Subscriber copy not for sale VOL. 21 | ISSUE. 10 | JUNE 2023 | WWW.INDUSTRIALAUTOMATIONINDIA.IN Cobots for Manufacturing Heat Exchanger – An Introduction Warehouse Automation: A Transformational Journey
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t the beginning of the 2018 film ‘Jurassic World: Fallen Kingdom’, mathematician Dr Ian Malcolm is shown testifying at a US Senate committee debate. In his opinion the dinosaurs should perish naturally to correct the wrongful cloning done by John Hammond. “We have amassed landmark technological power, and consistently proven ourselves incapable of handling it”, is how Dr Malcolm put it, succinctly. After the dramatic events depicted in the film, in the closing scenes, Dr Malcolm declares the beginning of a neo-Jurassic Age, where humans and dinosaurs must coexist. Life imitates art, it is said. With a wee bit of stretching of the imagination, one can perhaps see the parallels in the actions of Sam Altman, CEO of OpenAI, the company responsible for creating artificial intelligence chatbot ChatGPT. At the Senate judiciary committee in mid-May, Altman declared his support to the regulatory guardrails for the technology that would enable the benefits of AI while minimising the harms. Implicit in that declaration is the human proclivity to misuse anything that has the potential to benefit mankind. “We think that regulatory intervention by governments will be critical to mitigate the risks of increasingly powerful models,” Altman said, his words chosen carefully. To continue in the same vein, from ‘I, Robot’ to the ‘Terminator’ series, enough has been depicted in the movies about the possibility of robots running riot, bolstered by AI. While the fears are not without basis, AI simply does not have the ‘common sense’ to make our fears true. The cover story of this edition is focussed on Robots in Manufacturing and how they are going to be an important part of the evolving smart manufacturing ecosystem. Interesting times ahead. Dr. M Arokiaswamy Editor & Publisher India's No.1 Industrial Automation Magazine INDUSTRIAL AUTOMATION A [email protected] Inviting people to the editor.
Edited & Published by Dr. M Arokiaswamy [email protected] Associate Editor Milton D’Silva [email protected] International Editor Bridget Joseph [email protected] Strategic Developments Benadicta Chettiar [email protected] For Advertisement/Editorial inquiries Ms. Ankita Mane [email protected] Mr. Sandip Shetye [email protected] Mrs. Sony Jha [email protected] Creatives & Design Creatives Department [email protected] Registered Office: IED Communications Ltd 903 Orion West, Station Road Santacruz West, Mumbai 400 054 Cell: 98200 93667/77770 15667. Web: www.iedcommunications.com Printed, published and owned by Dr. M Arokiaswamy. Printed at Jyothi Process 63, Shiv Shakti Industrial Estate, Andheri Kurla Road, Opp Mittal Estate, Andheri, (E), Mumbai 400059 All content/information published in the magazine is copyright of the publisher, all rights reserved. Reproduction of any material from this magazine in any manner without written permission of the publisher is prohibited. Although every effort is made to ensure accuracy, no responsibility whatsoever is taken for any loss due to publishing errors. Industrial Automation will not be responsible for claimed attributes in product information, Highly recommend detailed enquiry with manufacturer/supplier before making purchase decision. Views and opinions expressed in articles and interviews are entirely that of the automation and responding person respectively and not necessarily endorsed by the publisher or the magazine. Disputes, if any, are subject to jurisdiction of competent courts and forums in Mumbai only. Customer care: Whatsapp: +91-9867223530 Email: [email protected] Working hours 10:00AM to 6:00PM (Monday to Saturday) Visit link for further details www.industrialautomationindia.in/advertisements Subscription Offers Check the last page or visit link for plan details www.industrialautomationindia.in/subscriptions India's No.1 Industrial Automation Portal INDUSTRIAL AUTOMATION Editorial Contents News Accelerating Pace of Robotics in Manufacturing Cobots for Manufacturing Enhancing Network Resilience for Your Industrial Control Systems Pepperl+Fuchs Celebrates 25 Years of Raging Success in India Arrival of Full-Scale Linear Motor Age-Linear Shaft Motor Fast and Accurate – Smart Laser Sensors for Precise Automation Revolutionising Manufacturing: The Role of Robotics Heat Exchanger – An Introduction Industrial Servers Ramp up AI for Robotic Arms Data is Key in Digital Transformation of Process Industry Intralogistics: Solutions for Energy and Data Management The Future of Cobots in Manufacturing ‘Increased payload capacity brings cobots closer to conventional robots’ Warehouse Automation: A Transformational Journey Automation ExpoSouth 2023 – A Maiden Success Power Generation: Business Opportunities Identified by NTPC Use of AI in Enhancing Data Centre Infrastructure Management Products 08 10 12 18 24 28 32 36 38 40 44 46 48 50 52 54 58 61 70 72 74 Cover Photo: 3d rendering of industry 40 concept – Image by Freepik 10| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition Dr M Arokiaswamy welcomes Tmt. S Madumathi, IAS, MD, TANSIDCO Ltd at the inauguration of Automation ExpoSouth 2023 at Chennai. A pictorial review of the event is featured in this edition from page 61. Visit: www.industrialautomationindia.in
Accelerating Pace of Robotics in Manufacturing How robots have moved from traditional assembly line jobs to perform in tandem with human workers. Pepperl+Fuchs Celebrates 25 Years of Raging Success in India Pepperl+Fuchs is known worldwide as a pioneer and an innovator in electrical explosion protection and sensor technology. 32 Arrival of Full-Scale Linear Motor Age-Linear Shaft Motor The application of Linear Shaft motors to various fields is rapidly expanding, says Mamoru Takabayashi. 36 Revolutionising Manufacturing: The Role of Robotics Researchers are exploring ways to make robots more collaborative and perform end-toend tasks, says Sunil David. 40 Industrial Servers Ramp up AI for Robotic Arms How smart 3D robotic visual defect inspection can detect defects based on training data. 46 www.industrialautomationindia.in Enhancing Network Resilience for Your Industrial Control Systems 28 18 It is essential to build a futureproof network to enhance network resilience for your industrial control systems. 48 Data is Key in Digital Transformation of Process Industry Endress+Hauser harnesses data and artificial intelligence to optimise internal processes along the value chain. Cover Story Organisers : IED Communications Ltd, Mumbai India Ph : 91-9820093667 / 7777015667 Email : [email protected] Website : www.automationindiaexpo.com Subscriber copy not for sale VOL. 21 | ISSUE. 10 | JUNE 2023 | WWW.INDUSTRIALAUTOMATIONINDIA.IN 11 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
L&T Technology Services and Critical Manufacturing to support Smart Manufacturing L&T Technology Services Limited, a leading global pure-play engineering services company, has announced its partnership with Critical Manufacturing, the provider of innovative, future-ready Manufacturing Execution Systems (MES). The strategic alliance initially sees the companies working with the multinational engineering group, Danfoss, to implement a comprehensive digital framework that harnesses cutting-edge technologies and next-gen capabilities. LTTS works with plant operators worldwide to optimise efficiency, improve productivity, and simplify operations while ensuring compliance with global sustainability standards. The Critical Manufacturing MES is designed from the ground-up to embrace Industry 4.0 technologies and provide a comprehensive pathway to smart manufacturing of sophisticated and complex products. Abhishek Sinha, Chief Operating Officer and Board Member at L&T Technology Services, said, "The advanced Critical Manufacturing MES complements our industry-leading technology services. Our combined expertise and understanding of the markets we serve, supported by the most modern MES platform for Industry 4.0 success, will enable us to drive better business outcomes for our manufacturing and industrial clients." The selection of the Critical Manufacturing MES is part of a Smart Manufacturing Journey for Danfoss, which aims to achieve greater visibility, create transparency, and enhance quality, secure IT/OT operations, and faster time to market. The platform will help standardise operations and processes to improve business process outcomes, compliance, and risk management. Danfoss has a large global presence with 97 factories in more than 20 countries worldwide. Siemens to acquire EV division of Mass-Tech Controls In a step to address the fastgrowing demand for electric vehicle (EV) charging infrastructure in India, Siemens Limited, signed an agreement today to acquire the EV division of Mumbai-based MassTech Controls Private Limited. The division is engaged in design, engineering and manufacturing of a wide range of AC chargers, and 30 to 300kW capacity DC chargers for various end applications for EVs. The cost of the acquisition is approximately Rs 380 million (EUR 4.3 million) on a cash free and debt free basis and subject to other adjustments that are mutually agreed between the parties to the transaction. Closing of the acquisition is subject to fulfilment of condition precedents as agreed between the parties and receipt of requisite regulatory, statutory and other approvals. Post the acquisition, the EV division of Mass-Tech Controls will be fully integrated into the e-Mobility Business Unit of the Smart Infrastructure Business, Siemens Limited. While Siemens has been active globally in the e-mobility infrastructure space for more than a decade, the addition of products will complete Siemens India’s portfolio of e-mobility solutions and will address the needs of the Indian market. The Indian market has unique requirements such as lower power rating and parallel charging. FPT Industrial chosen by Maserati for new Gran Turismo Folgore FPT Industrial, the powertrain brand of Iveco Group (MI:IVG) and world-leading manufacturer of low environmental impact solutions, and Maserati, the legendary House of the Trident, have worked closely together to create the new Maserati Gran Turismo Folgore, the first car in the Brand’s history to adopt a 100% electric powertrain. The new car from Maserati – symbol of power and elegance for almost a century – the Gran Turismo Folgore is based on 800V technology and has been developed with cutting-edge technical solutions derived from Formula E. As a key point, it is equipped with three 300 kW permanent-magnet motors integrated into front and rear FPT Industrial electric axles, delivering up to 761 hp to the vehicle. This powerful and efficient system allows for an astonishing 2.7 sec 0-100 km/h time, with a top speed of 325 km/h. Perfectly in keeping with Maserati’s DNA, the FPT Industrial ePropulsion system offers superb performance, combined with the high quality and elegance typical of the Trident. Jointly developed by FPT Industrial and Maserati, the FPT Industrial eAxles – a single-motor electric axle at the front and a two-motor electric axle at the rear – deliver top levels of power density (up to 4.83 kW/kg). These axles are a first from the FPT Industrial brand, and feature a compact and lightweight design thanks to their fully aluminum structure. NEWS 12| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
HMS Networks expands range of nextgeneration gateways HMS Networks has launched the Anybus® Communicator™ EtherCAT Main Device, a highperformance gateway that provides an easy and reliable way to connect EtherCAT subordinate devices to different industrial networks and control systems. In recent years, EtherCAT has rapidly gained popularity and is now the third most widely installed industrial network in factory automation globally, and the preferred choice in the semiconductor industry. As the number of subordinate devices utilising EtherCAT continues to increase, there is a growing demand for high-performance gateways that can seamlessly connect these devices to other major industrial networks. The Anybus Communicator EtherCAT Main Device addresses this demand by providing a reliable solution for connecting EtherCAT subordinate devices to PROFIBUS, EtherNet/IP, PROFINET, or Modbus-TCP control systems. With the Anybus Communicator, users can quickly and effortlessly scan the EtherCAT network for devices directly from its web user interface. The Communicator automatically identifies each device and maps its data to the control system, eliminating the need to manually search for and import device description files (ESI). The award-winning Anybus NP40 industrial network processor ensures that the Communicators meet demanding requirements in terms of industrial performance, reliability, and security. Featuring new hardware and software, the gateways enable instant data transfer – up to 10 times faster than their predecessors. Users can also exchange significantly more data between the networks as the gateways transfer up to 1 500 bytes to and from connected PLCs. ABB India expands manufacturing footprint of drives portfolio ABB India has expanded its production footprint with a new line for variable speed drive modules at the Peenya factory in Bengaluru. The new line will produce drives ranging from 75 kW to up to 250 kW and will cater to all major industrial segments. ABB’s variable speed drives are used to control the speed of electric motors to match the actual demands of the process to improve energy efficiency and performance in any industrial application or any building globally. When added to the existing motor of a pump, fan or compressor, a drive can typically reduce power consumption by up to 25%. Part of the integrated campus that houses ABB’s corporate office and other business’ factories, this new production line aims to meet the growing demand of domestic and global customers. With local manufacturing, now customers in India will get faster access to the products, their customisation options, and quick serviceability. The expansion will also strengthen the local supplier eco-system for ABB low voltage AC drives portfolio. “This expansion demonstrates our commitment to innovation, delivering world-class sustainable products and solutions for the Indian market as well as to enriching the local supplier base,” said A R Madhusudan, President, Drive Products, ABB India. GEAPP forges critical partnerships in India to accelerate clean energy transition The Global Energy Alliance for People and Planet (GEAPP) in India announced critical partnerships aimed at supporting India's ambitious mission of achieving clean energy independence by 2047. GEAPP will partner with the Indian Railways to support their solarisation of transport, Ashoka University to develop knowledge documents and research papers for policymakers, and Mahatma Phule Renewable Energy & Infrastructure Technology Limited (MAHAPREIT) to build the Waste to Energy (WTE) and Compressed Biogas (CBG) market. GEAPP also announced ENTICE – the International Energy Transitions Innovation Challenge, an initiative that focuses on supporting innovators to reach scale on energy transition-focused ideas and solutions. Announcing GEAPP's ambitions in India, Ravi Venkatesan, Chairman of the Global Energy Alliance for People and Planet (GEAPP), stated that "GEAPP is a unique multipartner vehicle focused on delivering a transformational pipeline of projects that will enable an equitable energy transition across emerging economies. Through strategic partnerships and innovative solutions, GEAPP in India is dedicated to empowering India's energy sector. Our ENTICE programme is designed to mainstream startups and entrepreneurs in solving critical problems, which will help India become a leader in renewable energy, offer a blueprint to lift other emerging economies out of energy poverty and deliver successful energy transitions." NEWS 14| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
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Rohde & Schwarz signal generators and analysers approved by Qualcomm The R&S SMW200A and R&S SMM100A vector signal generators and the R&S FSW and R&S FPS signal and spectrum analysers from Rohde & Schwarz have been approved by Qualcomm for testing the Qualcomm® QRU100 5G RAN Platform – an O-RAN compliant solution with architecture flexibility designed to facilitate scalable and cost-effective 5G network deployments. OEMs providing RUs for Open RAN infrastructure adopting the Qualcomm QRU100 5G RAN Platform can be confident that these Rohde & Schwarz solutions meet the necessary sub-6 GHz test requirements for design verification and production. Several Rohde & Schwarz test solutions have been approved by Qualcomm Technologies, Inc. in their latest Qualcomm® Development Acceleration Resource Toolkit (QDART) release for testing the Qualcomm QRU100 5G RAN Platform in the 5G NR FR1 frequency range. OEMs who integrate the solution from Qualcomm Technologies in their radio units (RU) can now rely on the R&S SMW200A and R&S SMM100A vector signal generators and the R&S FSW and R&S FPS signal and spectrum analysers during design verification testing (DVT) and production testing. Deploying 5G networks with infrastructure that meets modern demands comes with major challenges, as achieving the right balance between high capacity, low latency and cost efficiency becomes increasingly difficult. The Qualcomm QRU100 5G RAN Platform is a comprehensive modem-RF solution that aims to address these challenges, helping operators and OEMs enable flexible network deployments by delivering O-RAN-compliant 5G solutions. Mitsubishi Electric India intensifies CSR initiatives in Bengaluru Quality education and a sustainable healthcare system is the way for a nation's growth and development. Mitsubishi Electric India has been contributing to create a sustainable society for all through its CSR initiatives across several cities of the country over many years now. The company's Corporate Social Responsibility strategy is aligned with United Nations Sustainable Development Goals and Government of India initiatives. Bengaluru being the centre for high-tech industry and IT hub of the country, attracts evolution and advancement. Mitsubishi Electric India's comprehensive approach to sustainability extends beyond their energy-efficient products and services, by supporting the development of important areas such as education, clean water & sanitation and healthcare across the city which eventually empowers the future of the nation. Since 2017, Mitsubishi Electric India has pro-actively strengthened the infrastructure and sanitation facilities for more than 16 government Schools, Hospitals, Industrial Training Institutes and Public Health Centres in and around Bengaluru through installation and regular annual maintenance of RO units, water cooler systems and air conditioning units. The CSR initiative has positively impacted more than 10,000 beneficiaries in the vicinity of the city. Intensifying its commitment towards community development and skill development, the company has installed air conditioning units at the computer labs of Government Industrial Training Institute located at Tumkur Roar, BT Centre, Bengaluru. UltraTech Cement to implement innovative technology from Coolbrook UltraTech Cement Limited and Coolbrook will jointly develop a project to implement Coolbrook’s RotoDynamicHeaterTM (RDH) technology in one of UltraTech’s cement manufacturing units. UltraTech will be among the first industrial players in using Coolbrook’s revolutionary technology for decarbonisation of cement manufacturing process. The RDH technology uses electrification from renewable sources for the heating processes in cement production and removes the need to use fossil fuels, thus helping to accelerate the decarbonisation of cement manufacturing. This project is a part of UltraTech’s efforts to leverage cutting-edge technology solutions to accelerate the decarbonisation of its operations in line with its 2050 Net Zero commitment. The successful implementation of the RDH technology is expected to reduce the use of coal-based thermal energy in cement production processes. The project envisages the use of Coolbrook’s RDH technology initially for replacing the use of fossil-fuel based energy in the drying of alternative fuels and the learnings from the project will be used to scale it up for deployment in the use of cement production processes. UltraTech had signed a memorandum of understanding (MoU) with Coolbrook in June 2022 to jointly explore the use of RotoDynamicHeater technology to electrify the cement manufacturing process. Coolbrook and UltraTech are now extending their cooperation following the successful large-scale pilot. NEWS 16| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
Aucotec to present system that fully implements the standard at CIRED At CIRED 2023 (June 12-15) in Rome, the leading international forum for the power distribution industry, Aucotec AG will, for the first time, show how IEC 61850 has been integrated into its Engineering Base (EB) software platform to a large professional audience. This unique, deep integration of the international standard is an essential step towards future security in substation planning and documentation, says Aucotec's Product Manager Michaela Imbusch. In the run-up to the congress, she points to current, high-pressure planning: "Almost all operators worldwide now have to significantly expand their capacities. These systems live on for decades, so securing the future is essential." IEC 61850 is THE issue in energy distribution circles and causes headaches for many grid operators. As well as setting down a uniform, manufacturer-neutral description of digital substations' structures, it also defines the ways to communicate with control and protection devices. Here, the IEC requires SCL (Substation Configuration Language) formatting. This language will become even more important in the future, as control-side systems will change significantly. "Bus technology is also being introduced here, from out in the field to control systems," says Imbusch. Information is transmitted via the bus line in IECcompliant SCL. This considerably reduces cabling. "There are already fewer control cabinets in substations, and in the long term there will only be servers," says the Product Manager. It's quite different with Aucotec's EB platform. Heavy machinery manufacturer Orkel grows with RealWear devices RealWear, the world’s leading provider of assisted reality solutions for frontline industrial workers, have announced that Orkel, a Norwegian manufacturer of compactors and other machinery for agriculture, industry and waste management, has standardised on RealWear wearable devices across its business and dealer network. Orkel aims to provide real-time customer and product support, eliminating wait times for in-person visits and avoiding costly downtime delays for farmers. The company’s initial purchase of 40 units through RealWear’s Gold partner Allegra AS, will be used for remote after-sales maintenance, remote servicing and remote commissioning of all its heavy agricultural machinery products. Orkel’s research and development team tested a variety of smart glasses before standardising on RealWear’s HMT-1® head-mounted displays. According to Orkel, RealWear’s rugged form factor, safety features, noise cancellation and long battery life were deciding factors. The innovative solution allows Orkel to connect its customers to its service technicians without the need for unnecessary travel. As part of Orkel’s aftersales support offering, each customer in need of commissioning or a technical service receives a kit consisting of the HMT-1, a branded Orkel hardhat, and mounting clips. The customer simply puts on the device, contacts the Orkel technician using voice commands and, after connecting, the technician can immediately see exactly what the customer sees through the head-mounted camera and easy to use software – VSight. The technician then solves the issue. LAMIERA 2023: a great success, highly positive results Highly positive results were achieved at the 22nd edition of LAMIERA, the international exhibition of sheet metal, tube and section cutting, forming and processing technologies, which took place at fieramilano Rho from Wednesday 10 to Saturday 13 May. The only trade show in Italy specifically dedicated to the sheet metal field, over the years, LAMIERA has become one of the most important events in the international scenario of the sector trade fairs, also thanks to the change of venue from Bologna to Milan in 2017.On a total floor space of 40,000 square meters, the key players of the exhibition were about400 exhibiting companies, of which 27% came from abroad, representing 22 countries. Promoted by UCIMU-Sistemi Per Produrre, the Italian machine tools, robots and automation systems manufacturers' association, and organised by CEU-Centro Esposizioni Ucimu, LAMIERA was exceptionally held just one year after the previous edition, which had been postponed for 12 months due to the public health emergency. Therefore, in order to recover its usual positioning in the odd years, the trade show did not follow its normal biennial schedule. Nevertheless, the achieved results have been more than satisfactory, both in terms of exhibitors and of visits. The visits of professional operators registered during the four exhibition days were about 19,000. 17 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition NEWS
COVER STORY
COVER STORY How robots have moved from traditional assembly line jobs to perform in tandem with human workers. As India is sparing no efforts in ramping up manufacturing capacities in existing industries and building new Greenfield facilities, robots are expected to be part of the evolving smart manufacturing ecosystem. Robots have also moved on from their traditional assembly line, welding and painting jobs to perform many other tasks including machine tending, inspection and testing, quality control, and several others. Apart from OEMs, a lot of startups and system integrators are today engaged in this effort. What is the extent of robots in the manufacturing industry today and what are the emerging contours of the smart industry ecosystem in India? What is the present status of sector wise robots penetration in India? What are the segments that are witnessing increased demand? “Robots have made significant strides in the manufacturing sector, especially in industries like automotive, electronics, and pharmaceuticals, being utilised for tasks such as assembly, welding, material handling, and quality control. In the healthcare sector, surgical robots are gaining traction, enabling more precise procedures. While the use of robots in agriculture is relatively limited in India, there is growing interest in employing them for tasks like harvesting, seeding, and weed control to enhance efficiency and address labour shortages. In logistics and warehousing, robots are increasingly being employed to meet the demands of ecommerce. They assist in order fulfilment, inventory management, and goods transportation. Education and research institutions in India are incorporating robots to facilitate learning and exploration in fields such as robotics, programming, and artificial intelligence,” says Rajesh Nath, Managing Director, German Engg Federation (VDMA) India Office. Subrata Karmakar, President, Robotics and Discrete Automation, ABB India Limited, quotes the latest International Federation of Robotics (IFR) report on the sale of industrial robots in India which mentions India has reached a new record of 4,945 units installed in 2021. This marks a 54 per cent increase as compared to the year before (3,215 in 2020). This makes India rank tenth highest worldwide in terms of annual robot installations, along with the robot density per human rapidly increasing. “With a 31 per cent share, the automotive industry continues to be the largest customer for the robotics industry within India, doubling their installations to over 1,500 units in 2021. In general, the highest share is held by the metal industry with 308 units followed by the rubber and plastics industry with 246 units and thirdly the electrical/electronics industry with 215 units,” he says. “New robot installations in India have seen a significant increase of over 50 per cent in robot units from 2020 to 2021; whereas the worldwide growth of robot installations from 2020 to 2021 has been 31 per cent,” concurs Frank Thomas, Associate Senior Consultant, ARC Advisory Group, Europe. He too cites the World Robotics report, presented by IFR, which says India now ranks at the 10th position in terms of annual robot installations. “The segments that are witnessing increased demand are electronics, automotive, and the metals and machinery segments, e.g., plastics and rubber machineries with integrated robots. The automotive industry remains the largest customer for the robotics industry in India with a share of 31 per cent in 2021. It is interesting to note that in 2020 the electronics manufacturing segment globally surpassed the robot installations of the automotive industry,” says Frank. Mahesh Wagle, Co-founder & Director, Cybernetik, adds another perspective, that of robot density, which in India stands at 4 for every 1000 employees. While this ranks India at the near bottom among the list of developed and even developing economies, it keeps open tremendous scope for expansion. “India’s automobile sector is the top user of robots in the country. As many as 60% of the country’s robots are located on the automobile industry’s shop floor as per IFR. Automobile majors regularly deploy robots for welding, Accelerating Pace of Robotics in Manufacturing “ ‘Robots have made significant strides in the manufacturing sector’ Rajesh Nath, Managing Director, German Engg Federation (VDMA) India Office. 19 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition Representative image. Photo by usertrmk on Freepik
assembly, and painting. The plant at Sanand that Tata Motors recently acquired from Ford is 90% robotised,” he says. According to him, robots have a natural advantage over humans in repetitive, dull tasks such as packaging, storage, and retrieval, making them useful in FMCG as well as in the warehousing section of multiple industries. Since traditionally the automotive industry has been the main user of industrial robots, the question is how will the electrification of mobility impact this dominance? “Traditionally, the automotive sector has been a major user of industrial robots, benefiting from their precision and automation capabilities in various manufacturing processes,” says Kiran Raju, CEO & Founder, Grene Robotics. “However, the electrification of mobility is set to have a profound impact on industrial robots. With the shift towards electric vehicles and other forms of electrified transportation, the demand for industrial robots is expected to soar. During my time working with DARPA, I worked on a project on autonomous vehicles and that is when I realised that the future of organisations will be driven by autonomy, automation and human-machine co-existence. Moving forward, manufacturers will require robots to handle increased production capacity for electric vehicles and their components. This transition may involve reconfiguring production lines to accommodate the specific requirements of electric vehicle manufacturing, such as battery assembly and electric motor production,” he adds. According to Saurabh Bhatnagar, Partner and Lead, Industrial Automation, Intelligence and Digitalization, KPMG in India, the automotive industry has been using industrial robots for more than seventy years, but there have been significant upgrades in the ways in which robots are used. “By employing robots, companies have experienced accelerated production, reduced costs, improved quality, and enhanced worker safety. As the competition grows stiffer and Health, Safety and Environment (HSE) norms become stricter daily, these aspects will become more critical in future,” he opines. To Saurabh, this shift towards EVs will require the reconfiguration of manufacturing facilities and the adoption of new automation technologies specifically designed for electric vehicle production, such as battery assembly and advanced electronics integration, due to this battery supply chain has also experienced a surge in demand. To address this need, battery manufacturers, auto ancillaries Original Equipment Manufacturer (OEM) are looking to robotic automation for fast and reliable manufacturing. “Thus, electrification in mobility will accelerate the robotic adoption in multiple industries,” he asserts. “The dominance of the automotive sector in the usage of industrial robots is anticipated to be significantly impacted by the electrification of transportation. The transition to electric vehicles (EVs) will bring about various changes, even though the automotive industry has traditionally been a significant user of industrial robots for jobs like welding, assembling, and painting in the manufacturing of internal combustion engine (ICE) cars,” says Mukund Shah, CEO, Affordable Robotic & Automation Pvt Ltd (ARAPL). He cites three distinct trends with EVs: an increase in the need for robots created expressly for battery manufacture; changes that could result from the integration of electric powertrain components and the installation of sophisticated sensor systems for autonomous driving; and as electric cars have fewer moving parts and less complicated engine and gearbox systems, it will result in easier manufacturing processes. The Covid pandemic struck a blow for digital transformation. Has this led to increased demand for robotic automation? “The disruption caused by the pandemic emphasized the need for resilient and adaptable manufacturing processes. To mitigate risks, businesses sought robotic automation solutions to reduce reliance on human labour, ensure social distancing measures, and maintain operations with fewer disruptions,” says Rajesh Nath. “Additionally, the pandemic highlighted the importance of localised production and supply chain resilience, leading to increased interest in robotics for reshoring manufacturing operations. The focus on hygiene and safety measures further fuelled the demand for robots to perform tasks that minimise human contact. Overall, the pandemic has acted as a catalyst, driving a surge in demand for robotic automation across various industries. The pandemic has thus significantly accelerated the demand for robotic automation,” he elaborates. To Subrata Karmakar, the pandemic had led to an acceleration of global mega trends – from labour shortages to consumer demand for personalised products all with the growing pressure to also operate sustainably. Hence, businesses are seeking to adapt their processes to overcome these challenges. “The key to navigating these trends is flexibility, which can be achieved through intelligent automation. By making use of robotics and automation solutions, such as ABB's, customers can gain flexibility, agility and adaptability in their operations. While automation has always been about increasing productivity and quality, in today's world flexibility and the ease of use have become strategic necessities. The equation is simple: those who cannot adapt – whether in production, logistics or distribution – simply will not survive,” he states. “One should not overstate the impact of Covid. Digitalisation is the major driver of improving the OEE of production equipment. Robots help lower the costs. Covid has led to a lack of workforce and thus has also fueled decision processes to invest in robots, but the digitalisation trend itself is the key driver,” says Frank Thomas. “Having said that, I’d like to “ ‘Flexibility and the ease of use have become strategic necessities’ Subrata Karmakar, President, Robotics and Discrete Automation, ABB India Limited “ ‘Robots are used in nearly all stages of an electronics manufacturing process’ Frank Thomas, Associate Senior Consultant, ARC Advisory Group, Europe. COVER STORY 20| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
state that the Covid pandemic accelerated robotic applications in the healthcare sector. During the pandemic, hospitals and clinics began using robots for a broader range of tasks to help reduce exposure to the infection. It is evident that the operational efficiencies and risk reduction provided by health robotics add value in a variety of ways. Robotic applications are of immense importance in such situations as they replicate human actions in hazardous environments, thereby minimising personal contact,” he explains. Mahesh Wagle believes robots demonstrated their capacity to maintain operational continuity even under the onslaught of the Covid-19 pandemic when lockdowns and severe travel restrictions were the norm. Apart from that, the consistent improvement in robot capabilities with the integration of machine vision, selflearning, and AI has led to greater adoption. “Quality, speed, consistency, and safety are the top USPs of automation. Robots add the edge of flexibility. Replacing human labour with robots minimises the bacterial load and, therefore, the chances of contamination. This makes robots useful for the food sector. In this industry, recalls are the worst productivity killer. The food industry also uses robots as vending machines,” he emphasizes. Another important point to deliberate upon is how the entry of cobots and AMRs/AGVs is changing the overall scenario of robotic automation in the manufacturing industry. Undoubtedly, the introduction of cobots and Autonomous Mobile Robots (AMRs)/Autonomous Guided Vehicles (AGVs) is revolutionising the manufacturing industry, fostering a more flexible, efficient, and responsive automation landscape. Cobots excel in promoting human-robot collaboration, harnessing the strengths of both parties to boost productivity and handle intricate tasks,” Kiran Raju. On the other hand, AMRs/AGVs are transforming material handling processes by minimising manual labour, reducing errors, and optimising overall efficiency. These advancements have allowed companies to adapt to evolving production needs, streamline workflows, and achieve enhanced productivity. “As more and more technologies are evolving, manufacturers are empowered to meet industry demands by embracing automation, driving progress, and charting the course for the future of manufacturing,” he points out. “The integration of cobots and AMRs/AGVs offers a flexible and scalable automation solution, increasing efficiency, reducing costs, and enabling manufacturers to adapt swiftly to changing production needs, ultimately leading to a streamlined and agile manufacturing process that unlocks new possibilities for productivity and innovation,” says Saurabh Bhatnagar. “Traditionally robots are utilised in process industries or continuous assembly lines now because of cobots and AMRs/AGVs, discrete manufacturing is adapting more and more robotic solutions. For example, a leading two-wheeler mobility company has employed five thousand robots and AGVs, another leading two-wheeler company has employed a large number of cobots for material handling, decal application, assembly, and some other processes. These companies experience significant percent downtime and productivity gains,” he explains. Based on his long experience, Mukund Shah is convinced the introduction of cobots (collaborative robots) and AMRs/AGVs (autonomous mobile robots/automated guided vehicles) into the industrial domain has had a substantial influence on the overall situation of robotic automation. In support of his assertion, he quotes the following examples of how these technologies are altering the industry: Increased flexibility and adaptability: Cobots are meant to be readily programmed and reprogrammed for multiple jobs and workflows, giving them flexibility and adaptability. This enables producers to respond rapidly to changing production requirements and easily handle lower batch sizes or frequent product modifications. Improved collaboration: Cobots are meant to work alongside human beings, aiding them in a variety of jobs. This partnership between people and cobots has increased manufacturing productivity, efficiency, and flexibility. Improved efficiency: AMRs/AGVs are autonomous robots capable of navigating and moving materials or items throughout a production plant, resulting in increased efficiency and productivity. While robots are gaining in versatility with integration of machine vision and greater use of AI/ML capabilities, is there a supporting infrastructure in terms of skills and system integrators? According to Rajesh Nath, the Indian manufacturing industry has been witnessing significant advancements in automation and robotics, including the integration of machine vision and AI/ML capabilities. However, the supporting infrastructure in terms of skills and system integrators is an important aspect to consider. “The presence of competent system integrators plays a crucial role in the successful implementation of robotics and automation solutions. System integrators are responsible for designing, installing, and maintaining robotic systems tailored to specific manufacturing requirements. While India has seen a growth in the number of system integrators, there is still room for further development and expansion of this ecosystem to meet the increasing demand for automation solutions. Also, VDMA India has been organising the symposium on “Robotomation” – Robotics and Automation trends in manufacturing. Through this, we have given a platform for the automation companies to interact closely with system integrators so that overall, the industry can benefit,” he elaborates. “ ‘‘The Sanand plant Tata Motors recently acquired from Ford is 90% robotised!’ Mahesh Wagle, Co-founder & Director, Cybernetik “ ‘Manufacturers are empowered to meet industry demands by embracing automation’ Kiran Raju, CEO & Founder, Grene Robotics. COVER STORY 21 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
“There already are robot data and analysis methods available today that increase the efficiency of a robot system, guarantee higher reliability and enable predictive maintenance. In addition, processes can be optimised through real-time data analysis. For example, ABB's Paint Atomizer uses machine learning to optimise performance/quality based on data with no human intervention,” says Subrata Karmakar. “Machine learning today allows the system to remember challenges and continuously improves item recognition and identification of optimal picking vectors, e.g., like a human being who learns by doing, a robot can learn over time and become increasingly flexible and effective. This will enhance tasks such as autonomous grasping, with a combination of vision systems and machine learning algorithms that help a robot understand the size and shape of the object and the correct gripper position and pressure to grasp it,” he adds. In the opinion of Frank Thomas, this is by far a large bottleneck. In the past the robot business has been a product business with high volumes on very well-known applications. With cobots, a large number of new applications in more flexible lower volume/higher mix production is evolving and the increased use of digitalisation software including vision systems and AI. “The robot business requires a system/solution business around very individual applications. Much more consulting is needed to understand the new applications and prepare the right choice of robots best matching to the individual needs of the end users. End users also often prefer to leverage the expertise of local system integrators. The transition from a product business to a solution business is ongoing but will take a considerable amount of time to be globally available and supported, also due to the lack of experts,” he suggests. “A major roadblock is the availability of a skilled workforce for programming robots and to maintain them. Given the importance of robots in industry and their high growth rate, it is a question of time that positive interventions by industry and policy makers fix these limitations,” says Mahesh Wagle. Being an interdisciplinary field that combines the mechanical, computer, and electronics streams, robotics education and practice requires an integrated approach. Few educational institutions in India offer robotics courses. This creates the supply crunch that is aggravated by the 12% growth in demand for robots. “Moreover, these courses focus on robot operations, not on the other two areas, viz., design and building of robotic systems and solutions. And because dealing with robots requires additional learning after graduation, the enthusiasm among students is low,” he laments, because robots can deliver on their promise only if integrated correctly in the overall manufacturing system. It takes skill and experience to choose the correct robot for the task, define the process flow, locate and program it, and incorporate safety considerations. Here again, the shortage of skilled manpower becomes a speed bump. Will the recent emphasis on manufacturing incentives for the electronics industry via PLI schemes lead to greater demand for robotic solutions? “The Production-Linked Incentive (PLI) initiative by the government is to enable and empower Indian enterprises to expand their operations, adopt automation solutions such as cobots, and effectively compete in the global marketplace. The PLI scheme represents a significant stride towards boosting the Indian economy,” says Kiran Raju. According to him, the automation drive facilitated by the PLI scheme is expected to not only bolster production but also increase the export of manufactured goods from India. “The scheme offers additional incentives to companies that achieve specific export targets, thereby supporting Indian manufacturers in becoming more competitive globally,” he opines. Saurabh Bhatnagar believes the recent implementation of PLI schemes in India, aimed at incentivising domestic manufacturing in the electronics industry, has sparked a surge in demand for robotic solutions. “These incentives have made it more appealing for companies to establish or expand their production facilities in the country. Robotic solutions offer enhanced efficiency, precision, and productivity, aligning with the goals of the PLI schemes to strengthen manufacturing capabilities. Especially, the electronics industry is expected to witness a significant increase in the adoption of robotic solutions as manufacturers seek to meet the scheme requirements and capitalise on the government-provided incentives,” he elaborates. Summing up, while most on the participants in this story are upbeat about the PLI schemes, Mukand Shah enumerates some of the reasons: i. PLI schemes are floated to remove competitive disadvantages compared to China and thus making the manufacturing sector competitive in cost and quality for the world market from India. ii. Robotic systems can conduct jobs with great accuracy on a consistent basis, eliminating human mistakes and assuring consistent product quality. This is especially significant in areas where accuracy and quality control are critical to the end output, such as electronics. iii. Robotic systems play an important part in automating many production processes. Companies may increasingly use robotics to increase efficiency, productivity, and precision in their production lines in order to promote domestic electronics manufacturing. iv. As the demand for electronics develops, manufacturers may need to swiftly increase their manufacturing capacity. Robotic systems provide flexibility and scalability, allowing businesses to swiftly respond to changing market needs with little delays or disturbances. Note: The responses of various experts featured in this story are their personal views and not necessarily of the companies or organisations they represent. The full interviews are hosted online at https://www.iedcommunications.com/interviews) “ ‘Electrification in mobility will accelerate the robotic adoption in multiple industries’ Saurabh Bhatnagar, Partner and Lead, Industrial Automation, Intelligence and Digitalization, KPMG in India “ ‘Robotic systems play an important part in automating many production processes’ Mukund Shah, CEO, Affordable Robotic & Automation Pvt Ltd (ARAPL). 22| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition COVER STORY
ROBOTICS Collaborative robots offer a cost-effective, adaptable and safe automation option, says Darshana Thakkar. With growing global competition, manufacturing companies are under pressure to reduce cost and sustain their business with profitability. Countries like China have captured the global market in almost all the industry sectors with their lowest prices. Despite having huge potential, India cannot compete with Chinese products worldwide due to higher product costs. For manufacturing companies in India, significant cost challenges lie in higher labour, electricity, and raw materials costs. In recent years, the fast growth of services and other commercial sectors has created a shortage of labour for manufacturing companies. With quick upgradation of technologies, many large corporates of India have already contributed dramatically by adopting the latest technologies. They are at par in using IIoT and Robotics in their manufacturing plants with the developed countries. In India the MSME sector contributes 30% of GDP and 45% exports in manufacturing. The MSME industry has thus made a considerable contribution to nation-building. Still, as a whole, the production volume is distributed in almost six crore small units, and their individual volumes and financial resources are insufficient to afford robotics in their plants. Limitations and roadblocks for MSMEs in adopting robotics 1. MSME companies are facing tremendous liquidity crunch due to many reasons. Delayed customer payment, lower margins due to increased labour, and other overhead costs are the main factors apart from the higher initial cost of the robots. 2. Industrial robots are made to perform in highvolume manufacturing processes with low variations. That makes it difficult for small companies to afford the initial and programming cost. 3. It is challenging to reprogram and redeploy new cell settings and part configurations. 4. Industrial robots lift and handle heavy and oversized parts, which can sometimes be hard to reach; they require larger space and fencing for human protection working on the shop floor. 5. Automation experts and programming engineers are required to use robots. For different processes and parts, programming is needed every time. MSME organisations can't afford the cost of highly skilled professionals to deal with small production volumes. 6. In countries like India, employment is still the biggest challenge. Robots replace manual labour. That is increasing overall unemployment. That creates insecurity among the workers with the entry of robots into the company. Addressing MSME concerns Dear MSME Business Owners, with my years of experience and investment in dealing with the MSME sector, I understand the areas of concern very well. I am sharing some insights that will be very effective and helpful in the automation and technology upgradation of your plant. As we all know, MSME owners are closely and emotionally connected with all the employees and are worried about their job if automation is done in the factory. We, the people of India, think twice before firing an employee unless it is a severe matter. So we prefer collaboration instead of competition. Cobots or co-robots are robots designed and conceived to interact physically with humans in a workspace; the term ‘cobot’ derives from collaborative robots. The cobot works alongside humans and eases the workload, increasing productivity, quality and accuracy. The origin of the cobot The first cobot was invented in 1996 by J Edward Colgate and Michael Peshkin. They call the cobot 'a device and method for direct physical interaction between a person and a computer-controlled manipulator'. Why cobots are proving an effective solution for MSMEs? 1. Easy Programming: Cobots are far more straightforward than traditional industrial robots. Free your employees from routine work and let them become robot operators with more time for the most critical tasks. With intuitive 3D visualisation, you move the robot arm to desired waypoints or touch the arrow keys on the easyto-use touchscreen tablet. 2. Fast Setup: Robot manufacturers have revolutionised the cobot setup, significantly reducing deployment time. Many standard cobot processes can be programmed after free online essential training. Instructor-led online or inclass modules are available for more advanced tasks. Expert advice is available from distributors, certified training partners, and systems integrators. Cobots for Manufacturing The robots Vs cobots equation. 24| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
3. Flexible Automation: Traditional robots can only do one thing. At the same time, cobots are lightweight, space-saving, and easy to redeploy to multiple applications without changing production layouts. Moving the cobot to a new process is fast and easy, giving the agility to automate even small batch runs and frequent line change-overs. 4. Collaborative and Safe: Give cobots dirty, dangerous, and dull jobs to reduce repetitive strain and accidental injuries to humans. The safety system in cobots is very high and reliable. Choosing the appropriate cobot Collaborative robots are becoming increasingly crucial for the MSME sector, and the demand for automation is growing significantly in post-Covid era. Each cobot has its unique features and specifications. Anyone who wants to start a cobot automation project must look closely at the requirements for successful integration. Range, load capacity, accuracy, speed and the number of axes are necessary specifications to look at beforehand. The appropriate selection based on the respective application and job specification is essential. I am sharing herewith key details of top cobots in the industry. 1. Universal Robots Universal Robots is the world's largest cobot cobot is that it performs under challenging settings such as machine tool loading, where the robot frequently comes in touch with cooling emulsions due to its dust- and waterproof protection class IP67. Payloads range up to 20 kilograms, and reach up to 1700 millimetres. 4. ABB ABB robots are versatile; two cobots are synchronised to feed parts to another cobot. Suitable for small parts, different payloads, and sizes make it ideal for precise applications. i. GoFa™ CRB 15000: It features integrated torque sensors in each of its six joints. Payload – up to 5 kg; and reach 950 mm with a Tool Center Point (TCP) speed of up to 2.2 m/s. ii. SWIFTI™ CRB 1100: It can be programmed and configured easily with the help of the graphical SafeMove configurator App and the wizard easy programming software on the FlexPendant. Payload – up to 4 kg; and reach 580 mm, with TCP speed of over 5 m/s. This cobot is 5 times faster than any other 4 kg cobot. iii. YuMi® - IRB 14000: With flexible hands, camera-based component positioning, parts feeding systems, and advanced robot control, this dual arm cobot is most suitable for small part assembly. Payload – 0.5 kg and reach – 559 mm iv. IRB 14050 Single-arm YuMi®: This compact and lightweight (9.5 kg) cobot can be mounted in any position, be it on the wall, ceiling, or simply upright on a workbench. The ultra-light magnesium arm has seven axes and can move similarly to a human arm, providing more mobility than a classic 6-axis robot. Payload – 0.5 kg, and reach – 559 mm. 5. KUKA Due to its sensitive technology, LBR iiwa cobot from KUKA can learn from its workers. This cobot can even document and optimise the results independently as it is connected to the cloud. Highly versatile, intuitive to operate, and reliable in contact with humans – the LBR iisy is a cobot for all production areas – most suitable where precision, speed, and agility are crucial. Payload ranges from 3 to 15 kg, and reach, from 760 to 1300 mm. manufacturer, with almost half the market share. They released two different series with a total of 7 different cobots. The CB3 series comprises the UR3, UR5, and UR10 models; and the E-series with the UR3e, UR5e, UR10e, and UR16e. All robots have 6 degrees of freedom, are incredibly flexible, and are easily integrated into existing production environments. Payloads range from 3, 5, 12.5 and 16 kilograms, and the reach, from 500 to 1300 millimetres. 2. Fanuc FANUC (Fuji Automatic Numerical Control) is a Japanese company offering robotics and automation products and services to help improve productivity and maintain a competitive edge. FANUC's cobot series comprises the CRX-10iA, CRX-10iA/L, CRX-20iA/L, and CRX-25iA models. Fanuc cobots are quick to install and easy to use. The Japanese cobots set a benchmark for reliability, ensuring sustainable productivity enhancement. FANUC cobots guarantee a secure return on investment. Payloads range from 4-35 kilograms, and reach from 550-1813 millimetres. 3. Yaskawa Yaskawa is the largest maker of industrial robots. The company's new cobot, Motoman HC20DT IP67, broadens the human-robot collaboration (HRC) spectrum. A unique feature of the Yaskawa ROBOTICS Key differences between industrial robots and cobots. 25 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
6. Franka Emika This German cobot can operate like a human arm regarding maneuverability and sensitivity. Franka Emika's programming platform is a workflowbased software program and user-friendly, by arranging different actions into a sequence to teach the robot a complete task through demonstration and parameter adjustment. The torque sensors in all joints of the cobot make it extremely sensitive. Payload is up to 3 kg, and reach, up to 855 mm. 7. Techman Robot Techman Cobots are the first to have an integrated vision system – the integrated camera at the robot arm's end and the associated programming interface feature smart recognition programs. Set tasks such as pattern recognition, object localisation, barcode scanning, and color recognition are relatively simpler. The software is easy to use by someone without programming knowledge. Four different cobots are on the market: the TM5-700, TM5-900, TM12 and TM14. Payload ranges from 4 to 14 kg, and reach, from 700 to 1300 mm. I hope the above preliminary information and features of cobots from the different manufacturers will inspire MSME manufacturers to think of plant automation with cobots. Conclusion Across the globe, manufacturers use automation to increase productivity, alleviate labour shortages and improve product quality. Collaborative robots offer a cost-effective, adaptable and safe automation option. Cobots expert in transformation of businesses that helps them achieve growth with speed and scale. She has invested 27 years in transforming Micro and Small Enterprises. Her rich experience in resolving pain areas and the MSME/SME industry's real-life problems are helping the organisation for quick results. Darshana has helped many MSMEs to increase profitability & achieve sustainable growth. She is keen on the growth of Indian Startups, providing mentoring and hand-holding support to startups to make them succeed quickly. She is very passionate about supporting women in pursuing their career and life goals. She is actively working for women's entrepreneurship and leadership development. She is: • Founder and CEO of Transformation • Certified Women Director by IICA, Ministry of Corporate Affairs, Government of India • Empanel and recognised Startup mentor and Trainer by CED, Government of Gujarat • Registered and Verified Business Advisor – Tata Nexarc, Tata Business HUB, Mumbai, and • Chairperson: MSME Support & PRO at Makarpura GIDC Association, Vadodara. MSME Transformation and Strategic Advisor – MSME Business Forum India, Darshana has received various accolades: • Winner of Gujarat Women's leader award 2022 by CMO Asia • Winner of Influential Women leader in business by Insight Success 2022 • Recognised as India's most trusted consulting company by Insight Success 2022 • Felicitated by Mentor my board in the gracious presence of Honourable FM Mrs. Nirmala Sitaraman during Women Director's conclave – 2022 • Felicitated by the president of Makarpura GIDC Association during the Suvarna Jayanti Mahotsav on 17th December 2022 for her excellent contribution in supporting MSME and startup Businesses. Apart from this, she is an author and publishes her blog, article, and case study related to the industry. Email: [email protected] can collaborate with people without wearing protective devices. In-built sensors and cameras ensure the robot doesn't injure human workers in the vicinity. Unlike standard industrial robots, it is simple to program, that's the major factor most suitable for MSME organisations. It can learn new actions using mobile applications and user-friendly software. Workers can also manually position a collaborative robot and store the settings in the software. In recent years cobot technology has progressed to the point that they are now accessible and inexpensive to small businesses. Darshana Thakkar is MSME Transformation Specialist and Founder, Transformation – The Strategy Hub. An Electrical Engineer followed by MBA – Operations with hardcore industry experience in managing business operations, Darshana is an Across the globe, manufacturers use automation to increase productivity, alleviate labour shortages and improve product quality. “ Top cobot manufacturers. 26| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition ROBOTICS
NETWORKING It is essential to build a futureproof network to enhance network resilience for your industrial control systems. An industrial control system (ICS) is one of the commonly seen automation systems in manufacturing applications. The purpose of deploying ICSs is to interconnect multiple industrial devices and machines to perform automated operations, with the goal of reducing manual effort and increasing operational efficiency. For example, a food and beverage factory can use ICSs to arrange the production schedule and procedures so that production lines can be operated as requested. As more industries evolve towards Industry 4.0, manufacturers are expecting more from ICSs. By connecting more field devices on an ICS network or even connecting multiple ICSs into one integrated network, manufacturers can collect field data and turn it into valuable information, which will allow them to optimise production efficiency and perform predictive maintenance. To make it a reality, it’s important to develop a reliable and secure network infrastructure for an ICS to ensure field data can be delivered with accuracy and integrity, which will allow accurate data analysis to be performed. Scenarios that industrial control system engineers frequently encounter To optimise production efficiency for manufacturing applications, system engineers are responsible for enabling connectivity for the increasing number of field devices that are being deployed into ICSs. This connectivity will allow factory operators to collect field data and analyse it. However, enabling this type of connectivity is easier said than done. Once the number of field devices connected to networks increases, system engineers frequently encounter three networking challenges. First, a network design that is not capable of meeting the increased number of field devices on one network. When more field devices are deployed on existing networks, and no evaluation has been performed to ensure that the network can cope, system engineers often experience poor network performance such as bandwidth overload or broadcast storms, resulting in network latency or even packet loss. These scenarios are often very detrimental to operational processes. Second, adding additional field devices into ICS networks increases the burden and complexity of daily operations. As the number of networking devices used to connect more field devices increases, system engineers must pay more attention to them. Without an efficient tool, it takes a significant amount of time and effort for system engineers to check the networking status on a regular basis. Third, as more field devices become connected, there is an increased chance that some devices will fall victim to a cyberattack, such as someone gaining unauthorised access. Without proper network protection in place, incorrect configurations or human error can easily lead to security breaches, resulting in unexpected system downtime and loss of revenue. Industrial control system engineers’ expectations To reduce obstacles when deploying numerous field devices on ICS networks, system engineers are looking for advanced networking solutions that can efficiently deliver data with accuracy and integrity. Nowadays, system engineers need high-performance networking solutions to ensure smooth data transmission for the increasing amount of field data found on one network. In addition, networking solutions that are secure by design can also reduce security concerns when more field devices are connected to networks. Last but not least, intuitive user interfaces for networking devices can make daily operations easier for system engineers. Get the most out of industrial control systems with futureproof networks To meet system engineers’ expectations as well as enhance network resilience, it’s recommended to develop a futureproof network infrastructure with high performance, security features, and enhanced usability to maximise network uptime. As a company with proven industrial networking expertise, Moxa has helped our customers in the manufacturing industry to build futureproof network infrastructure that achieves optimised production efficiency for their manufacturing applications. For manufacturing innovators who are building a futureproof network to get the most out of their ICSs, our solutions can offer them three main benefits. Benefit 1: Superior Network Performance Delivers Smooth Data Transmissions Ensuring smooth data transmissions for an increasing number of connected field devices can be challenging. Innovators within the Enhancing Network Resilience for Your Industrial Control Systems Interconnecting multiple industrial devices. 28| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
manufacturing sector might encounter unexpected packet loss when more field devices are connected to their ICS networks. To solve this problem, we suggest enhancing network performance to ensure there is sufficient bandwidth as well as traffic control functions. In order to do this, first build your ICS networks to support Gigabit transmission and use link aggregation functions to maximise throughput. This way, you can provide sufficient bandwidth for the increasing amount of data that is being transmitted across your ICS networks. Then, adopt traffic control functions to ensure your data can be delivered as requested. One important thing to remember is that advanced functions that can help avoid traffic storms and prioritise data transmissions will be beneficial. Our high-performance managed switches support 2.5GbE bandwidth and advanced traffic control functions to help manufacturing innovators build a futureproof network for ICSs, paving the way to realize optimised production efficiency. Expert Tip: When your networks need to connect more field devices, you need better network performance, which includes larger bandwidth Our networking devices were developed based on the IEC 62443-4-1 secure product development lifecycle guidelines and aim to act as a secure building block for your ICS network infrastructure. Furthermore, our networking devices are equipped with security features to enhance the overall security of the network, which significantly reduces cybersecurity risks. Expert Tip: The most effective and industryproven method to enhance cybersecurity for your connected ICSs is to implement security standards such as IEC 62443. The security standards include guidelines that provide clear instructions for how you can protect your networks and reduce cybersecurity risks. Benefit 3: Simplify Network Management to Increase Operational Efficiency Operating ICSs that include numerous connected field devices increases the complexity of network connections. To reduce the burden of operating the network, we suggest innovators within the manufacturing sector choose networking devices that come with intuitive user interfaces. Our networking devices have a built-in userfriendly web GUI that allows you to easily monitor the networking device status and quickly modify connection settings if necessary. In addition, our networking devices also support an easy-to-use management tool that simplifies network management from the initial installation all the way to daily maintenance of the ICS networks. Expert Tip: Managing ICS networks can be a real challenge without the right tools. Ensuring your networking devices support an intuitive user interface and easy-to-use network management software will tremendously and more advanced traffic control functions to ensure smooth data transmissions. Benefit 2: Enhance Network Security to Reduce Cybersecurity Risks As the number of field devices being connected to networks increases, so does the chance of a cyberattack. Therefore, many manufacturing innovators are starting to pay more attention to the importance of cybersecurity. We suggest they follow international security standards to strengthen network security for their ICSs. The IEC 62443 standard is one of the most widely used security standards that was designed for industrial automation and control systems. By adopting the security guidelines, it can significantly enhance the security of your ICSs. NETWORKING Building futureproof network infrastructure. Customer speak: what a manufacturing innovator has to say. 29 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
improve the efficiency of your daily operations. Conclusion To make yourself more competitive within the manufacturing industry, it’s essential to build a futureproof network to enhance network resilience for your ICSs. Our EDS-4000/G4000 Series managed switches are a game-changing networking solution. Our switches are equipped with up to 2.5GbE bandwidth and link aggregation functions to maximise network bandwidth for ICS networks. Efficient network operations are essential. Our EDS-4000/G4000 Series not only features an intuitive web GUI but also comes with our MXview network management tool to help you visualise the network status, even on a largescale network. Visit our microsite to learn more about what our Ethernet switches can do for your industrial applications: https://www.moxa.com/en/spotlight/industrialethernet/eds-4000-g4000-industrialmanaged-switches/index.htm To make it easier for you to control your traffic flow and deliver data as requested, our advanced functions such as traffic storm control, ingress data limit, and QoS can all help. To enhance network security, our EDS4000/G4000 Series managed switches are certified with IEC 62443-4-2 standards, providing security features such as VLAN, IEEE 802.1X, port security, and ACL to reduce the risk of unauthorised access to your ICS networks. Moxa EDS-4000/G4000 Series managed switches. Operating ICSs that include numerous connected field devices increases the complexity of “ network connections. FMI Analysis: CybersSecurity in Robotics The increased use of robotics and autonomous machines, according to the market research report, is driving end users to look for cybersecurity solutions. In order to automate many industries, artificial intelligence, and robotics are also combined. The burgeoning robotics and self-working tool industries are popular with the elderly population. The growing number of cyber-attacks on robotic and autonomous systems is encouraging the widespread use of cybersecurity in these systems. It increases the end user company's loss by a factor of several. Robotic cyber-attacks are becoming more prevalent due to the increased adoption of smart technology. Common cyber-attacks include distributed denial of service (DDoS), spoofing, man-in-the-middle, tapering, and reply attacks. “At the hardware, firmware/OS, and application levels, robots are vulnerable to cyberattacks. As a result, there is a huge increase in demand for cybersecurity management services. Additionally, the demand for cybersecurity in the robotics market is being fuelled by the greater adoption of artificial intelligence, machine learning, robotics, and automation in all other verticals. By implementing robotic cybersecurity solutions, businesses are bolstering their security wall. Additionally, built-in systems that provide cyber safety and security are changing how the market is growing,” says a Senior Research Analyst at FMI. The market is being driven by the quick automation of many sectors and the increased use of big data, machine learning, and artificial intelligence. Additionally, there is an increasing need for robotic technology across a range of sectors, including security, space exploration, entertainment, healthcare, and underwater exploration. Additionally, there are commercial uses in the manufacturing, food preparation, military, and customer service industries. The demand for cybersecurity solutions for robots and autonomous systems is being driven by the increased financial and data theft threats from cyberattacks. These technologies allow for immediate danger identification and reaction, shielding the business from irreparable harm. Robotics and artificial intelligence work together to foresee dangers and stop the spread of viruses. Emergency personnel are typically alerted when eldercare robots are needed. Additionally, it is employed to give out prescribed medication and inform medical personnel about the patient's health. These cyberattacks on these medical robots have the potential to destroy critical data and endanger the user. Therefore, the business introducing its robots is pre installing cybersecurity programs. 30| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition NETWORKING
EVENTS Pepperl+Fuchs is known worldwide as a pioneer and an innovator in electrical explosion protection and sensor technology. Pepperl+Fuchs, the German multinational pioneer in Electrical Explosion and Sensor Technology, completed a significant milestone, marking its 25 years of successful operations in India. Over the past quarter-century, Pepperl+Fuchs has taken the Indian market by storm through its intelligent innovations, fueled by the passion for automation and disruptive technologies. The company's easily integrated specified solutions have helped them emerge as a prominent player in the Indian industry, thus fostering strong Indo-German business relations. Founded in Mannheim, Germany, in 1945 by Walter Pepperl and Ludwig Fuchs, the small radio workshop has become a 7,100-employee-strong technology think tank with unique patents and ground-breaking automation solutions. Recognising the immense potential of the Indian market, Pepperl+Fuchs set up its first office in Bengaluru in 1998, marking the beginning of its journey in India. Today, Pepperl+Fuchs's India operations are backed by a team of 125+ members and operations spread across its Bengaluru Headquarters and 7 Regional Sales Offices. To commemorate 25 years of Excellence in India, Pepperl+Fuchs organised a day-long Corporate Meet and Greet at ITC Windsor, Pepperl+Fuchs Celebrates 25 Years of Raging Success in India Dr Gunther Kegel delivering the keynote. Mr Michael Fuchs (Jr) Lighting the Lamp at the event. 32| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
Bengaluru. Mr Michael Fuchs Jr., shareholder, CEO Dr Gunther Kegel, and other eminent board members Mr Lutz Liebers, Mr Reiner Mueller, Mr Charles Hertogh, Mr Michael Kessler, Mr Roolf Wessels, Mr Shane Parr, Mr Daniel Winkler, Mr Thomas Schellerer, Mr Thampy Mathew (Managing Director, India Operations), Mr Rudolf Kaehny and Mr Ravi Agarwal (Managing Director, India Factory Automation) started their day with a Meet and Greet with Pepperl+Fuchs employees, sharing gratitude and latest industry insights. Consul General of the German Consulate in Bengaluru, Mr Achim Burkart, graced the gathering and shared valuable learning moments, discussing the vivid opportunities in the Indian and global markets. The event saw its highlight with CEO Dr Kegel honouring Mr Thampy Mathew – Managing Director, Pepperl+Fuchs India, for his 25 years of service and strong leadership and mentoring that guides the Company to its zenith. Michael Fuchs Jr, reiterated his father Mr Michael Fuchs Sr’s vision for setting new benchmarks in the industry with the help of the Indian team, recognising the backbone of the company to be ‘Passionate Employees’ while also thanking the Sales Team for their extraordinary achievements. The German delegates were also applauded and received by the Company's young Indian workforce through cultural dance. Fuchs Sr and Mr Clause Michael in Dubai that decided the origin of P+F's India operations has expressed deeply the desire to hoist a CLEAN and GREEN P+F flag fluttering merrily in the Indian skyline. By that, the entire team of P+F pledges to remain thought leaders with its automation solutions with the help of the fourth largest subsidiary, the India operations team. We cannot wait to see our India team grow and rank higher through shared dedication, values, and passion for innovation." Pepperl+Fuchs has come a long way since its inception, and the past 25 years have seen nothing but focused growth and expansion for the Company. Today P+F has transformed itself into a Euro 50 million Company and added a new wing of 30+ in-house IT experts in the Bengaluru HQ, supporting and delivering globally. To support Global Engineering Services (SEC), a curated team of 10 experts has been hired in-house. Moreover, to cater to a newly identified target market of Euro 6 million, Pepperl+Fuchs Manufacturing India Limited sets its base in Chennai, where a team of 75+ manufactures Aluminium and SS Junction boxes to keep up with ever-growing market demands. The unit in Chennai is all set up for success and to keep up the supply in the Indian and Middle Eastern markets. Pepperl+Fuchs stands strength to strength with two headquarters in Bengaluru (PA) along with sales offices in Delhi, Mumbai, Kolkata, Chennai, Pune and Dr Gunther Kegel shared lively anecdotes at the event, where he reminisced about the glorious 78 years of Pepperl+Fuchs. Dr Kegel called the event his ‘homecoming’, marking his return visit to the India operations after the global pandemic. The Indian team gladly received the beloved CEO with his charisma, transforming the Indian team from the mere workforce to ‘kins’. Managing Director for Pepperl+Fuchs' India Operations, Mr Thampy Mathew, narrated wonderful messages of inspiration and innovations from when the Company started to operate in India. "A conversation with Mr Michael EVENTS Mr Thampy Mathew giving the Welcome Speech. Mr Thampy Mathew honoured for his 25+years service in P+F 33 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
Hyderabad. The glorious 25 years also celebrates P+F's dedication to successfully supporting Indian market sectors, including oil and gas, petrochemical, refining, pharmaceuticals, fine chemicals, fertilizers, power plants, etc. Pepperl+Fuchs lays a strong vision to keep on educating the Industry with technological leadership in electrical innovation and automation while also waging war against sustainability, and overall economic progress by expanding its footprint further, introducing new technologies, and forging deeper collaborations with Indian partners. About Pepperl+Fuchs Pepperl+Fuchs is known worldwide as a pioneer and an innovator in electrical explosion protection and sensor technology. The Company's primary focus thrives on individual customer requirements. With a passion for automation and ground-breaking technology, Pepperl+Fuchs is committed to working in partnership with unique customer requirements now and in the future. Pepperl+Fuchs understands the demands of the markets and caters to Pepperl+Fuchs is known worldwide as a pioneer and an innovator in electrical explosion protection and sensor technology. developing specific solutions and integrating them into one-of-a-kind processes. The Company was established in 1945 by Walter Pepperl and Ludwig Fuchs in Mannheim, Germany, and to date celebrates the principles of inventiveness, entrepreneurial foresight, and self-reliance. counterfeit products that remain a threat to human safety and security. With a solid focus on setting new milestones and standards in the Industry and thriving on perpetual world-class innovations, the Company works towards turning the India division into the third-largest Sales and Automation subsidiary. Pepperl+Fuchs envisions playing a vital role in driving India's digital transformation, Mr Michael Fuchs (Jr) cutting the Silver Jubilee cake. A view of the audience. 34| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition EVENTS
MOTORS & DRIVES The application of Linear Shaft motors to various fields is rapidly expanding, says Mamoru Takabayashi. I feel that linear motors have become increasingly used around the world these days. Users began to adopt linear motors from the viewpoint of differentiation and superiority from products of other companies in the business strategy. Traditionally, linear motion systems for industrial machinery and measuring instruments have mainly been using a rotary stepping motor or servo motor with a combination of ballscrew converting rotary motion into linear motion. However, with the enhancement of performance of industrial machines and measuring instruments, higher speed and higher positioning accuracy are required. There is a limit in linear motion system by ballscrew, and it is said that the drastic enhancement of performance over the past has not been fundamentally expected. This has become a limit to the contradictory high speed and resolution due to the one which depends on the resolution of the motor and the ballscrew pitch. It is very difficult to reduce the velocity stabilities to less than 1% in 10mm/sec by the conventional method. Here, I introduce a Linear Shaft Motor developed and manufactured by GMC Hillstone Co Ltd. Linear Shaft Motors are innovative motors that fundamentally change motion control with these conventional configurations. Structure and operating principle of linear shaft motor It is simple and consists of a shaft containing magnet and forcer containing coil (Figs. 1 and 2). The shaft is a stainless-steel tube filled with equally spaced Nd-Fe-B magnets. The forcer is arranged in three phases (U/V/W) with the coil surrounding the shaft. Since it is three-phase, it is possible to use drivers from other manufacturers. The forcer and shaft are non-contact, so that there is a gap when installed in the system. At this time, there is no effect on thrust even if it is installed eccentrically, and mounting is simple. This is a very important point in practical use. The operation principle is that the thrust force is generated by the action of the magnetic flux generated from the permanent magnet and the current flowing in the coil (Fleming's left hand law). Features of linear shaft motor It has the following features due to the structure: 1. Positioning accuracy depends on linear scale. High-precision positioning is realized by using highprecision linear scale. No backlash 2. Because it is coreless, cogging hardly occurs. Very good speed ripple at low speed (see Fig. 3) 3. Simple structure with large degree of freedom, and 4. Magnetic flux generated by the permanent magnet is wrapped 360 degrees around the outer coil, making effective use of the magnetic flux. Comparison with other linear motors The positioning between the Linear Shaft motor and other linear motors is shown below (see Figs. 4 and 5). As a linear motor, it is common to have a core. But the ripple due to cogging is large and the magnetic attraction force is also large. As a result, improvement of expected accuracy, reliability and maintenance-free are inhibited. On the other hand, Linear Shaft Motor has almost no thrust ripple and realises high accuracy. Assembly becomes simple because of no attracting force. These are features of a coreless linear motor. As for flat type coreless linear motor or U-shaped linear motor, heat is easily trapped in a state where the coil is sandwiched by the magnet (see Figs. 6 and 7). The coil of the Linear Shaft Motor is exposed and easily radiates heat. Applications of linear shaft motor Fig. 8 shows the assembly example of Linear Shaft Motor. Users can choose different stroke lengths to suit each application. At the same time, diameter of the shaft can be selected according to required thrust. As a rough indication, I will show differences in application with differences in size of shaft diameters. Small diameter (about Φ4 to 12 mm): mainly suitable for desktop-type devices. Small diameter shafts are often adopted in the stage related to microscopes, and there are observation applications such as industrial products and bio-related products. In this industry, high resolution image and its image processing are required; high resolution (scale) at the same time high precision with low ripple performance of Linear Shaft motors are required. In this type, a cross roller guide is used to draw out the features of a Linear Shaft motor such as high accuracy and low ripple at low speed. Stepping motors are also often adopted for desktop-type equipment at low cost and easy control, but the stepping motors have unique noise. Low noise is required in the analyser field, and quiet Linear Shaft motors meet this requirement. Arrival of Full-Scale Linear Motor Age-Linear Shaft Motor Linear shaft motor and structure 36| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
Medium diameter (~Φ35mm): This size is often adopted in the field such as machine tools and semiconductors where high thrust, high speed and high precision are required. It is also a big advantage that it is non-contact and maintenance-free. Large diameter (~Φ60mm): Shaft with the largest 60.5mm diameter has a 3,100 N acceleration thrust force, and they are for special applications. Unique driving method is possible with Linear Shaft Motor (see Fig. 9). For example, a plurality of forcers can be driven independently on a single shaft. This operation cannot be performed with a ballscrew. Also it is possible to double the thrust by tandem In the past, some niche markets required subnano level control. But they have expanded into various fields, and Linear Shaft Motors have begun to be used here. In addition, further evolution is expected, such as built-in scale and actuators using rotary and Linear Shaft motors. Mamoru Takabayashi is Managing Director of Nippon Pulse Motor Co Ltd. Nippon Pulse is a global manufacturer and Tier 1 supplier of precision motion control products for original equipment manufacturers. The company provides a wide array of motion control solutions to meet various needs, including industry-leading stepper motors, the innovative Linear Shaft Motor, controllers and drivers. drive connecting the forcer on one shaft. And there is parallel drive using a Linear Shaft motor in parallel. Parallel drive is mainly effective for system construction in guntray style. Furthermore, by fixing the forcer and moving the shaft side, it is also possible to operate without considering the durability of cable. Various configurations are possible depending on the engineer's ideas.There are many applications mainly on the horizontal axis (XY axis). However, for use on the gravitational axis (z axis), counter balance is required when power is turned off. Summary The application of Linear Shaft motors to various fields as coreless type linear motors is rapidly expanding. Engineers are selecting linear motors from the first development stage. MOTORS & DRIVES Low ripple Comparison with flat type motor Classification of linear servo motor Flat type and U-shaped linear motor Conventional flat type linear motor 37 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
T&M Micro-Epsilon now presents laser sensors equipped with integrated EtherCAT and EtherNet/IP interfaces. Optical measurement methods such as laser sensors play an important role in automation technology. For precise distance measurements, laser triangulation sensors are the tool of choice. These measure and test geometric quantities in numerous industrial sectors. For direct integration into the production environment, Micro-Epsilon now presents laser sensors equipped with integrated EtherCAT and EtherNet/IP interfaces. This combines precision and ease of integration in an extremely compact sensor. Measuring sensors used in factory and plant automation must meet numerous requirements. In addition to accuracy, high measurement and processing speeds, as well as measurement results that are as reproducible as possible, are required. There is an increasing demand for modern interfaces that allow easy integration into existing control environments. The laser sensors enable highly accurate displacement, distance and position measurements in a wide range of measurement tasks while offering high costeffectiveness. EtherCAT and EtherNet/IP interfaces for precision and flexibility in line applications With the introduction of the new optoNCDT 1900 laser triangulation sensor with EtherCAT, MicroEpsilon offers a powerful solution for use in factory and plant automation. The latest models are now equipped with an integrated EtherNet/IP interface. The integrated fieldbus interfaces enable easy integration of Micro-Epsilon sensors into Industrial Ethernet control systems. Due to these integrated, modern interfaces, the sensors offer advantages especially in high speed processes and in the networking of several devices and machines. Integration via EtherCAT or EtherNet/IP facilitates communication, especially in modern plants. Thanks to direct data output, the measured values are available in real time. An oversampling function also contributes to fast acquisition of measurement values. Highest signal stability for dynamic measurements For the first time, the optoNCDT 1900 sensors offer a two-step measurement value averaging feature to optimise the signal. The averaging enables a smooth signal at edges and steps while avoiding signal overshoots. This is particularly favorable for fast measurements of moving parts, as a precise signal curve is ensured. Fast and Accurate – Smart Laser Sensors for Precise Automation Laser triangulation sensors used in optical measurement methods. optoNCDT laser sensors enable fine positioning of the print head. 38| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
Application diversity in factory and plant automation The innovative laser triangulation sensors are used wherever high demands are made on precision and ease of integration. The sensors are used, for example, in sophisticated factory automation, automotive manufacturing, 3D printing and measuring machines. surface reflections, these sensors provide precise measurement results which are used to adjust the height and to detect the edges. Positioning gauge heads in measuring machines Coordinate measuring machines are often used to measure components. optoNCDT laser triangulation sensors are used to position sensor heads quickly. Thanks to their advanced technology, these laser sensors enable fast and accurate positioning of the measuring head. Position detection of the car body For automated processing of car bodies, an exact determination of the car body position relative to the machining tool is necessary, e.g., drilling, punching or mounting of assemblies. For high precision distance measurement onto metallic or painted surfaces, laser triangulation sensors are used. Here, their insensitivity to ambient light and their high measurement accuracy in particular are decisive advantages. Micro-Epsilon India Private Limited, Pune. Tel.: +91 20 4913 1030. Fax: +91 20 4913 1001. Email: [email protected] High-resolution fine positioning when printing PCBs In printing, soldering and assembly processes of printed circuit boards, the exact height positioning of the print head is crucial for a flawless process. optoNCDT 1900 laser sensors enable precise positioning of the print head. Regardless of T&M High-precision distance measurement on metallic or painted surfaces.
ROBOTICS Researchers are exploring ways to make robots more collaborative and perform end-to-end tasks, says Sunil David. During the 3rd Industrial Revolution in the 1950s and which reached its peak in the late 1990s, manufacturing industries across the world underwent significant change – one of which was the introduction of robots and automation on the shop floor. The primary purpose was to increase productivity and reduce operating costs. Over the last few decades as we are currently in the 4th Industrial Revolution, the integration of Robotics in manufacturing has transformed the industry, revolutionising production processes and driving efficiency to unprecedented levels. Robotics in manufacturing is being used in multiple different areas due to automation. Robot applications in manufacturing include welding, assembly, shipping, handling raw materials, and product packing. For this reason, multiple manufacturers are leveraging robotic automation for an increased number of tasks. Today, robots collaborate with human workers (cobots) on almost all tasks on the shop floor or in a warehouse. Robotics in manufacturing is widely being used for repeated tasks and to streamline the assembly workflow. Many industries involve three types of work – Dull, Dirty and Dangerous, and it is here that robots can play a huge role in carrying out dangerous and voluminous tasks and thus protect and ensure safety of human workers. Moreover, human workers can suffer from fatigue and get distracted over long shift hours, potentially leading to injury or error. The use of robots in manufacturing can help these industries reduce and remove such mistakes because of their high level of precision and accuracy. Robotic process automation (RPA) is a widely used software technology powered by AI with multiple use cases across different industries Revolutionising Manufacturing: The Role of Robotics Representative image. Press photo by KUKA AG 40| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
including manufacturing. Such robots can attempt to emulate human minds, accelerate operations, and ensure transformation of business processes. RPA can be a key enabler within the supply chain, collaborating with backoffice operations and IT systems to ensure quick completion of repetitive tasks like purchase management orders and invoice processing. The key benefits of robotics are as follows: Robotics can save time and costs Robot applications in manufacturing today take less time and lower investments to produce compared to the past. Robots are equipped with quality improvements and controlled safety requirements built into state-of-the-art facilities, reducing labour expenses and unplanned downtime, and they can also work continuously, boosting output significantly and reducing downtime. Robots can be scaled up or down for specific production needs Robots may be scaled up or down to be deployed in enterprises that have specific production needs depending on order volumes. They are used in high production, high volume applications as well as in low to medium-volume industrial settings. Due to advancements in technology robots may now be swiftly programmed and set up for new tasks and can be deployed in several locations across production manufacturing in areas of programming, engineering, end-effector design, operators, data analysts, and in robots manufacturing and systems integration. To assist with machine maintenance, human workers are needed. The main application of robotics in the manufacturing industry is as follows: Material handling From large containers to blood samples, robots are used today to handle a continually expanding range of materials, primarily stable or hazardous. This technique also reduces the risks of injury to human employees because the robots never become tired or make errors while carrying out their basic tasks. Robots can now do more tasks, which imply that employees can now be redeployed to more complex processes and value added works and this is bound to increase employee experience. Picking, packing and palletizing After the product has been manufactured, picking and packaging robots can carry out a variety of tasks. These robots quickly choose individual parts, pack them appropriately, and palletize them. Robotic picking and packing can boost your production with accuracy since they can choose and pack items faster. Loading of machinery Robots that load and unload machinery are widely used in manufacturing line tasks involving the loading and unloading of parts. It may become increasingly challenging and dangerous for human workers to load and unload parts from a machine. Robotic machine loading will enhance output, safeguard your employees from potential harm, and eliminate tiresome, repetitive labour. Assembly Assembling together product pieces takes a lot of time and effort, and errors in judgement, boredom, and other uncontrolled variables can easily derail the assembly line process and thus impact production. A robot can substitute such a system, streamlining procedures and drastically lowering the likelihood of errors. Additionally, this allows the assembly process' human components to concentrate on the key aspect of quality. plants. Robotics has expedited production processes, allowing for higher volumes of output within shorter timeframes and thus enhances productivity. Robots can enhance precision and accuracy Within the manufacturing industry there is a lot of emphasis on ensuring quality control so as to ensure products are manufactured with zero defects and no wastage. Robots have improved quality control through precise and consistent operations, minimising errors and defects. Robots improve workplace safety Since Robots can perform hazardous tasks, it goes a long way in ensuring worker safety, and thus reducing the risk of accidents and injuries which is extremely important. Robots are easily programmable There are currently two simple ways to program robots. The first method which is known as offline programming, enables a user to model a whole cell or work area and create the series of actions needed to complete a specific task. The second method is with a teach pendant, where a programmer or engineer directs the robot via a series of actions. The instructions can then be saved and changed as needed. Robotics can create new jobs Robotic automation also helps create new jobs in ROBOTICS Representative image. Photo by Possessed Photography on Unsplash 41 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
Welding Heat and pressure are used to connect metal components, which is an extremely risky operation that demands flawless accuracy. The production process might be hampered, the metal component can be ruined, and major harm can occur from the slightest welding error. Due to these factors, robots are increasingly being used for welding tasks. Painting Industrial paint robots are widely used in the automobile sector to uniformly paint components and equipment without leaving paint drips or markings. They are accurate, ensure every drop of paint is used, and apply the precise quantity to each piece of machinery. Industrial painting robots are made to be thin and flexible enough to go into nooks and crannies that would be challenging and time-consuming for human painters to access. Adoption of robots globally and in India According to the World Robotics 2021 Industrial Robots report published by the International Federation of Robotics (IFR), a record 3 million industrial robots operated in factories worldwide, with an increase of 10% from 2020. The sale of new robots grew slightly at 0.5% despite the global pandemic, with 384,000 units shipped globally in 2020. The IFR estimated global robot installations to rebound strongly and grow by 27% in 2022, exceeding the record level achieved in 2021. A new record of 486,800 units was installed globally in 2022 – an increase of 27% compared to 2021. Asia/Australia saw the largest growth in demand: installations were up 33%, reaching 354,500 units. The Americas increased by 27%, with 49,400 units sold. Europe saw double-digit growth of 15%, with 78,000 units installed. There were less than 100 robots made annually for industries in India about 15 years ago, and now we are seeing approximately 5,000 to 6,000 robots built every year. The automotive and pharma industries are investing heavily in industrial automation. The capital expenditure is high, while labour costs are low but automation is inevitable now in order for the Indian manufacturing industry to be competitive in the global market. While automotive companies like Maruti, M&M, Tata Motors, BMW, Hyundai, etc., have been early Sunil David has 28 years of experience in the IT and Telecom industry of which close to 20 years was with AT&T, one of the top Communication Service Providers of the World and a Global Fortune 100 Firm. Until recently, Sunil was the Regional Director (IoT) India and ASEAN for AT&T India where he was responsible for building the IoT strategy, Sales, Business Development and also worked on building a robust IoT partner ecosystem; and was also actively involved in a number of marketing initiatives to help enhance the AT&T brand in the IoT space. In his new phase of life, Sunil is Advising and Consulting AI and IoT Startups that are aspiring for the next level of growth. Sunil has been a recipient of a number of Awards and Recognitions including 6 awards in 2021 and 3 this year from various Industry bodies and media conglomerates in recognition for his work in Digital Technology advocacy, Digital Skilling initiatives, contributing inputs towards IoT policy creation for India and for contribution to National Institute of Electronics and Info Tech, an Autonomous Scientific Society of MeITY, Ministry of Electronics and IT, Govt of India for contributing inputs on the syllabus and specific courses in the Emerging tech space (IoT, Cloud, AI ) that needs to be incorporated into the Curriculum of State and Central Govt Universities. NASSCOM Foundation and IBM India have also planted tree saplings in Sunil’s name for his contribution to the Tech Industry. using robots in their factories and are scaling up use of these robots as their production volumes increase, there are manufacturers like JSW Steel, ABB (a manufacturer of robots), Sterling and Wilson, Ola, etc., who have deployed robots on their shop floors and are clearly seeing the benefits. For example, in the ABB Smart Factory in Neelamangala in Karnataka, the company has been able to achieve productivity improvement of upto 100% with 30% less space. Conclusion Researchers are exploring ways to make robots more collaborative and perform end-to-end tasks. And with the advent of AI and powered by 5G Networks, robots in manufacturing are collecting data and helping manufacturers make better decisions for the future and help them in their manufacturing process. This also requires human workers on the shop floor to upskill and learn to collaborate and work with robots to ensure they are far more productive and efficient. Overall, the future of robotics looks very promising and is bound to revolutionise the manufacturing industry in times to come. Researchers are exploring ways to make robots more collaborative and perform “ end-to-end tasks Representative image. Photo by Simon Kadula on Unsplash 42| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition ROBOTICS
3D PLANT SIMULATION w w w. a p e x i z . c o m scan to watch SIMULATIONS
HVAC What is a heat exchanger? This article explains the concept and the types. A heat exchanger is a device that facilitates the process of heat exchange between two fluids that are at different temperatures. Heat exchangers are used in many engineering applications, such as refrigeration, heating and air conditioning, power plants, chemical processing, food processing, automobile radiators, and waste heat recovery units. There are many instances where the use of a heat exchanger is deemed practical. For instance, high-temperature exhaust gasses from power plants and engines contain a large amount of heat which can be recovered by installing a heat exchanger before the smokestack. Gasketed plate heat exchangers Gasketed plate heat exchangers are efficient heat exchanger devices formed by a series of corrugated thin metal sheets and gaskets. The hot and cold fluids between the plates are separated by sealing gaskets so that they flow independently in the flow channels on both sides. The heat transfer coefficient of gasketed plate heat exchangers is 3-5 times higher than that of the shell and tube heat exchanger because the hot and cold fluids can reach a high degree of turbulence when they flow in the plate channels which have certain corrugated shapes on the plate surface. Gasketed heat exchangers can be fully customised to meet your exact requirements. Depending on the application media you can choose between traditional, semi-welded, free flow, sanitary plate heat exchangers as well as evaporators and condensers. How gasketed plate heat exchanger work In a gasketed plate heat exchanger, the plates are fitted with elastomeric gaskets which seal the channels and direct the fluids into alternate channels. The plate pack is assembled between a frame plate and a pressure plate, and compressed by tightening bolts fitted between these plates. The channel plates and the pressure plate are suspended from an upper carrying bar and located by a lower guiding bar, both of which are fixed to the support column. The physical design of the gasketed plate heat exchanger allows easy cleaning and modification of capacity by the addition or removal of plates. Advantages of gasketed plate heat exchanger 1. High heat transfer rate 2. Less heat loss 3. Compact structure, space-saving 4. Easy to change heat transfer area 5. Easy to clean and repair 6. Wide range of application, and 7. Long service time Welded heat exchangers A welded plate exchanger is similar to a gasketed plate and frame heat exchanger except Welded seams replace the gasketed seals allowing this exchanger to be applied in applications of high temperatures and pressures. Built from 316 Stainless Steel, welded plate heat exchangers provide exceptional corrosion resistance. Corrugated plates produce highly turbulent flow in a true counter-current direction. This results in high efficiency and a very compact heat exchanger design. Due to the smaller size and reduced material content, they can be the most economical heat transfer choice in applications where gaskets are not acceptable. How welded heat exchangers work A welded plate heat exchanger is a type of heat exchanger that uses welded plates to transfer heat between two fluids. Welded plate heat exchanger consists of a series of thin metal plates, which are welded together to form a series of channels or passages. The plates are designed to create a large surface area for heat transfer and are typically made of materials that have high thermal conductivity, such as stainless steel or titanium. The two fluids that need to be heated or cooled flow through the different passages of the heat exchanger, with each fluid flowing through alternate passages. As the fluids flow past each other, heat is transferred between them through the thin metal plates.The lack of gaskets or seals also means that welded plate heat exchangers are less prone to leakage and require less maintenance. Welded plate heat exchangers are commonly used in applications where high pressures or Heat Exchanger – An Introduction “Heat exchangers from Danfoss are designed with a Single purpose in mind – to create optimal heat transfer” Heat exchanger – a device that facilitates the process of heat exchange. 44| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
temperatures are involved, such as in chemical processing, oil and gas production, and power generation. They are also well-suited for applications where the fluids being transferred are corrosive or have a high fouling potential, as the smooth surface of the welded plates makes them less prone to fouling compared to other heat exchanger designs. Advantages of welded heat exchanger 1. High temperature and pressure resistance 2. Low investment costs through heat transfer with maximum efficiency 3. Corrosion resistance 4. Low maintenance 5. Compact structure 6. Reliable, and 7. Fully welded without gasket. Brazed heat exchangers A brazed plate heat exchanger consists of corrugated plates that combine to create channels through which a hot medium and a cold medium can be distributed. Brazed plate heat exchanger can be used for a range of functions in a heating or cooling system. Brazed plate heat exchangers are widely used in many different industries and often in large-scale residential heat networks. They play an important role in delivering air conditioning process and production, refrigeration, data center cooling and residential heating. How brazed heat exchangers work The brazed plate heat exchanger is in principle constructed as a package of corrugated channel 4. Resistance to changes in pressure and temperature, and 5. Small hold-up volume and high performance. Common heat exchanger applications At home Around the home, they’re commonly found in central heating combi boilers and help to heat and cool down the water efficiently and safely. They’re also found in your refrigerator, ensuring it stays at a stable, cool temperature. Public spaces Car engines produce a lot of heat and this needs to be managed effectively to prevent dangers. Cars often use a combination of fans and air flow, with fins to dissipate heat, and the use of a coolant fluid. Industrial Heat exchangers are also used widely in different industrial applications. This includes power generation, the manufacture and storage of food, chemical engineering, and even in the running of air and marine transport Defence Even in the defence sector, we find heat exchangers. They are installed, for example, on the navy surface and auxiliary ships as well as on submarines. They cool nuclear submarine propulsion motors. Durga Mechatronics Pvt Ltd, Mumbai. www.durgamechatronics.com plates between front and rear cover-plate packages. The cover-plate packages consist of sealing plates, blind rings and cover plates. Connections are mounted on the cover plates and can be customised to meet specific market and application requirements. During the vacuumbrazing process, a brazed joint is formed at every contact point between the base and the filler material. This design creates a heat exchanger that consists of two separate channels or circuits. Advantages of brazed heat exchanger 1. Low operational cost 2. Double-walled design that provides the ultimate protection against leaks 3. Tried-and-true fishbone technology HVAC Gasketed plate heat exchanger. Welded plate exchanger. 45 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
VISION SENSORS How smart 3D robotic visual defect inspection can detect defects based on training data. While vision technology has been primarily advanced by improvements in 2D image sensing, it has become a critical component and a major driving force of industrial automation. Vision technology has enabled the use of robotics in a vast range of applications that dramatically enable higher and more effective operations. In the field of 3D vision technology, robots guided by vision can locate individual components, determine the correct application, and complete the assembly scenario. Over the course of the many stages of development, vision technology has been embraced by many companies who have seen the indirect value to their customers and a direct value to their production processes. Project introduction In the post-pandemic era, an unstoppable force swept through the globe. Growing by leaps and bounds, it left a blazing trail across e-commerce platforms. That force is, of course, online shopping. The incredible growth of post-pandemic e-commerce is estimated to continue expanding to 13.7% in 2021, reaching $908 billion (eMarketer). For sale is any kind of service and product that can be purchased and shipped directly to a consumer’s home. Although the positive sales forecasts give ecommerce enterprises reasons to celebrate, they also spell out very clearly the need for better and more efficient logistics systems at the warehouse level. A typical process can consist of a camera and a computer with the associated software. In a typical example of a vision-guided robotic (VGR) system, the vision system (camera and software) is set up to determine the position of a component while it is on a conveyor. The vision system identifies the location of the components and sends the coordinates to the robot. In turn, the robot positions the attached gripper over the target component to select it. While the system may seem simple enough there are existing difficulties in integrating the vision system to match the type of camera with the intended expectations of the system – difficulties, more often than not, stemming from lack of knowledge by an integrator or solution builder. In contrast to a VGR system, traditional automation is defined as serial production, large single product sizes, and limited flexibility. Introducing a new element into a traditional production line is a time-consuming and costly process, and often a large investment. VGR systems can operate with very little mechanical setup, often eliminating the need to set pick-up positions for components. Parts with varying shapes and sizes can be picked up and placed as required. The versatility and flexibility to implement the vision system is a key factor that results in more effective operational processes. Additional benefits also include: 1. High machinery efficiency, reliability, and flexibility Industrial Servers Ramp up AI for Robotic Arms Vision technology enables use of robotics in various applications. 46| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
2. Reduction in manual work 3. Quality control application 4. High residual value 5. System requirements. For enterprises, quality control has been dependent on a visual inspection model. The traditional machine vision systems have a high failure rate when presented with defect types in samples with high variation between similar parts. Augmenting the inspection process with the power of smart technology helps to deliver highprecision detection results. Compared to machine vision systems using computer vision technology confined to rule-based algorithms, smart 3D robotic visual defect inspection can detect defects based on training data. In this case, the client was a logistics and supply chain management enterprise. They planned to implement a 3D robotic vision system in their warehouse logistics to classify inventory by size and detect defective packages. They required a 3D vision system with the capability to support the use of 3D cameras for pieces and bin-picking applications. The customer’s warehouses housed multiple conveyors running 24/7. In the middle of the conveyors, the controlling systems are spaced ten metres away from the robotic arms and 10 GigE industrial 3D camera process large volumes of 3D information data. The Highly flexible solution combines the Power over Ethernet (PoE) technology on the Advantech PCIE 1182 to eliminate compatibility and special wiring problems. By using PoE technology, the frame grabber can connect directly to the 3D camera ensuring a direct connection over regular Cat 6 cable even at distances over five metres. The SKY-640V2 is a 4U rackmount server embedded with a 3rd Generation Intel® Xeon® Scalable processor supporting 4 x PCIe x16 double-deck cards and 3 x PCIe x8 singledeck cards. The large number of expansion slots enables support for applications demanding flexibility, i.e., the simultaneous use of frame grabber and motion control cards. Why Advantech The comprehensive 3D robotic vision solution simply met the customer’s requirements. The frame grabber, motion control card, GPU card and server system met all compatibility needs. The latest 10 GigE 3D camera technology accurately captured images by PCIE-1182 frame grabber that were sent to the SKY640V2 for real-time inferencing for identification of defective products. Complicated robotic motion control, highperformance computing, and smart inferencing were done on SKY-640V2 locally with its Intel Xeon Scalable processor and multiple PCIe expansion slots for highperformance graphic analysis. The impact of the SKY-640V2 is channeled through the high computing power of the server and onto the robotic arm for improved operational efficiency. As an added critical metric for automation deployment, the use of smart technology has led to the initiation of maintenance measures through predictive analytics. Just as analytics help to differentiate between the geometric positioning of a package, the same technology has helped to maintain the equipment by the precise measurement of degradation. With Advantech’s 3D robotic vision solution, updating the logistics inspection system has been an example of successful logistics operation efficiency. installations. For the inspection system, large volumes of 3D images at high resolutions had to be processed and analysed in seconds. The traditional vision technology faced limitations: the existing data transmission method for the 3D camera employed a camera link (PoCL) cable with a five-metre distance limit. It was not capable of processing high transmission volumes and congruent robotic arm operations. To leverage smart technology for robotic visual inspection in real-time, the client required a solution with substantial computing power at the edge and large storage capacity to store the volume of images, as well as the necessary bandwidth required for the data transmission. System description The comprehensive 3D robotic vision solution from Advantech was composed of a frame grabber (PCIE 1182), a GPU card (NVIDIA A100GPU), and a system server (SKY 640V2). While the 3D camera and sensor are positioned above the package conveyor, high-definition images are taken and transmitted to the PCIE 1182 where they are collected and analysed in real time by the SKY 640V2 server. To drive the visual computing workflow, the frame analysis is accelerated through the high-end NVIDIA A100 GPU to deliver exceptional true real time collaboration. The latest NVIDIA Ampere Architecture with 19.5TFLOPS FP64 Tensor Cores and 40/80GB GPU Memory, provides the best performance to VISION SENSORS Comprehensive 3D robotic vision solution from Advantech. 47 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
DATA Endress+Hauser harnesses data and artificial intelligence to optimise internal processes along the value chain. But only rarely does data find its way beyond the confines of the devices, machinery and systems that generate it. Now that could all change, thanks to smart field instrumentation, digital interfaces and cloud-based analytical tools. The possibilities are endless, particularly when sensors in the physical world are linked up to artificial intelligence. Industry at a turning point And yet there are areas of industry where change is afoot, says Birkhofer. The latest generation of smart instruments can supply a wealth of supplementary data alongside their actual measurements, including information on the sensors and processes themselves. There are technologies that provide a secondary channel for rapid, secure data transfer from the field right up to the corporate level that is completely distinct from process control in the plant itself. Furthermore, a host of projects have already demonstrated how this data can be turned into useful information and valuable knowledge. “Digitalising process plants is beginning to emerge more and more from the confines of pilot installations and small-scale projects,” Birkhofer says. And, he adds with conviction, “We are at a turning point.” For plant operators, it’s all about efficiency, security, and quality in the face of competitive pressure and a general shortage of skilled workers. It follows that there is an enormous number of potential use cases. Analysing data at the level of individual measuring points can already bring significant benefits. But the data generated from instruments and processes only reveals its true value after central aggregation, be that in a cloud application or edge computing system. Aggregation brings scalability to data gathering and processing, with individual use cases no longer requiring their own dedicated software. A further possibility is to link data from the field with other data sources such as weather forecasts and ERP systems, all in real time. Virtual & physical world A particularly exciting prospect is to combine multiple data sources using artificial intelligence. “Big data applications can glean highly complex Data is Key in Digital Transformation of Process Industry Smart instruments can supply a wealth of supplementary data. 48| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
insights in fractions of a second, given the right data inputs,” says Florian Falger, Market Manager at the Endress+Hauser Level+Pressure Innovation Lab. One of the team’s activities is finding ways to precisely determine maintenance intervals for measuring instruments and entire plants with the help of specialised algorithms and artificial intelligence. Thus, they are laying foundations for something that many companies in the process industry want: predictive maintenance. “Large chemical plants, for example, operate around the clock,” Falger explains. “Even planned maintenance is a costly undertaking. Predictive maintenance would help to minimise the plant downtime involved and avoid unscheduled outages, as well as reduce workload and costs.” A clear advantage Endress+Hauser harnesses data and artificial intelligence to optimise internal processes along the value chain. The result is improved transparency, quality, and efficiency – for customers, too. Here are five examples. Easier interaction Shopping like Amazon, searching like Google: endress.com is Endress+Hauser’s online platform for cooperation with customers. “To continue improving our website, we collect information about users’ surfing and purchasing behaviour,” explains Vincent Dessus, Head of Digital Business Development at Endress+Hauser. The company uses this data to make it easier for customers to find, select and order the right devices for their needs. An algorithm uses initial entries made in the device configuration, along with user location data, to determine the product typically ordered by customers there. Then it automatically fills in the next few fields. There is also a new ‘Get quote’ feature: “We noticed that although online customers don’t expect an individual quote, they do still need an official document,” says Vincent Dessus. “Now they can get a PDF quote in seconds.” Smart production Artificial intelligence supports laser welding in pressure transmitter production. “Conventional algorithms don’t reliably recognise the welding position,” says AI expert Dr Jawad Tayyub from Endress+Hauser Level+Pressure. “That means the people at the welding stations must check it every time. They often must make corrections manually, which is monotonous and tiring work.” reports are used to identify the cases in question, since sometimes all that is needed is a routine service. “This lets us service or recall the devices in good time – before our customers experience any issues,” De Stasio says. The data also helps with new developments and with detailed understanding of the root causes of instrument damage: “Often, environmental conditions at the installation site are a factor in servicing,” adds Thomas Fricke, Head of Marketing Services at Endress+Hauser Temperature+System Products. Plans are under way to improve the application by using AI and integrating other sources such as m Transparent purchasing The Endress+Hauser Group has over 50 sales centres. As well as selling products, they increasingly offer solutions and services. This involves sourcing materials, such as mechanical accessories, and expertise from third parties. “To add transparency and structure in this area, an AI application scans through texts from all our SAP systems and assigns the third-party items to merchandise categories. It would take months for humans to analyse and interpret these tables,” says Oliver Blum. The AI system was trained by employees, and the sales team is working on enhancing the data quality. “This means we can now pool our purchasing activities and increase quality for customers,” Blum adds. Source: https://changes.endress.com/sites/default/files/ 2023-05/E%2BH_22_002_changes2- 22_EN_Web_221018.pdf Artificial intelligence immediately increases the correct detection rate to over 98 per cent, making work easier and reducing the number of rejects. “We do that using a neural network taken from the medical sector,” Tayyub explains. A comparable network helps doctors to detect skin cancer. The raw data is similar in both cases: image analysis largely concerns monochromatic areas that clearly stand out against their surroundings. Optimised shipping Endress+Hauser does not keep a stock of measurement devices. Given the multitude of variants, almost every instrument is one of a kind and made to order. Many regions handle shipping from a central logistics hub. “At our North American and European hubs, an algorithm ensures that products reach the customer on time. The AI is flexible to find the best logistics service for each delivery based on historical and current data,” explains Oliver Blum, Corporate Director of Supply Chain. The algorithm ensures the deliveries are reliable, even in unsettled times: in 2021, 91.2 per cent of deliveries in Europe arrived on time. Proactive service What is the long-term performance of measuring instruments in the field? Endress+Hauser introduced a specialised web application several years ago to find out. “An overnight database run condenses every service case worldwide into a single graphic, so we can see at a glance whether there are frequent events with a particular device,” explains Enrico De Stasio, Head of Lean Administration. These DATA Combining multiple data sources using artificial intelligence. 49 | INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition
INDUSTRY 4.0 Conductix-Wampfler, backed by extensive experience with OEMs, offers state-of-the-art intralogistics system solutions. Intralogistics systems are a vital part of operations, with growing importance in today’s competition – Conductix-Wampfler offers tailormade solutions for energy and data management, having extensive knowledge of the market’s requirements and trends, including decades of experience with most leading OEMs, system integrators and end-users. Automated warehouses for electronic commerce, retail, food & beverage, fast moving consumer goods, micro-fulfilment, healthcare, electronics, fashion, and other industries are no more at the fringes of the value chain, but at its’ heart, guaranteeing quick fulfilment of customer orders. Receiving and storing, space efficient high-bay storage, order picking, dispatching, and shipping, they all require a cost effective, powerful, sustainable, scalable, and flexible mix of technologies: 1. Automated Storage & Retrieval Systems 2. Shuttles 3. Electric monorail systems 4. Sorters 5. Automated guided vehicles 6. Autonomous mobile robots 7. Rail guided vehicles 8. Pallet wrappers 9. Extendable conveyors, and 10. Very narrow aisle forklift trucks Conductix-Wampfler has extensive experience working with intralogistics system OEMs worldwide. From our large product portfolio, we can recommend the optimum solution for individual applications across many different industries without bias towards single technology. With our global presence and local support, we partner closely with OEMs and end-user customers for both small- and large-scale projects, striving for technical optimization with minimum complexity. Our continuous research & development efforts are geared towards new solutions and continuous improvements of products for this industry. Conductor Rails – Power Electrified Monorail Systems (EMS), Rail Guided Vehicles (RGV), and baggage handling systems. The 0831 Series are ideal for AS/RS stacker cranes. The recently introduced PEplus for conductor rails works well for electric conveyors of all types, providing safety and simplicity. Charging Contacts – Use to provide contact type charging to AGV’s having CE and UL approval. Spring-Driven and Motor-Driven Reels – Manage cables used to power transfer cars and other moving equipment. Options for cost effective, powerful, sustainable, scalable and flexible mix. Intralogistics: Solutions for Energy and Data Management 50| INDUSTRIAL AUTOMATION MAGAZINE | June 2023 Edition