The PI Series pressure transmitter for sanitary applications is a 316 stainless steel unit that is rated IP69K and tested to withstand high-pressure cleanings and extreme washdown conditions. The transmitter offers an accuracy of 0.2% of full scale and is designed for a variety of application solutions including line pressure, filter monitoring, pump protection and tank level. The transmitter features a four-digit integrated display that provides continuous indication of pressure value. Its programmable display offers simple pushbutton setup that enables adjustment of the scaleable analog output. The transmitter can be placed in direct contact with media -- its base is completely smooth, preventing media from sticking.

ifm efector inc.

The L Series viscosity-insensitive flowmeter assures delivery of circulating lubrication oil to bearings in industrial machinery. These piston-style flowmeters maintain ±5 percent accuracy for lubrication oils with a viscosity range between 40 and 200 centipose. Although operating in the 40-200 CP viscosity range is standard, a meter can be optimized for specific viscosities within that range. The meters can monitor lube oil flow rates from 7.6 to 75.7 liters per minute. The meters monitor rate of oil flow, provide flow rate indication to assist in problem diagnosis, and resound immediately if flow goes too low. L Series meters are mechanical units that require no power.

Universal Flow Monitors, Inc.

The SS5P steam trap improved production and reliability of equipment in biotech industries through its self-modulating free float which has only one moving part, eliminating valve wear and providing a long service life for the trap. Its electro-polished crevice free-design results in minimal bacteria buildup. Free drainage is ensured under no-load conditions. Its instant discharge capability reduces the size of the condensate collection leg. The thermostatic trap is suitable for pure and clean steam applications.

TLV® Corporation

The new, enhanced KPSI Series 705 submersible level transducer features static accuracy of +/-0.25% FSO and is suited to highly viscous or slurry environments. Its standard housing construction is 316 stainless steel, with titanium available as an option. Vented gage applications are virtually maintenance-free with the SuperDry™ vent filter. For enhanced reliability in the field, Pressure Systems offers a proprietary, 2-part lightning protection system.

Pressure Systems

Cyclonaire vaccum pumps are designed specifically for Dilute Phase vacuum conveying. Each vac uum pump comes standard with a premium inlet filter with filter service indicator, exhaust silencer, safety pressure relief valve, belt guard protector, adjustable belt tension base and a 10-foot suction hose. Engineered for specific applications, each vacuum pump package can also be custom built for elevation, temperature, and noise-reduction requirements. The vacuum pumps can be used with many dry bulk materials, including powders, granules, and pellets.

Cyclonaire Corporation

The Adalet wireless DIN rail mount industrial wireless system is now available with a battery powered transmitter option for applications with no available power source. Class I, Division 1 and rugged NEMA 4A versions are also available. This unit makes it possible to collect real time data signals in applications such as tank level, pump control, petrochemical, sensor monitoring, oil & gas, waste/wastewater.

Adalet Wireless

The IDENT Control real-time RFID product identification and data collection system now supports DeviceNet and Ethernet/IP bus systems. This functionality facilitates seamless connection to any DeviceNet scanner, or ControlLogix or CompactLogix system using Ethernet/IP. The incorporation of PCCC functionality also allows connection to SLC 5/05 and PLC 5 systems. IDENT Control provides operational flexibility by supporting IO sizes from 8 bytes up to 248 bytes. A multiplex option eliminates mutual interference challenges without programming changes, allowing all four system heads to operate simultaneously and in close proximity to one another. The system is suitable for inventory, part identification, routing and error tracking applications.

Pepperl+Fuchs

Offering 6 channels of simultaneous particle counting, the PC-GW3016 displays both cumulative and differential particle count data on its easy-to-read 9.65 cm touch screen. This is a handheld meter capable of logging 3000 sets of measurements on-board or a virtually unlimited number of readings when interfaced to a mobile PC. It may be used as a stand-alone display unit and data-logger, to record the 6 particle size channels, and optionally to measure %RH and temperature with the available PC-GW6-RHCF plug-in probe.

Gray Wolf Sensing Solutions

These miniature optical liquid level switches reliably detect the presence or absence of liquids using solid state technology with no moving parts. They are available as basic switches, microprocessor compatible TTL-output devices and high power transistor output versions capable of switching currents up to 800 mA. These new liquid level switches offer different housing options including plastic polysulphone and rugged stainless steel versions for corrosive environments. They are suitable for a wide range of applications such as medical equipment, HVAC, compressors, hydraulic reservoirs, machine tools and leak detection as well as food, beverage and pharma ceutical processing.

Sensortechnics, Inc.

The DMP Insertion MagProbe Series features a redesigned probe tip. The "flat tip" design allows the use of larger conductors, which will reduce fouling in applications where suspended solids are present. This type of meter can be universally applied to a large range of pipe sizes without hardware changes. MagProbe sensors are available in various lengths to accommodate limited access mounting configurations and installation in pipe diameters up to 3048mm. Hot-tap sensors are installed and retracted from process piping without draining or depressurizing the system and without system shutdown.

Dynasonics

The Model 2810 RF Vector Signal Analyzer is optimized for automated testing of wireless devices and transmitter circuits in production test environments, as well as in new product and device research and development. It uses an advanced software-defined radio architecture with a 500MHz digital signal processor, enabling fast data acquisition and processing. Production test engineers can drastically reduce test times, while R&D engineers and scientists can reduce the time it takes to acquire large sets of data. For example, in the case of users searching for spurious emissions from devices under test, the model 2810 can perform a 200MHz span sweep using a narrow resolution band width of 100 Hz in approximately 15 seconds.

Keithley Instruments, Inc.

The Z789 Zener Diode Barriers provide 300ohm/284V, diode return, positive polarity operation making them a good intrinsic safety choice in hazardous area applications such as those found in refineries and chemical plants. It features quasi ground floating wiring. The barriers are available in one, two and three channel versions and more than 75 models for AC and DC applications. A replaceable fuse version facilitates circuit loop checks and reduces space.

Pepperl+Fuchs

Class 1, Div 1 rated piston and diaphragm differential pressure sensors can be safely operated where flammable gases or vapours often exist because of their robust, sealed enclosures. The switches and electrical connections in these units are housed in special UL, CSA, FM and ATEX approved enclosures. The epoxy-coated, cast aluminum enclosures have two mounting lugs, two 3/4" NPT electrical conduit ports, and meet Class 1, Gr. B, C, and D; Class 2 Gr. E, F, and G; and Class 3 specifications. They also meet NEMA 3, 4X, 7, 9, and 12 specifications. They are available in gauge, switch and transmitter version in pressure ranges from 0-5 inches of water to 0-300 psid and maximum line service is up to 5,000 psig.

Orange Research Inc.

McMillan's 101 & 102 Series Flo-Sensors provide precise liquid flow measurement for OEM applications. The flow sensors can be constructed from plastic or brass, and provide a 0-5VDC analog output proportional to flow rate. Flow rates can be measured as low as 13mL/minute. With better than ±3.0% linearity (full scale) and 0.2% repeatability (full scale), these flow totalizing systems provide accurate measurement of liquid flow, suitable for critical flow measurement applications without advanced instrumentation. Compact packaging allows for easy integration into new or existing equipment.

McMillan Company

Long before a new vehicle makes it to the dealer's lot, and before the vehicle's parts are made, someone needs to design and build the machines that produce these parts. Tri-Way Manufacturing Technologies Corporation works with automotive suppliers and automobile manufacturers like General Motors, DaimlerChrysler and Ford to build the machine tools used in the preliminary stages of new vehicle production.

Based in Windsor, Ontario, Tri-Way is one of the largest manufacturers of metal-cutting machinery in North America. In the automotive industry, Tri-Way specializes in building machine tools and systems used to produce a wide variety of power train components, such as connecting rods, crankshafts, transmission plates and intake and exhaust manifolds.

When Tri-Way is awarded a job from an automobile manufacturer, the engineers receive a list of approved components and a part print that defines what the automobile part will look like when it comes off the machine. After reviewing these documents, Tri-Way's application engineering group outlines the best process for machining the part and formulates the manufacturing plans and specifications.

Challenge

Tri-Way received an order from an automotive parts supplier to build an eight-station dial table machine used to produce left and right aluminum rocket covers for the customer.

The supplier provided Tri-Way with a list of approved components that included the Allen-Bradley® ControlLogix® controller and Remote I/O communications network from Rockwell Automation. Tri-Way immediately contacted its Allen-Bradley distributor, Electrozad Supply in Windsor to help implement the ContolLogix platform and meet the detailed part specifications outlined by the automotive supplier.

Part of the Rockwell Automation Integrated Architecture, the Allen-Bradley ControlLogix controller leverages the Rockwell Automation Logix Control Platform including a common control engine, networking technology and communications services to increase functionality, scalability and flexibility while reducing costs.

"Although we've been a Rockwell Automation customer for 25 years, we didn't have any design experience using the ControlLogix platform," said Bob Crow, controls engineering manager, Tri-Way. "We were excited about the opportunity to implement this advanced control system, but we were also apprehensive about the amount of time it would take us to get the system up and running. It can often take more than a month to implement a new control system, and we weren't thrilled about dedicating that amount of time to implementation."

Another challege Tri-Way faced was reducing its start-up time. Prior to implementing the new control platform, it took Tri-Way an average of 52 weeks to produce a machine.

"OEMs are under great pressure to provide equipment as quickly as possible because manufacturers are working in a "just-in-time" environment and face several penalties if the product is not delivered on schedule, " said Crow.

Solution

After reviewing the specifications provided by the automotive supplier, the distributor suggested that Tri-Way request a deviation from the approved list. "Our customer specified using strictly Remote I/O, and our Allen-Bradley distributor thought by using some newer technologies like ControlNet™, PowerFlex® 700 AC drives and a Microsoft® Windows®-based user interface, we would be able to more effectively meet customer needs," said Crow. "Implementing these newer products allowed us to offer GM, and future customers, more advanced control capabilities."

Tri-Way was granted approval to deviate from the original specifications and use the ControlNet network in addition to Remote I/O. By running the discrete I/O and HMI on ControlNet, Tri-Way achieved faster data transfer and response. Tri-Way also used Kinetix® motion to control the rate of speed at which the tooling was fed into the machine and rotated when making a cut. Integrated Kinetix motion on the SERCOS interface® network allowed Tri-Way to leverage the Control Tags already in the Logic. This reduced engineering and programming demands and increased system throughput, improving overall cycle time, all with the common RSLogix™ 5000 programming software environment.

At the same time, Tri-Way was also allowed to switch from Allen-Bradley 1336 drives to Allen-Bradley PowerFlex 700 AC drives. The PowerFlex drives provided tight torque control and closed-loop regulation to meet the high-performance demands of this particular application. The drives also feature an innovative bookshelf design that optimizes panel space by allowing side-by-side mounting.

Finally, Tri-Way also changed the original machine specifications by adding a PC user interface running Rockwell Software® RSView® HMI software. RSView provides an intuitive interface for operators, supports reporting and tracking functions, and allows users to easily make necessary changes. Reusing the tag database from the ControlLogix to program the HMI in RSView represented further engineering savings to Tri-Way.

Results

In less than two weeks, Tri-Way's new control system was fully integrated and operational. According to Crow, it normally takes at least a month, if not longer, to get a new control system fully implemented -- and in most cases there are still lingering issues.

"The Rockwell Automation solution was seamless. We couldn't believe the ease with which we were able to start up the system and configure the various components and networks," said Crow. "The ease of integration and flexible connectivity of the ControlLogix platform allowed us to use four different communications networks in one machine -- a task we've never attempted before."

The new Tri-Way machine includes an Ethernet module, a SERCOS interface motion module, ControlNet and Remote I/O. It also uses two ControlLogix processors, one for motion and one for all remaining functionality, including control of two robots -- one to load the machine and one to unload the machine.

The machine produces two rocker covers every nine seconds, an extremely aggressive cycle time for a machine of this size and twice as fast as the industry standard of 18 seconds. For Tri-Way's customer, it represents a 50 percent savings in machine expenditures and 40 percent less required floor space. These are significant savings from just one machine.

Also with the new control platform, Tri-Way was able to reduce its start-up time by 75 percent, delivering the machine 10 days faster than the conventional system. With nearly eight extra days of machine availability to produce parts, the solution contributed to more than $1.5 million in additional production.

The development tools within the ControlLogix programming software (RSLogix 5000) allow Tri-Way to reuse its engineering resources and reduce software engineering and integration time by 400-600 hours for future projects. This reuse of engineering also will reduce risks associated with new projects, since engineers already know how the machines will perform.

The tag-based programming environment allows programmers to work in parallel on the electrical design and application code. In the past, programmers responsible for writing code sat in limbo until every last field device was assigned to a physical address. With tag aliases, programmers can write code independent of electrical connection assignments.

The programmer creates tags (also referred to as symbolic addresses) based on system device needs and can then write the program or create generic code blocks. At a later date, the device tags are easily mapped to the I/O. Tag-based aliases are more meaningful, providing faster and more accurate troubleshooting that minimizes the need for drawings or cross-referencing during machine diagnostics. This not only saves engineering and integration time for Tri-Way, but reduces start-up time for the customer too.

"ControlLogix is the best possible control solution. It's the most complete control system I've ever seen, and we get local support from Rockwell Automation, which is a value that gets passed along to our customers," said Crow. "As part of the Rockwell Automation® Integrated Architecture, ControlLogix provides painless integration between motion, HMI, drives and sequential control, and has helped create a new engineering standard for Tri-Way."

Rockwell Automation

Canadian Industrial Equipment News June 2007

Back to Contents