MAAC machinery saves 50% of support cost using eWON remote access

Remote access enables MAAC machinery to connect to their machine just as if they were beside them and to have access to PLC’s, Drives and HMI devices and any other device connected to the machine subnet including an IP camera.

Benefits

  • Save maintenance trip
  • Deliver a cutting-edge service
  • Improve flexibility
  • Quick and efficient troubleshooting

Re-posted from eWon’s success story June 4, 2017
Read the Success story MAAC machinery saves 50% of support

Tri-Phase Automation is a distributor of eWon in Wisconsin.
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Automatic Milking System

aaeon-automatic-milk-systemApplication Story from AAEON

Removing milk with no more effort than flipping a switch

Traditionally, we picture milking as a farmer sitting beside an udder of a cattle or sheep as he/she laboriously pull down the teats of the animal, spouting milk into the bucket below. However, the practice of hand milking has long since been retired from being the sole way of milk extraction to recreational activities for some “good old days” experience. The dawn of Industry 4.0 has ushered in a digital revolution that gives many traditional industries, such as dairy farming, a technological facelift and propels its operations towards a very promising prospect. In Australia, for example, removing milk from cattle needs no more effort than flipping a switch

AAEON’s Solution GENE-A55E Subcompact Board

GENE-A55E Subcompact Board

Automatic Milking Systems, or Robotic Milking Systems, existed since the 20th century with the rise of computer technology. Programs and software that drive these machines are often the results from many hours of trial and error, troubleshooting and experimentation. Furthermore, specific requirements from different farms mean that programs have to be specially written, leading to additional testing efforts. The cost, size, as well as sophistication of the machines themselves often translate to the fact that total replacement is not a practical, or even viable, option for smaller dairy farmers.

To address the above mentioned concerns, AAEON provided the solution in form of the GENE-A55E subcompact board, whose main highlight is its support for legacy software and hardware.

Supporting the long-standing but still widely used Industrial Standard Architecture (ISA) bus, the board offers its users the ability to directly program buses without the need for drivers that are required in newer systems. This feature allowed users to leave their tried-and-true programs and software untouched as instructions are written straight into the bus with no additional modifications necessary to the program’s code. The support of the ISA bus also opened up capabilities such as precision motion control (of the robotic arm and teat cups), digital I/O (for functions such as emergency stopping and LED indications) and CAN BUS (for communications).

Also present on the board is Ethernet technology that grants a true Industry 4.0 experience. With it, any factors that might contribute to an unfavorable milking condition, such as unconducive weather or poor cattle health, can be made known to the user via wireless means so that appropriate measures can be taken even before milking begins. And after it does, data such as the amount of milk collected, the cattle’s physical condition and duration of the process will be sent in real time to a companion app in the user’s PC, tablet or smartphone. In addition, via the onboard expansion options, capabilities including cleaning the cattle before milking to ensure untainted milk and sampling of the collected milk can be added easily.

As an added benefit, and especially applicable in a farm setting, the board’s fanless design negates problems stemming from moving parts. On top of that, the computing unit of the machine, where the board is housed in, can be built completely enclosed, preventing the entry of dust or other matter and allowing it to be washed with water without compromising its functionality. Users of the GENE-A55E may expect a long product life cycle of more than 5 years.

Benefit:

AAEON’s continued support for legacy hardware helped dairy farmers modernizes their operations without the need for a complete overhaul of their assets. Its feature rich board design enhances performance of their machines to include the latest technologies.

Read the fully story: Automatic Milking Systems

eWON/HMS Remote Networking Solutions

eWon/HMS Remote Networks

This solution allows system integrators to establish secure industrial networks linking multiple remote sites to central control rooms through permanent VPN connections. Benefit from a seamless access to your remote sites data at any time.

What does Remote Networks solutions allows you to do?

  • Quickly set up a VPN-based extranet network
  • Replace your legacy modem or radio solution and benefit from the reliability of the Internet connectivity
  • Interface your PLCs to your SCADA/supervision system

Water and Wastewater Solution With WAGO

WAGO, the pioneer of CAGE CLAMP® spring pressure connection technology, offer an extensive range of automation solutions such as the fieldbus independent WAGO-I/O-SYSTEM, interconnect and interface technology.

CHALLENGE:

Tough demands are placed on technical equipment in the water and wastewater sector: Toughness in aggressive atmospheres, high resistance to shock and vibration and easy installation and handling for reducing installation and maintenance time are just a few of the modern challenges at hand.

APPLICATION:

WAGO  components equipped with Cage Clamp
Convenient fault detection of decentralized pump stations and a cost-effective connection via radio technology, e.g., from the scraper bridge to the control technology, demand practical and low-maintenance solutions to benefit wastewater plant employees. Reliability, quality and ease of use combine to play a decisive role in processing automation efficiency.

BENEFIT:
Daily, WAGO components equipped with CAGE CLAMP® Spring Pressure Connection Technology prove their value under the harshest conditions. Over the years, WAGO has developed an enviable safety record, including approvals for use in potentially explosive environments, an impressive array of robust components that readily withstand aggressive environments and safe, truly maintenance-free connections.

ID Readers Enable Part Traceability of Direct Part Mark Products

cognex-id-reader-enables-part-tracebility-of-direct-part-mark-productWhen Canadian energy services company Packers Plus needed to read challenging dot peened codes on a variety of parts, they specified Cognex® DataMan® handheld ID readers. The company’s StackFRAC® system consists of many parts, each marked with a unique 2D Data Matrix code that enables traceability throughout its useful life.

Traceability delivers two important benefits for Packers Plus. First, it reduces rework costs by providing better manufacturing process control and ensuring that the right parts are used at every stage of production. Second, it enables Packers Plus to quickly retrieve information on 100% of the parts in every system that has been shipped out their door, including production history and quality control information.

In the past, Packers Plus manually recorded information such as lot numbers, heat numbers, quality control measurements and other information in a spreadsheet. “This was a very time-consuming manual process that took approximately four hours for each product, so we only did it when necessary,” said Marlon Leggott, Director of Manufacturing for Packers Plus. “Another problem with the manual process is that it is susceptible to mistakes, such as data entry errors.”

Selecting marking and reading tools

Packers Plus considered a number of different options for improving traceability when it installed its new ERP system. Kurtis Weber of iTech Tool Technology helped Packers Plus design the traceability solution. “We looked at labels with standard line bar codes but determined they would have to come off during assembly, which would negate many of the advantages of serialization,” Weber said. “RFID tags don’t work well with various metal parts because of interference with reading and writing the tags. Laser marking overcomes all of these problems but laser marking machines begin at $50,000 and have to be enclosed — which causes problems when used to mark large pieces — and cannot easily be moved from place to place. We recommended a dot peen marking system because it is permanent, does not rely on fragile RF transmissions, costs only about $10,000 per machine, and is available in fixed or mobile models. The mobility allows us to easily move around the plant and successfully mark any size part in a variety of orientations.” With dot peen marking, a carbide or diamond-tipped stylus pneumatically or electromechanically strikes the material surface.

Packers Plus then faced the difficult challenge of reading the marked parts. The challenge arises from the fact that Packers Plus makes parts with curved surfaces and many different materials and coating combinations. Nearly any reader can be adjusted to provide perfect accuracy on a particular combination but Packers Plus wanted a reader that could deliver high levels of accuracy on any part. “We recommended Cognex DataMan handheld readers because they adjust the lighting to match the part and use the industry’s most  advanced algorithm  for picking out the 2D Data Matrix code from the background,” Weber said. “This is the only product I have seen that is capable of accurately reading the wide range of parts used by Packers Plus.” 

Read More:

ID Readers Enable Part Traceability for Direct Part Marked Products

Sensors for Forklift and Mobile Equipment

Sensors for forkliftsMobile machines such as forklifts, elevating work platforms, or container stackers, require precise positioning of heavy loads and effective control of rapid movements for transporting materials. Heavy-duty, resilient sensors guarantee precision and reliability both in warehouses and in outdoor applications.

Fork Inclination Monitoring – Inclination Sensor

  • Detects the horizontal angle of the fork while the truck is in motion
  • Prevents the truck tipping when transporting heavy loads

Nonmechanical Hand Detection – Capacitive Grip Sensor

  • If the hand is removed from the joystick, the engine is stopped and hydraulic pressure is lowered
  • Inadvertent joystick actuation is virtually impossible

Fork Height Monitoring – Laser Distance Sensor

  • Height monitoring for safe fork movement
  • Forklift speed can be adjusted according to fork height

Fork Extension Monitoring – Positioning System

  • Monitors the fork positions for controlled fork extension

High Efficiency Liquid Nitrogen Dosing

High Efficiency Liquid Nitrogen Dosing

Product Used: SMAC LCA31 series linear

Problem: Traditionally the pneumatic cylinder is used to control a valve for liquid nitrogen dosing. The pneumatic cylinder gave an impact on the valve when closing. The liquid nitrogen is cooling the valve seal to temperatures that metal seals are like glass and become brittle. Impact damages the closing seal so that they need replacement every half year. This shuts down the line for quite a long time.

High Efficiency Liquid Nitrogen Dosing with SMAC actuators
Liquid Nitrogen Dosing Diagram

Solution: SMAC actuators’ highly repeatable & positioning coupled with high speed allows the user to more precisely & repeatedly control the dosing amount. SMAC actuators also allow for easy change over for different dosing requirements. Another advantage is the life of the SMAC actuators as well as the extended life of the dosing valve, as SMAC’s unique Soft-Land function prevents damage to the valve when closing. This will result in increasing valve’s life time. These features will increase uptime and increase profitability for end user.

SMAC Advantages

  • Better force control of liquid nitrogen dose for cost savings on the amount of liquid nitrogen used. (Soft-Land)
  • SMAC actuator is fully programmable in force, speed, and position.
  • SMAC actuator can be easily set-up and make quick change via GUI to run a different motion profile for the liquid nitrogen valve. No mechanical adjustments required.
  • Programmable motion profile dosing valve.
  • Dosing valve stroke verification.
  • SMAC actuator’s exceptional long-life over 100,000,000 cycles increasing uptime and lowering replacement cost.

Wind Power – Lightning Protection For Wind Turbines

Lightning Protection

Wind power is a form of solar energy. The uneven heating of the atmosphere by the sun, the irregularities of the earth’s surface, and rotation of the earth cause winds. Wind flow patterns are modified by the earth’s terrain, bodies of water, and vegetation. We use this wind flow to generate electricity.

The terms wind energy or wind power describes the process by which wind is used to generate mechanical power or electricity. Wind turbines convert the kinetic energy in the wind into mechanical power. This mechanical power can be used for specific tasks (such as grinding grain or pumping water) or a generator can convert this mechanical power into electricity.

So how do wind turbines make electricity? Simply stated, a wind turbine works in the opposite way of a fan. Instead of using electricity to make wind, like a fan, wind turbines use wind to make electricity. The wind turns the blades, which spin a shaft, which connects to a generator and makes electricity.

Since most wind turbines are 60-150 meters high they are very susceptible to lightning strikes and power surges. IEC 61400-24  (VDE 0127 part 24) is the basis for the design of the lightning protection concept.

Pepperl+Fuchs offers a complete line of products designed to protect industrial equipment like wind turbines from the hazards of lightning strike. Products offering surge protection, lightning protection, signal isolation, and safe grounding paths are available.

Injection Molding Company Increases Throughput and Eliminates Mess & Maintenance with Integrated Electric Actuators

A Customer Success Story

Customer:  A plastic bottle cap manufacturing company located in Europe.

Application:  Injection Molding – Ejection of molded parts from mold.

Throughput goals were not attainable with existing hydraulic and pneumatic cylinder solution. In addition, the existing solution required significant maintenance over the life of the machine resulting in an unacceptable amount of machine downtime.

Application Solution

The customer selected the Exlar® GSM and GSX Integrated Motor / Actuator due to their high power density and speed. In addition, the compact form factor of the GSM and GSX (comparable to a hydraulic cylinder) required minimal engineering design changes to accommodate.

According to the customer, in addition to offering a superior product solution Exlar Corporation’s service and support team provided a high level of communication throughout the project and specifically addressed all needs of the application.

Exlar GSX electric linear actuator

Benefits

Converting to the Exlar GSM and GSX products resulted in a significant increase in machine productivity, both in terms of increased throughput and reduced machine maintenance / downtime. Additional benefits of the Exlar solution include increased part quality and reduced scrap.

Primary, Secondary, and Tertiary Sewage Treatment

Tri-Phase Automation is a distributor of Pepperl+Fuchs’ products for waste water treatment facilities. You have at your disposal a wide range of I/O isolators and intrinsically safe barriers for nearly all measurement technology applications, e.g. pressure, differential pressure, temperature, flow, level, positioner, Remote I/O, and much more.

Challenge

The demands on technical equipment and water quality regulations continue to evolve. In addition, the volume of water treatment has grown.  With these changes and growth, important supplemental measuring points need to be set up, particularly in decentralized parts of the sewage treatment plant. A sewage treatment plant can cover hundreds of acres and include multiple buildings. Greater amounts of data need to be recorded centrally, and the effort involved in commissioning and maintenance has to be reduced to service all field devices and drives centrally from the control room over a fieldbus system in network segments.

Application Solution

The field instruments and control is truly distributed throughout the sewage treatment plant. FOUNDATION fieldbus, PROFIBUS, and in many cases Hart technology have solved the problem of centralized control. It is likely that upgrades and retrofitting of drinking water and waste water treatment plants will include fieldbus solutions.

Benefits

Field instruments and control is distributed throughout the sewage treatment plant.