefits which include:
and analytics. Thus, the ability to Engineer’s Handbook, predictive
understand the historical and current maintenance has the ability to reduce 1. Reduction in total manufacturing


24 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com



INDUSTRIAL
AUTOMATION
AUTOMATION TECH INNOVATION
REVIEW #PREDICTIVE MAINTENANCE

cost (TMC) – In manufacturing, components – Automating regular 3 steps to automating
maintenance costs, repairs, and costly predictive maintenance activities predictive maintenance in
replacements add up to a considerable ensures the task is completed as and manufacturing facilities
proportion of the TMC of developing when due. The discipline of keeping to As with most manufacturing concepts
a product. Automating predictive a strict schedule where maintenance or business models, steps to adopting
maintenance helps reduce these is concerned increases the life span an automated predictive maintenance
costs in significant ways. These ways of components in a machine. This culture exist. These steps include the
include having knowledge of a piece is because the machine and its following:
of equipment’s life span, scheduling components will be equipped with the
planned downtimes, and planning resources needed to keep it running Integrating data capture devices
inventory lists for spare parts. until the next maintenance cycle. in equipment – The first step to
Automated predictive maintenance automating predictive maintenance
initiatives lead to planned downtimes 3. Reduced accidents on shop floors involves the capture of relevant data
that reroute production away from – from the equipment. In greenfield
affected equipment. They also In manufacturing facilities, material facilities, the general manufacturing
eliminate the possibility of human handling equipment is responsible equipment used is equipped with
errors in calculations which can delay for approximately 85 fatalities and sensors and actuators that monitor
the repair or maintenance activities thousands of injuries yearly in the performance and the health of
associated with shop floor equipment. US alone. These incidents occur due components. In brownfield facilities,
The automated process also comes to dysfunctional forklifts, employee data capture can only be achieved
with its own butterfly effect on an negligence, and more importantly, after the integration of smart devices
enterprise’s spare parts inventory. The poorly maintained material handling into legacy equipment.
knowledge of the task to be done can equipment. This is where automating A smart human-machine interface
be used to automate the purchase of predictive maintenance activities come device can be used to track the
replacement parts ahead of time, thus into play. With proper maintenance, temperature, vibration, and other
reducing excessive stocking while material handling equipment and aspects of a piece of equipment on
ensuring the maintenance team has all other engineering assets will function the shop floor. With these historical
the tools required for the task. as expected without springing any data in place, as well as downtime
surprises on unsuspecting shop floor or failure-rate data, the process of
2. Increased service life of machine workers. automating predictive maintenance


































26 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

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INDUSTRIAL
AUTOMATION
AUTOMATION TECH INNOVATION
REVIEW #PREDICTIVE MAINTENANCE

activities across a shop floor can be accomplished. The highlighted above.
manufacturing enterprise will also need to set up industrial
cloud solutions, analytical applications, and a functional An enterprise’s success in integrating automated predictive
ticketing or alert system to automate the predictive maintenance relies on the commitment levels of the
maintenance process. management team and employees. Only then can the
automation process be successful as everyone understands
Algorithms to monitor patterns in real-time – For their role within an automated manufacturing shop floor.
manufacturing enterprises just starting out, it is
understandable that historical data that provide context Conclusion
into an equipment’s health is unavailable. This is where When automating predictive maintenance, the use
machine learning and artificial intelligence come into of pilot programs to get everyone on the same page
play. Enterprises will either need to purchase services is recommended. If the automation is properly done,
or build applications powered by algorithms that enable manufacturing organizations can reduce downtime by 55%
condition-based monitoring. These services are among the and repair and overhaul time by approximately 60%. An
applications highlighted in the first point in this section. effective maintenance culture will also reduce expenditure
It is also important to note that there are different on equipment replacement while creating a conducive
techniques for assessing comparative machine data as the environment for increased productivity.
IT infrastructure kick-starts the process and the equipment
collects data. Manufacturers can choose to purchase the
related data from platforms offering Data as a Service
to their industry niche or make extrapolations using the
equipment’s repair or maintenance guide as a standard.

A fundamental mind-set change to maintenance – The
success of integrating automated predictive maintenance
in a shop floor still depends on management and employee
knowledge of predictive analysis. This is why the need to
create a management and employee policy on automating For more information,
predictive maintenance is important. Stakeholders within Email: [email protected],
the four walls of the manufacturing outfit must understand [email protected]
what it takes to automate and the benefits it brings as Website: www.exorint.com

































28 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

modular





Linear robots
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Room, line, flat gantry




Paralell kine
Delta robot




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Robot
Articulated arm robot Scan the below
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/automation





g i u s ® n I ( P ) a i d . d t L . t v Dodda Nekkundi Indl Area-2nd Phone - +91-80-68127800
36/1, Sy No. 17/3, Stage, Mahadevapura Post, Fax - 91-80-68127802
NCPR Layout, Euro School Road, Bangalore- 560048

INDUSTRIAL
TE
V
A
CH INNO
AUTOMATION
AUTOMATION TECH INNOVATION
TION
REVIEW #THERMAL IMAGER
The new thermal imager testo 883:
Advance assistance for those who work in

predictive maintenance, condition monitor-


ing & facility management



Measuring technology expert Testo is offering efficient assistance to its customers involved in predictive
maintenance and facility management, in the form of the new thermal imager testo 883. This thermal imager,
which offers the best image quality and automatic image management, was developed, and manufactured
entirely in Germany. This remarkable camera greatly reduces the day-to-day workload of those who specialize
in the efficient operation of plants.































Maintenance makes all the difference
In the day-to-day work, maintenance, safety auditors and
facility management experts can make all the difference
between experiencing a successful day with achieved
production targets or less productive days with losses due to
unplanned downtime. To add to that, their work is made more
difficult by constant high time pressures, administrative and
documentation efforts that are not very often productive and
inadequate tools could be a challenge too. That is the reason
why the experts require the best maintenance equipment.

The image quality is what matters
The testo 883 thermal imager offers an infrared resolution of
320 x 240 pixels, which can even be expanded up to 640 x of the thermal image.
480 pixels with the built-in testo SuperResolution technology.
And the manual focus always guarantees the user full control Automatic image management


30 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com

INDUSTRIAL
AUTOMATION
TECH INNOVATION AUTOMATION
#THERMAL IMAGER REVIEW

A typical problem in maintenance
occurs due to a lot of similar measuring
objects, for example, from switch
cabinets a lot of similar thermal images
can be obtained while inspection. In
order to clearly allocate the images
after an inspection, earlier it was
necessary to create elaborate lists
or add a voice comment to each
thermal image. Testo Site Recognition
technology solves this problem
by automatically recognizing the
measuring location and saving and
managing the thermal images. It rules
out the possibility of any mix-ups,
prevents errors during evaluation and
saves a lot of time by eliminating the need for manual image Application areas
assignment. In the industry where machines and equipment like motors,
generators, gear boxes, bearings, shafts are continuously
Networked working operational, it becomes equally important to ensure their
The testo 883 thermal imager integrates seamlessly into health and proper working conditions. Early identification
Testo’s digital measuring technology portfolio. With the testo of imminent malfunctions, wears, damages or defects on
Thermography App, thermal images can be quickly analysed plants and machines is critical and same goes for electrical
on a smartphone/tablet or shared with colleagues, decision components like switching cabinets. Similarly, serious threats
makers and managers. Readings from the testo 770-3 clamp like hotspots, short circuits, cracks, corrosions can jeopardize
meter and testo 605i smart thermo-hygrometer are also the power output of solar PV plants and its components. For
integrated directly into the thermal image. For example, when such predictive maintenance application, Wi-Fi enabled testo
checking switching cabinets, the load status can be recorded 883 is the ideal instrument.
directly in the thermal image to reliably assess the condition Health of a building, construction quality, improper heat
of the system. transfer, leaks, cracks, or moulds in the structure can also be
easily monitored. In addition to that, for any facility, right from
shopping malls, hospitals,
exhibition centres, meeting
rooms or even airports, proper
checking of air ventilation &
conditioning systems and
their installations is must
because it directly influences
human comfort and
health which can be easily
addressed with new testo
883.











For more information,
Website: www.testo.com


www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 31

INDUSTRIAL
AUTOMATION TECH INNOVATION
AUTOMATION
REVIEW
emPower Your Control Cabinet with


WAGO Power Supply Pro 2




ast, flexible, as cost-ef-
fective as possible – in
the face of increasing cost
Fpressure, scarce resourc-
es and tight delivery times. The
demands on the control cabinet
industry are steadily increasing.
Production processes are under-
going increasing digitization and
automation to reduce costs and
save time. That’s where power
supplies play a decisive role. But
what does a modern power sup-
ply look like? And what must it be
able to do? With the WAGO Pow-
er Supply Pro 2, WAGO launches
future-ready devices that power here for savings potential. This study of Control Cabinet
your application: Choose the Power of the Possible! Manufacturing 4.0 shows that switching from project-specific
or order-oriented circuit diagrams to modular circuit diagrams
Save Time with Modular Circuit Diagrams can save up to 45 % of the time of the engineering process.
A modern power supply must basically do one thing: There is significant potential for optimization such as this in
Convert alternating current into a safely electrically isolated control cabinet manufacturing and in the power supply, since
direct current. It is also necessary to save time and money many work steps are still performed without automation even
simultaneously – but how? According to a 2017 study by today. 92 % of the study participants surveyed still rely on
EPLAN and the Institute for Control Engineering of Machine two-dimensional engineering. But why? One industry that is
Tools and Manufacturing Units at the University of Stuttgart, facing particular challenges in this regard is the automotive
planning and creating the circuit diagram accounts for industry.
over 50% of the design time. There is significant potential
Automotive Industry: Increasing Demands on
Power Supplies
If a production system in automobile manufacturing is idle
for even a few minutes, it can quickly cost several thousand
Rupees and mean fewer vehicles produced. That’s all the
more exasperating if it’s caused by the failure of a power
supply whose original price was only a fraction of these
costs. To avoid this, it is essential to choose a reliable power
supply. Availability plays an important role for automobile
manufacturers above all else. An important selection criterion
for the power supply is its theoretical life expectancy. It’s
worth taking a close look at the datasheets when selecting
the power supplies: Comparable devices may differ
significantly upon closer inspection. A long life expectancy
is usually also associated with low heat generation and low
power loss. The example of power loss makes clear that
intelligent selection and dimensioning of power supplies can


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also reduce energy costs. automation and control level.


The Crucial Difference: the Right Intelligent Overload Behavior
Control Cabinet Cooling Applications with high output
The higher the power loss is, the more requirements call for professional power
the power supply heats up. That affects supplies capable of reliably handling
the control cabinet air conditioning in power peaks. The WAGO Power Supply
particular: The costs for cooling the Pro 2 gives you the power of the possible
control cabinet increase. Even a couple for all projects. Its load management
degrees of extra heat in the control features corresponding intelligence – after
cabinet mean significantly higher energy all, the point is to supply power reliably to
consumption. Therefore, manufacturers your equipment and protect it at the same
of air conditioners for control cabinets time. With TopBoost, PowerBoost and
recommend a temperature of 95 °F (35 further parameterizable overload behavior,
°C). However, if a higher temperature is the WAGO Power Supply Pro 2 protects
set, as is the case with some automotive your equipment and provides intelligent
industry users, for example 100 °F (38 current and switching modes. 150 %
°C), the delta of five degrees contributes significantly to PowerBoost and up to 600 % TopBoost are available for
reducing the energy costs and CO2 emissions. The control reliable, fail-safe equipment availability.
cabinet components and the power supplies must however
be appropriate for this. The designers need to take the Resource-Efficient Energy Use
derating curves of individual components into account. But Small but powerful: The difference lies in the details. We can
not with the new WAGO Pro 2 Power Supplies, which can show how with a small example: The typical efficiency of a
operated up to +140 °F (+60 °C) without derating. simple power supply with nominal power of 960 W is 91
%. With the Pro 2 Power Supply, the efficiency is 96 %. At
Pro 2 – the New Heart of Your Control Cabinet first glance, this five percent doesn’t seem like much, but it
WAGO’s efficient power supplies always deliver a makes all the difference: The superior efficiency of the Pro 2
constant supply voltage – whether for simple applications Power Supplies eliminates 55 W of power loss. Calculated
or automation with greater power requirements. A high- with respect to an operating time of five years, this means
efficiency design permits space-saving dimensions; a uniform significant savings of energy costs and one metric ton of CO2
housing design and a digital twin make the implementation at the same time. For comparison: A 80-year-old beech tree
very easy. Another advantage: Plug-in connections enable growing 75 feet (23 m) tall can store one metric ton of CO2 –
pre-assembled cabling and faster installation. so with several hundred power supplies in a production line,
that would already be a whole forest. As you can see, a small
Power with Communication for Industry 4.0 difference but a big effect!
The WAGO Power Supply Pro 2 is structured in such a
way that the most important operating status information Challenging Environmental Conditions
can be read off the front, or further valuable data can be Whether in the arctic or the desert – the WAGO Power
retrieved through the controller. Real-time status information Supply Pro 2 can be started and operated from −40 °C to
is essential in order to assess situations in real time and +70 °C. Low derating begins > 60°C and allows 70 % output
respond deliberately. Therefore, the WAGO Power Supply power even in 70°C applications, and even at an elevation
Pro 2 has various functions and components that keep the of 5,000 m above sea level. Furthermore, the wiring in the
user informed. The LED bar chart on the front provides a WAGO Power Supply Pro 2 is very robust against transients.
reliable indication of the current output power, as well as Overvoltage category III ensures safe operation in power
overloads/load reserves. Furthermore, the LEDs indicate the grids with overvoltage surges or control cabinets with
selected operating mode, warnings and errors. regenerative drive controllers.
In terms of data collection and read-out of status
information, the Pro 2 Power Supply can be connected to For more Information
a dedicated communication module at any time, allowing E-mail: [email protected]
selection of the desired protocol for coupling to the https://www.wago.com/in/power-supply-pro2


www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 33

INDUSTRIAL
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AUTOMATION TECH INNOVATION
REVIEW
Red Lion Controls Expands Secure


Remote Access Offering with


Acquisition of MB connect line GmbH





ed Lion Controls, an operating company of UK- Red Lion Controls’ strong global presence,” stated Siegfried
based Spectris plc, is pleased to announce the Müller, CEO and founder of MB connect line.
acquisition of MB connect line GmbH, a leading
Rprovider of secure connection of machines and ABOUT RED LION CONTROLS
plants for remote access, data collection, and M2M-communi- Red Lion has delivered innovative solutions to global markets
cation. The addition of MB connect line supports Red Lion’s since 1972 through communication, monitoring
strategy to deliver secure, easy-to-use edge connectivity and control for industrial automation and networking. The
solutions - enabling organizations worldwide to gain company’s technologies enable customers worldwide to gain
secure real-time data visibility that drives productivity. real-time data visibility that drives enhanced productivity.
Headquartered in Dinkelsbühl, Germany, MB connect Red Lion is part of Spectris plc, the productivity-enhancing
line is a recognized leader of Secure Remote Access, instrumentation and controls company.
Industrial IoT, and Industrial Security services. MB
connect line’s highly secured hardware and software
solutions enhance Red Lion’s modular and rugged
industrial automation and networking technology.
The addition of MB connect line builds on the strategic
collaboration announced between the two companies
in 2019. The acquisition expands Red Lion’s portfolio by
adding a full complement of products from an
industry recognized leader in industrial cyber-security
and offers customers a Remote Service Portal for remote For more information
monitoring and remote configuration. Customers will be Web: www.redlion.net
able to meet the demands of industrial environments and
strengthen their operational resiliency with secure remote
access solutions. ABOUT MB CONNECT LINE
“Red Lion Controls and MB connect line are a powerful Founded in 1997, MB connect line is an independent
combination. With a shared focus on secure connectivity medium-sized business forerunner when it comes to
solutions, we will be better positioned to serve our customers solutions for professional communication via internet –
seeking to strengthen their operational resiliency with the especially for secure connection of machines and plants for
convergence of Information Technology and Operations remote maintenance, data collection, M2M-communication
Technology. Red Lion is very excited about starting this and cloud connectivity. With the remote service platform
new chapter, supporting customers with a broader product mbCONNECT24 and wide range of data modems, industrial
offering and greater technical resources,” stated Jack Lee, routers, firewalls and Industrial IoT devices, MB connect line
President of Red Lion Controls. offers complete customer solutions.
“With the acquisition of MB connect line by Red Lion
Controls, we are taking the next step in our successful
partnership. MB connect line will continue to expand its
comprehensive portfolio of solutions for secure remote
maintenance and networking as well as edge and cloud
connectivity. MB connect line is very excited to work together
with Red Lion Controls to provide the best solutions for the For more information
digital transformation in the industry - and to benefit from www.mbconnectline.com


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HMS presents communication solutions

for Battery Energy Storage Systems




HMS Networks is now presenting several communication solutions for the rapidly expanding battery market.
Battery Energy Storage Systems (BESS) require communication capabilities to connect to batteries and
peripheral components, communicate with the power grid, monitor systems remotely and much more.



































attery Energy Storage Systems (BESS) may be one Since the battery market has been spearheaded by the car
of the keys to solve the energy crisis and make the industry, CAN is the com-munication standard of choice
world more sustainable. Since green energy in many systems. Here, HMS offers an extensive portfolio
Bsources such as wind and solar are not always of communication solutions via the Ixxat brand – for PC
available, large battery parks can make it possible to store the connection, networking, line extension, galvanic isolation and
energy to use when there is less sun or wind. more.
In networking, the protection of components is crucial, both
BESS need to communicate from external sources (like lightning strikes) and from system-
Battery Energy Storage Systems are made up of battery cells related issues (AC/DC noise). Device protection is a must to
which are combined into battery packs which can then be avoid damage.
combined into containers which in turn can make up battery
parks the size of several football fields. The systems can Networking gateways
use new or recycled batteries and combine many different Battery Energy Storage Systems often combine a variety of
components. However, these large battery parks need a different equipment from different industries within a single
lot of communication capabilities in order to work. HMS application – batteries, BMS, PLCs, fire detection units or air
now presents a comprehensive package of communication conditioning. To combine different equipment, it is necessary
solutions catered for this application area. to interconnect various protocols and network standards.
CAN, Modbus, BACnet, KNX and other proto-cols can be
Error prevention and networking of CAN-based easily linked via intelligent gateways from HMS, which
devices handle the all-important data exchange while also enabling


www.industrialautomationreview.com MARCH-APRIL 2022 | IAR 35

INDUSTRIAL
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REVIEW


















Ixxat SG-gateways handle communication between
®
energy and industrial protocols whereas WEBfactory
i4SCADA allows highly adaptable data visualization.
also provide robust cybersecurity fea-tures, such as firewall,
OpenVPN , TLS encryption and user management. These
®
pro-tective measures are indispensable to protect against
cyber-attacks.


“We see a rapidly growing demand for communication
Ixxat products from HMS for CAN-based networking and solutions in Battery Energy Storage Systems as society as
device protection. a whole is turning to more sustainable energy sources such
centralized control. as wind and solar,” says Alexander Hess, General Manager
In addition, these gateways can selectively filter, map and, at HMS Business Unit Ixxat. “Communication is needed to
if necessary, manipulate the data in order to realize the best get BESS systems to work and HMS offers an extensive
possible data exchange. portfolio of industrial communication solutions to solve the
communication issues at hand in these systems.”
Cloud/SCADA connectivity and remote access
Intelligent networking is also required in order to connect to More about communication for Battery Energy Storage
cloud solutions or SCADA systems. This connection can be Systems: www.ixxat.com/bess
made by using SG (Smart Grid) gateways from HMS that
support both energy and industrial fieldbus protocols, as well HMS Networks AB (publ) is a market-leading provider
as protocols required for cloud connection. of solutions in industrial information and communication
The SG gateways enable centralized control as well as technology (Industrial ICT). HMS develops and manufactures
®
®
®
remote access for predictive maintenance, logging or products under the Anybus , Ixxat , Ewon and Intesis
®
data visualization using the i4SCADA solution from the brands. Development takes place at the headquarter in
®
HMS-owned company WEBfactory . The SG gateways Halmstad and also in Ravensburg, Nivelles, Igualada,
®
Wetzlar, Buchen, Delft and Bilbao. Local sales and support
are handled by branch offices in Germany, USA, Japan, China,
Singapore, Italy, France, Spain, the Netherlands, India, UK,
Sweden, South Korea and UAE, as well as through a
worldwide network of distributors and partners. HMS
employs over 750 people and reported sales of SEK 1,972
million in 2021. HMS is listed on the NASDAQ OMX in
Stockholm, category Large Cap, Information Technology.





For more information
Networking gateways from HMS are well-suited for use [email protected]
in BESS. [email protected]

36 IAR | MARCH-APRIL 2022 www.industrialautomationreview.com



INDUSTRIAL
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AUTOMATION PRODUCT
REVIEW SHOWCASE



M12 Push-Pull

Connectors by


Phoenix Contact



























Phoenix Contact has extended its existing M12 portfolio to
include new push-pull connectors with internal locking. The
cross-manufacturer locking system based on IEC 61076-
2-010 enables easy cabling and space-saving device
connection.
The tool-free connection offers significant advantages
during installation, especially in confined spaces and enable easy module-to-module communication. The entire
applications with a high cabling density, such as in factory series now encompasses overall widths of 20, 25, and 50
automation. Components can be inserted and removed mm as well as overall heights of 77, 100, and 122 mm.
faster, enabling you to reduce the installation time by up to Standardized device connections such as RJ45, USB,
80 percent compared to screw connections. D-SUB, and antenna sockets are also supplemented
In addition to the M12 flush-type female connectors for by codable PCB connectors for the housing series. The
front and rear mounting, there is now also an M12 push- connectors with 3.5 mm and 5.0 mm pitches are designed
pull flush-type female connector that is countersunk into for currents up to 16 A and voltages up to 300 V. They are
the device and sits flush with the housing. This saves compatible with the existing connection technology range.
installation space and allows for compact housing designs. The coding element integrated into the connector parts
In combination with the existing M12 push-pull connectors provides reliable protection against mismatching thanks to
with external locking, flying leads enable extensions in the connection of connectors and headers for the first time.
field. Thanks to standardization, the product range offers
cross-manufacturer compatibility and availability worldwide.

ICS series DIN Rail Housing
Phoenix Contact is now supplying its modular ICS series For more information
DIN rail housings in an overall width of 50 mm. The new Phoenix Contact India Pvt. Ltd.
electronics housings accommodate up to four printed circuit F-26/2, Okhla Industrial Area
boards, making them suitable for even more powerful Phase -2, New Delhi – 110020
automation concepts such as I/O groups. DIN rail connectors E-mail- [email protected]


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HEAVYCON - Heavy-duty connectors by Phoenix Contact


Compatible insertion, flexible combination connection technology, which also supports connections based
Dynamic and flexible production on RJ Industrial. Another data module is designed for an RJ45
processes rely on local plug-in connector with crimp connection.
components – in other words, Yet another plug-in connector module from the Heavycon
machines and plants need to Modular family built for Industrial Ethernet in the Gigabit
be arranged and installed using range shields the conductor pairs in the connector itself, and
functional assemblies. These meets the minimum requirements of the Cat 6 transmission
assemblies are interconnected class. Thanks to the module’s end-to-end shielding, data is
with reliable industrial plug-in transmitted without any interference whatsoever.
connectors that need to be flexible
enough to accommodate future Compatible plugging – flexible combination
modifications and expansions. Heavycon Modular – the latest Full flexibility with heavy-
range of heavy-duty plug-in connectors from Phoenix Contact – duty connectors: you can
features modular inserts for a broad range of applications. always create the right
The next step in optimizing manufacturing involves enabling plug-in connection for your
even more flexible installation and operation of machines and requirements with robust
plants, as is called for by the Industry 4.0 initiative. Heavy-duty housings from our three series
plug-in connectors for linking up data, signals, and power lines types and matching contact
offer a confusing variety of modules and housings with an inserts which can be combined:
overwhelming number of configuration options.
HEAVYCON STANDARD – versatile, corrosion-resistant metal
Free choice of connection technology housings with single locking latch or double locking latch
Our contact inserts provide you
with consistently compatible HEAVYCON EVO – freely selectable cable outlet direction with
interfaces, which can be flexibly swivel bayonet lock
combined, for all conventional
sizes and with a variety of HEAVYCON ADVANCE – robust without compromise and
connection technologies. cost-effective with direct mounting
In addition to fixed-position
versions, modular contact inserts are available in various Blind plugging: Docking frames for modular
performance classes. Combine modules for data, signal, and connections
power transmission in one connector – simply snap into the HEAVYCON docking frames
snap-in frame and you’re done. allow the time-saving installation
Fast connection technologies such as Push-in or QUICKON and maintenance of plug-in
insulation displacement connection enable cable connection systems. The floating sockets
within seconds. You can use our fixed-position and modular and the leading guide pin on
contact inserts in every housing series. the docking frame enable safe
and blind contacting of plug
Data transmission based on copper and fiber connections in areas where the interfaces cannot be seen. The
optics robust frame is fitted with modular contact inserts. You can
Both the facility’s production controller data as well as the create your customized interface by combining a wide range of
production data itself are transmitted via data lines. Transfer transmission media in a single frame.
can take place via shielded copper cables or fiber-optic cables. For more information
Heavycon Modular provides modules for connecting RJ45 plug- Phoenix Contact India Pvt. Ltd.
in connectors and supports fully preassembled and tested RJ45 F-26/2, Okhla Industrial Area
patch cables. The flexibility of the Heavycon Modular system is Phase -2, New Delhi – 110020
further enhanced by IDC (Insulation Displacement Connector) E-mail- [email protected]


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