Automation Technologies 4/2014

Automation Technologies 4/2014

Automation Technologies 4/2014


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international<br />

ONLINE Edition<br />

4<br />

October <strong>2014</strong><br />

Shanghai<br />

Chinese hub for automation<br />

technologies and business<br />

Exhibition<br />

Shanghai and IAS<br />

are waiting<br />

Export Association<br />

Turkey and USA –<br />

future cooperation<br />

Machinery Safety<br />

Challenge with<br />

economic potential<br />

Quality Control<br />

Thermal imaging<br />

cameras at BMW<br />

www.ate-magazine.com<br />

in cooperation with

Editorial<br />

read editorial<br />

The future has begun<br />

Dear readers,<br />

Global competition and continuous market changes put pressure on the<br />

production industry. Costs must be reduced and profits maximised.<br />

This is also the case in China.<br />

Dirk Schaar<br />


Andreas Wolf<br />

Hannover Fairs International<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>



table of content<br />

China is the place to be<br />

with its strong position in<br />

machine production<br />

Shanghai and the IAS Show<br />

<strong>2014</strong> are waiting<br />

The automation market<br />

in China from Bernstein’s<br />

perspective<br />

Turkish Machinery to expand<br />

in the US machinery market<br />

like us on facebook<br />

News and Markets<br />

The importance of<br />

photovoltaic for the<br />

agriculture in Nicaragua<br />

Connectivity at sea<br />

Humans working together<br />

with robots: safe and flexible<br />

Columns<br />

Editorial<br />

Product News / Imprint<br />

News and Markets<br />

Big picture: Balloon Fiesta at IMTS show in Chicago<br />

What do you expect from the Chinese automation market<br />

in the next years?<br />

The <strong>Automation</strong> Market in China from Bernstein’s perspective<br />

Turkish Machinery to expand in the US Machinery Market<br />

Plastics for longer life – a very special birthday tour<br />

Industrial <strong>Automation</strong> IA Beijing: Comprehensive solutions<br />

for intelligent manufacturing<br />

Global Machinery Safety: Challenge with economic potential<br />

sensors and measurement<br />

High-performance 2D laser scanner with integrated<br />

control interface<br />

Smart Wireless Technology helps improve leak detection<br />

control and drive technology<br />

The importance of photovoltaic for the agriculture in<br />


www.escha.net<br />

Bright prospects for Industrial<br />

<strong>Automation</strong> North America<br />

High-performance 2D laser scanner<br />

with integrated control interface<br />

robotic<br />

Round connectors M12x1 | M8x1<br />

Drag-chain adapted<br />

10 million cycles<br />

Backgrounds and perspectives of the<br />

new USB 3.0 interface<br />


Sercos and Rexroth help streamline servo-driven<br />

case packers<br />

Difficult conditions – Connectivity at sea<br />

Components and Software<br />

Working together with robots: safe and flexible<br />

Enclosures: more than just a housing<br />

Machine Vision<br />

Thermal imaging cameras in automotive quality<br />

control at BMW<br />

Torsion-resistant<br />

10 million cycles | 360°<br />

Weld-field immune<br />

IP67<br />

See you at Industrial <strong>Automation</strong> Show<br />

11-15 Nov. <strong>2014</strong> | Hall E3/B08<br />

ESCHA <strong>Automation</strong> Connectivity (Shanghai) Co., Ltd.<br />

2060 Duhui Road, Building F, 2nd Floor, Minhang District<br />

201108Shanghai |+862152968180| info.china@escha.net

News and Markets<br />

WIN EURASIA <strong>Automation</strong> 2015 will<br />

take place in March<br />

The 2015 WIN EURASIA <strong>Automation</strong><br />

- World of Industry, the<br />

international event for industrial<br />

technology and capital goods in<br />

Turkey, will take place from<br />

19-22 March 2015 at the Tüyap<br />

FairConvention and Congress<br />

Center in Istanbul. The event that is organized by<br />

Deutsche Messe AG in collaboration with<br />

Hannover Messe Bilesim Fuarcilik A.S. combines<br />

four trade fairs: Hydraulic & Pneumatic<br />

EURASIA, Otomasyon EURASIA, Electrotech<br />

EURASIA and Materials Handling EURASIA.<br />

Highlights will be the Industrial Activities<br />

Summit, company and product presentations,<br />

panel discussions and matchmaking program. In<br />

<strong>2014</strong>, 77,000 visitors attended the event and 1,950<br />

companies exhibited their products and services.<br />

www.win-fair.com<br />

WIN INDIA will return to New Dheli<br />

in December<br />

This year’s WIN INDIA - World of Industry, India’s<br />

international event for industrial technology and<br />

capital goods, will take place from 10-13 December<br />

<strong>2014</strong> at the Pragati Maidan exhibition centre<br />

in New Dheli. The event that is organized by<br />

Deutsche Messe AG in collaboration with<br />

Hannover Milano Fairs India combines four trade<br />

fairs: MDA INDIA, Industrial <strong>Automation</strong><br />

INDIA, Surface Technology INDIA and CeMAT<br />

INDIA. Highlights will be live demonstrations,<br />

application parks, industrial forums, the<br />

Purchase Managers’ Summit as well as an extensive<br />

networking program. In 2013, when the trade<br />

fair took place for the first time almost 11,500<br />

visitors attended the event.<br />

www.win-india.com<br />

New accreditation for CSA Group’s lab in Turkey<br />

CSA Group, a leading global organization in standards<br />

development and testing and certification<br />

services, is expanding local services with a new<br />

accreditation for its lab in Turkey. The new accreditation<br />

allows for testing of information technology<br />

equipment, uninterruptable power systems,<br />

machinery, lighting control systems, including LED<br />

modules, lighting fixtures and non-metallic materials<br />

under TS EN ISO/IEC 17025:2012. Since 2002,<br />

the lab in Izmir has been offering product safety<br />

tests and certification services for household appliances,<br />

AV equipment and electrical equipment.<br />

The lab plans to further expand its scope of services<br />

to meet growing client needs in the areas of machinery,<br />

LED Lighting, IT equipment and automotive.<br />

www.csagroup.org<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

TKD Kabel expanding international<br />

presence<br />

Ready-to-install<br />

cable carrier systems:<br />

e-chains ®<br />

For the first time, German-based cable specialist<br />

TKD Kabel will generate more than 50 % of its<br />

annual revenue in foreign markets. This achievement<br />

was made possible by the company’s<br />

expanded international presence. In the last two<br />

years alone, TKD has established three new<br />

national subsidiaries. This latest expansion began<br />

in October 2012 with the launch of TKD Italia,<br />

followed by TKD Cable Suzhou in China in the<br />

middle of last year and TKD Mexico at the end of<br />

2013. “Our three ‘youngsters’ have enjoyed strong<br />

growth from the beginning – and turned into a<br />

real fixture in their respective markets”, says<br />

Dr. Wilhelm Engst, CEO of TKD Kabel.<br />

+ chainflex ® cables<br />

= readychain ®<br />

www.tkd-kabel.de<br />

Binder opens subsidiary in<br />

Singapore<br />

Having already established subsidiaries in China,<br />

USA, France, UK, Sweden and the Netherlands<br />

“Binder Singapore” opened this month. The<br />

manufacturer of circular connectors continues<br />

with its company philosophy of strengthening<br />

the headquarters in Neckarsulm as the heart of<br />

the company and expanding its international<br />

presence. Managing shareholder Markus Binder<br />

is fully convinced of Singapore as a hub: “From<br />

there we can perfectly serve the local demands in<br />

South East Asia, India, Middle East and the Asia<br />

Pacific region with our broad portfolio.” Binder<br />

has moved into office and warehouse premises in<br />

the “Singapore German Centre”.<br />

www.binder-connector.de<br />

readychain ®<br />

is a pre-harnessed system that is<br />

ready to plug-and-play upon delivery. Available<br />

from 24 hours! ... plastics for longer life ®<br />

Request a free sample: Tel. +49 2203 9649-800<br />

readychain@igus.eu www.igus.eu/rc<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong><br />

Igus-englisch.indd 1 23.09.<strong>2014</strong> 15:12:23

News and Markets<br />

Deutsche Messe expands its industrial<br />

tradeshow portfolio in the U.S.<br />

Deutsche Messe AG has organized Industrial<br />

<strong>Automation</strong> North America in the U.S. since 2012<br />

and launched MDA North America in <strong>2014</strong>. The<br />

success of these two events underscores the<br />

ongoing re-industrialization trend in the U.S.,<br />

where low labor and energy costs are spurring on<br />

industrial production and filling manufacturers’<br />

order books. Following this trend, in 2016<br />

Deutsche Messe will organize three additional<br />

events – ComVac North America, Industrial<br />

Supply North America and Surface Technology<br />

North America – which cover compressed-air<br />

and vacuum technology, industrial subcontracting<br />

and surface treatment, respectively. These<br />

five trade fairs will run parallel to IMTS (International<br />

Manufacturing Technology Show) from 12<br />

to 17 September 2016 at McCormick Place in<br />

Chicago. With more than 2,000 exhibitors and<br />

110,000 trade visitors, IMTS is North America’s<br />

leading trade fair for manufacturing technology.<br />

www.ia-northamerica.com<br />

Eaton intensifies cooperation<br />

with SAE<br />

Power management company Eaton and SAE<br />

Schaltanlagenbau Erfurt GmbH (SAE) have finalised<br />

a cooperation agreement which will see<br />

them work closely together to build machine<br />

control panels for export to North America, and<br />

also for use in large scale projects. “The requests<br />

from machine builders for support in exports to<br />

the North American market have continued to<br />

increase in recent years,” reports Martin Kram,<br />

Sales Director Germany, Eaton Electrical Sector<br />

EMEA. “The requirements that have to be met in<br />

order to be allowed to supply machinery to the<br />

USA and Canada differ in their complexity considerably<br />

from the European IEC standards. The<br />

extension of our partnership with SAE now puts<br />

us in the position of being able to also offer our<br />

customers the systems as well as the specialist<br />

know-how.” Headquartered in Erfurt, Germany,<br />

SAE has over 200 employees and has specialised<br />

in the development and manufacture of switchboards<br />

for automation technology and machine<br />

building, as well as power and low-voltage power<br />

distribution systems up to 5,000 A. The company<br />

focuses on projects for export to the North<br />

American market.<br />

www.eaton.com<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and Markets<br />

Eplan with three new subsidiaries<br />

New Eplan subsidiaries have been founded in Japan, South Africa<br />

and Turkey. Until now, the three countries have been supported by<br />

co-operation partners. At the start of the year, Eplan Software &<br />

Services K.K. was founded with its headquarters in Tokyo. In June,<br />

the new subsidiary Eplan Software & Services (Pty) Ltd. started<br />

trading in South Africa. The office was established in Edenvale near<br />

Johannesburg. A further subsidiary was established in July in Turkey:<br />

Eplan Yazılım ve Yazılım Hizmetleri A.S. trades in Istanbul. “As a<br />

manufacturer of engineering solutions, we can market new products<br />

and our comprehensive service portfolio better and much more<br />

quickly”, explains Haluk Menderes (photo), Managing Director of<br />

Eplan Software & Service. “Our customers, who are largely active in<br />

international circles, profit from our extensive presence in the global<br />

market and a uniformly high-quality level with respect to services.”<br />

www.eplan.de<br />

EtherCAT Technology Group: 1,000 th member in Asia<br />

Two successful Ether-<br />

CAT Plug Fests , along<br />

with two Safety over<br />

EtherCAT seminars in<br />

Japan and Korea , highlight<br />

the widespread<br />

implementation of<br />

EtherCAT and support<br />

of the EtherCAT Technology<br />

Group (ETG) on<br />

the Asian continent.<br />

Almost 80 participants attended this year’s Ether-<br />

CAT Plug Fests, the developer meetings conducted<br />

by the ETG, in Japan and Korea. ETG events in<br />

Japan have seen particularly overwhelming growth,<br />

with significant increases in member attendance<br />

over the past four<br />

years. Conducted for<br />

the first time in 2010,<br />

the EtherCAT Plug<br />

Fest in Japan has reached<br />

the same attendance<br />

level as its<br />

European counterparts.<br />

Looking back at<br />

the success of the<br />

EtherCAT events in<br />

Japan and Korea , the latest milestone of the ETG is<br />

hardly surprising , given the recent welcome to the<br />

organization ’s 1,000 th member in Asia.<br />

www.ethercat.org<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

BARE IS<br />



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At Basler, we have a unique vision of value.<br />

Learn more at baslerweb.com.

news and markets<br />

big<br />

our<br />

picture<br />

Chicago<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

news and markets<br />

Balloon Fiesta at IMTS show in Chicago: If there is<br />

one thing anyone who attended IMTS remembers,<br />

it is the fantastic balloon that appeared on the front<br />

lawn of McCormick Place and the exhibition halls.<br />

Two of our editors stayed in Chicago to pursue the<br />

latest trends in the American automation sector for<br />

you. More in this issue…<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>


The place to be<br />

Gerald Scheffels<br />

China is by far the biggest market for machines<br />

– and the largest manufacturer of machines, too.<br />

This means: The Chinese industry attracts the<br />

global manufacturers of machines as well as<br />

their suppliers.<br />

hall plan

ead article<br />



Shanghai and IAS are waiting<br />

Shanghai is not only the most important industrial city<br />

of China but also one of the largest cities in the world.<br />

The city is a major transport hub and an important<br />

cultural and educational center with numerous universities,<br />

colleges and research institutions. This also means that<br />

there is an important location for the automation industry.<br />

The trade fair IAS will be again the impressive proof.


IAS hall plan<br />

read article

news and markets<br />

“What do you expect from the<br />

Chinese automation market in<br />

the next years?”<br />

China remains one of the world’s fastest growing economies and<br />

the fastest growing market for manufacturing. China has also<br />

experienced double-digit growth in many segments of automation.<br />

The Data from National Bureau of Statistics showed: the main<br />

business revenue of enterprises in industrial automatic control<br />

system equipment manufacturing industry was CNY 0.1997 billion<br />

in 2011, CNY 0.2450 billion in 2012, and up to CNY 0.2686 billion by<br />

the end of November 2013, which exceeded the total of 2012.<br />

Industrial automation industry has become one of the driving<br />

forces to promote rapid growth of economy in China.<br />

With the industrial transformation of China, more and more largescale<br />

equipment require a control system with higher precision,<br />

which means there will be more high-end products in the market in<br />

future. For the purpose of precision, labor cost control and real-time<br />

on site operation, there will be more robotic applications. The<br />

Chinese government keeps supporting high-tech industries and<br />

cultivating new economic growth area, the technology of domestic<br />

brands has been substantially increased and local suppliers are<br />

confident to compete with foreign technologies in some automation<br />

segments now. The R&D and production target are highly<br />

based on customer needs, which could lead to polarization of<br />

automation products: one side are highly precise or customized<br />

control systems, the other side are standardized products for<br />

low-end users. Market for mid-end products is shrinking and<br />

system integration is playing a more important role.<br />

John Jiang, Managing Director, Lapp Kabel Shanghai Co. Ltd.

news and markets<br />

For Harting, the Chinese automation market will represent one of the major growth<br />

markets also in the future. At the same time, we can see that the market is in a<br />

transition phase. If, in the past, it was characterised by a rather conservative<br />

approach in terms of connectivity, which became visible in the high demand for<br />

classic board-to-board connectivity, today it features not only innovative backplane<br />

solutions but also mezzanine connectors.<br />

Also in China, decentralisation further asserts itself through ethernet<br />

communication. To this purpose, automation profiles are used. Interestingly<br />

enough, a large number of profiles is required - not just regional<br />

ones - in addition to CC-Link, also Ethernet IP, Profinet or EtherCAT.<br />

Among market players, it is the globally established automation<br />

manufacturers who make decisions regarding connectivity also at a local level, as<br />

well as an increasing number of Chinese manufacturers. For us, a very special<br />

highlight is represented by the fact that we have fitted with har-flex the internal<br />

connection between two PCBs in the HMI of a renowned Chinese manufacturer. Thus<br />

we will be continuing our growth path in China.<br />

Andreas Huhmann, Strategy Consultant Connectivity & Networks at the Harting Technology Group<br />

Visit us!<br />

➔ Nov. 04.–08. <strong>2014</strong> · Shanghai<br />

Hall W2 · Booth B112<br />

Get connected<br />

with innovative cables and systems for<br />

industrial applications<br />

The FieldLink product range offers:<br />

Fieldbus cables for factory automation<br />

Cables and cable systems for drive technology<br />

The Quality Connection<br />

Business Unit Industrial Solutions · www.leoni-industrial-solutions.com

news and markets<br />

The <strong>Automation</strong> Market in China<br />

from Bernstein’s perspective<br />

Uwe Birnbaum, Nicole Steinicke<br />

International safety is becoming more and<br />

more important for the Chinese market.<br />

Bernstein AG ranks among the world’s leading<br />

providers of industrial safety technology<br />

and has a Chinese subsidiary located in<br />

Taicang. With its comprehensive range of<br />

switches, sensors, enclosures, suspension<br />

systems and other components for industrial<br />

applications, Bernstein offers effective and<br />

versatile solutions that address a range of<br />

issues.<br />

Bernstein products are designed to perfectly integrate<br />

in individual system solutions, conforming<br />

to rigorous international safety guidelines. In addition<br />

to classic plant and machine construction,<br />

Bernstein also works with customers in a range of<br />

industries including lift construction, automotive,<br />

agriculture, conveyor construction, automation<br />

engineering, wood-working, renewable energy,<br />

medical technology industries, AS-Interface and AT-<br />

EX. In 2005 Bernstein established a branch and set<br />

up a manufacturing plant in Taicang, situated 50 km<br />

north from the business metropolis of Shanghai. The<br />

expansion of the Chinese market offers significant<br />

opportunities for industrial safety engineering.<br />

Market development in general<br />

Since early 2000, before the economic crisis in<br />

2007/2008, the worldwide automation market developed<br />

rapidly at an average annual growth rate of<br />

8-9 %. China enjoyed annual average growth of up to<br />

20 % at that time. Bernstein ’s Chinese subsidiary was<br />

established just two years before the outbreak of the<br />

global economic crash which seriously hit the whole<br />

industry. While the world market took several years<br />

to recover, the Chinese market recovered faster than<br />

expected with growth in China remaining stable at<br />

7-8 %. Export trade, an important part of the wellknown<br />

Chinese success story of the last two decades,<br />

continued to play a vital role in the country’s growth<br />

whilst a new focus on the domestic market began to<br />

gain increasing momentum.<br />

Huge investment was made in the field of automation<br />

for the automotive industry and machine building<br />

for improvement of the production standards.<br />

This was triggered by the market development in<br />

general and also expressed in China’s 12th Five-Year<br />

Development Plan of high-end equipment manufacturing<br />

industry.<br />

The plan pointed out the importance of upgrading<br />

manufacturing, but also improving the production<br />

efficiency, technical level and product quality. A<br />

transition from “Made in China” to “Designed in<br />

China” became the focus.<br />

The aim is that China’s machinery products shall<br />

be considered as an “intelligent generation” by 2030.<br />

It is also forecasted that Power Generation in China<br />

will double by adding 1,500 gigawatts of capacity in<br />

the same period of time. Actually, this is not a new<br />

industrial revolution, but rather an evolution already<br />

started several years ago.<br />

Impact of the daily business<br />

Let us first consider product and production<br />

related requirements: customers need better monitoring<br />

and control capabilities than ever before<br />

and the needs of respective product categories are<br />

getting more complex. Large volumes of data<br />

needs to be measured, transported via a bus system<br />

and processed, resulting in more complex<br />

products. The needs of machine builders are no<br />

longer the same; they are interested in more customized<br />

solutions rather than standard products

news and markets<br />

and want to obtain an end-to-end solution from<br />

the supplier.<br />

High quality level and machine safety<br />

In view of the rapid evolution of technology, Bernstein<br />

has observed that safety aspects are getting<br />

more and more important in China. On the one hand<br />

this concerns the safety of humans, and on the other<br />

hand the process safety management concerning<br />

minimizing stand-still times of machines. Stable production<br />

processes must be ensured. This goes along<br />

with a growing demand on energy efficiency solutions<br />

due to tremendous increases in energy costs.<br />

Awareness of the importance of safety started with<br />

CCC certification in 2002. Another important milestone<br />

was China’s GB 22530-2008 safety standard for<br />

rubber and plastic injection molding machines. 50<br />

basic standards and regulations for safety related<br />

applications have since been published in China.<br />

The National Machinery Safety Standardization<br />

Technical Committee, which was founded in 1994, is<br />

responsible for ensuring these regulations and standards<br />

are controlled and adhered to. However, the<br />

National Standardization Management Committee<br />

and the State Administration of Work Safety are also<br />

organisations to be mentioned here.<br />

View of automation technology<br />

The high specifications demanded by the quality<br />

guidelines and machine safety standards no longer<br />

only concern products manufactured for export, but<br />

also for domestic and industrial customers. This<br />

change in quality awareness has resulted in a new<br />

way of thinking in China – products at favorable prices<br />

are no longer the main focus and it is now understood<br />

that modern, high-quality products and services lead<br />

to satisfied customers. Foreign brands were trendsetting<br />

in the past. Today it’s just a question of time<br />

that more and more domestic companies are raising<br />

their standards of processes and products as well.<br />

Of the 740 Chinese companies engaged in the<br />

automation industry, about 50 % are located in<br />

About<br />

Company name: Bernstein Safe Solutions Co., Ltd<br />

Headquarters: BERNSTEIN AG, Porta Westfalica, Germany<br />

Employees: appr. 540<br />

Products: Switches, sensors, enclosures, suspension<br />

systems and other components for industrial applications<br />

the area of Shanghai, Jiangsu and Zhejiang – already<br />

catching up with international companies. The<br />

competition for foreign companies is getting more<br />

serious. Even so, China is still the most important<br />

region of growth for international companies.<br />

New evolutions and conclusion<br />

The awareness of safety (human and machine)<br />

aspects and the automation level is growing. Due to<br />

the increasing complexity, the industrial market<br />

requests more and more total solution providers and<br />

system integrators. Component suppliers are<br />

becoming less important. To be successful in the<br />

future, it is compulsory to offer to customers high<br />

quality products with absolutely competitive prices<br />

and a service perfectly in keeping with the customer’s<br />

requirements. Focusing on specific regional<br />

needs is vital in order for companies to be able to<br />

react quickly and remain flexible.<br />

The whole world “goes smart”. So does the Chinese<br />

<strong>Automation</strong> Industry. Sensors, switches, actuators<br />

will be “intelligent” and can be connected to a bus<br />

system. By using AS- Interface, Bernstein products<br />

can be connected via a gateway to e.g. Profibus,<br />

Ethernet, controlLogix, CANopen, CC-Link and other<br />

bus and control systems. Bernstein is ideally prepared<br />

to meet the future demands of the Chinese<br />

market of controlling and monitoring applications in<br />

different industries such as Automotive, Agriculture,<br />

Transportation, Material Handling and <strong>Automation</strong><br />

Engineering industries, as well as Medical Technology.<br />

www.bernstein.eu/en<br />

Author: Uwe Birnbaum, Managing Director<br />

of Bernstein Safe Solutions Co., Ltd., Taicang,<br />

China;<br />

Nicole Steinicke, editor, <strong>Automation</strong><br />

<strong>Technologies</strong>, Mainz, Germany


Bright prospects for Industrial<br />

<strong>Automation</strong> North America<br />

Peter Becker<br />

Robotics and mobile solutions. Only two of the growing<br />

trends in automation that have been key topics at this<br />

year’s Industrial <strong>Automation</strong> North America in Chicago.<br />

But there was even more to discover as our editorial<br />

team saw for themselves at the fairground.


video<br />

Video review of the fair<br />

video<br />

Interview with Larry Turner<br />

read article


Turkish Machinery to expand i<br />

in the US Machinery Market<br />

The Industrial <strong>Automation</strong> North America fair in Chicago<br />

marks a renewed interest in Turkish Machinery given their<br />

recent expansion and market growth in Europe.<br />

Since Turkish Machinery is on its way to strengthening its<br />

position in the manufacturing industry in Europe, as well<br />

as in many developing countries, it now plans to foster a<br />

greater partnership with the US machinery and machine<br />

tool industry.


read article<br />

video<br />

the turkish export association

News and markets<br />

A very special<br />

birthday tour<br />

Iglidur on tour in Chicago<br />

Plastics for longer life – that is the slogan of<br />

Igus. To prove their point, the iglidur car<br />

travelled around the world and inspired<br />

engineers on<br />

almost all<br />

continents. Watch<br />

our video of the<br />

car in Chicago<br />

Video<br />

Peter Becker<br />

If you read our magazine thoroughly, you<br />

will already know: German polymer specialist<br />

igus sent a Smart car around the world<br />

– equipped with 56 of the manufacturer’s<br />

bearings to prove their capabilities in every<br />

possible climate and environment. Our<br />

editorial team finally met the car and its<br />

drivers at Industrial <strong>Automation</strong> North<br />

America in Chicago.<br />

Author: Peter Becker, editor,<br />


About<br />

Company name: igus<br />

Established: 1964<br />

Headquarters: Cologne, Germany<br />

Turnover: € 427 million<br />

Employees: 2,400 worldwide<br />

Products: motion plastics, plastic components for moving<br />

applications: energy chain systems, cables, polymer bearings,<br />

linear bearings, low-cost automation<br />

On October 18, Igus turned 50. We wish the specialist<br />

for cables, energy chains, connectors and<br />

bearings: Happy birthday! To celebrate this special<br />

day and to promote their idea of motion plastics, they<br />

had an unusual idea: the company equipped an orange<br />

Smart car with 56 of its bearings made of plastics<br />

and sent it on a trip around the world. The tour started<br />

in India in January – followed by stops in China, Japan,<br />

Brazil, Canada and the US, among others, and will<br />

continue across Europe in the upcoming months.<br />

With this ambitious effort, the company wants to<br />

prove the resilience and durability of their bearings in<br />

automotive and moving applications. And according<br />

to Stefan Kombüchen, head of marketing and corporate<br />

communications at Igus, to whom we spoke at<br />

Industrial <strong>Automation</strong> North America in Chicago, the<br />

results were impressive: “The car has driven 54,500 km<br />

until our stop in Chicago and, so far, we hadn’t had<br />

any problems at all despite the harsh climate conditions<br />

in the deserts of India or the cold of Alaska.”<br />

After its stop in Chicago, the orange car travelled to<br />

Detroit and New York, before it returned to Germany;<br />

to celebrate igus’ 50 th anniversary in Cologne.<br />

We had the opportunity to take a look at the car for<br />

ourselves in Chicago. Watch our video including<br />

footage of the car in Chicago and a video interview<br />

with Stefan Kombüchen.<br />



IA Beijing: Comprehensive<br />

solutions for intelligent<br />



Industrial <strong>Automation</strong> Beijing <strong>2014</strong> is one of the<br />

most significant shows in China’s northern area.<br />

More than 200 leading automation enterprises<br />

displayed high-grade products and solutions of<br />

industrial automation. Read more about<br />

the importance of this exhibition and<br />

what are the demands of Chinese<br />

customers? Watch our video<br />

statements and find out.<br />

read article


Global Machinery Safety:<br />

Challenge with economic potential<br />

John McAuliffe<br />

In a globalized economy, international companies are looking for ways to<br />

standardize their production processes and associated machinery and plants.<br />

A special challenge is the machinery safety, because depending on the<br />

country, the requirements and provisions differ significantly. With its<br />

International Service Group Pilz has adjusted to this challenge.

ead article<br />



High-performance 2D laser<br />

scanner with integrated<br />

control interface<br />

Arno Hagemann<br />

The 2D laser scanners in the R2000<br />

family of Pepperl+Fuchs are noted for<br />

their exceptional detection performance<br />

in distance measurement technology.<br />

The latest device variant now makes it<br />

particularly easy for users to benefit<br />

from the system‘s facilities.

The Germany-China Business Association.<br />

Exchange expertise.<br />

Extend your network.<br />

Since 1987, the German-Chinese Business Association (DCW) has made it its mission to work for<br />

better economic relations between China and Germany. Our non-profit association has become a<br />

valuable platform for members and partners to initiate and deepen long-term partnerships. DCW<br />

members are united in a common goal: Create the right conditions for sustainable growth in trade<br />

and investment between Germany and China.<br />

As a member, you will join over 380 companies, organizations and private individuals in working towards<br />

these goals. Members enjoy a range of privileges that include the following:<br />

• Talk to us about your business plans in China<br />

• Find new business partners on the online platform www.DeZhong.de<br />

• Participate in our regional seminars to exchange experiences and gain new expertise<br />

• Join business delegations to China, connect to member companies of European partner organisations<br />

• Gain online access to our member-only information archive<br />

• Benefit from discounts at professional conferences, trade fairs and other events<br />

• State your views on fair investment and trade relations and help us draft our next position paper<br />

• Present your company as a contributor for better economic relations between China, Europe, and<br />

Germany<br />

The advantages of a membership are available to both private individuals and businesses. They will be<br />

granted to all employees of your institution or company.<br />

We are excited about welcoming you to our network. If you have any question, please do not hesitate to<br />

talk to us.<br />

www.dcw-ev.de<br />

German-Chinese Business Assiciation<br />

Unter Sachsenhausen 10–26 · 50667 Cologne, Germany<br />

Phone: +49 221 120370 · Fax: +49 221 120417 · E-mail: info@dcw-ev.de


Smart Wireless Technology<br />

helps improve leak detection<br />

New regulations often demand changes in industrial<br />

production sites. To meet the newly established<br />

requirements by the government, BP had to ensure<br />

continuous leak detection at its plant in Geel,<br />

Belgium. A wireless transmitter network by Emerson<br />

Process Management in combination with hydrocarbon<br />

sensors was installed to enable continuous<br />

monitoring of tanks, valves and pipelines.


read article<br />

Providing unmatched precision.<br />

Delivering Providing 360° unmatched performance.<br />

precision.<br />

Advancing Delivering intuitive 360° performance.<br />

control.<br />

Advancing intuitive control.<br />

R2000 Detection<br />

2DR2000 Laser Detection Scanner<br />

2D 2D 2DLaser Scanner<br />

R2000 Detection – Object detection as easy it can be<br />

R2000 Detection – – Object – detection as easy easy easy it can it can it be can be be<br />

Stable, wobble-free scanning axis for precise field monitoring<br />

Stable, wobble-free scanning axis axis axis for for for precise field field field monitoring<br />

Highest angular resolution on the market allows detection of extremely small objects<br />

Highest angular resolution on on the on the the market allows detection of of of extremely small small small objects<br />

User-defined detection fields make configuration simple, intuitive, and user friendly<br />

User-defined detection fields fields fields make make make configuration simple, intuitive, and and user and user user friendly<br />

www.pepperl-fuchs.com/A-distance-ahead<br />



The importance of<br />

photovoltaic for the<br />

agriculture in Nicaragua<br />

Klaas Eßmüller, Dennis Kortstock<br />

A school project in Hamburg is looking at the specific application<br />

of photovoltaics in agriculture. The main focus is on the<br />

development and sizing of solar-powered groundwater<br />

irrigation systems. This is a learning process in<br />

which control equipment and the Siemens<br />

expertise also play a role.

ead article<br />



Sercos and Rexroth help streamline<br />

servo-driven case packers<br />

Brenton Engineering designed a new line of side-loading<br />

case packers to exceed current “green manufacturing”<br />

end user trends, featuring servo control to increase speed<br />

and reduce energy costs within a compact footprint.


read article<br />

video<br />

Peter Lutz about the future of Sercos


Connectivity at sea<br />

Valentin Scheltow<br />

The demands placed on products in the maritime markets<br />

vary depending on the location, and are often extremely<br />

high. The crucial environmental factors in this sector are<br />

vibration, salt water mist and magnetic compatibility<br />

with compasses. Connectors and Ethernet Switches by<br />

Harting perform well even under these difficult conditions.

ead article<br />



Humans working together<br />

with robots: safe and flexible<br />

Peter Becker<br />

According to Larry Turner, CEO Hannover Fairs USA,<br />

robotics is one of the growing branches in automation.<br />

Robot specialists Universal Robots presented the third<br />

generation of its products, UR5 and UR10, at Industrial<br />

<strong>Automation</strong> North America featuring advanced safety<br />

functions and true absolute encoders.

ead article


Enclosures:<br />

more than just a housing<br />

Michael Schell, Christan Moritz<br />

Enclosure housings protect the electrical equipment housed inside them,<br />

as well as the people who operate a switchgear or controlgear systems.<br />

Protection requirements and safety procedures are defined by various<br />

guidelines depending on the operating site, sector or application.<br />

In order to comply with these guidelines, various tests are required.

ead article<br />



Camera change with potential:<br />

USB 3.0 instead of FireWire<br />

René von Fintel<br />

How long will I be able to maintain my<br />

FireWire camera system? When should<br />

I switch, and which interface should I<br />

pick? Users of FireWire cameras around<br />

the world are wondering these things<br />

at the moment. The new USB 3.0 interface<br />

and its standard USB3 Vision are<br />

an attractive successor due to the<br />

technical proximity to FireWire. Basler,<br />

a globally active developer of industrial<br />

cameras, explains the backgrounds<br />

and perspectives.


read article<br />

video<br />

USB 3.0


Thermal imaging cameras in<br />

automotive quality control<br />

Chris Brown, Frank Liebelt<br />

The BMW 5-Series, 6-Serie, 7-Series and 3-Series Gran Turismo are<br />

produced in the Dingolfing plant in Lower Bavaria. Around 18,500<br />

people work at the site. Basic functions from signal horn to enginespecific<br />

performance are thoroughly tested. Thermographic<br />

cameras are ideally suited for this type of quality control and<br />

ensure the proper functioning of automobile production.

ead article<br />


imprint<br />

Editor-in-chief:<br />

Dirk Schaar; Email: d.schaar@vfmz.de<br />

Editorial board:<br />

Peter Becker; Email: p.becker@vfmz.de<br />

Nicole Steinicke; Email: n.steinicke@vfmz.de<br />

Small and fast – temperature<br />

transmitter with IO-Link<br />

Assistant editor:<br />

Svenja Stenner<br />

Design/Layout:<br />

Sonja Schirmer, Doris Buchenau, Anette Fröder,<br />

Conny Grothe, Melanie Lerch, Mario Wüst<br />

E-Paper Designer:<br />

Katja Rüdell, Mathias Göbel<br />

Managing editor:<br />

Winfried Bauer<br />

Publisher:<br />

Vereinigte Fachverlage GmbH<br />

Lise-Meitner-Str. 2<br />

55129 Mainz, Germany<br />

Managing director:<br />

Dr. Olaf Theisen<br />

Publishing director:<br />

Dr. Michael Werner; Email: m.werner@vfmz.de<br />

Advertising sales director:<br />

Beatrice Thomas-Meyer<br />

Advertising sales manager:<br />

Oliver Jennen; Email: o.jennen@vfmz.de<br />

Sales representatives<br />

Austria<br />

Heinz-Joachim Greiner<br />

Email: verlagsbuero-greiner@vfmz.de<br />

Brazil<br />

Carlos Frederico Graf Schaffgotsch<br />

Email: datadress@vfmz.de<br />

China<br />

Oliver Jennen<br />

Email: o.jennen@vfmz.de<br />

France<br />

Marc Jouanny<br />

Email: marc-jouanny@wanadoo.fr<br />

Great Britain<br />

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Email: rob.brewer1@btinternet.com<br />

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Oliver Jennen<br />

Email: o.jennen@vfmz.de<br />

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Hermann Jordi<br />

Email: info@jordipublipress.de<br />

Poland<br />

Dr. Miroslaw Bugajski<br />

Email: premiummedia.mb@gmail.com<br />

Russia, Ukraine, Kazakhstan<br />

Natalia Hretschkova<br />

Email: nhrethkova@ivdk.ru<br />

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Email: verlagsbuero-mezger@vfmz.de<br />

USA, Canada<br />

Aryan Zandieh<br />

Email: aryan@hfusa.com<br />

Advertising disposition:<br />

Helge Rohmund; Email: h.rohmund@vfmz.de<br />

In cooperation with:<br />

Hannover Fairs International GmbH<br />

Messegelände, 30521 Hannover, Germany<br />

Modular designed controls:<br />

no cables, no batteries<br />

Powerful ace USB 3.0 Cameras<br />

with 2 and 4 MP CMOSIS Sensors<br />

Monitoring energy consumption<br />

with CC-Link IE<br />

EKS Engel presents Industrial<br />

Ethernet switch with Profinet<br />

conformance class B<br />

Additional Partner:<br />

ZVEI - Zentralverband Elektrotechnik- und<br />

Elektronikindustrie e. V.<br />

Moskauer Deutsche Zeitung<br />

Internet:<br />

www.ate-magazine.com<br />

Second year (<strong>2014</strong>)

2. rubrizierungsebene I 1. rubrizierungsebene<br />

China<br />

November 4-8, <strong>2014</strong><br />

Shanghai New International Expo Centre (SNIEC), Shanghai<br />

Discover International Industrial Intelligence &<br />

<strong>Automation</strong> at<br />


Your Exchange Platform for Innovation, Components and Applications<br />

■ The Industrial <strong>Automation</strong> Show is China’s biggest industry<br />

networking hub. It offers the following advantages:<br />

▪ Ideal framework for successfully gaining new customers<br />

▪ Enhanced opportunity to transact direct business deals,<br />

since the 70,000 trade visitors at the show come armed<br />

with concrete investment plans<br />

▪ All the leading manufacturers appear as exhibitors here<br />

▪ Presents an overview of all the latest innovations<br />

▪ Affords you an opportunity to measure yourself against<br />

the competition<br />

■ Thanks to the official government support and corresponding<br />

media attention, exhibiting companies benefit<br />

from enhanced brand recognition, and their solutions are<br />

presented to a large audience.<br />

■ Government support of the event promotes direct contact<br />

with decision-makers from government and interest groups<br />

who hold the key to investments. This affords you a comprehensive<br />

overview of planned investment projects and can<br />

help significantly accelerate the decision-making process.<br />

Mr. Michael Peng, Marketing Manager of Beckhoff <strong>Automation</strong> (Shanghai) Co., Ltd.<br />

“Beckhoff participates at IAS since 2005. We consider it as the best automation show in China,<br />

widely viewed as a barometer of Chinese industrial development. We are satisfied with everything at IAS 2013, the topic,<br />

the visitors’ number, the delegations and other supporting service, everything is amazing! We really appreciate that HMFS<br />

provides such a platform for us to show our products. Best wish to IAS.“<br />


1. Rubrizierungsebene I 2. rubrizierungsebene<br />

Reach international markets.<br />

New business is<br />

just one click away.<br />

52 Industrielle <strong>Automation</strong> online 4/2013<br />

www.fh-intralogistics.com<br />

www.mda-technologies.com<br />


Editorial<br />

The future has begun<br />

Dear readers,<br />

Global competition and continuous market changes put pressure on the<br />

production industry. Costs must be reduced and profits maximised.<br />

This is also the case in China. Increasing acquisition and production<br />

costs drive up demand for flexible and energy-efficient production with<br />

modern automation systems. Innovations play a decisive role in the<br />

land of superlatives, especially where the use of IT and software, or<br />

production and industrial, facilities that are completely linked to each<br />

other in a network is concerned.<br />

These are the subjects on which everything is centred when the gates of<br />

the open Industrial <strong>Automation</strong> Show IAS <strong>2014</strong> in Shanghai. In combination<br />

with two other events, this one has in the meantime become one<br />

of the leading trade fairs for tool machines and metal processing,<br />

production, processing and Industrial Building <strong>Automation</strong>, as well as<br />

conventional and renewable energies in Eastern China. If you visit IAS<br />

in early November, you will see that the subjects of Industry 4.0 or<br />

Smart-<strong>Automation</strong> are increasingly gaining in importance. The first<br />

products are already subject to field tests or even in actual use. The<br />

future of the smart factory has begun.<br />

Many corresponding subjects or those that are a basic prerequisite for<br />

the pioneering technologies can also be found in the current issue of<br />

AUTOMATION TECHNOLOGIES – from sensor to control technology to<br />

industrial image processing: learn more about the potential of USB 3.0<br />

instead of FireWire when using cameras, how the future cooperation of<br />

man and robot can become safer and more flexible, how plug connectors<br />

and Ethernet switches can be perfectly adjusted to rough environments,<br />

and why machine safety poses a challenge with great economic<br />

potential. Additionally, we have many new technologies<br />

and products from the world of industrial<br />

automation at hand.<br />

Enjoy your read!<br />

Dirk Schaar<br />


Andreas Wolf<br />

Hannover Fairs International<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and Markets<br />

The place to be<br />

Gerald Scheffels<br />

China is by far the biggest market for machines<br />

– and the largest manufacturer of<br />

machines, too. This means: The Chinese<br />

industry attracts the global manufacturers<br />

of machines as well as their suppliers.<br />

two – have become the Asian “workbench” not only<br />

for domestic manufacturers but also for many foreign<br />

suppliers of, say, hydraulic systems, pneumatic components,<br />

sealings, bearings and transmissions.<br />

Though there will be growth rates in the future,<br />

there are clouds on the horizon in form of increasing<br />

cost pressure, mainly – but not only – for the manufacturers<br />

of consumer goods.<br />

There is no doubt: For the manufacturers of<br />

hydraulic and pneumatic components, power<br />

transmissions and automation technology like control<br />

systems and robotics, China is the place to be –<br />

the eastern regions of China, to be precise, because it<br />

is here where many large and smaller manufacturers<br />

of machines are located.<br />

Impressive increase of the economy<br />

The rise of China within the last ten years is embarassing<br />

indeed, especially in the field of industry<br />

and machinery. In the range of the top machine facturers,<br />

China has achieved the number one position<br />

with a production value of € 678 billion (2012). In<br />

2008, it was just € 271 billion – an impressive increase<br />

over just five years.<br />

The number two, the USA, produced less than a half<br />

with € 330 billion. Japan follows on position three,<br />

while Germany is the world´s fourth largest machine<br />

manufacturer with a volume of € 248 billion. In the<br />

competition of machine exporting countries, China<br />

has acquired the third position after Germany and<br />

the USA.<br />

Strong position in machine production<br />

The strong position in machine production attracts,<br />

of course, the world-wide suppliers of drive and control<br />

and automation components. This is why fairs<br />

like the Industrial <strong>Automation</strong> Show (IAS) Shanghai<br />

are an important platform for building new business.<br />

The eastern provinces and global cities of China –<br />

including Shanghai and Guangdong, to name just<br />

Best-in-class or “good enough”?<br />

For the (domestic and foreign) machine producers,<br />

these news bear a positive aspect. When cost issues<br />

are concerned and wages are rising, industrial<br />

automation seems to be the right answer, and this is<br />

exactly what happens in the industrialized areas of<br />

China. So there are good opportunities for the worldwide<br />

automation industry and its suppliers.<br />

Chinese and foreign manufacturers are competing<br />

fiercely here, and both have learned from experience.<br />

The Chinese companies have constantly raised the<br />

quality, performance and productivity of their equipment,<br />

whereas the European manufacturers have<br />

realized that instead of best-in-class components and<br />

systems, “good enough”-equipment often is the better<br />

choice in many applications. With this strategy, they are<br />

very successful: China has become the most important<br />

market for German machine manufacturers.<br />

Chinese machines with European<br />

components<br />

In tIn the course of the approximation of quality and<br />

performance standards, many Chinese machine<br />

manufacturers use components like motors, drives<br />

and control systems hydraulic or pneumatic systems<br />

from global leaders like Bosch Rexroth, Eaton,<br />

Siemens, B&R, Beckhoff, Rockwell and Weidmüller.<br />

Others have acquired European systems suppliers<br />

like Linde Hydraulics and Fluitronics. And, of course,<br />

the Global players are well established in China. Just<br />

one example: Festo, a German-based specialist for<br />

pneumatics and automation, has 42 locations in<br />

China and employs more than 1800 people.<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and Markets<br />

What will the next five-year-program<br />

bring?<br />

Specialists of investment good industry all over the<br />

world are keen to know what the next five-yearprogram<br />

will contain and in which way it will affect<br />

the Chinese industry both as the most important<br />

manufacturer of and the biggest market for machines.<br />

It is expected that the plan, which will be valid from<br />

2016 to 2020, is aiming at a yearly growth rate of 7 %,<br />

putting a stress on sustainable industries and<br />

avoiding an “overheating” of sectors like the building<br />

trade. Furthermore, it is probable that the liberalization<br />

of regulations will be continued. With the “China<br />

(Shanghai) Pilot Free Trade Zone”, the economic<br />

administration has already a kind of “prototype” for<br />

its upcoming reform projects.<br />

Good reasons for optimism<br />

Even if the yearly growth rates of the Chinese economy<br />

will calm down a bit, there is no need for pessimism,<br />

as far as the automation industry and, all in<br />

all, the investment goods industry and their suppliers<br />

are concerned. Seen from now, there will still be<br />

significant growth, starting from a very high level.<br />

Today, China is by far the biggest market for automation<br />

technology including robotics. And as the<br />

wages and the standard of living are rising, the need<br />

for a higher degree of automation will continue. This,<br />

in fact, makes the Industrial <strong>Automation</strong> Show (IAS)<br />

Shanghai a place to be visited.<br />

www.industrial-automation-show.com/EN<br />

Author: Gerald Scheffels, specialized<br />

journalist, Wuppertal, Germany

News and markets<br />

Shanghai and IAS are waiting<br />

Shanghai is not only the most important<br />

industrial city of China but also one of the<br />

largest cities in the world. The city is a<br />

major transport hub and an important<br />

cultural and educational center with<br />

numerous universities, colleges and<br />

research institutions. This also means that<br />

there is an important location for the automation<br />

industry. The trade fair IAS will be<br />

again the impressive proof.<br />

“Global competition and constant market changes<br />

put nonstop pressure on the manufacturing industry<br />

to cut costs and maximize profits. This is also true in<br />

China, where increasing labor and production costs<br />

are driving demand for modern, energy-efficient<br />

manufacturing and automation systems”, says<br />

Dr. Andreas Gruchow, Member of the Managing<br />

Board, Deutsche Messe AG and organizer of the<br />

exhibition. And he continues: “Accordingly, innovation<br />

plays a crucial role in these industry sectors,<br />

particularly when it comes to using IT and software<br />

to build manufacturing plants and industrial facilities<br />

that are completely networked and self-operating<br />

– what we in Germany call Industry 4.0. “<br />

And this is what the visitor will see, when coming to<br />

the Industrial <strong>Automation</strong> Show <strong>2014</strong> (IAS) in Shanghai.<br />

Organized by Deutsche Messe AG and Hannover<br />

Milano Fairs Shanghai Ltd, the Metalworking and<br />

CNC Machine Tool Show <strong>2014</strong> (MWCS), Industrial<br />

<strong>Automation</strong> Show <strong>2014</strong> (IAS) and Energy Show <strong>2014</strong><br />

(ES), three themed shows under China International<br />

Industry Fair (CIIF) will open the doors from 4 to<br />

8 November <strong>2014</strong>. “Metalworking and CNC Machine<br />

Tool Show, Industrial <strong>Automation</strong> Show and Energy<br />

Show are eastern China’s leading trade fairs for<br />

machine tools and metalworking, production,

News and markets<br />

process and industrial building automation, and<br />

conventional and renewable energies, respectively.<br />

At this year’s events you will see that Industry 4.0 is<br />

taking hold, and products and services are now being<br />

developed with the smart factory of the future in<br />

mind”, explains Dr. Gruchow.<br />

This year, the 5-day exhibition will continue its<br />

expansion with more exhibitors, debuts and innovative<br />

services, receiving again more than 110,000 visitors<br />

and buyers. In 2013, IAS gathered 503 top-level<br />

enterprises to compete in the display area of<br />

35,000 m 2 . ABB, Siemens and Schneider Electric,<br />

three big global industry players attended. For the<br />

current event big companies such as Beckhoff,<br />

Pepperl+Fuchs, Rittal, Turck, Schmersal, B&R, Lapp,<br />

Euchner, Kübler, Wago, ifm elctronic and Pilz are<br />

expected.<br />

“These three fairs are important to China’s industrial<br />

marketplace because they provide an annual<br />

showcase for the latest technologies and trends. We<br />

organize these fairs according to the interests of visitors,<br />

emphasizing the topics that are most important<br />

in the key areas of precision manufacturing, industrial<br />

automation, and energy conversion, distribution,<br />

transmission, and storage, to create a platform where<br />

companies can quickly find the products and<br />

services they need to remain competitive”, says<br />

Dr. Gruchow.<br />

The three halls (W1-W3) are divided into specialized<br />

display areas to demonstrate latest products<br />

and technology in integrated solution, transducers,<br />

embedded system, sensors, connectors, servo<br />

motors, electric system, etc.<br />

What‘s more? Lots of conferences, meetings and<br />

lectures round off the event. Functional Safety and<br />

Energy Efficiency Conference will take place for the<br />

second time in the Chinese market, inviting professionals<br />

from end users, exhibitors, government<br />

agencies and academic institutions to present their<br />

technology, service and energy saving solutions. And<br />

again: In the German Pavilion, visitors will find a<br />

large spectrum of high-tech products „Made in<br />

Germany“. 30 exhibitors are waiting for dialogue and<br />

exchange of experiences.<br />

“China remains a booming market, and our fairs<br />

provide access to it. I wish everyone much success<br />

on the show floor”, Dr. Gruchow concludes.<br />

Voices from exhibitiors and vistors<br />

“We participate at IAS since 2005. We consider<br />

it the best automation show in China, widely<br />

viewed as a barometer of Chinese industrial<br />

development. We are satisfied with<br />

everything at the last show, the topic, the<br />

visitor numbers, the delegations and other<br />

supporting service, everything is amazing!”<br />

Beckhoff China<br />

“Compared with IAS 2012, both quality and<br />

quantity of visitors during IAS 2013 have been<br />

improved significantly. During the show, we<br />

met some of our potential customers, and we<br />

achieved pretty good results. Besides, the<br />

organizer of the show, HMFS, has strong<br />

ability to coordinate and execute, which<br />

helped us a lot in booth constructing and<br />

moving-out.”<br />

Weidmüller Interface (Shanghai) Co., Ltd.<br />

“IAS 2013 attracted a great number of<br />

manufacturing enterprises to show their<br />

products and brands from several different<br />

angles, especially those European companies.<br />

During the show, we managed to know more<br />

advanced facilities and learn the development<br />

trends of automation industry. We would not<br />

hesitate to visit IAS <strong>2014</strong>, and we expect more<br />

foreign exhibitors next year.”<br />

Hitachi Elevator (Shanghai) Co.,Ltd.<br />

www.industrial-automation-show.com<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and market<br />

Bright prospects for<br />

Industrial <strong>Automation</strong><br />

North America<br />

Peter Becker<br />

Robotics and mobile solutions. Only two of<br />

the growing trends in automation that<br />

have been key topics at this year’s Industrial<br />

<strong>Automation</strong> North America in Chicago. But<br />

there was even more to discover as our<br />

editorial team saw for themselves at the<br />

fairground.<br />

The weather was great when our editors arrived at<br />

O’Hare airport in Chicago. But there were not<br />

only bright prospects regarding the weather. The<br />

forecast for the second Industrial <strong>Automation</strong> North<br />

America at McCormick Place was good, too. Industrial<br />

<strong>Automation</strong> North America <strong>2014</strong> and the inaugural<br />

Motion, Drive & <strong>Automation</strong> (MDA) North<br />

America <strong>2014</strong> trade shows and conferences were<br />

co-located with IMTS – The International Manufacturing<br />

Technology Show – providing the events with<br />

a well-known and established partner in North<br />

America.<br />

This co-location was one of the reasons for the fair’s<br />

success. But for the organizers, there were even more<br />

reasons to be happy as Larry Turner, CEO Hannover<br />

Fairs USA, points out: “We doubled our size from<br />

2012 and sold out the show six months before the<br />

event.” Industrial <strong>Automation</strong> North America and<br />

Motion, Drive & <strong>Automation</strong> North America together<br />

attracted 194 exhibiting companies from 14 countries,<br />

covering more than 50,000 ft² of exhibition<br />

space in the East Building of McCormick Place.<br />

Together with the IMTS, the show attracted more<br />

than 114,000 total registrants.<br />

Author: Peter Becker, editor,<br />


AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and market<br />

Up-to-date and international<br />

Addressing many of the current challenges of the<br />

fourth industrial revolution, or Industry 4.0, Industrial<br />

<strong>Automation</strong> North America <strong>2014</strong> focused on a<br />

variety of core topics, such as flexible manufacturing,<br />

network security, technology integration,<br />

worker productivity, as well as data collection and<br />

analysis. The show’s roster of global exhibitors<br />

expressed excitement about the growth of the <strong>2014</strong><br />

event since its founding in 2012 and acknowledged<br />

that attending the show is a critical component of<br />

their North American brand extension and end-user<br />

marketing programs.<br />

National pavilions from Germany, Taiwan and Italy<br />

added to the internationality of the event. And the<br />

organizers are expecting this trend to grow even<br />

further. Turner paints a picture of the future of the<br />

fair: “In 2016, we already got delegations coming in<br />

from the Netherlands and South Korea. We see it<br />

even expanding from an international standpoint.”<br />

Exhibitor highlights<br />

Among the exhibitors at Industrial <strong>Automation</strong><br />

North America were some of the leading companies<br />

in their respective branches such as Beckhoff <strong>Automation</strong>,<br />

Molex, Rockwell <strong>Automation</strong> or Weidmüller.<br />

Beckhoff incorporated Google Glass in a demonstration<br />

of a wearable Human Machine Interface (HMI)<br />

Video review of the fair<br />

Our editorial team captured the fair for you.<br />

Watch our video impressions from<br />

McCormick Place, Chicago.<br />

Video<br />

Interview with Larry Turner,<br />

CEO Hannover Fairs USA<br />

We had the<br />

opportunity<br />

to interview the<br />

CEO of Hannover<br />

Fairs USA at the fair<br />

in Chicago. Watch<br />

the full interview<br />

regarding the<br />

future of the event,<br />

trends in the North<br />

American market and the cooperation<br />

with Hannover Fairs in Germany here.<br />

for operation and monitoring. Its smart technology<br />

solutions represent the fusion of the Internet and<br />

automation technologies within the framework of<br />

advanced manufacturing. Molex presented “quick<br />

disconnect” connectors that enable the replacement<br />

of motors in production lines, eliminating costly<br />

downtime in the production process. Weidmüller<br />

launched its “u-remote” distributed I/O platform<br />

with IP 20, ensuring faster installation and setup and<br />

improving machine performance and productivity.<br />

Patty Roberts, Rockwell <strong>Automation</strong> Marketing<br />

Manager, summarizes: “Industrial <strong>Automation</strong><br />

North America is the meeting place for advanced<br />

manufacturing innovations, strategic partnerships<br />

and product collaborations. The show gave us the<br />

ability to expand our presence in discreet manufacturing<br />

and to secure new business leads.”<br />

A look into the future<br />

The CEO of Hannover Fairs USA was pleased with the<br />

event as well – and the organizers have big plans for<br />

2016: “Overall, attendees were very satisfied with the<br />

show and plan on returning in 2016. To that end, we<br />

expect to double our space in the East Building at<br />

IMTS 2016 and look forward to introducing additional<br />

product and service categories.” The next<br />

Industrial <strong>Automation</strong> North America and Motion,<br />

Drive & <strong>Automation</strong> North America events will be<br />

held from September 12-17, 2016.<br />

www.ia-northamerica.com<br />

Video<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Turkish Machinery to expand<br />

in the US Machinery Market<br />

The Industrial <strong>Automation</strong> North America<br />

fair in Chicago marks a renewed interest<br />

in Turkish Machinery given their recent<br />

expansion and market growth in Europe.<br />

Since Turkish Machinery is on its way to<br />

strengthening its position in the manufacturing<br />

industry in Europe, as well as in<br />

many developing countries, it now plans to<br />

foster a greater partnership with the US<br />

machinery and machine tool industry.<br />

Adnan Dalgakıran, President of the Board at<br />

Turkish Machinery said “with rapid development,<br />

Turkish Machinery sector is increasing its<br />

export share in the Turkish economy and exports.<br />

Turkey’s machinery exports, which were USD 3.0 billion<br />

in 2003, have reached USD 14 billion in 2013.<br />

The ratio of exports to imports in the machinery sector<br />

has gone up from 29 to 45 % in the last 10 years.”<br />

According to Dalgakıran, “Turkey currently exports<br />

into more than 200 countries and is already expanding<br />

into Latin America. Significant cooperation opportunities<br />

exist for both the US and Turkey at this<br />

time.” By participating in this international trade<br />

event as well as targeted advertising, “Turkish<br />

Machinery aims to expand awareness about the<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and Markets<br />

Joint partnership: The board members of Turkish<br />

machinery Sevda Kayhan Yılmaz (left) and Ferdi Murat<br />

Gül (right) with the editor of automation technologies<br />

Nicole Steinicke<br />

quality as well as the recent technological developments<br />

in their machinery sector and the benefits of a<br />

strategic joint US – Turkey partnership.” The Turkish<br />

machinery industry is growing exponentially due<br />

much in part to a very strong partnership already<br />

existing with Germany and the Netherlands.<br />

Dalgakıran, ‘‘Given the success in the German market<br />

and the knowledge gained from this relationship,<br />

Turkey is now poised to enter the US market and<br />

ready to build an equally profitable partnership.’’ Given<br />

their rapid growth, enormous potential now exists<br />

for the US market in terms of shared technology and<br />

joint projects in research and development, increased<br />

marketing opportunities, brand purchases, as well as<br />

shared technical training and expertise. Dalgakiran<br />

went on further to state that, “with an improved<br />

mutual understanding and awareness, economic and<br />

commercial opportunities abound for both countries.<br />

International manufacturing standards<br />

Turkey is a rapidly growing market and has shown<br />

consistent stable growth in the manufacturing and<br />

machinery sector. Its proximity to developing countries<br />

also makes it highly attractive to the US since its<br />

strategic location allows for strong economic and<br />

trade relations with many countries. It has a young,<br />

dynamic, creative and affordable highly skilled workforce<br />

and a strong infrastructure with increasing<br />

tools for government sponsored financial support. It<br />

has shown rapid adaptation to international manufacturing<br />

standards and has the highest quality of<br />

machinery equipment. It has a strong domestic<br />

supply of raw materials.<br />

Foreign trade and exports are on the rise<br />

Turkish foreign trade is equally on the rise. Exports,<br />

which were 47billion USD in 2003, rose to 152 billion<br />

USD in 2013. The Machinery and accessories industry<br />

accounts for most of this growth, having almost<br />

doubled its production in this sector in the past ten<br />

years. Turkey is the sixth largest manufacturer of<br />

machinery in Europe and is preferred by leading<br />

countries throughout the world.<br />

Turkish machinery exports comprise an average<br />

annual growth of 20 %, while imports have shown an<br />

average annual growth of 15 % in the last decade.<br />

Due in part to their strategic partnership, Germany<br />

and the Netherlands account for the largest shares of<br />

this expansive growth. US currently has a 4.8 % share<br />

in Turkish machinery exports and imports roughly<br />

4 %. With the American manufacturing industry once<br />

again on the rise, there are many opportunities surfacing<br />

for a joint partnership and joint growth at this<br />

time.<br />

Turkish export association for machines<br />

and accessories<br />

The export association for machines and accessories<br />

(MAIB) represents the machine exporters of Turkey.<br />

The association took up its work in 2002 and coordinates<br />

all activities that promote export of the industrial<br />

area. It has more than 8,000 member companies.<br />

The promotion group machinery (MTG) founded by<br />

the association in 2007 has the objective of making the<br />

Turkish engineering industry more widely known in<br />

and outside the country. For this purpose, it participates<br />

in international trade fairs, organizes delegation<br />

travels and promotional campaigns.)<br />

Photographs: teaser fotolia/ate<br />

www.turkishmachinery.org<br />

In conversation with Sevda<br />

Kayhan Yılmaz and Ferdi<br />

Murat Gül<br />

The export association for machines and<br />

accessories (MAIB, Makine ve Aksamları<br />

İhracatçıları Birliği) represents the machine<br />

exporters of Turkey. On the exhibition<br />

Industrial <strong>Automation</strong><br />

and the Motion, Drive &<br />

<strong>Automation</strong> North<br />

America we met the two<br />

board members and<br />

talked about there<br />

existing collaborations,<br />

concrete future objectives and about<br />

there specific expertise. Please take a<br />

look at the video for an even better<br />

impression at the button below.<br />

Video<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and markets<br />

IA Beijing: Comprehensive<br />

solutions for intelligent<br />

manufacturing<br />

Industrial <strong>Automation</strong> Beijing <strong>2014</strong> is one of the most<br />

significant show in China’s northern area. More than 200<br />

leading automation enterprises displayed high-grade<br />

products and solutions of industrial automation. Read<br />

more about the importance of this exhibition and what<br />

are the demands of Chinese customers? Watch our videostatements<br />

and find out.

News and markets<br />

James Fu, General Manager,<br />

Hannover Milano Fairs Shanghai<br />

Rainer Glatz, Managing Director,<br />

VDMA<br />

Joerg Kersten, General Manager,<br />

Murr Electronic Components<br />

Florian Koch, Sales Director Asia,<br />

item Industrietechnik<br />

Volker Palm, General Manager,<br />

Wago Electronic<br />

Dr. Andreas Risch,<br />

Managing Director, Turck<br />

Eelco van der Wal,<br />

Managing Director, PLCopen<br />

Xin Ye, Managing Director,<br />

ifm electronic<br />

The Industrial <strong>Automation</strong> Beijing <strong>2014</strong>, one of<br />

Hannover Messe’s global industrial shows and<br />

moreover the leading trade fair for process, factory<br />

and building automation systems and solutions,<br />

closed successfully at the Beijing Exhibition Center<br />

on May 9th. The annual industrial event is making<br />

progress on the basis of appropriate market positioning<br />

and industrial development, said James Fu,<br />

General Manager of the event organizer Hannover<br />

Milano Fairs China Ltd: “We spare no effort to forge<br />

Industrial <strong>Automation</strong> Beijing into the most influential<br />

show in China’s northern area. It serves the market,<br />

develops with the market and is in accordance<br />

with the goal to revive and transform the industrial<br />

sector, especially the equipment manufacturing<br />

industry in Northern China, thus facilitating trade<br />

cooperation between Chinese and international<br />

enterprises, and promoting the development of<br />

China industry. ”<br />

After leading the industrial trend by 3D printing in<br />

the last year, this year’s fair offered further solutions<br />

and discussions on the progress of Industry 4.0.<br />

Based on continuous research on market and accurate<br />

analysis on demand of clients, Industrial <strong>Automation</strong><br />

Beijing focuses on the demand of market.<br />

In contrast to the past, the show transformed from<br />

solely product display to intelligent manufacturing,<br />

setting up four sectors: robot/machine vision,<br />

sensor/connector, motion control/electrical system/<br />

transmission equipment and the German pavilion.<br />

As the largest professional fair in this region, the<br />

event attracts groups of industry leaders every year.<br />

Since the inauguration of Industrial <strong>Automation</strong><br />

Beijing in the north market, its influence has been<br />

increasing, creating easy access to this market for<br />

domestic and foreign enterprises. More than 20<br />

exhibitors from Germany, Japan, the US, Italy,<br />

Switzerland, India, Denmark, and other foreign<br />

countries and regions presented their products.<br />

International exhibitors accounted for as high as 60<br />

percent of all the participating companies. The<br />

exhibition area covered 20,000 square meters and<br />

the number of trade visitors and buyers hit 15,105 in<br />

the three days of exhibition, up 10 percent compared<br />

with the prior year.<br />

Why is Industrial <strong>Automation</strong> Beijing such an<br />

important fair and what are the demands of Chinese<br />

customers? Watch our videos statements and find out.<br />

www.industrial-automation-beijing.com/EN<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Global Machinery Safety:<br />

Challenge with economic potential<br />

John McAuliffe<br />

In a globalized economy, international<br />

companies are looking for ways to standardize<br />

their production processes and associated<br />

machinery and plants. A special challenge<br />

is the machinery safety, because depending<br />

on the country, the requirements and<br />

provisions differ significantly. With its<br />

International Service Group Pilz has adjusted<br />

to this challenge.<br />

Author: John McAuliffe, Head of<br />

International Service Group at Pilz<br />

The scale is enormous: hundred’s of machines, in<br />

more than 20 plants on four continents. The task:<br />

to carry out a safety-related assessment on the worldwide<br />

plant and machinery of a US global player and<br />

develop concepts for optimising that plant and<br />

machinery.<br />

Such international projects are the main area of<br />

activity of ISG, the International Service Group of the<br />

German based automation company Pilz. ISG coordinates<br />

and supports international projects within<br />

the Pilz group. This incorporates consulting, technical<br />

implementation as well as training in the field of<br />

machinery safety. Moreover, the international<br />

machinery compliance services are an integral part of<br />

the portfolio.<br />

Regular training sessions held by the ISG and by<br />

the Customer Support department based at the<br />

company’s headquarters in Ostfildern played an<br />

important role, as did the efficient transfer of knowledge<br />

within Pilz.<br />

The challenge is to provide and apply local knowledge<br />

on a transnational basis and to operate across<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

News and markets<br />

borders with the same level of quality. However, that<br />

doesn’t just apply to machinery safety. Even in general<br />

automation tasks a holistic approach to retrofit<br />

projects, for example, ensures that productivity and<br />

energy efficiency are increased.<br />

Passport for machinery<br />

International services are not only of interest for<br />

major international corporations but also for machine<br />

builders wishing to export their machines abroad. For<br />

example, a renowned European press manufacturer<br />

was recently faced with the task of exporting its<br />

machinery to South Korea.<br />

The strict requirements of KOSHA (Korea Occupational<br />

Safety and Health Agency) apply in this case. If<br />

the specifications of the Korean certification body<br />

are not met, the machines may not be imported into<br />

Korea. An international team with experts from<br />

Germany, Korea and the ISG followed the prescribed<br />

conformity assessment procedure to draw up the<br />

necessary documents, which certify the safety of<br />

presses in accordance with KOSHA specifications. By<br />

producing these “passports for machinery”, Pilz is<br />

opening up access to new markets for machine<br />

builders.<br />

Internationally certified training<br />

program<br />

Pilz provides an international training and qualification<br />

program for companies wishing to build up or<br />

update their knowledge, because they want to<br />

relocate machinery themselves for example. One<br />

component illustrates its international orientation<br />

particularly well: with the CMSE, Certified Machinery<br />

Safety Expert, Pilz has worked with TÜV Nord to<br />

implement the first internationally certified training<br />

program in the field of machinery safety. It covers<br />

general knowledge of plant and machine safety as<br />

well as information regarding country-specific<br />

standards.<br />

Economic benefits<br />

International work on standards is important not<br />

only because it sets uniform product standards, but<br />

because it also creates the market transparency that<br />

suppliers and users need. So a plant or machine used<br />

within the European Union must meet the specifications<br />

of the Machinery Directive – irrespective of<br />

where it was developed or manufactured, where it<br />

was imported from, or where it was assembled or put<br />

into service (again). Similar regulations also apply<br />

for other regions. Even when these are not legally<br />

binding everywhere, international corporations are<br />

increasingly working in conjunction with an experienced<br />

partner to define their own internal safety<br />

Pilz has worked with TÜV<br />

Nord to implement the<br />

first internationally certified<br />

training program in the<br />

field of machinery safety.<br />

John McAuliffe<br />

standard, which is then binding for all suppliers. An<br />

industrial company only needs one or two machine<br />

designs for all its production facilities worldwide. It<br />

can reflect its machine and safety standards towards<br />

new markets and produce there with the same standardized<br />

and controlled processes.<br />

However, such safety standards do not only generate<br />

value for the companies, because although the<br />

protection objective, safe work place’ should be the<br />

same all over the world, the situation is very different<br />

in different countries. Among others, the social<br />

consensus differs on how large in the respective<br />

country the acceptable residual risk can be. With<br />

their in-house safety standards global players also<br />

contribute to the fact that in the emerging countries<br />

the knowledge about machine safety is built up and<br />

the safety culture is filled with life.<br />

www.pilz.com<br />

About<br />

Company name: Pilz GmbH & Co. KG<br />

Headquarters: Ostfildern, Germany<br />

Employees: about 1,700 worldwide<br />

Products: <strong>Automation</strong> technology and a total solutions<br />

supplier for safety and control technology<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

sensors and measurement<br />

High-performance 2D laser<br />

scanner with integrated<br />

control interface<br />

Arno Hagemann<br />

The 2D laser scanners in the R2000 family<br />

of Pepperl+Fuchs are noted for their exceptional<br />

detection performance in distance<br />

measurement technology. The latest device<br />

variant now makes it particularly easy for<br />

users to benefit from the system‘s facilities.<br />

Author: Arno Hagemann, Business<br />

Development Manager at<br />

Pepperl+Fuchs in Mannheim,<br />

Germany<br />

Typical tasks in the 2D laser scanner‘s area of<br />

application include area monitoring and collision<br />

avoidance, as well as, in particular, detection of<br />

objects close to surfaces. However, detection performance<br />

is only one side of the coin, so that customers<br />

can resolve these and comparable tasks quickly and<br />

cost-effectively. An efficient overall concept also<br />

includes simple parameterization options and a<br />

standardized interface to systems. In the new model,<br />

therefore, Pepperl+Fuchs has combined remarkable<br />

properties and functions to cope with all aspects.<br />

These include, inter alia, pulse ranging technology, a<br />

360° rotating sensor system including an interactive<br />

all-round display, as well as a powerful control interface<br />

with switching outputs.<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

sensors and measurement<br />

01 Detecting small overhangs<br />

next page<br />

True light run-time measurement with<br />

light pulses<br />

Like all scanners in this series, the current R2000<br />

variant is based not on one of the frequently used<br />

indirect measurement methods such as phase correlation,<br />

but the innovative pulse ranging technology<br />

(PRT), a true light run-time procedure. The laser<br />

diode does not send a continuous light, but rather<br />

individual light pulses, so that the scanner can calculate<br />

the exact distances of the destination points from<br />

the time until their reflections arrive at the receiver<br />

element. Because the energy density of the discrete<br />

light pulses is up to 1000 times higher, this procedure<br />

is far superior to other commonly used methods. The<br />

R2000 scanners are characterized by a detection<br />

range and operational reliability previously unknown<br />

in this device class. Even in a strong extraneous light<br />

and dark, poorly reflective destination objects, they<br />

always deliver clear results.<br />

In the R2000 laser scanner, the developers at<br />

Pepperl+Fuchs have combined the benefits of pulse<br />

ranging technology with a rotating 360° measuring<br />

system. In conjunction with the very small beam<br />

diameter of just a few millimeters, the clever design<br />

allows not only complete all-round visibility, but also<br />

realizes at the same time an angle resolution of up to<br />

80 millidegrees. At rotational frequencies up to<br />

30 Hz, measuring rates of up to 45 kHz are achieved.<br />

By its high speed and precision, the 2D scanner is<br />

able to safely detect even moving objects and the<br />

smallest of objects such as thin wires, and even at a<br />

distance of five meters it still achieves a resolution of<br />

about 7 mm. The rotating measurement module<br />

ensures a precisely level scan area and guarantees a<br />

high degree of repeat accuracy. The mirror optics<br />

used also play their part: they do not use lens optics<br />

or mirror mechanics, so a typical source of imprecision<br />

has been eliminated.<br />

Freely programmable monitoring fields<br />

Through the integrated control interface, the R2000<br />

is now able to assess the measurement data independently<br />

and provide the results at up to four<br />

switching outputs as yes/no or good/bad information.<br />

The binary switching signals can be further processed<br />

without any problems by any controllers or other<br />

decentralized intelligent automation components. In<br />

particular, the user no longer has to engage in tedious<br />

programming to analyze and interpret the individual<br />

measurement data.<br />

The monitoring fields are conveniently defined<br />

with the help of a device type manager (DTM). This<br />

DTM can be used, for example, in an FDT frame<br />

application such as PACTware, so that graphically<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

sensors and measurement<br />

02 The 2-dimensional sensor<br />

R2000 for reliable detection<br />

Company name: Pepperl+Fuchs Group<br />

Headquarters: Mannheim, Germany<br />

Turnover: € 500 m<br />

Employees: more than 5,600<br />

Products: industrial sensors, process interfaces<br />

About<br />

supported parameterization of monitoring fields<br />

takes place on the PC screen. Any geometric shapes<br />

can be handled, so that any room or subarea—including<br />

of setup objects—can be represented, such as<br />

lounges with planters, elevator cars, parking or<br />

storage areas, locks, etc. A monitoring field can<br />

extend over a full 360°, but likewise may only include<br />

a subarea. Up to four fields can be configured.<br />

Control functionality with logically<br />

linkable I/O ports<br />

During operation, the scanner constantly compares<br />

the current measurement data with the defined<br />

monitoring fields. As soon as it notices deviations or<br />

detects objects that should not be present in the<br />

monitoring field, the system sets the associated switching<br />

output. As the fields and inputs can logically be<br />

linked in virtually any way with the outputs, the laser<br />

scanner additionally provides simple flexible control<br />

functions. Configured I/O ports are used as input to<br />

remotely activate - or occasionally deactivate - the<br />

scanner, for example when loading and unloading.<br />

In collision avoidance applications, switching<br />

between different-size monitoring fields is conceivable:<br />

if a driverless transport system moves at a<br />

reasonably high speed, a larger monitoring field is<br />

required to bring the vehicle to a halt in good time in<br />

front of an obstacle, while if the vehicle is moving<br />

more slowly a smaller field would suffice.<br />

Another special feature is the interactive all-round<br />

display. On the back of the rotating measurement<br />

module 24 LEDs are arranged such that they use a<br />

predestined semi-transparent housing area as a<br />

projection surface. Any text or graphics can be<br />

displayed such as status, warning, or diagnostic<br />

messages during operation. During commissioning,<br />

however, the interactive, fingertip-controllable display<br />

serves as a medium for device configuration<br />

with menu navigation; a PC or notebook is then no<br />

longer required. The R2000 works with visible red<br />

light and can be aligned by the visible light beam<br />

without auxiliary aids. It fulfills laser class 1 and<br />

requires no special eye-protection measures. The<br />

compact sensor can always be suitably installed<br />

even under very cramped conditions. It can be aligned<br />

in any way, even overhead and close to floors or<br />

surfaces. The detection range on natural surfaces is<br />

10 m, and 30 m on reflectors.<br />

Numerous application<br />

possibilities<br />

Pepperl+Fuchs has equipped the latest variant of the<br />

2D laser scanner in the R2000 Series with a powerful<br />

measurement data analysis feature. The device independently<br />

completes the field monitoring tasks with<br />

which it is entrusted and provides one or more results<br />

at up to four switching outputs as a yes/no or good/<br />

bad answer. The system combines high detection performance<br />

with simple handling and impresses with<br />

low response times and high immunity to extraneous<br />

light. There are numerous application possibilities in<br />

area monitoring, as well as in overhang, gap and compartment-occupied<br />

checks. On driverless transport<br />

systems, stock feeders, suspended conveyor systems<br />

or freely navigating platforms, the R2000 provides a<br />

valuable service in the avoidance of collisions.<br />

www.pepperl-fuchs.com<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

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About<br />

Company name: Emerson Group<br />

Headquarters: St. Louis, Missouri, USA<br />

Turnover: $24.7 bn (2013)<br />

Employees: 132,000 worldwide<br />

Products: process management systems, measurement<br />

and analytics, …<br />

Smart Wireless Technology<br />

helps improve leak detection<br />

New regulations often demand changes in<br />

industrial production sites. To meet the<br />

newly established requirements by the<br />

government, BP had to ensure continuous<br />

leak detection at its plant in Geel, Belgium.<br />

A wireless transmitter network by Emerson<br />

Process Management in combination with<br />

hydrocarbon sensors was installed to enable<br />

continuous monitoring of tanks, valves and<br />

pipelines.<br />

Leak detection on large sites can be both difficult<br />

and expensive. BP is using Smart Wireless technology<br />

from Emerson Process Management as part<br />

of a leak detection system that helps enhance safety<br />

at its chemical production centre in Geel, Belgium.<br />

The wireless technology provides a reliable way to<br />

gather information from hydrocarbon sensors that<br />

continuously monitor storage tanks, valves and pipelines<br />

throughout the plant, and to deliver that infor-<br />

mation to the control system so operators can be<br />

notified of any leaks. This automated monitoring<br />

system has enabled BP to meet the latest government<br />

regulations for storage and handling of flammable<br />

liquids.<br />

New regulations<br />

“BP is committed to reducing waste, emissions and<br />

discharges and ensuring that production facilities<br />

like the one in Geel meet the highest standards of<br />

health, safety and environmental performance,” said<br />

Bob Karschnia, vice president, wireless at Emerson<br />

Process Management. “By combining Emerson’s<br />

wireless technology with hydrocarbon sensors, BP<br />

has been able to expand the view the operators have<br />

and enhance its existing leak detection practices,<br />

helping to improve site safety.”<br />

BP operators were making twice-daily inspection<br />

rounds using portable leak detectors, but new and<br />

stricter government regulations required continuous<br />

monitoring. To meet these regulations, sensors that<br />

detect liquid hydrocarbons were integrated with<br />

Emerson’s smart wireless technology installed at<br />

Geel to enable cost-effective liquid hydrocarbon leak<br />

detection even from remote locations with the site.<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Sensors and Measurement<br />

Wireless transmission<br />

The installation was user-friendly. Based on<br />

IEC 62591 WirelessHART communications, Emerson’s<br />

proven Smart Wireless technology eliminated<br />

the need for new instrumentation cabling and associated<br />

trenches and ducting, saving an estimated<br />

50 % of the cost and 90 % of the time required to<br />

install a conventional wired system.<br />

The leak detection system uses Emerson’s Rosemount<br />

702 Wireless Discrete Transmitters in combination<br />

with Pentair (formerly Tyco) Fast Fuel Sensors<br />

and Trace Tek Sensor cables. When one of the<br />

sensors detects xylene or benzene, the associated<br />

Rosemount 702 wirelessly transmits an alarm signal<br />

to a Smart Wireless Gateway that relays it to the<br />

control room, where operators monitor and record<br />

the status for accurate incident reporting and time<br />

stamping in the host control system.<br />

Leak detection for large sites<br />

The sensor cables are attached to the concrete base<br />

surrounding tanks so that leaks from the tank wall<br />

can be detected. They are also laid underneath connecting<br />

piping and draped around the tank flanges<br />

and manholes. The sensors have been installed to<br />

detect hydrocarbons in sump wells and pump skids.<br />

“Combining Emerson’s wireless technology with<br />

hydrocarbon sensors provides an ideal leak detection<br />

solution for large sites such as production plants and<br />

tank farms,” said Karschnia. “It’s another example of<br />

how users are taking advantage of this technology to<br />

gain business benefits – including enhanced safety<br />

and regulatory compliance – in applications beyond<br />

the process itself.”<br />

Photographs: Teaser/oranaments fotolia<br />

www.emersonprocess.com<br />

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www.pepperl-fuchs.com/A-distance-ahead<br />


The importance of photovoltaic<br />

for the agriculture in Nicaragua<br />

Klaas Eßmüller, Dennis Kortstock<br />

A school project in Hamburg is looking at<br />

the specific application of photovoltaics in<br />

agriculture. The main focus is on the development<br />

and sizing of solar-powered<br />

groundwater irrigation systems. This is a<br />

learning process in which control equipment<br />

and the Siemens expertise also play a role.<br />

Author: Klaas Eßmüller, Industry<br />

<strong>Automation</strong>, Siemens AG;<br />

Dennis Kortstock, Industry <strong>Automation</strong>,<br />

Siemens AG, Germany

There are a few things you have to know about Nicaragua:<br />

The country is rich in natural resources and<br />

has a huge potential to produce agricultural products.<br />

But local farmers have to live under climatic<br />

conditions that are defined by extreme rainfall on the<br />

one hand and several months of drought on the othcontrol<br />

and drive technology<br />

Topic of a Hamburg school project with its partner city<br />

León in Nicaragua is the practical application of solar<br />

powered groundwater irrigation systems in agriculture<br />

next page<br />

Robert Heiden, a physics teacher at a school in<br />

Blankenese, a suburb of Hamburg, has recognized<br />

the signs of the times. “Renewable energy will<br />

become a major issue for the generation growing up<br />

now” Together with Clemens Krühler, his colleague<br />

from the technology department, and Kirsten<br />

Ahrncke who teaches social studies, Robert Heiden<br />

is supporting the EduaRD (Education and Renewable<br />

Energy and Development) project at his school.<br />

Photovoltaic project in Nicaragua<br />

It is offered as a series of electives and looks not only<br />

at the interactions between economic productivity<br />

and how societies develop. It also wants to offer practical<br />

insights into the interaction between physical<br />

and biological processes. And it looks at the growing<br />

importance of future technologies to make use of<br />

renewable energy.<br />

A partnership between the city of Hamburg,<br />

Germany, and the city of Léon in Nicaragua is helpful<br />

in this respect. The three dedicated teachers realized<br />

that they could use this connection for a practical<br />

photovoltaic project as part of EduaRD. And so the<br />

first project group traveled to Nicaragua in 2003 to<br />

demonstrate the practical use of solar power in agriculture<br />

on-site. A solution that was so successful that<br />

the project still exists today and 20 additional plants<br />

have been implemented since then.<br />

er. The existence of an entire family could easily be in<br />

danger if one of the two rainy seasons were to fail.<br />

During the drought period, farmers have a hard time<br />

to supply their fields and plantations with water. In<br />

rural areas without any electricity, they can only<br />

pump the groundwater manually to water the<br />

parched soil. This means productivity is low; so low<br />

that Nicaragua cannot support its own population<br />

sufficiently despite its huge areas of arable land.<br />

The problem is not water which is available in<br />

abundance even during the drought period. The<br />

problem is simply to bring this water to the surface.<br />

Solar power as solution<br />

This is where EduaRD comes into play. Robert<br />

Heiden and Clemens Krühler discovered rather<br />

quickly that there was a crucial connection. The same<br />

sun that dried out the soil and made plants wither<br />

also supplied energy in abundance. This means it<br />

makes sense to use exactly this energy to provide<br />

plants with the water that is available in large quantities<br />

underground.<br />

At the start of the project, students were asked to<br />

calculate the biological and physical correlations of a<br />

project and to use these insights to determine the<br />

technical key figures of a solar powered irrigation<br />

Shortage despite abundance<br />

01 Students from Hamburg use solar energy to<br />

operate irrigation systems to pump groundwater<br />

to the surface during drought periods so that it<br />

can be used to water the fields<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

previous page<br />

plant. More specifically, the question is how much<br />

water specific plants need to grow, how much of it<br />

evaporates and how much water must be supplied to<br />

adequately irrigate a field of a specific size.<br />

Realization of a solar powered<br />

irrigation plant<br />

Because they had to cover a lot of new ground, the<br />

two teachers hired outside experts to assist them<br />

with the project. For example, an electrical engineer<br />

from Nicaragua who lived in Hamburg and quickly<br />

seized the opportunity to build a company which uses<br />

solar power in his native country. Since then solar<br />

powered irrigation plants have been implemented<br />

with his support on-site; these plants are a big step<br />

forward for the farmers in Nicaragua and offer important<br />

insights here in Germany.<br />

“Such a project takes about two years from the first<br />

calculations until we install the plant on-site,”<br />

explains Clemens Krühler. „The students learn a lot<br />

from these practical objects. They gain decisive<br />

insights into the use of one of the most important<br />

energy sources of the future. And they learn firsthand<br />

about the potential of photovoltaics to sustainably<br />

change the economic and social conditions in<br />

many regions around the globe.“<br />

„It is interesting to see that about half of the<br />

students stay in touch with this topic as they move<br />

on,“ adds Robert Heiden.<br />

And the last project went even a step further: “We<br />

wanted to compare the efficiency of different pumps.<br />

And we wanted to know exactly how much water is<br />

needed for how many hours of sunshine,” explains<br />

Krühler. “This means we are constantly measuring all<br />

decisive parameters with our latest project, such as<br />

sun exposure, voltage and current flow of the electrical<br />

system as well as quantity and pressure of the groundwater<br />

pumped from the well.”<br />

Data in transatlantic dialog<br />

Siemens was consulted to help with the realization of<br />

this job. The company has more than just a consulting<br />

role in the project today. Siemens donated the<br />

TeleControl Basic telecontrol system to control and<br />

About<br />

Company name: Siemens Industry Sector<br />

Headquarters: Nuremberg, Germany<br />

Employees: more than 100,000<br />

Products and systems: motion control system Simotion,<br />

CNC automation system Sinumerik, drives family Sinamics,<br />

industrial automation systems Simatic and customer<br />

services<br />

02 TeleControl Basic telecontrol<br />

technology from Siemens is used<br />

to monitor and control the<br />

remote systems in Nicaragua

control and drive technology<br />

monitor remote substations using wireless GPRS<br />

technology. TeleControl Basic uses the TeleControl<br />

Server Basic control center software to connect the<br />

control center with two substations that each consist<br />

of one SIMATIC S7-1200 controller with CP1242-7<br />

communication processor. A Simatic HMI operator<br />

panel of the type KP300 is used for operation on-site.<br />

The system, including sensors and back-up battery,<br />

was installed by students during their project trip in<br />

the summer of 2013 in a research area used by the<br />

agricultural institute of the university in Léon, Nicaragua.<br />

The system is installed in a control cabinet<br />

right next to the groundwater pump and is supplied<br />

with power by its own photovoltaic system. It<br />

currently records the performance data of two<br />

pumps from different manufacturers which are<br />

directly transmitted to Blankenese via GPRS. A server<br />

is installed there to collect the constantly transmitted<br />

data and store it in a database.<br />

The benefits of the telecontrol system are the costefficient<br />

connection of the substations by means of<br />

the public GPRS network and the encrypted data<br />

transmission. Several thousand data values can be<br />

buffered in the communication processor to bypass<br />

any downtimes of the transmission path. Fully automatic<br />

time stamps are used to correctly archive the<br />

process data in the control system later.<br />

Photovoltaic ensures farmers an<br />

economical harvest<br />

“We not only want to collect practical data about<br />

the performance of the different pump models. We<br />

also want to use the data for a variety of calculations<br />

and for more insights into the amount of water<br />

required depending on the weather,“ describes<br />

Kühler the system and adds: „Someday we should<br />

be able to determine, based on the size of a field<br />

and the fruit grown there, how much groundwater<br />

is required for irrigation and what size pump is<br />

needed for the job.”<br />

03 The two Remote Terminal Units in Nicaragua each<br />

consist of a Simatic S7-1200 controller with CP 1242-7<br />

communication processor; the values measured on site<br />

are directly transmitted to the “control center” at the<br />

school in Hamburg via GPRS<br />

Then the farmers in Nicaragua will not only grow the<br />

fruits and vegetables as permitted by Mother Nature.<br />

For the first time, they will not be impacted by weatherrelated<br />

uncertainties. And they will be able to actively<br />

market their products and produce exactly when it<br />

fetches the highest prices in the market.<br />

Local farmers who are already using solar powered<br />

irrigation systems as part of the EduaRD project are<br />

experiencing the benefits associated with it even<br />

today. Lost harvests which almost destroyed their<br />

families are now a thing of the past. Even during the<br />

dry season, they are now able to bring in additional<br />

harvests. This situation has a tremendous impact on<br />

economic prosperity and the living situation of the<br />

people in Nicaragua.<br />

It is no wonder that photovoltaics are on the verge<br />

of a breakthrough in Nicaragua. It all started with two<br />

dedicated teachers and a handful of inquisitive<br />

students in Hamburg-Blankenese.<br />

www.siemens.com/telecontrol<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Sercos and Rexroth help streamline<br />

servo-driven case packers<br />

Brenton Engineering designed a new line of<br />

side-loading case packers to exceed current<br />

“green manufacturing” end user trends,<br />

featuring servo control to increase speed<br />

and reduce energy costs within a compact<br />

footprint.<br />

Brenton Engineering, a large provider of packaging<br />

and palletizing equipment located in Alexandria,<br />

MN, USA, spent months consulting with customers<br />

and vendors before designing the next generation of<br />

its BrentonPro Series of case packer machines.<br />

“Customers wanted a faster and simpler all-servo<br />

machine,” said Mike Grinager, VP of Technology for<br />

Brenton Engineering. “Our design reduces the<br />

complexity of the machine. We took out the pneumatics,<br />

which was the most expensive aspect of the<br />

About<br />

Company name: Sercos International e.V.<br />

Headquarters: Süssen, Germany<br />

Membership: More than 90 member companies worldwide<br />

Products: SERCOS-enabled products for any automation<br />

application<br />

machine, and our engineers removed more than<br />

200 moving parts, reducing costs by one third. Plus,<br />

the integrated servo motors and drives that we now<br />

use require less space than even the smallest<br />

motors we used previously,” said Grinager.<br />

As a result, the BrentonPro Mach-2 case packer is<br />

an all-servo-driven, side-load case packer featuring<br />

an IndraDrive Mi motor integrated drive system with<br />

Sercos distributed I/O, an IndraMotion MLC motion<br />

logic controller and the IndraControl VEP40 human<br />

machine interface (HMI) all from Bosch Rexroth,<br />

Illinois.<br />

According to Grinager, the multi-axis machine<br />

reaches speeds of up to 25 cases per minute and can<br />

accommodate a variety of cases, including RSC,<br />

HSC, tray, wrap-around, knock-down and harness<br />

for cartons, bottles, cans and tubs. During operation,<br />

an empty case blank is picked by vacuum and set in<br />

the machine. The case is moved through loading and<br />

sealing sections of the machine, which are powered<br />

by servo-driven flap traps. After loading, the full case<br />

is indexed through a compression and sealing area.<br />

The completed case is then discharged on the customer’s<br />

takeaway conveyor.<br />

Cost-effective and simple solution<br />

Brenton developed the Mach-2 case packer to minimize<br />

the environmental impact of packaging operations<br />

through the appropriate use of electric servo drives,<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>


Rexroth’s motor integrated drive system helped Brenton<br />

Engineering cut out more than 200 moving parts,<br />

reducing component costs by a third<br />

resulting in lower energy consumption, zero air consumption<br />

and less product and packaging waste. On average,<br />

the Mach-2 is expected to generate energy savings<br />

of up to 25 % compared with the first generation machine.<br />

The company worked closely with local Bosch<br />

Rexroth distributor Motion Tech <strong>Automation</strong>,Oakdale,<br />

Minnesota during this phase of the development.<br />

“We recommended Rexroth’s IndraDrive Mi motor<br />

integrated drive system, which is an cost-effective<br />

and simple solution,” said Shawn Nelson, sales engineer<br />

at Motion Tech.Nelson said that Rexroth’s<br />

IndraDrive Mi system combines each servo motor<br />

and drive amplifier into one compact unit mounted<br />

directly on the machine, outside of the control cabinet.<br />

A single cable running from the cabinet is daisychained<br />

to each motor/drive unit and provides both<br />

power and communication. As a result, Rexroth’s<br />

design has the potential to reduce a machine’s<br />

cabling needs by more than 80 %.The IndraDrive Mi<br />

is also 50 % smaller than a traditional servo system,<br />

which uses a separate servo drive and motor. This<br />

architecture also eliminates the need for an air conditioning<br />

unit from the control cabinet and the need<br />

to maintain or replace expensive filters. “Our machine<br />

has a cleaner appearance without all the wires<br />

running to and from the electrical cabinet,” said<br />

Grinager. “Because of the small motor integrated<br />

drive units and fewer cables, the machine allows<br />

easy access for the operator to maintain it.”<br />

“The motor integrated drive units help reduce the<br />

size of the electrical cabinet,” added Nelson. Because<br />

the drives are integrated directly with the motors outside<br />

of the control cabinet, the size of the Mach-2<br />

control cabinet is reduced by 25 %. Up to 20<br />

IndraDrive Mi units can be connected from one power<br />

supply without additional distribution boxes. The<br />

IndraDrive Mi accommodates the multiple functions<br />

of the Mach-2 case packer without increasing the size<br />

of the electrical cabinet. In addition, integrating the<br />

drive control and motor into one component provides<br />

a more flexible “plug and play” capability. More motors<br />

can be installed for machine upgrades or other machine<br />

configurations such as unique infeeds.<br />

Another advantage: versatility. Although the<br />

IndraDrive Mi system allowed to design a machine<br />

with a smaller footprint, the space in the machine’s<br />

The Future of Sercos<br />

We interviewed Peter Lutz,<br />

Managing Director Sercos<br />

International, and talked about<br />

industry trends and their impact on<br />

Sercos. Additionally, Lutz gave as<br />

an idea of their most important<br />

markets and their plans for the<br />

future of the interface.<br />

case compression area was too compact to accommodate<br />

any integrated motor/drive unit. The solution<br />

was Rexroth’s near motor drive system IndraDrive<br />

Mi with inverter KMS: a distributed drive<br />

unit that can be mounted on the machine near a servo<br />

motor and seamlessly connected with the Indradrive<br />

Mi cables. Brenton Engineering’s controls<br />

tea also used the IndraDrive Mi distributed input/<br />

output system (I/O). Having four I/O outputs directly<br />

on the motor eliminated the need for extra wiring.<br />

Simplify the design<br />

Motion synchronization and control are handled<br />

through Sercos digital communication to each servo<br />

drive. The case packer utilizes synchronous, electronic<br />

camming technology provided by Rexroth’s system<br />

solution IndraMotion MLC. The controller hardware<br />

IndraControl L40 features FlexProfile functionality,<br />

combining synchronous and time-based steps into a<br />

single data function which optimizes system performance<br />

and recovery and the changeover time. In addition,<br />

Rexroth’s IndraControl VEP40 HMI, which was<br />

mounted to the frame, integrates with the rest of the<br />

machine components via OPC communications. The<br />

HMI is an embedded terminal with a Windows CE operating<br />

system and a 12-inch TFT touchscreen display.<br />

“The Mach-2 has become a standard for Brenton<br />

Engineering,” concluded Grinager. “Rexroth technology<br />

allowed us to simplify the design of the Mach-2<br />

case packer and reduce extraneous parts and energy<br />

consumption in the machine. The ability to daisychain<br />

servo motors led to less wiring and contributed<br />

to a smaller electrical cabinet and ultimately an<br />

overall smaller machine footprint.”<br />

www.sercos.com<br />

Video<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>


Connectivity at sea<br />

Valentin Scheltow<br />

The demands placed on products in the<br />

maritime markets vary depending on the<br />

location, and are often extremely high. The<br />

crucial environmental factors in this sector<br />

are vibration, salt water mist and magnetic<br />

compatibility with compasses. Connectors<br />

and Ethernet Switches by Harting perform<br />

well even under these difficult conditions.<br />

About<br />

Company name: Harting Technology Group<br />

Brands: Han, Ha-VIS<br />

Headquarters: Espelkamp, Germany<br />

Turnover: Author: Valentin €484 m Scheltow, (2013) Industry<br />

Employees:<br />

Segment Manager<br />

more<br />

Shipbuilding<br />

than 3800 worldwide<br />

at<br />

Harting in Espelkamp, Germany<br />

Products: electrical and electronic connectors, Ethernet<br />

switches, …<br />

The shipbuilding market is extremely vigorous:<br />

each year some 6,000 cargo ships are under construction,<br />

with the estimated lifetime of vessels being<br />

some 20-25 years. Harting products have a long<br />

history of utilization in marine applications. The<br />

company’s products are known for their long service<br />

life under harsh environmental conditions and have<br />

proven their durability.<br />

Demands in shipbuilding<br />

Resilient components that feature encapsulation<br />

against environmental influences while offering the<br />

same properties as conventional devices and applications<br />

are in demand in the shipbuilding sector.<br />

Connectors should be easy to handle, flexible and<br />

provide maximum performance at sea as well. Their<br />

reliability – also under extreme conditions – should<br />

not fall short of their performance in conventional<br />

applications.<br />

Certified technology<br />

Certifications prove that components by German<br />

manufacturer Harting are up to the task in harsh<br />

maritime conditions: Classification society Germa-<br />

Author: Valentin Scheltow, Industry<br />

Segment Manager Shipbuilding at<br />

Harting in Espelkamp, Germany


nischer Lloyd (GL) has approved connectors from<br />

Harting Technology Group for almost all shipbuilding<br />

areas. The company’s Ethernet switches have<br />

been successfully certified by Norway‘s Det Norske<br />

Veritas (DNV) for use on ship‘s bridges as well as on<br />

offshore platforms.<br />

On- and offshore applications<br />

Han-Inox and HPR connectors are already in use on<br />

open decks and on offshore cranes. Thanks to their<br />

high vibration resistance, connectors from the Han<br />

family of products are also deployed in the controls<br />

for dual-fuel engines, which are built to the highest<br />

environmental standards. Here, the connectors are<br />

mounted directly on the engines, with associated<br />

heavy exposure.<br />

Harting Ethernet switches are ideally suited for<br />

monitoring, control and automation systems on<br />

vessels. These switches have also been successfully<br />

tested by the BSH (German Federal Maritime and<br />

Hydrographic Agency) to determine if they exert<br />

influence on the magnetic compass on the bridge.<br />

Connector on MAN Diesel monitoring and control system<br />

In conclusion, the certified products by Harting are<br />

more than fit for use in numerous locations onboard<br />

ocean-going vessels.<br />

Photographs: MAN Diesel & Turbo SE, teaser fotolia/ate<br />


Esben Østergaard, CTO of Universal Robots, explains<br />

the patented new safety concept: “When a human<br />

enters the robot’s work-cell, the robot arm can opercomponents<br />

and software<br />

Humans working together<br />

with robots: safe and flexible<br />

Peter Becker<br />

According to Larry Turner, CEO Hannover Fairs USA, robotics is<br />

one of the growing branches in automation. Robot specialists<br />

Universal Robots presented the third generation of its products,<br />

UR5 and UR10, at Industrial <strong>Automation</strong> North America featuring<br />

advanced safety functions and true absolute encoders.<br />

huge picture of one of the manufacturer’s robot<br />

A arms greeted the visitors of the company’s<br />

booth at Industrial <strong>Automation</strong> North America at<br />

McCormick Place in Chicago. The Denmark-based<br />

company entered the market in 2008 with the idea of<br />

providing a user-friendly and flexible lightweight<br />

robot for dull or harmful jobs that can run potentially<br />

without safety cages. Since then, the company has<br />

seen substantial growth and sells its products in<br />

more than 50 countries.<br />

After initial risk assessment, the collaborative<br />

Universal Robots can operate alongside human<br />

operators without safety guarding. This makes it easy<br />

to move the light-weight robot around the production,<br />

addressing the needs of agile manufacturing<br />

even within small- and medium sized companies. If<br />

the robots come into contact with an employee, the<br />

built-in force control limits the forces at contact,<br />

adhering to the current safety requirements on force<br />

and torque limitations. At the fairground in Chicago,<br />

near the shore of Lake Michigan, Universal Robots<br />

had set up several robot arms and control units to<br />

demonstrate the latest features of its newly developed<br />

third generation of UR5 and UR10 products.<br />

The focus was on safer operation of the collaborative<br />

robots and humans as well as on optimized startup<br />

time.<br />

Safety first<br />

Author: Peter Becker,<br />


next page<br />

And the target group may widen even more thanks to<br />

the user-friendly programming of the products made<br />

in Denmark. Operators with no programming expeate<br />

in reduced mode, and then resume full speed<br />

when he leaves again. Or, the robot can run full speed<br />

inside a CNC machine for example, and then reduced<br />

speed when outside.” To achieve a switch<br />

between normal and reduced safety mode, eight<br />

safety functions are monitored by the new patented<br />

safety system: Joint positions and speeds, TCP positions,<br />

orientation, speed and force, as well as the<br />

momentum and power of the robot. The settings can<br />

only be changed in a password protected area.<br />

Another innovation is the true absolute encoders,<br />

allowing faster start-up because the robot’s position<br />

is recognized upon power-up. “With the integration<br />

of the true absolute encoder, our robotarms can be<br />

integrated easily into other machineries while startup<br />

also becomes faster and simpler for all applications”,<br />

says Østergaard. Unlike most other industrial robots<br />

with incremental encoders that work like absolute<br />

encoders, until the battery runs out, the encoders in<br />

the UR robots are not battery driven, therefore named<br />

“true absolute encoders” eliminating the need to<br />

frequently reinitialize the robot arms since their<br />

position in space is known despite the robot not<br />

requiring battery power to achieve this function.<br />

Based on user feedback<br />

But inside of the robot arm itself, as well as in the<br />

controller, are more hidden surprises; Sixteen additional<br />

digital I/Os doubles the number of built-in<br />

I/Os which are easy to configure either as digital signals<br />

or as safety signals. The control box has a revised<br />

design and a rebuilt controller to further improve the<br />

01 Robot arms and control units at the booth<br />

in Chicago<br />

possibilities for connecting equipment to the control<br />

boxes. “We are the only manufacturer of lightweight<br />

robot arms with a long lasting experience in a wide<br />

variety of industries. Our R&D department worked<br />

hard in order to integrate input and feedback from<br />

end users into our product development,” comments<br />

Enrico Krog Iversen, Universal Robots CEO, on the latest<br />

development from Denmark. “With our flexible<br />

robot-arms, we address a broad target group – whether<br />

it is (un-)loading of CNC machines in a ten-man<br />

firm or a gluing-process at an automotive manufacturer,<br />

everyone benefits from our robots. Because they<br />

perform the dull or harmful jobs that needed to be done<br />

by humans before,” says Iversen.<br />

Addressing a bigger audience<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

components and software<br />

The future of Universal Robots<br />

We talked to Edward Mullen, National Sales Manager for<br />

Universal Robots in North America, at Industrial <strong>Automation</strong><br />

North America in Chicago. He gave us an overview over the<br />

company’s plans in North America as well as for its future in general.<br />

Watch the full video interview here.<br />

Video<br />

rience are able to work with the robot. “We have a<br />

user interface that is easy to set up. You can give it to<br />

any level employee and they can take it and program<br />

the robot themselves”, elaborates Edward Mullen,<br />

National Sales Manager for Universal Robots in<br />

North America. The user only has to move the robot<br />

arm to desired waypoints or touch the arrow keys on<br />

a tablet PC. According to Mullen, this approach<br />

opens up a large amount of different fields for the<br />

robot to be used in: “By empowering people to program<br />

the robot themselves, we get into some unique<br />

applications of companies that have never even<br />

thought about using robotics before.”<br />

About<br />

Company name: Universal Robots<br />

Headquarters: Odense, Denmark<br />

Turnover: € 17,9 m (2013)<br />

Employees: 110 (<strong>2014</strong>)<br />

Products: lightweight robot arms UR5 and UR10<br />

Plans for the future<br />

The development of Universal Robots has not come<br />

to an end, yet. The company’s global sales target for<br />

<strong>2014</strong> is 2,000 robots followed by a doubling of sales<br />

every year from <strong>2014</strong> to 2017. Mullen states more<br />

ambitious goals of the Danish manufacturer: “We are<br />

committed to becoming the leader in this industry<br />

with this product and there will be more version of<br />

the UR robot with more features in the next two or<br />

three years.”<br />

www.universal-robots.com<br />

02 Edward Mullen explaining the new features of the<br />

robot arms<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

One gripper for<br />

all purposes<br />

At Industrial <strong>Automation</strong> North America, Universal Robots and<br />

Empire Robotics showcased the cooperation of the robot arms<br />

UR5 and the gripper developed by the young American company.<br />

The Versaball gripper quickly adapts to a variety of manufacturing<br />

tasks with a fraction of the engineering time and effort.<br />

Historically, robot integrators have spent a great<br />

deal of engineering resources designing specialized<br />

and varied grippers for industrial production.<br />

Empire Robotics’ Versaball delivers a solution that<br />

easily adapts to a variety of tasks. The product is a<br />

squishy balloon membrane full of loose sub-millimeter<br />

particles. The soft ball gripper easily conforms<br />

around a wide range of target object shapes and sizes.<br />

Using a process known as “granular jamming”, air is<br />

quickly sucked out of the ball, which vacuum-packs<br />

the particles and hardens the gripper around the object<br />

to hold and lift it. The object releases when the<br />

ball is reinflated. In a matter of minutes, the gripper<br />

can be programmed or reprogrammed to pick and<br />

place parts that vary and parts with varied orientations<br />

such as objects that fall randomly on a conveyor.<br />

The demo<br />

Company name: Empire Robotics<br />

Headquarters: Boston, MA, USA<br />

Employees: 6<br />

Products: Versaball gripper<br />

About<br />

Video of the demo<br />

Empire Robotics‘ CTO<br />

John Amend explained<br />

the operating principle of<br />

the gripper. Watch the video<br />

of the joint demo<br />

with Universal<br />

Robots here.<br />

For the demo at the fair, the gripper was mounted on<br />

Universal Robots’ UR5 robot. The demonstration<br />

illustrated how the Versaball attached to a UR robot<br />

arm offers an optimal choice for safe, collaborative<br />

robot applications with humans working in close<br />

proximity to robots. Unlike hard grippers, the<br />

balloon-shaped gripper by Empire Robotics conforms<br />

to and grips a wide range of objects – even<br />

lightbulbs – without reprogramming.<br />

Mutually beneficial cooperation<br />

“Empire Robotics’ Versaball is one of the most<br />

unique gripper technologies on the market,” said<br />

Ed Mullen, National Sales Manager with Universal<br />

Robots in North America. “We foresee the gripper as<br />

having the same, positive impact on collaborative<br />

robotics as our robot arm has had. The fact that the<br />

gripper is soft between grips and can be deployed on<br />

the fly further extends the safety and flexibility benefits<br />

of our robot arms.” Bill Culley, President of<br />

Empire Robotics, added: “Our gripper compliments<br />

the flexibility of the UR5 and UR10 robots with a<br />

solution that has minimal impact on the bottom line<br />

and shrinks time between product cycles, pushing<br />

robotics into small- and medium-sized manufacturing<br />

facilities.”<br />

www.empirerobotics.com<br />

Video<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Components and Software<br />

Enclosures:<br />

more than just a housing<br />

Michael Schell, Christan Moritz<br />

Enclosure housings protect the electrical<br />

equipment housed inside them, as well as<br />

the people who operate a switchgear or<br />

controlgear systems. Protection requirements<br />

and safety procedures are defined by<br />

various guidelines depending on the operating<br />

site, sector or application. In order to<br />

comply with these guidelines, various tests<br />

are required.<br />

Author: Engineer (UAS), MBA Michael Schell, Head of Product<br />

Management Power Distribution at Rittal<br />

Christan Moritz, state certified technician, Product Manager<br />

Power Distribution at Rittal<br />

The most well-known requirement of an enclosure<br />

housing is the IP protection class IEC 60529. The<br />

directive specifies the protection measures against<br />

the penetration of solid objects, dust and water. In<br />

addition, there are many other requirements for<br />

enclosure housings, such as resistance to corrosion<br />

or the protection of individuals during electrical<br />

faults. These requirements, as well as their testing<br />

and verification, are specified in several standards.<br />

It should be noted that, depending on each market<br />

segment (e.g. North America, Europe or Asia), additional<br />

approvals are needed. In many regions worldwide,<br />

the IEC standard or a translated standard<br />

thereof in a national version is directly recognised. In<br />

North America, Nema standards or UL approvals are<br />

required to verify protective functions instead of the<br />

IEC standards. The field of application can also entail<br />

additional requirements - for example, additional<br />

provisions apply for ships or railways.<br />

112 AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Components and Software<br />

next page<br />

Accredited test laboratory<br />

In order to receive approval from some organizations,<br />

such as UL, Lloyds or DNV, in addition to the<br />

initial testing, manufacturing sites are also regularly<br />

checked. If auditing is successful, these classification<br />

societies grant the right to provide enclosures with<br />

their approval mark until the next inspection. Therefore,<br />

we can expect constant quality of enclosure<br />

housings from manufacturers who have their manufacturing<br />

processes regularly checked by such organizations.<br />

As one of the world‘s leading system providers for<br />

housings and enclosure technology, Rittal has an<br />

accredited laboratory for various tests at its company<br />

headquarters in Herborn, Germany. In addition to<br />

the necessary initial testings of new products, the<br />

01 A standardised manufacturing process ensures an identical structure for enclosure housing,<br />

even for a wide variety of sizes<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Components and Software<br />

previous page<br />

02 Dipcoat priming of enclosure frame scaffolding at the plant in Rittershausen<br />

manufacturer regularly checks the different features<br />

of the enclosure. This ensures a high quality standard<br />

for the enclosure systems in the long run. Thanks to<br />

the platform concept and the company‘s standardized<br />

manufacturing, this also applies to single special<br />

constructions that may differ greatly from mass produced<br />

components.<br />

About<br />

Company name: Rittal GmbH & Co. KG<br />

Brands: system enclosure SE 8, system platform TS 8,<br />

switchgear system Ri4Power, …<br />

Headquarters: Herborn, Germany<br />

Turnover: € 2.2 Bn<br />

Employees: more than 11 000 worldwide<br />

Products: enclosures, power distribution, climate control,<br />

IT infrastructure, software and services<br />

Protection against corrosion<br />

Modern enclosure housings meet cutting-edge technology<br />

requirements and comply with the applicable<br />

standards. Hence, protection against corrosion is no<br />

longer to be performed with a simple coating of the<br />

metal insert. In order to ensure long-term protection<br />

against corrosion, a defined process with different<br />

process stages, ranging from cleaning to powder<br />

coating of the primed housing, is needed. Long-term<br />

protection against corrosion is essential in order to<br />

ensure protection for staff and equipment when operating<br />

electrical switchgear and controlgear systems<br />

thanks to their housing, even after many years.<br />

For electrical enclosures, protection against corrosion<br />

is stipulated by the IEC 62208 or the IEC 61439<br />

standards. The related required corrosion test is<br />

performed in accordance with the IEC 60068-2<br />

standard. Based on the standard for testing, a differentiation<br />

is made between indoor and outdoor<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Components and Software<br />

installation, depending on the installation site of the<br />

housing. In order to verify resistance to corrosion, a<br />

salt spray test is performed to simulate, over the<br />

course of a few days, the actual year-long corrosion<br />

process.<br />

Rittal‘s enclosure housings spray-finished sheet<br />

steel plates for indoor use and are corrosion-resistant,<br />

as prescribed by requirements, thanks to a<br />

standardized coating process. When the primary<br />

manufacturing of the housings has been completed,<br />

the first work step involves cleaning and de-greasing<br />

the housings to ensure long-term adhesion of the<br />

subsequent coatings. Immediately after de-greasing,<br />

the first protective coating is applied using a nano<br />

ceramic pre-treatment. For the second coating, the<br />

housings are completely immersed in a dip tank and<br />

receive an electrophoretic dipcoat primer. The last<br />

step for protection against corrosion involves powder<br />

coating, which gives the outer layer of the enclosure<br />

its structure. If, during subsequent operation of the<br />

system, the upper layer is damaged, two further<br />

layers can be provided to protect it against rust<br />

formation.<br />

Safety for people<br />

A further requirement for enclosures is the safety of<br />

people in the proximity of, or that operate, electrical<br />

switchgear and controlgear systems. It is regulated<br />

by the IEC 61439 standard. This standard contains<br />

several requirements that describe the mechanical<br />

properties of housings. During electrical faults, the<br />

enclosure housings are heavily loaded due to an<br />

internal increase in pressure or due to a magnetic<br />

effect during a high short-circuit current. The internal<br />

increase in pressure occurs, for example, in the<br />

case of a short-circuit cut-off by larger circuit breakers,<br />

which generate an electric arc during switch off.<br />

Furthermore, the magnetic field produced by a<br />

copper busbar, especially during high short-circuit<br />

The new IEC 61439 standard will<br />

be valid from 1 November<br />

The IEC 61439 standard defines the basic<br />

requirements and verification for the manufacturing<br />

of electric switchgear and controlgear<br />

systems for low voltage applications. Here,<br />

great attention is paid in particular to the<br />

mutual influence of different electrical<br />

equipment and the mechanical requirements<br />

for housing, which have been recently incorporated<br />

in this standard. The European version of<br />

the IEC 61439 standard, the EN 61439 standard,<br />

and also the German version, the DIN EN 61439<br />

standard, will only be valid starting from<br />

1 November <strong>2014</strong>, since on this date, at the<br />

latest, the previous EN 60439 standard will<br />

be withdrawn.<br />

currents, as well as the effect of neighbouring copper<br />

busbars, also have an effect on housing components,<br />

such as the mounting plate. The housing must ensure<br />

that an enclosure door does not open during a<br />

short-circuit cut-off or that a busbar system remains<br />

firmly attached even during a short circuit. A control<br />

enclosure door that opens or flying debris may injure<br />

people in the proximity of the switchgear and controlgear<br />

system.<br />

Therefore, it is important for enclosure housings to<br />

maintain their mechanical strength even after many<br />

years, as it was at the beginning of the installation,<br />

and to not lose their strength due to rust or other<br />

factors. In order to ensure this in the long-term, and<br />

with constant quality, a standardised manufacturing<br />

and spray-finish process is crucial.<br />

www.rittal.com<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Machine Vision<br />

Camera change with potential:<br />

USB 3.0 instead of FireWire<br />

Basler ace USB3 Vision cameras are available in resolutions from<br />

VGA to 14 MP; they have attractive prices and are easy to integrate<br />

René von Fintel<br />

How long will I be able to maintain my FireWire camera system?<br />

When should I switch, and which interface should I pick? Users of<br />

FireWire cameras around the world are wondering these things<br />

at the moment. The new USB 3.0 interface and its standard USB3<br />

Vision are an attractive successor due to the technical proximity to<br />

FireWire. Basler, a globally active developer of industrial cameras,<br />

explains the backgrounds and perspectives.<br />

Author: René von Fintel is Team<br />

Leader Product Management at Basler<br />

AG in Ahrensburg, Germany<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Machine Vision<br />

next page<br />

FireWire doubtlessly is one of the most successful<br />

camera interfaces in the world. However, their life<br />

cycle is slowly coming to an end. Users of FireWire<br />

cameras will be facing the question of how to continue<br />

with their camera system in future and which<br />

interface to switch to in the medium term. Generally,<br />

they have several to choose from. The most important<br />

interfaces that are currently an option are USB<br />

3.0, Gigabit Ethernet and Camera Link. Each interface<br />

technology has some specific benefits. Gigabit<br />

Ethernet is limited to a bandwidth of 100 MB/s, but<br />

offers benefits because it can use very long cables<br />

(up to 100 m) and makes it easier to set up multicamera<br />

systems. Camera Link Full is based on a<br />

frame grabber setup, but offers a bandwidth of up to<br />

850 MB/s. Generally, the closer the interfaces are to<br />

each other in their technical principles, the easier it<br />

will be to switch. This specifically applies when<br />

switching from USB 2.0 or FireWire to USB 3.0.<br />

The reason for this is that FireWire is no longer<br />

supported.<br />

There are various reasons for switching from<br />

FireWire to another interface. The most relevant ones<br />

most certainly are:<br />

n FireWire hardware is growing more and more<br />

expensive and more and more difficult to procure. It<br />

will no longer be available in the medium term.<br />

n Changes to the software or transfer to any other operating<br />

system require a change. Windows 8 no longer<br />

offers natural FireWire support, while the 3.0<br />

Host Controller can be used at once without even<br />

installing any drivers.<br />

n The bandwidth has grown insufficient for current<br />

and, particularly, future requirements to the Vision<br />

system, such as higher frame rates, higher resolution<br />

and a different pixel format.<br />

n Savings in the overall system justify the one-time<br />

integration effort quickly.<br />

The technology: FireWire versus USB3<br />

Vision<br />

It is often said that USB 3.0 and its standard USB3<br />

Vision are the most logical and recommended<br />

replacement due to the very similar technical<br />

properties. The two interfaces are not only similar,<br />

but USB 3.0 also offers true added value, as the table<br />

makes clear (see figure 1).<br />

Two other important properties should be mentioned:<br />

CPU-load and real-time capability. Even data<br />

rates in excess of 350MB/s will hardly put any strain<br />

on the CPU using USB 3.0, due to its direct memory<br />

access on the host computer. Blocks are reserved<br />

before image transfer to enable the mechanism to<br />

01 Technical data by FireWire and USB3 Vision in<br />

comparison<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Machine Vision<br />

previous page<br />

cope without any copying process. The resulting<br />

overhead is very low, i.e. there is only a small difference<br />

between the gross and net data rates.<br />

Speaking of real-time capability of Vision systems<br />

usually refers to different points in the system where<br />

latency times and time-related jitter may occur. The<br />

latency time includes the averaged absolute time,<br />

while jitter is the time-variation from each same<br />

sensor to minimise the change effort. Alternatively, a<br />

deviating sensor of the same or similar sensor size<br />

and sensitivity is an option. The housing size of the<br />

USB 3.0-camera should be similar, but never larger<br />

than the previously used FireWire-camera (figure 2).<br />

The setup behind the camera usually is a little<br />

simpler: The camera is connected to the PC via a<br />

FireWire-cable and plugged either into a PCIexpress<br />

FireWire is slowly but steadily losing support in the PC world.<br />

It will disappear from the market in the medium term.<br />

process step to the next same process step. The timerelated<br />

jitter is the more important aspect for determining<br />

in advance when the next process step that<br />

depends unconditionally on a previous one may<br />

happen. When performing measurements for<br />

real-time capability, it turned out that USB 3.0 has<br />

shorter latency/jitter times than FireWire does, and<br />

is the more beneficial interface in the sense of<br />

real-time capability.<br />

Replacement effort: changes to<br />

hardware…<br />

In case of replacement, changes arise to the hardware<br />

and software. As an example, we are looking at<br />

a single-camera system for classic object inspection.<br />

The complete mechanics in this system are adjusted<br />

to this object, i.e. the distances are coordinated with<br />

the lens used, the chosen sensor format and its resolution.<br />

The specific lighting may also be adjusted to<br />

it. If this setup is to be equipped with USB 3.0, it is<br />

beneficial to select a USB 3.0-camera with the same<br />

card or the sockets directly connected to the mainboard.<br />

For precise triggering, another cable may be<br />

used for hardware triggering at the camera. On the<br />

PC-side, the cable and either the entire PC hardware<br />

or the PCIexpress card must be replaced.<br />

… and software<br />

The integration effort for software may vary much<br />

more strongly. Two extremes can be differentiated.<br />

n Version 1: Proprietary, DCAM-based software<br />

environment. The proprietary software supports only<br />

DCAM-compatible cameras and cannot be used as<br />

easily for cameras with newer interface standards<br />

such as the USB3 Vision. The software interface must<br />

be reprogrammed for the GenICam standard. The<br />

good news is that porting to GenICam is only required<br />

once to be ready for other current and future Machine<br />

Vision software interfaces as well. GenICam is the<br />

standard that all interface technologies have to meet.<br />

n Version 2: GenICam-based software environment.<br />

Only slight adjustments are required. Ideally, the<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

Machine Vision<br />

03 Amortisation of the investment: Switching to USB 3.0<br />

pays off purely from the point of view of procurement<br />

02 Hardware and software changes are required when<br />

switching from FireWire to USB3.0; the figure shows a<br />

single-camera system for classic object inspection<br />

software environment has all drivers for USB3 Vision<br />

and camera control included in an update.<br />

A look at economic efficiency<br />

The calculation example in figure 3 shows how the<br />

change to USB 3.0 will pay off from the point of view<br />

of procurement. Switching to a USB 3.0-model with<br />

the same sensor, mainly expenses in the software area<br />

are required to adjust the software interface to the new<br />

camera interface. A smaller share is additionally<br />

required for hardware to attach the camera and install<br />

USB 3.0 with cable and ports. Using the same sensor<br />

means that no adjustments to the lenses,<br />

machine mechanics or lighting are required. The comparison<br />

shows that the break-even point will be<br />

reached within the first year. From the second year<br />

onwards, savings in the larger five-digit area are<br />

possible. The example is based on a number of 100<br />

cameras. The costs for cables and hardware have not<br />

been considered, with savings expected here as well<br />

(USB 3.0 hardware setups tend to be cheaper by 20 %).<br />

Photographs: lead fotolia<br />

www.baslerweb.com<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

machine vision<br />

Thermal imaging cameras in<br />

automotive quality control<br />

Chris Brown, Frank Liebelt<br />

The BMW 5-Series, 6-Serie, 7-Series and<br />

3-Series Gran Turismo are produced in the<br />

Dingolfing plant in Lower Bavaria. Around<br />

18,500 people work at the site. Basic functions<br />

from signal horn to engine-specific<br />

performance are thoroughly tested. Thermographic<br />

cameras are ideally suited for<br />

this type of quality control and ensure the<br />

proper functioning of automobile production.<br />

New vehicles are subjected to a number of individual<br />

and automated quality control measures<br />

including analysis in one of ten separate roller dynamometers.<br />

Basic functions from signal horn to<br />

engine-specific performance are thoroughly tested,<br />

as is the BMW Night Vision System, based on a Flir<br />

detector. The entire process just takes a few minutes,<br />

during which each correct function has to be confirmed<br />

either automatically or by an inspector who<br />

sits in the vehicle monitoring displayed inspection<br />

data. The tests vary in both type and duration according<br />

to the specification of each model and are<br />

programmed to be conducted in an automated<br />

sequence.<br />

Author: Chris Brown, Business Development<br />

Manager EMEA, Flir Systems Limited, UK;<br />

Frank Liebelt, journalist, Frankfurt, Germany<br />

Simple, fast and reliable testing<br />

Whilst cost- and time-efficient testing is the common<br />

goal, identifying the optimum procedure for each<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

machine vision<br />

next page<br />

The BMW plant in Dingolfing, Germany,<br />

is using thermal imaging cameras for<br />

electro-thermography of switch cabinets<br />

and rooms and for quality control<br />

inspection task needs individual consideration. This is<br />

the case, for example, when testing the exhaust flaps on<br />

the dual exhaust system. Twin tail pipes are a feature of<br />

the high performance BMW vehicles with large,<br />

8-cylinder engines. On the BMW M5 model the<br />

requirement is different again, as the exhaust flap on<br />

the second tailpipe is only activated at a specified RPM.<br />

The reason for this may be at first surprising as it’s<br />

all about acoustic design but the sound of a powerful<br />

engine should be impressive. Therefore a BMW M5<br />

only opens the second tailpipe exhaust flap when it is<br />

really needed. Of course this feature has to be<br />

inspected which is more complicated than it appears<br />

at first glance.<br />

To check the efficiency of this operation thermal<br />

imaging cameras – a different brand to FLIR – were<br />

initially specified for each dynamometer rig. Their<br />

purpose was to visualise the thermal profile of the<br />

respective tailpipes in the dual pipe exhaust system.<br />

Thermal imaging cameras<br />

check exhaust flow<br />

Each system comprised two thermal imaging cameras,<br />

mounted to inspect the left and right tail pipes<br />

from above and the side. The solution was not only<br />

expensive to buy but costs also increased with time<br />

as the cameras required frequent repair. After eight<br />

years the viability of a new system was therefore<br />

evaluated.<br />

Robert Halbritter of Flir Systems’ sales partner and<br />

integrator Topa GmbH, offered a very attractive<br />

solution that would halve the cost of new camera<br />

hardware. He recommended the use of a single,<br />

fix-mounted Flir A310 with a 45º lens for each dynamometer.<br />

The advantage: that which was previously<br />

inspected using two cameras mounted on the sides<br />

could now be visualised using a single centrally positioned<br />

Flir camera. This is possible as the field of view<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

machine vision<br />

previous page<br />

01 Thermal images of the rear end view as you can see by the left: the exhaust flaps open at a higher rpm –<br />

the inspector can see if the flap is functioning properly from changes in the thermal profile<br />

of the camera with 45º wide-angle lens is capable of<br />

showing the entire end of the vehicle from a distance<br />

of approximately 2 m. As a result comprehensive<br />

inspection could be conducted by just 10 cameras,<br />

one for each dynamometer, instead of the 20 units<br />

required by the previous system.<br />

Simple solution – huge potential<br />

The Flir A310 generates an analogue thermal imaging<br />

video signal with a frame rate of 30 Hz. This model is<br />

particularly suited to recording exhaust flow as it is<br />

simple to integrate and provides easy access to PAL<br />

video.<br />

Chris Brown explains: “The camera also provides<br />

multiple connection options.” He is responsible for<br />

fixed thermal imaging cameras for automation applications<br />

at Flir Systems GmbH. “The Flir A310 has a<br />

digital output for alarms and for controlling external<br />

devices. Additionally the data can be transmitted via<br />

TCP IP or Ethernet and the Flir A315 even supports<br />

the GigE Vision standard as well as the GeniCam<br />

protocol.”<br />

Careful monitoring<br />

The performance of the exhaust system is checked on<br />

a monitor in front of the vehicle which displays a thermal<br />

image. From this the inspector can see if the flap<br />

is functioning properly from changes in the thermal<br />

profile. Even though the Flir A310 can visualise heat<br />

distribution using various colour palettes, the simplest<br />

and clearest option is used here: black and white.<br />

The reason for this is the irregularity in air flow of<br />

the exhaust streams. A relatively high amount of air is<br />

displaced and the exhaust stream does not remain<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

machine vision<br />

02 Fix-mounted thermal image camera Flir<br />

A310 with a 45° lens for each dynamometer<br />

constant. The flow rate also has to be taken into<br />

consideration. These are all factors that could be be<br />

visualised using a wider colour spectrum but could<br />

serve to confuse the inspector. In the final analysis all<br />

that is required of this test is confirmation that the<br />

flap is opening and closing correctly.<br />

autumn of 2011 and have been in operation, around<br />

the clock, since then.<br />

Photographs: background and ornaments fotolia<br />

www.flir.com<br />

Global market leader<br />

BMW’s decision to switch to the Flir camera solution<br />

suggested by Topa was based on the companies good<br />

reputation for quality service and post-sales support.<br />

The technical implementation of the solution also<br />

played an important role. “We were often on site and<br />

able to support BMW with the installation and<br />

calibration of the cameras,” says Robert Halbritter of<br />

Topa. The reliability of the Flir A310 speaks for itself.<br />

The first camera systems were installed in the<br />

About<br />

Company name: FLIR Systems, Inc.<br />

Headquarters: Wilsonville, Oregon, USA<br />

Turnover: $ 1.5 billion (2013)<br />

Employees: 2,800 worldwide<br />

Products: thermal imaging systems, visible-light imaging<br />

systems, locator systems, measurement and diagnostic<br />

systems, and advanced threat detection systems for all<br />

industries<br />

AUTOMATION TECHNOLOGIES 4/<strong>2014</strong>

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