What’s New in Process Technology Mar 2012

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 1

http://www.ams-ic.com.au

ON THE COVER 0312CONTENTS

WHAT'S NEW IN PROCESS TECHNOLOGYMARCH 2012

4 Redundancy in industrial networks

Part 1

8 New products

16 Hot products online

20 Changing, machining, compensating Current trends in robot accessories

34 As I see it Energy saving has benefits beyond compliance

Your copy of What's New in Process Technology is now available as an online eMag.

NOW in DIGITAL!http://www.processonline.com.au/latest_issues

The Beamex MC6 Advanced Field Calibra-

tor and Communicator is a solution to new

process industry requirements. The MC6 is

an advanced, high-accuracy field calibrator

and communicator. It offers calibration capa-

bilities for pressure, temperature and various

electrical signals. The MC6 also contains a full

fieldbus communicator for HART, FOUNDA-

TION Fieldbus and Profibus PA instruments.

The ease of use is what really makes the

MC6 unique. It has a large 5.7″ colour touch

screen with a multilingual user interface. The

robust IP65-rated dustproof and waterproof

casing, ergonomic design and light weight

make it a suitable measurement device for

field use in various industries, such as the

pharmaceutical, energy, oil and gas, food and

beverage, service as well as the petrochemical

and chemical industries.

The MC6 is one device with five different

operational modes, which means that it is

fast and easy to use, and you don’t have to

carry equipment in the field. The operational

modes include meter, calibrator, documenting

calibrator, data logger and fieldbus communica-

tor. In addition, the MC6 communicates with

Beamex CMX calibration software, enabling

fully automated and paperless calibration

and documentation. The MC6 is more than

a calibrator.

Beamex is also introducing a new version of

the CMX calibration software that, together

with the MC6, offers new and improved pos-

sibilities for paperless calibration management.

The MC6 takes a unique and unoccupied

position on the market, as it is a calibrator

and communicator that combines advanced

functionality and accuracy with usability. This

is groundbreaking because, typically, products

with many functions are not very easy to use.

AMS Instrumentation & Calibration Pty Ltdwww.ams-ic.com.au

4 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012 www.ProcessOnline.com.au

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REDUNDANCY IN INDUSTRIAL NETWORKSPART 1Glenn Johnson, Editor

The costs of failure in today’s industrial networks can be very high, making network redundancy essential.

The failure of individual components in factory automation, processing and substation applications are inevitable

and can never be totally avoided - so they have to be handled in a way that minimises impact on the system. While high availability can be achieved by using completely redun-dant systems, such as duplicated sensors, actuators, controllers and networks, it is usually far too expensive a proposition to implement.

Some parts of the system can provide resilience, however, and one such element is the networking component. While many technologies used in plants are designed to be robust, networking components are wholly electronic and rely on cables and wireless links, all of which can be more easily damaged or interrupted in some way, so the capability to design a ‘self-healing’ network is important.

With the increasing use of ethernet as a communication technology in plants and factories, it is possible to take advantage of ethernet redundancy technologies to pro-vide a fault-tolerant network. Most ethernet switches and routers today support various types of redundancy mechanisms that only require some additional cabling and software configuration to implement, and which pro-vide a standby and failover mechanism to secondary network paths.

Network redundancy can be achieved at both the data link layer (Layer 2) and the network layer (Layer 3), with Layer 2 re-

dundancy being provided by switches within a TCP/IP subnet, and Layer 3 redundancy generally being provided by routers, routing traffic via different TCP/IP subnets. Naturally, routing means higher overhead and lower performance, so in this article we will focus only on standardised Layer 2 redundancy techniques. This is not to say that Layer 3 redundancy is not useful in industrial networks in appropriate situations, but this article will focus mainly on redundancy within a single network in which high performance recovery is a must.

But there are choices to be made - dif-fering redundancy protocols and designs will provide different levels of protection and performance. So it is necessary to un-derstand the differences to determine what is sufficient for the particular application. For example, can the process tolerate a delay of a few seconds while the network redundancy ‘heals’ a fault, or is millisecond response required? Some ethernet hardware may support different redundancy technolo-gies, so choosing the right technology to support your needs is important - as is the architecture of the network as a whole if you want to successfully implement a fast failover capability.

Ethernet does not tolerate loopsIt is a basic requirement of a functioning ethernet network that there are not any loops. Loops result in data frames circulat-ing endlessly, flooding the network. So all

www.ProcessOnline.com.au MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 5


Industrial ethernet

ethernet networks need to be implemented to make sure there is only a single path between any two devices.

For redundancy, however, there must be an alternative path available, in case the primary path becomes unavailable. For this to work, it must be possible to have multiple physical paths between devices, but to make sure that only one path is active at any one time.

The main way this has been achieved is through monitoring the communication paths, detecting failures and switching to the backup path if the main communication path fails. There are several protocols that can achieve this functionality, but they vary in their performance. All changeover mechanisms of this type depend on detecting the fault, then reconfiguring the network to a new topology (alternate paths) to re-establish communica-tion - and these steps all take time. The protocols available on the market can differ greatly in their failover speed, which is in turn also affected by the size and design of the network.

Link aggregationA simple form of redundancy is link aggre-gation, or link redundancy (Figure 1). Link Aggregation Control Protocol (IEEE 802.1ad) provides the ability to bundle groups of switch ports between switches to form one link with the aggregated bandwidth of the individual links. In the event that a single connection fails, the remaining links keep working with reduced bandwidth. To best take advantage

of link redundancy, it is most effective if the physical links (cables) are routed via differ-ent paths, to minimise the risk of multiple link failures. Spanning treesOne of the first protocols developed to implement redundancy was the Spanning Tree Protocol (STP) that was developed in the early 1990s. Designed for failover in IT networks, the failover time for this protocol can be as long as 10 seconds, but can handle different network topologies, including mesh networks. Apart from the slow failover time, it also has a limitation in the number of switches between endpoints in the network, due to the time required to converge on a new configuration. Although larger networks can be built, depending on the topology, the original RFC for STP recommended that the number of hops (the number of bridges or switches between any two devices) should be no more than seven.

Spanning tree protocols work by creating a tree of connections between switches and by disabling all the connections that are not part of the tree (and that would form loops), as shown in Figure 2. Special frames called Bridge Protocol Data Units (BPDUs) are used to communicate between switches and to set up optimal paths in the network, with one switch defined as the ‘root bridge’ for the tree (by default the switch with the lowest MAC address, but can be manually defined). When the topology changes, Topology Change

Notification BPDUs are used to announce the change, resulting in a recalculation of the spanning tree, and the activation of backup paths to re-establish the network.

STP has generally been replaced by the Rapid Spanning Tree Protocol (RSTP), an improved version of STP that was defined by the IEEE 802.1 working group in 1998. RSTP networks support a larger number of switches (20 in a path) and the typical failover time is around one second. Regardless of the failover time, however, neither STP nor RSTP can provide deterministic failover. The failover time will vary depending on the particular implemented topology and the location of the individual failure. Restricting RSTP to simple ring networks and with careful configuration, it has been shown to be possible to keep failover times down to around 100 ms, however.

The main benefit of a spanning tree protocol is that depending on the design, it is possible to design a network that is resilient to more than one simultaneous link failure. For example, the loop configuration in Figure 2 can recover completely from only one failure (a weakness of loop topologies). If a second link were to fail (both links 3 and 5), then a switch or even a whole section of the loop would be isolated. In the alternative configuration of Figure 2 (a partial mesh), there are multiple backup links, and this allows, for example, two links to fail (such as links 4 and 6), and the network should reconfigure to allow the network to keep working (assuming in the example that the two failures disconnected

Figure 1: Link aggregation allows links between switches to be bundled to increase bandwidth. Redundancy is improved if the links have differ-ent physical paths.

Figure 3: In MRP, switches react to received recon-figuration frames from the Media Redundancy Manager (MRM). Subrings are also supported through Subring Managers (SRMs).

(left) Figure 2: Spanning tree protocols (STP and RSTP) create a tree of connections between switches, disabling connections that would form loops.

MARCH 2012 - WHAT'S NEW IN PROCESS TECHNOLOGY 7www.ProcessOnline.com.au

Industrial ethernet

both ports of a single switch, which would effectively isolate the switch - such as links 4 and 7).

The disadvantage of spanning tree protocols is that while, with careful design, the recovery time can potentially be low, it is also not predictable. The recovery time will depend on the topology, the location of the failure and the number of failures that occur - and the larger the number of switches, the more the recovery time increases.

Media Redundancy ProtocolSTP and RSTP are enterprise network pro-tocols supported in all managed ethernet switches. A protocol commonly found in industrial ethernet switches that is designed more for industrial applications is Media Redundancy Protocol (MRP). It is defined in IEC 62439 as an industry standard for high-availability networks and is a standardised version of the HIPER-Ring protocol first re-leased by Hirschmann and Siemens in 1999. It is exclusively for ring networks, but can guarantee deterministic ring failover.

The reason that MRP can have a predeter-mined recovery time is that it is not a protocol in which all the switches need to reconfigure their forwarding ports hop-by-hop and ‘con-verge’ to a new topology, as in Spanning Tree protocols. Instead, one of the switches is configured in the role of Media Redundancy Manager (MRM), which sends frames out of one of its ring ports and receives them on its other ring port, in both directions, while

maintaining one port closed to normal data. All other switches act as Media Redundancy Clients (MRCs), and can act on configuration frames received from the MRM, as well as detect and signal link changes on their ring ports (Figure 3).

With MRP, the failover time is nearly independent of the number of switches in the ring, because MRP control frames are forwarded as multicast frames through the ring, and so can be processed nearly si-multaneously in all switches, resulting in a maximum reconfiguration time of around 200 ms and a typical time of less than 80 ms.

As stated above, however, ring topologies have the weakness that they cannot tolerate more than one failure.

MRP (along with many proprietary ring technologies) also has the ability to support subrings. Depending on the support that is included by your hardware vendor, some switches can be configured as Subring Managers (SRMs), allowing them to take part in two rings. For example, two of the MRC switches in Figure 3 could be configured as SRM switches and connect a subring of additional switches off another of their ports. The two switches then take part in two rings - the original ring being known as the basis ring. The subring will need to have at least one other switch, since there needs to be a switch taking the role of MRM for the subring.

It should be pointed out, however, that the subrings need to be configured on different

VLANs, so further configuration is required to share traffic between the rings.

Proprietary solutionsMany industrial ethernet switch manufactur-ers offer their own proprietary redundancy protocols (see Table 1). If you don’t mind being ‘locked in’ to a particular vendor for your network, or at least a part of it, then you may be able to take advantage of redundancy protocols that perform better than RSTP or MRP and offer additional features to enhance the redundancy further. However, if you need interoperability between vendors you will have to either settle for a standardised protocol or design a hybrid architecture in which sections of the network use proprietary redundancy, while others are linked using standard protocols.

In Part 2The approaches to network redundancy discussed so far have focused on standard network topologies in which there is a single path between any two points. Redundancy depends on the paths being reconfigured in the event of failure and, depending on the protocol used, there may be a trade-off between speed of recovery and the number of concurrent failures that can be recovered.

In Part 2 of this article we will discuss fully redundant network architecture approaches in which total redundancy is achieved using independent paths between any two devices - PRP and HSR.

Company Technology Claimed recovery time Network size Topology URL

Advantech X-Ring <10 ms 30 Ring www.advantech.com

Hirschmann HiPER Ring <500 ms 200 Ring www.belden.com

Fast HiPER Ring <60 ms 200 Ring

Moxa Turbo Ring <20 ms 250 Ring www.moxa.com

N-Tron N-Ring ~30 ms 250 Ring www.n-tron.com

ORing O-RSTP ~20 ms 40 Any www.oring-networking.com

O-Ring <10 ms 250 Ring

Open-Ring Variable 250 Ring

Rockwell Automation Cisco REP 20-250 ms Unknown* Line/Ring www.rockwellautomation.com

Weidmüller Turbo Ring <20 ms Unknown* Ring www.weidmuller.com.au

Westermo Cisco REP <20 ms 200 Ring www.westermo.com

Table 1: Examples of proprietary ethernet redundancy offerings. (*Some data unavailable to the author at the time of writing.)


FLASHING AND ROTATING BEACONSBanner Engineering’s EZ-Light K50 Beacon is now

available in rotating and strobing models that radiate

a bright, attention-getting signal with intense LEDs -

providing a suitable lighting solution for areas with

high ambient light, including outdoor environments.

The K50’s intense light is viewable from all direc-

tions, and offers three functions for each model - solid

ON, single and double strobe for strobing versions

and solid ON and two rotating speeds for rotating

lights. The K50 strobing model also emits light from

the top. Featuring a microprocessor-based design,

the K50 offers custom configurations on the strobe

rates and rotation speeds, allowing customers to

meet application-specific needs.

Similar to the original K50 model,

the strobing and rotating versions

are intended for indoor and

outdoor general status indica-

tion and are designed for use

in areas with high levels of

ambient light where a standard

indicator light may go unnoticed.

With a rugged, sealed IP67-

and IP69K-rated thermoplastic

housing, all models of the K50 are

suitable for both dirty and washdown

environments. The K50 lights are available

in 12-30 VDC operation, as well as cabled

or quick disconnect models.

Micromax Pty Ltd

Contact info and more items like this at wf.net.au/M742

NEWPRODUCTS

PROFIBUS COMMUNICATION TERMINALThe IB IL PB-MA-PAC inline I/O communication terminal enables

the integration of Profibus devices into the Phoenix Contact

automation solution. The terminal can be integrated into the

I/O system either as a Profibus DPV0 master or slave.

With a maximum data width of 64 bytes in/out, its primary

use is to connect existing Profibus devices into an automa-

tion solution from Phoenix Contact. This is especially true for

medium-sized applications built using the Easy Automation

system based on compact controllers. Users can connect

up to 16 DP slaves at a maximum baud rate of 12 Mbps.

A memory stick is integrated into the front side of the

terminal for storing the DP master configuration data.

If service is required, the terminal can be directly replaced

without having to reconfigure it. Profibus parameters such

as the transmission speed can be set directly in the PC

Worx automation software using a configuration tool.

The Profibus terminal expands the Easy Automation system

for class 100 compact controllers to provide an additional option

for communicating with external fieldbus devices.

Phoenix Contact Pty Ltd

Contact info and more items like this at wf.net.au/L959

KPI AND STATUS DISPLAY SYSTEMThe Red Lion ProducTVity Station is a solution for collecting, recording and

displaying critical key performance indicators (KPIs) and machine status mes-

sages on any TV, monitor or projector equipped with a DVI/HDMI interface.

The ProducTVity Station is able to collect data from a wide range of au-

tomation components. Using a library of over 200 communications drivers,

it can communicate with PLCs, VSDs, energy meters and barcode scan-

ners. Additionally, the PTV can be expanded with I/O modules, allowing it

to directly accept digital and analog inputs from a range of sensors.

A fully programmable graphical interface allows users to create

high-definition visual management displays. A built-in data logger can

record key performance indicators, as well as alarms and events for later

review. It can synchronise its log files with any FTP server or Microsoft

SQL Server for further analysis.

Control Logic Pty Ltd

Contact info and more items like this at wf.net.au/P226


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MANAGED GIGABIT POE ETHERNET SWITCHThe ORing RGPS-7084GP-P is an industrial 12-port rack-

mount managed gigabit PoE ethernet switch with eight

10/100/1000Base-T(X) PSE ports and four 1000Base-FX SFP

ports. It provides advanced IP-based bandwidth management that can

be used to control each IP device’s maximum bandwidth.

The switch is user friendly and can provide IP cameras

and NVR’s with more bandwidth and limit other devices’

bandwidth. The switch also supports application-based QoS

to set data-stream priority according to the TCP/UDP port

number. It also provides advanced DoS/DDoS auto preven-

tion. If there is a surge in IP flow the switch will lock the

source IP address for a specified time to prevent the attack.

All functions of the switch can be managed centrally or

via the internet.

ICP Electronics Australia Pty Ltd


SECURE REMOTE ACCESS SOLUTIONProviding more than a VPN or RDP, the Secomea

secure remote access solution creates a transparent

yet highly secure channel over the internet or mobile

network between the client terminal and the destina-

tion network or host.

With the use of an intermediary cloud, GateManager,

a number of benefits are realised over other methods.

Setup is an easy, almost ‘out of the box’ solution.

Authentication is via client certificate,

eliminating password sharing and

changing when staff leave the or-

ganisation.

Traffic is initiated by the local Site-

Manager device and can use commonly

accessible TCP ports to work within

firewall rules. The client programming

software sees the equipment as if it

were locally connected so there is no

need for intermediate site PCs.

The SiteManager is available with a

USB port for accessing devices such

as low-end PLCs. There is also an

ethernet port, serial port, digital I/O and

the option of a 3G/GPRS modem model.

All models include pre-defined device

agents for all leading brands of PLCs,

HMIs and other industrial devices. Fur-

thermore, by connecting both the wired and

wireless (3G) uplinks, a built-in failover func-

tion ensures that the connection is maintained

if one uplink fails.

Daanet Pty Ltd


DISSOLVED OXYGEN SENSORSThe DO6400 and DO6441 process dissolved oxygen sen-

sors from Sensorex are fast-response submersible galvanic

sensors available with either a built-in 4-20 mA output signal

capability for direct connection to a PLC or to a standard

4-20 mA transmitter and local display.

The DO6400 and DO6441 are suitable for long-term continu-

ous deployment in wastewater and aquaculture applications.

Their galvanic sensor construction and electronics combine

performance, ease of use and low maintenance to offer a

reliable low life-cycle cost instrument for use in submerged

water applications.

The low maintenance sensors feature reliable galvanic

cell technology and a large-volume electrolyte reservoir for

long-term continuous deployments. The easily replaceable

membrane is available in either durable Teflon or wide-span

HDPE membrane for faster response. An optional integral

temperature sensor is also available for both models.

The DO6400 features a mV output (0.25-20 ppm) and the

DO6441 offers a built-in 4-20 mA output (0-100% and 0-200%).

The DO6400 series sensors are designed for easy installation

and maintenance with a positive fit and easy-to-grip body

design. They feature a Noryl body with silver cathode and

operate at temperatures up to 50°C.

If an external transmitter with local display is required, the

DO6400 series is compatible with the Sensorex DO500 and

DOMA 4-20 mA loop-powered transmitters. The transmitter

display can be programmed to read per cent saturation, mg/mL

or ppm DO. Temperature is also visible on the display via a

Pt100 temperature sensor (automatic) or manual input.

Envirosensors Pty Ltd


NEWPRODUCTS


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now available online!

NEW White Papers

For these and more White Paper downloads, visit www.processonline.com.au/white_papers

SIMULATION TOOLSMathWorks has released updated versions of two products, Robust

Control Toolbox and Simulink Control Design, which enable engineers

to automatically tune complex control systems modelled in Simulink.

Most embedded control systems have a fixed, decentralised archi-

tecture with simple tuneable elements such as gains, PID controllers

and low-order filters. Enhancements to Robust Control Toolbox and

Simulink Control Design let engineers automatically tune all controller

elements without changing the controller structure. This eliminates the

need for tedious and time-consuming methods of tuning multiloop,

decentralised control systems such as successive loop closure.

With the new capabilities, control engineers can select Simulink

blocks to tune; specify requirements for bandwidth, stability margins

and tracking performance; automatically tune all control system param-

eters simultaneously; and update selected Simulink blocks with tuned

values. The resulting design can be verified by simulating the model.

MathWorks Australia


Oxygen measurement on air separation plantsIndustry consumes vast quantities of oxygen and nitrogen

annually, all of which is obtained from the air around us. There are

two main techniques used to separate these two primary gases

from air. These processes are cryogenic separation and pressure

swing adsorption (PSA).

Portable gas detection for safety in confined spacesIn today’s working environment, confined spaces are ongoing

areas of review. Nearly all workers can expect to come in contact

with a gas detector during their working career but few have the

opportunity to understand the basics. Are you safe?

Machine vision inspection: benefits, applications and vendor selection tipsIn recent times, the technology options for machine vision

inspection systems have increased, the cost of these solutions

has reduced and hence the adoption has dramatically increased.

These solutions, if implemented wisely, can provide a competitive

advantage for manufacturers as well as provide cost savings.

Control systems and operational security - are you properly covered?Security has always been a relevant concern during the design and

deployment of automated control systems. But recent worldwide

events, combined with technological and industry trends of the

last decade, have significantly raised the visibility and public

awareness of this issue.

WIRELESS REMOTE NETWORK MODULEThe WNM wireless network module from

Moore Industries provides a low-cost wire-

less communications link between field sites

that are in rugged or impassable terrain,

with a single unit transmitting for up to 48

km and the ability to act as a repeater for

a virtually unlimited transmission range, and

in both point-to-point and point-to-multipoint

network architectures.

The bidirectional WNM employs spread

spectrum frequency hopping technology

to avoid interference problems caused by

crowded radio spectra. This technology al-

lows multiple radio networks to use the same

band while in close proximity. Operating at

standard operating frequencies of 902 to 928

MHz (48 km range) or 2.4 to 2.4835 GHz

(24 km range), the WNM does not require

a regulatory licence and can typically be installed without performing

costly RF site surveys.

When it is set in the Smart Switch Ethernet (SSE) mode, the WNM

enhances the speed and reliability of data packet transmission by

determining the most efficient path of broadcast (including direct to

a single radio or to some or all radios in a network) on a packet-

by-packet basis.

The WNM can be used with the Moore Industries NCS NET Con-

centrator System, as well as other SCADA and distributed I/O systems.

WNM models are available for data communications networks that

use ethernet and serial (RS485) communications.

The WNM utilises 128-bit AES encryption, 32-bit CRC error detection

and ARQ for robust and secure communications. The industrial DIN

rail-mount metal enclosure also ensures that the WNM can be used

in rugged environments, including ambient temperatures from -40 to

75°C and relative humidity of 5 to 95%.

Moore Industries Pacific Inc



Mitsubishi Electric 700 Series drivesFR-D700 - the ultra compact inverter

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THREE PHASE INPUT FR-D700 SERIES• FR-D740-012-EC ............................0.4kW• FR-D740-022-EC ............................0.75kW• FR-D740-036-EC ............................1.5kW• FR-D740-050-EC ............................2.2kW• FR-D740-080-EC ............................3.7kW• FR-D740-120-EC ............................5.5kW• FR-D740-160-EC ............................7.5kW

FR-D700 DRIVE FEATURES:• Compactperformance.• Safestopfunction.• InbuiltoperationpanelwithLEDmultifunctiondisplay,operationalkeysandpotentiometer.

• Keypad,externalornetworkoperation.• Easystartoperationfunction.• RS-485/MODBUSRTUcommunicationsformultidropnetworksand/orMitsubishiPLCinverterinstructions.

• SpacesavingfootprintmountsdirectlyonmatchingEMCfilters(requestseparately).

• Sidebysideinstallation,noclearancerequiredbetweenVSD’s

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Western AustraliaAI AutomationPh: (08) 9528 7598Fax: (08) 9528 7598

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Available from:


Stawell Gold recovery exceeds expectations through flotation upgrade

A major Australian gold mine at Stawell in Central Victoria has far exceeded its own expectations following an upgraded flotation circuit developed in partnership with Outotec Services.

The Stawell Gold Mine of Northgate Minerals, Toronto, aimed to increase recoveries by 3.5% from the upgraded plant. This upgrade was implemented after Stawell changed its production profile to process lower grade ore at higher throughput rates.

The mine, which has produced more than two million ounces in its 26-year history, previously employed a flotation circuit consisting of a bank of eight mechanical trough cells in the rougher circuit, followed by two banks of two OK3 Outotec cells as cleaners. The feed rate to the cells was between 90-105 tph, at 50-55% solids. The overall flotation circuit was not performing at optimal rate due to entrainment problems in the rougher cells when feed density increased from 45 to 55% solids, typically at 105 tph.

In anticipation of future production levels and as part of Stawell's focus on operational excellence, it was decided to upgrade the flotation circuit. Following a site audit from Outotec Services, a two TankCell-20 configuration

equipped with larger TankCell-30 mechanisms was proposed to help optimise flotation. The larger mechanisms would allow operation at very high percent solids (50% and over).

The TankCell design also allows a much deeper froth depth and better concentrate grade through optimised launder lip length and surface area. Outotec Services was commissioned to handle the complete turnkey solution of the new rougher circuit, including design, supply, installation and commissioning.

The schedule was demanding but achievable, with work to commence in February 2010 and be completed in September 2010, just 30 weeks later. It was decided to adopt the partnering approach between Stawell and Outotec Services, because this collaborative method ensured open communication, with all parties having greater ownership of the project and its aims.

The close teamwork between Stawell and Outotec Services resulted in meticulous planning and the site remaining fully operational at all times. Pipework and electrical easement ducts, for example, were rerouted early in the project. Tie-in points for new cells and rerouting of pipework were also planned up front in the project and all disruptive work was completed during shutdowns.

The project overcame a number of challenges, including an extremely limited footprint, which was adjacent to a gabion wall, close to the run-of-mine pad and also close to a reagents shed, which could not be moved. Additionally, existing process requirements at Stawell required specific elevations for the new TankCells. Structural stability was the main issue when designing the tank support structure due to the height of the tanks and the limited footprint. Sufficient stiffness was required such that the operation frequencies of the TankCells would not interfere with the natural frequency of the tank

support structure. Through FE modelling of the structure, section sizes and bracing orientations were optimised to produce the required stiffness.

The civil work was also highly challenging. Following the discovery of an underground slab during the excavation work, test work on core samples from various layers was required. Fortunately, only part of the slab needed to be removed and all parties worked hard to ensure the project stayed within project timelines.

The weather proved to be an additional hurdle as the site experienced the wettest seasonal weather in recorded history during the project. Simple tasks, such as curing of the paintwork, normally taking 24 hours, took days instead. Despite such challenges, the turnkey installation of the new rougher circuit, along with blowers for the complete flotation circuit, was completed within deadlines. Because all tie-in points had been already carefully planned upfront, commissioning was a seamless exercise. On 13 September 2010, just 30 weeks from commencement, the new circuit, complete with TankCell technology, was commissioned and brought on line.

Designed to cope with projected increases in production and considerably more operator friendly than its predecessor, the new TankCell-20 cells have quickly proved their worth at the site. The air demand for the old rougher cells, for example, was estimated at over 3000 Am³/h, whereas the estimated air demand on the Outotec TankCells is a maximum of 992 Am³/h.

The Outotec FloatForce rotor-stator mechanism, with its unique design, delivers enhanced flotation cell hydrodynamics and improved wear life and maintenance.

Following the flotation upgrade at Stawell, the targeted recovery rate improvement was projected at 3.5%. The actual recovery rate, however, improved instantly by 4.5%. Payback was also impressive, occurring within less than four months.

"The projected payback was 5.5 months, so it was a pleasant surprise when it happened so soon" explains Jodie Hendy, Senior Metallurgist at Stawell.

"Maintenance on the Outotec TankCells has also been minimal since the upgrade. Basically, we check the cells during shutdowns, but there has been no maintenance required in the nine months since commissioning.

"The TankCells have really delivered on their reputation. Basically, they do exactly what they are supposed to do."

Outotec Pty Ltd


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Our connections deliver so much more than fl uid systems.

Your Swagelok representative is your connection to so much more than you expect. Yes they’re experts in their own right. But beyond that, they can tap into the global knowledge accrued in more than 65 years of research, development and innovation. Your authorized Swagelok representative is ready to work with you and provide you with the tools and problem-solving solutions that deliver a real business edge and so much more too – because in this business you need all the right connections. Visit swagelok.com/connections.

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http://www.swagelok.com/connections


HOT PRODUCTSON WWW.PROCESSONLINE.COM.AU THIS MONTH

>

>

>

NEPHELOMETERHach’s Filter Trak FT660 laser nephelom-

eter detects changes in turbidity as low

as 0.0005 NTU.

Hach Company

WF.NET.AU/M572

INCLINOMETERSFraba Posital has introduced industrial and heavy-

duty versions of its Accelens (ACS) inclinometers,

featuring either a plastic or aluminium housing.

Plant Control & Automation

WF.NET.AU/M805

POWER QUALITY ANALYSERSThe Fluke 430 Series II power quality analysers are

designed to help facilities reduce electrical power con-

sumption and improve the performance and lifespan of

electromechanical equipment.

Fluke Australia Pty Ltd

WF.NET.AU/M803

>FIELD-INSTALLABLE RJ45 PLUGThe RJ Industrial 10G is an up-

grade of Harting’s RJ45 connector

that requires no tools for connec-

tion, and features a future-proof

design for 10 Gigabit Ethernet.

Soanar Limited

WF.NET.AU/M924

>

ULTRASONIC GAS FLOW METERThe Flexim ultrasonic gas flow meter

performs non-invasive ultrasonic

gas and liquid flow measurements

using clamps with high precision

and speed on both fast and slow

flow rates.

TechRentals

WF.NET.AU/M926


http://www.weidmuller.com.au


SKID-MOUNTED BAG DISCHARGE SYSTEMThe Flexicon Bulk Bag

Discharging System with

integral Pneumatic Con-

veying System transfers

material from bulk bags

to silos and other stor-

age vessels. Unlike most

discharging systems that

move material from bulk

bags to smaller storage vessels and process equipment, this positive

pressure pneumatic system is designed to fill bulk storage facilities on

islands, or other locations unable to receive large volumes of bulk mate-

rial by rail or bulk truck.

The discharger portion of the skid-mounted system

includes a cantilevered I-beam with electric hoist and

trolley to lift and position bulk bags without the use of

a forklift. A Spout-Lock clamp ring forms a high-integrity

seal between the clean side of the bag spout and the

clean side of the equipment, while a Tele-Tube telescop-

ing tube maintains constant downward pressure on the

clamp ring and bag spout, elongating the bag as it

empties to promote complete discharge.

Material flow is aided by Flow-Flexer bag activators

that raise and lower opposite bottom sides of the bag

in timed intervals.

A Bag-Vac dust collector integral to the dust-tight system

creates negative pressure to collapse empty bags prior to

retying and disconnection, eliminating dust emitted during

manual flattening of empty bags.

The unloader's surge hopper is equipped with a high-capacity rotary

airlock valve to feed material into a pneumatic conveying line, leading

from a positive displacement blower, at high rates.

Flexicon Corporation (Australia) Pty Limited


BEACON TOWER LIGHTBanner Engineering’s EZ-Light TL50 beacon tower

light is a hybrid of the company’s TL50 tower and

K50 beacon lights. Similarly to the alternative TL50

models, the beacon tower is segmented and may

be ordered with up to four different coloured LED

lights - red, yellow, green or blue - which allows

several messages to be conveyed at once. These

segments can easily flash or rotate their bright sig-

nals, in addition to displaying a solid ON indication.

The bright output of the LED beacons provides

easy-to-see indication from all directions when

multiple lights may need to be on simultaneously -

allowing operators to effectively monitor equipment

from a distance. TL50 audible models with easily

adjustable sound intensity are available, in addition

to multiple bracketing options, enhancing the beacon

tower’s functionality and placement options. It also

has a wide 12-30 VDC operating

range, enabling it to be used

in battery-powered mobile

applications.

The EZ-Light tower lights

come completely preas-

sembled and preconfigured,

saving time and money in

the instal lat ion process.

Equipped with LED technol-

ogy, these lights reduce power

consumption, making them an

energy-efficient solution. Both the

general purpose and audible models

of the TL50 beacon tower use Euro integral quick

disconnect (QD) connectors, while the robust design

of the indicator allows for direct machine mounting.

Micromax Pty Ltd


NEWPRODUCTS

http://www.krohne.com

mailto:industrialsoftware.com.au

http://www.veederline.com.au


http://www.krohne.com


The need for greater robot reliability and efficiency is leading to the development of new technologies in robot accessories.

In dealing with industrial robot efficiency, cycle rate and process reliability largely depend on their front ends, the grippers and other tools and also from the effectors’ interfaces to the robot arm. Robot accessories have a great influence on the robot’s per-

formance, flexibility and fields of application. The latest developments in quick-change systems, driven tools, compensation units and power sensors show that the potentials of modern accessory components are enormous. Experts assume that their importance for handling, assembly and manufacturing will continuously increase.

Quick-change systems provide speed in productionGrippers, tools and other effectors can be quickly exchanged by means of quick-change systems. This reduces machine downtime and

CHANGING, MACHINING, COMPENSATINGCURRENT TRENDS IN ROBOT ACCESSORIES

increases the flexibility of the robot. While an experienced operator requires between 10 to 30 minutes for the manual exchange without using a changing system, a quick-change system can reduce the same operation to less than 10 to 30 seconds. The use of a quick-change system always makes sense in areas where new products or product variants have to be regularly exchanged, where various effectors for handling or machining are required and where downtimes, due to maintenance of components and tools, need to be minimised.

Quick-change systems usually consist of two components: a quick-change head, mounted on the robot arm and a quick-change adapter, which is connected with the tool. During a tool change, both components are automatically or manually coupled, as well as all the electric, pneumatic and hydraulic feed-throughs. Ideally this is done pneumatically via a self-retaining locking system and is controlled via


but also for jobs with heavy grippers, vacuum gripping systems, hy-draulically-, pneumatically- or electrically-driven machining spindles, riveting applications, welding tongs or stud welding applications with automatic material feeding. Moreover, they can be used in the automotive industry for assembly or for presses. Due to their high payload, they can be used for the set-up of flexible production lines, where lightweight and heavy work pieces are alternately machined.

Integrated valves improve energy efficiencyIf the energy efficiency of a plant needs to be increased, quick-change systems are also playing an important role. Microvalves that are integrated in a quick-change system can replace a complete valve terminal. At every cycle, the piston area of the actuator is filled with compressed air as well, which saves a lot of time. If you are using a three metre long feeding hose with a 4 mm diameter, the integrated valves will reduce the air consumption by 90%. At the same time, the cycle time increases, since the compressed air is directly actuat-ing. Instead of cable and wire bundles, just one pneumatic line for compressed air and power supply is required. Both lines can usually be fed through the centre bore and can be integrated in the arm of a SCARA robot. Bending tools for grinding, polishing and deburringBesides handling, robots are also used in specific machining processes such as drilling or milling. During grinding, polishing, brushing and deburring however, they usually reach their limits, since it is impossible to replace experience, sense of proportion and the sure instinct of a human being compared to a robot. There has always been the risk that burr residues are left, or that more material has been removed than required. Moreover, tools quickly wear out, or break.

Now there are driven tools, which are axially or radially seated and can compensate for deviations between the robot path and the work piece contour. In order to machine surfaces of metals and plastics with a robot, the grinding wheels or polishing brushes are clamped in air-driven finishing tools. The slowly running special tools generate a high torque. Since they bend in the axial direction, a uniform con-tact pressure is also given for uneven surfaces. It can be controlled via air pressure and ranges between 14 N and 74 N. The tools are very rigid crosswise to the surface, but in the machining direction they have a defined flexibility. Tool wear, inaccuracies in work piece

A quick-change assembly with three locking systems.

integrated sensors. Since alignment of the effectors is already defined by the quick-change system, no time is lost due to re-adjustment.

When selecting a quick-change system, end users and system integrators should pay attention to compact dimensions, a low weight/force-ratio, short change times and exactly dimensioned energy transfer modules. Modular systems are particularly economic where various electronic and fluid modules can be combined with each other according to the application. Force-free locking and unlocking with a so-called no-touch locking system would be ideal, since it also ensures safe locking, even if the clearance between head and adapter amounts to several millimetres.

Since industrial robots are becoming more powerful and weights of several kilograms can be handled, special heavy-load systems are gaining importance. They are suitable for handling heavy work pieces,

THERE IS NO DOUBT THAT PNEUMATICALLY AND

MECHANICALLY COMPENSATING ACCESSORY

PRODUCTS CAN BE HELPFUL AND IN MANY CASES

ARE PERFECTLY SUITABLE. HOWEVER, EXTREMELY

PRECISE RESULTS CANNOT BE ACHIEVED WITH THEM

WITHOUT IMPROVED SENSITIVITY TO THE WORK PIECE.

Robotics


position, as well as slight deviations of the robot arm from the given robot path are therefore compensated for. This improves the quality of the machining results, the tool service life of the used tools and programming time is reduced by up to 75%.

Chamfering spindles follow a similar concept. They try to imitate the manual chamfering operation as accurately as possible. In con-trast to the finishing tools, high frequency spindles work at speeds of up to 65,000 rpm. Their spindle and motor system is flexibly seated on a self-aligning bearing. Several pneumatic pistons assure that the spindles can offset radially or axially up to nine millime-tres. Therefore, the compressed air motor can move relative to the housing and deviations between the tool path and the actual work piece contour are compensated. Even in cases of components with an irregular shape, a uniform result can be achieved. The rigidity of the deburring spindle can be controlled via a separate air connection and clean-cut deburring edges can be assured in every installation position. Depending on the adjusted air pressure, forces between 3.1 N and 42.3 N are acting on the milling cutter’s cut surface, and depending on the material, working speeds of up to 0.3 m/s are possible. Since less fixed points have to be defined during the robot’s path programming, the programming time is reduced if deburring spindles are used.

Compensation units without pneumaticsIn order to avoid problems during joining, assembly or insertion, compensation units ensure the necessary compliance between effec-tor and robot arm. They avoid plant malfunctions and damages, and increase process reliability. The latest generation of these flexible modules do not require pneumatics. Compliance in two directions is adjusted via springs with adjustment screws and in three direc-tions via elastomer elements. Since the units are working without pneumatic elements, they are very flat and particularly suitable for use in confined areas. Smooth running roller guides can compensate for smaller compensation forces without stick-slip effects. Spring-actuated return pistons ensure a high repeat accuracy.

Force and torque sensors provide more sensitivityThere is no doubt that pneumatically and mechanically compensating accessory products can be helpful, and in many cases are perfectly suitable. However, extremely precise results cannot be achieved with them without improved sensitivity to the work piece. Future trends are toward the increased use of intelligent force and torque sensors, which help to provide the robots with the necessary sensitivity. Today, they are being used to record the process forces and to transfer them to the control unit. The robot path can be precisely readjusted, and as a result, consistent force and machining results are obtained.

An example of a force-torque sensor is the FTNet from Schunk. It measures the forces and moments in all six degrees of freedom. The sensor is provided with an interface to the robot control unit, and connection is greatly simplified. The high-precision sensor provides a high-speed data output of up to 7 kHz. There are four possible communication protocols (ethernet, EtherNet/IP, DeviceNet and a CAN-Bus), remote control via the LAN and configuration via a web interface that offers interface compatibility with numerous applications. It can be used for product tests, robot assemblies or for machining tasks such as grinding and polishing and also for robot surgery, ap-plications in the field of rehabilitation, in neurology and in many more areas. With sensors such as this, even difficult assembly, machining and finish-machining tasks, which have so far been done manually or with a complex special machine, can be automated.

ConclusionThe need for greater robot reliability and efficiency is leading to the development of new technologies in robot accessories. These technologies are leading to dramatic improvements, not only in the efficiency of tool changing, but in the accuracy and repeatability of the work a robot can perform, potentially expanding the application of robots into tasks previously not considered for robotic application.

Romheld Automation Pty Ltd


Figure 4: Intelligent sensors such as the FTNet measure exactly the forces and moments occurring during machining.

Figure 2: Integrated microvalves can reduce air consumption by up to 90%.

Figure 3: FTNet force-torque sensor.Figure 1: A heavy-duty quick-change locking system capable of loads up to 700 kg.

Robotics

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

ProcessTechnologyRegional Roadshow2012NOW IN ITS

8TH YEAR

PROCESS CONTROL | AUTOMATION | INSTRUMENTATION | SAFETY

•Brisbane May 14•Gladstone May 15•Mackay May 16•Townsville May 17

Exhibiting companies include:

To register or for more info visit: www.regionalroadshows.com.au

If you work in mining, minerals, metals processing, utilities, food and chemical manufacturing and processing then the Regional Roadshows are designed for you. Don’t miss out ...

NEW TRAINING SESSIONS FOR 2012• TuneaPIDflowloop• TroubleshootasimpleTCP/IPindustrialethernet

network using four simple utilities• Write,installandtestamotorcontrolPLCladder

logic program • BasicsofModbusdatacommunicationsprotocol

installationandtroubleshooting• Arcflashprotectionandprotectivesafetyequipment• Variablespeeddrives—testingandtroubleshooting

Includes FREE: • Access to exhibition• Training sessions - NEW• Lunch and networking drinks• Product demonstrations • Prize draws

Trainingby:Supportedby:

Coming soon ... to a city near you!

NEW vendor training sessions


LEVEL GAUGE WITH ENHANCED OVERFILL DETECTIONHoneywell has announced key enhancements to its 854 Servo level

gauge, which is now equipped with a Servo Auto Test feature. This

solution has been approved for Safety Integrity Level-2 and 3 (SIL-2/

SIL 3) applications and increases the gauge's diagnostic coverage.

The updated gauge provides high-accuracy level measurements in bulk

storage tanks during inventory control and custody transfer applications.

This provides oil and gas facilities with an updated tank solution that

ensures safety, regulatory compliance and cost-effectiveness.

The Servo Auto Test feature can be used in overfill protection loops

that require SIL-2 or SIL-3 solutions to prevent any spillage, complying

with safety and environmental standards. Additionally, the Servo Auto

Test solution can be loaded onto all existing 854 Servo units with a

simple software patch.

The increased diagnostics of the 854 Servo level gauge allow it to

detect failures inside the gauge or in the application and report this

to higher level systems for further action, mitigating the possibility of

mechanical failure.

Honeywell Limited


EXPLOSION-PROOF PRESSURE SWITCHESThe United Electric Controls One Series

electronic pressure switches and elec-

tronic temperature switch have a fully

adjustable set point and deadband

and 0.1% repeatability, and area

available in Type 4X enclosures for

explosion-proof and non-incendive

area classifications.

Each One Series model incor-

porates intelligent self-diagnostics

and can report detected faults before they

become major safety issues. Plug port detection

protects against sensor clogging. Nuisance trip filter-

ing reduces false and spurious signals. The ability to

capture pressure spikes and valleys provides process

information to aid in the commissioning and debugging process.

These switches are designed to be highly repeatable and

fully adjustable deadband switches for applications with a

high cycle rate. With no moving parts, the One Series digital

solid-state design is suitable for controlling pump and com-

pressor stop/start cycles. With its digital process display

and available 4-20 mA output, the One Series can provide

the functions of a switch, gauge and a transmitter with one

connection to the process.

For plant upgrades, 2-wire models use existing plant wiring.

Loop-powered models provide high-capacity switching and a

4-20 mA output. External power supply models can handle

currents up to 10 A or two fully independent set points and

deadbands and the 4-20 mA output.

Multiple sensor types and ranges are available - gauge

pressure up to 6000 psi, differential pressure up to 200 psid,

and RTD temperature from -184 to 538°C.

Pryde Measurement Pty Ltd


http://www.daanet.com.au/support


Quality ISO 9001

WLAN AP ROUTERSThe Hirschmann OpenBAT range

is a modular system that enables

industry-standard WLAN access

points and clients to be config-

ured via the internet.

This range, comprising the

BAT-R (IP20) and BAT-F (IP67)

ser ies, supports the IEEE

802.11n transmission standard,

which facilitates data speeds of up to 450 Mbps in both the

5 GHz and the 2.4 GHz bands.

Suitable for the power supply industry, the gas and oil sectors

and rail transportation, they can be used to set up fast and stable

infrastructure and meshed networks plus wireless distribution

systems (WDS) or point-to-point connections.

The core component of this new hardware is a wireless module

specifically designed for applications in industrial environments,

with integrated ESD protection and bandpass filters. MIMO

(multiple-input, multiple output) technology ensures a stable

wireless connection even in the presence of reflections or

other forms of interference. Fast roaming guarantees

uninterrupted connections when transferring from one

radio cell to another.

The CPU platform facilitates a LAN connection via

Gigabit ethernet. The access points and clients also pos-

sess potential-free contacts as well as one V.24 and one USB

interface that can be used for analog or DSL modem connections

for WAN routing or remote maintenance. All combinations operate

at temperatures up to 70°C and also fulfil stringent demands as

regards shock and vibration resistance.

The access points and clients can be equipped with one or two

wireless modules.The LAN connections can also be configured

with one or two ports and these can be used for twisted pair

cables or SFP transceivers.

Belden Australia Pty Ltd


NEWPRODUCTS

TABLET PCThe IceRock-08A is a fanless industrial tablet PC with

an 8″ touch screen.

The IceRock-08A is powered by an Intel Atom Z530P with

full hardware acceleration and its high graphic performance

supports H.264, MPEG1/2/4, VC-1/WMV9 high-definition

decoding, eliminating the need for software decoding.

Lightweight at only 1 kg, this low-power, easy-to-use tablet

PC has an IP62-rated front panel providing resistance to

spills and dust and features an 8″ LED-backlit TFT LCD

touch screen and up to 4 h battery life. A mobile broad-

band internet connection over 3G mobile phone networks

is possible.

The wireless LAN in-

tegrated PIFA antenna

on the IceRock ensures

an uninterrupted wireless

connection and provides

up to IEEE 802.11n op-

eration, while the prein-

stalled Bluetooth mod-

ule (transmission up to

20 m) communicates with

a wider range of electronic

devices from mobile phones to barcode readers.

Other features include an ambient light sensor which au-

tomatically adjusts the brightness of the screen for optimum

visibility and energy efficiency; eight programmable function

keys to access frequently used applications with the touch

of a button; a built-in 1.3 MP video intercom device for real-

time communication suitable for use in low light situations;

and a built-in g-sensor that is used to automatically toggle

between portrait and landscape display modes for a more

comfortable viewing experience.

ICP Electronics Australia Pty Ltd


http://www.onetemp.com.au


10-year warranty and this is just the beginning!

• PT100 and Thermocouple (K,J,E,N,T,R & S) inputs

• 4-20mA loop powered output with display selectable units (Deg. C/F or output loop current in mA)

• ABS or Stainless Steel IP67 housing available

• Simple configuration via USB port without the need for external powering

• Standard mini USB cable included and free software provided

• Galvanic input/output isolation

• User trim feature (with lock option)

• Economically priced for OEM applications

UNIVERSAL TEMPERATURE TRANSMITTER WITH INTEGRAL DISPLAY

STATUS SEM710

NMW 2012 IN SYDNEYTO FEATURE A RECORD 12 PRODUCT ZONES

National Manufacturing Week (NMW) 2012 returns to Sydney this May, and it’s going to be big: 10,000 anticipated visi-tors, over 300 local and international manufacturing industry

suppliers and a record 12 Product Zones.Co-located with Austech - Australia’s premier advanced manu-

facturing and machine tool exhibition - NMW 2012 will be occupy most of the Sydney Showground from 8 to 11 May. Attendance is free and for trade only. NMW recommends visitors register online to avoid the queues.

For exhibitors, NMW 2012 is an opportunity to meet over 10,000 potential clients; for visitors, it’s the place to source the latest prod-ucts and services across all industry sectors. Visitors can also gain relevant education, debate critical industry issues, obtain technical information and network with peers.

This year, NMW will feature innovations from many of the world’s leading manufacturing suppliers. Smaller companies are also featured, reflecting Australia’s growing capabilities in manufacturing for low-volume, high-value niche markets.

NMW 2012 sees two new product zones added to the event: Sustainable Manufacturing and Metals & Composites. Each zone is

colour coded, making it easier for visitors to find areas of specific interest. In addition to the two new Zones, NMW 2012 will once again host the Air Technology, Automation & Robotics, Electrical, Electronics, Engineering, Health & Safety, Information Technology, Materials Handling, Process Control & Instrumentation and Welding Technology Zones.

“We intend that all visitors to NMW 2012 come away with new contacts and ideas for their businesses - so that NMW, as a whole, achieves its goal of being the event that strengthens Australia’s manu-facturing sector,” said Paul Baker, Exhibition Director for NMW 2012.

NSW Premier Barry O’Farrell has backed NMW 2012, saying, “By bringing together customers and suppliers, and promoting new technologies and innovations, trade events such as NMW are crucial to ensuring our local businesses remain internationally competitive.”

By Alice Richard

What’s New in Process Technology is a media partner for the Air Technology Product Zone. Collect your copy of the magazine from the Media Table.

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http://www.zigsense.com.au

http://www.wandbinstruments.com.au


Our Sydney Systemhaus is ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions,’ making Bürkert the ideal partner for large and small scope projects. In addition to standard panels, we engineer custom panels with pneumatics, I/O, transmitters and programming to meet your wider control system needs. Call on Bürkert to build your 2012 panels.

We make ideas flow

www.burkert.com.au | 1300 888 868

Three of the 500+ panels we built in 2011

WNIPT Ad 201203 HP.indd 1 6/02/2012 2:54:58 PM

WIRELESS HART INSTRUMENT ADAPTERThe Honeywell OneWireless Adapter (OWA) allows manufacturers to

improve plant efficiency by converting field devices that use the HART

protocol into devices that can transmit data over an ISA100.11a-compliant

wireless network.

By allowing any HART device to communicate over the wireless network,

the OneWireless Adapter helps improve the flow of information and gives

operators the data they need to make the right decisions at the right time.

Honeywell's OneWireless range includes field instrumentation, input/

output devices, mobile devices, network components and related ser-

vices. It enables plants to support a wide range of wireless devices from

multiple suppliers on a single mesh network. Based on the ISA100.11a

standard, OneWireless provides highly reliable data communications in

harsh industrial environments, as well as features that provide secure

data encryption, fast data response time, prolonged battery life, easy

installation and room for future expansion as plant needs change.

The OWA adapter provides wireless access to four HART dynamic

variables (PV, SV, TV and FV), multivariable data, performance information,

calibration information, diagnostics and device configuration parameters.

Honeywell Limited


WIRELESS AP/BRIDGESMoxa has released the AWK-3131 and

AWK-4131 series, two high-bandwidth

3-in-1 industrial wireless AP/bridge/

clients that provide secure wireless

coverage both indoors and out.

Both series are fully compliant

with the IEEE 802.11n stand-

ard for a maximum bandwidth

of 300 Mbps and are back-

ward compatible with existing

802.11 a/b/g deployments.

The company's 802.11n products use a combined technique

of MIMO (multiple input, multiple output), channel bonding and frame

aggregation. MIMO is the key technology for enhanced data rates in

802.11n networks. It enables a link where both the transmitting end

and the receiving end are equipped with multiple antennas, creating

multiple paths for the radio signals. This technology eliminates the

effects of multipath fading on the receiving end for improved wireless

range and reliability. The 802.11n standard couples MIMO technol-

ogy with the channel bonding operation in the physical layer, which

bonds two 20 MHz channels together to increase the bandwidth that

is available for data transfer to 40 MHz. Finally, frame aggregation

technology greatly reduces the average delay by packing multiple

frames in a single transmission. Together, these three elements of

802.11n network technology ensure high reliability while satisfying

higher throughput demands up to 300 Mbps.

Both the AWK-3131 and AWK-4131 series feature rugged housings

that are necessary for harsh industrial environments. Both series also

feature industrial-grade QoS and VLAN for efficient data traffic man-

agement and integrated DI/DO for on-site monitoring and warnings.

The AWK-4131 is an outdoor model with an IP68-rated metal hous-

ing that is designed to withstand harsh environments and extreme

temperatures from -40 to 75°C.

CrispTech Pty Ltd


http://www.burkert.com.au


No profile - fans off!

The apt Hiller Group (apt Hiller GmbH) in Monheim, Germany, makes aluminium semifinished products for markets in Europe. The custom profile solutions are produced on the most modern systems with fully automated process technology. In run-out lengths of up to 60 metres, the profiles are transported via giant cross conveyors to a cold saw roller table. At the same time, the cross conveyors function as refrigerated tables on which the roughly 500°C profiles from the press are cooled down to 30-40°C. Ventilators which blow air from below through the conveying belts accelerate this process.

The refrigerated table is equipped with four rows of 45 fans. Each fan has a diameter of 500 mm. "All in all, that amounts to a power consumption of around 80 kW, which, depending on the process, runs through from Sunday evening to Saturday after the last shift," says Hans-Joachim Hopf from apt Hiller. However, since the flexible production of different profiles means the refrigerated table is not always equally full, he wanted to find a solution to control the rows of fans if necessary, to find a way to switch off the fans above which no profile is currently located.

What Hopf needed was a sensor solution that detects the presence of profiles, independent of their strength, form, condition and position. In addition,

he wanted a solution that didn't require an opposing installation, like with reflectors or receivers. Scanning sensors were therefore the optimum choice, and in particular he chose the LRS 36 switching light section sensors from Leuze electronic.

M e c h a n i c a l a s s e m b l y ove r t h e refrigerated table was out of the question for him due to the costs and also because he wanted to avoid configuring the sensors in the hot air stream. Even though the assembly of the sensors under the conveying belts meant the danger that their function could be impaired if the optics were to get contaminated, it was decided that this was the better solution.

In contrast to light scanners, light section sensors do not create punctual light spots. Instead, they project a divergent light beam by means of line illumination. This allows the height profiles of objects to be determined with an inclined setting angle. In this way, the light section technology offers a large array of functions with regard to safe object detection and a large detection range at the same time. Furthermore, both the transmitter and the receiver are integrated in a single housing. The sensor determines depth and width information and enables the detection of objects on the basis of preconfiguration. To do this, 16 analysis windows and 16 inspection tasks are available which can be set by means of a PC via an ethernet interface.

In addition to the measuring variants of the Line Profile Sensors (LPS), which measure object prof i les and supply 3D information, switching Line Range Sensors (LRS), as they are used at apt Hiller in Monheim, make completely new functionality possible. Comparable to a laser scanner, the devices detect the presence of objects - even in undefined object positions. With its large detection range of up to 800 millimetres, the LRS opens new

application fields without complex sensor solutions, sensor combinations or additional evaluation units.

The sensor determines depth and width information and enables the detection of objects on the basis of preconfiguration. To do this, 16 analysis windows and 16 inspection tasks are available which can be set by means of a PC via an ethernet interface.

The compact design of the LRS 36 devices made placing them between the fans easier. Furthermore, there was enough distance to the conveying level so that, in the end, widening the light beam up to the transport height of the profiles yielded a sufficiently wide detection range which covers the 500 mm 'gauge' of the fans.

Since the line range sensors can detect the profiles independent of their position throughout the total detection range, a single sensor per fan row is enough. The profiles, however, are manufactured in differing lengths of at least 20 m and, depending on the profile type, arches can develop due to normal heat expansion, or the profiles can be inclined. This is why a second row of light section sensors is installed at a distance of 18 m from the first. This ensures that profiles are detected by at least one sensor even in the worst case. When neither sensor detects a profile, the fan row is switched off after a short time delay.

"With this energy-saving measure, we have reduced the operating time of the fans by about 25%. What that means monetarily for 80 kW of power can be easily calculated," says Hopf, who has since put his worries about the contamination of the optics to rest and confirms that the function is reliable.

Balluff-Leuze Pty Ltd



PRECISION SERVO COUPLINGSServoClass couplings from Zero-Max are designed to

increase speeds in electronic assembly systems. They

are also suitable for all types of automation, packag-

ing and other types of automated assembly, including

most systems using ball screws and servo motors.

ServoClass couplings provide high torsional stiff-

ness, zero backlash and low hysteresis to ensure

repeatable precise positioning at speeds up to

10,000 rpm. Their robust design ensures precise

system operation in automated 24/7 applications.

This is especially important where stresses occur at

increased speeds in a servo system.

Designed with 304 stainless steel disc packs and

7075-T6 aluminium hubs, ServoClass couplings are in-

herently strong, durable and precisely balanced. To en-

sure precise alignment of the assembled components,

ISO 4762 CL12.9 corrosion resistant socket head

cap screws are used, with a carefully controlled

assembly process.

ServoClass couplings are available in single and

double flex models in bore sizes from 4 to 45 mm.

All models and sizes feature clamp style hubs and

operate in temperatures from -30 to +100°C.

Naismith Engineering & Manufacturing Co Pty Ltd


NEWPRODUCTS

ETHERNET SWITCHESWeidmuller has released a range of high-performance, unmanaged

industrial ethernet equipment. The range includes a choice of fast

ethernet or gigabit unmanaged switches and 10/100 media converters.

All switches are housed in robust metal casings which act as a

heatsink, eliminating the need for fans and case venting. This pro-

vides IP40 protection and stops any foreign objects from penetrating

the device and causing failures. They have been built to withstand a

wide operating temperature up to 85°C as well as high vibration and

to deliver high EMC protection.

The plug-and-play switches all come standard with a universal low-

voltage power supply of 18-72 VDC/13-50 VAC.

The gigabit switch

range incorporates a

choice of combina-

tion ports. Users can

choose between five

or eight RJ45 ports

or a gigabit switch

with six RJ45 ports

and two combination

ports, totalling eight

RJ45 outlets. If a sin-

gle or multimode fibre port is required, users can insert up to two

plug-in fibre outlets to convert two gigabit RJ45 ports into fibre ports.

The gigabit range has an operating temperature of -40 to 85°C.

Other models available include the entry-level IES10 fast ethernet

range. These are available in 5- or 8-port switches with a single

universal power supply. The IES20 fast ethernet range includes both

copper and fibre ports and a dual universal power supply. The IES20

models also have an operating temperature range of -40 to 85°C.

Weidmuller Pty Ltd


http://www.techrentals.com.au


MODULARISED 15″ PANEL PCiBase’s iPPC-1500 15″ panel PC with Intel Atom Processor D2700

features a modularised design fitted with the IB806 motherboard,

and the slim aluminium chassis has a professional feel that is

quite different from the conventional heavy industrial PCs.

It comes equipped with a low-power CPU to minimise

overall system power consumption. An automatic light control

system detects any changes in the lighting environment so

that LCD power consumption can be automatically adjusted

according to changes in the external environment.

The panel PC supports a digital I/O interface, four USB,

audio, two LAN ports, CRT and RS232/422/485 serial ports

and a DC-in jack for 12 VDC and optional 9-36 V wide

range voltage input. Users can expand the RAM modules

and storage hardware without the need to disassemble

the whole system. Front panel buttons allow adjustment of

brightness and sound. Six hot keys are reserved for user

definition. It also has a

PCI expansion slot and a

2.5″ HDD drive bay.

With a resistive touch panel

meeting IP65 standards, the

panel PC can be deployed

into various work environments

and interactive applications

including factory automation.

A flexible VESA-mount support

supports wall-mount, desktop

or rackmount installations.

Backplane Systems Tech-nology Pty Ltd


NEWPRODUCTS

COMPRESSORSSullair has introduced the Champion CSD compressor range, in addition

to a larger model to complement its existing CSE family. The CSD range

offers a combination of efficiency, output and quiet operation. Likewise,

the efficient CSE50 model extends

the CSE range with a cost-effective

55 kW compressed air solution that

is suitable for a broad spectrum of

industrial applications.

The gear-driven CSD compres-

sors are currently available in two

sizes. The smaller 55 kW unit

(CSD55) has an output pressure

choice of 7.5 or 10 bar, and is rated

for a maximum free air delivery of

163 L/s. The larger 75 kW CSD75

similarly has a choice of output pres-

sures and can deliver a maximum

of 210 L/s.

The CSE50 (rated at 55 kW) provides a belt-driven alternative and

extends the CSE range from 15 to 55 kW. It has an output pressure of

either 7.5 or 10 bar and is rated for a maximum of 141 L/s free air delivery.

All three compressors have IP55-rated motors which are fully MEPS2

compliant and feature a totally enclosed fan-cooled (TEFC) design for low

temperature rise. IP54-rated electrical cabinets are standard, along with

'deluxe control' to provide multiple compressor sequencing, scheduled

on/off switching and remote monitoring. The CSD55, CSD75 and the

CSE50 can be further upgraded to meet specific application require-

ments, with options including 'dirty environment packs', mine electrics

and complete skid packaging.

Sullair


http://www.turck.com.au


SOUND AND VIBRATION SOFTWAREThe latest version of the NI Sound and Vibration Measure-

ment Suite software provides a comprehensive collection of

analysis and signal processing tools for noise, vibration and

harshness (NVH) testing, machine condition monitoring (MCM)

and audio test applications. Engineers can use the suite as

stand-alone software or combine it with NI hardware and

NI LabVIEW system design software to simplify test system

development and control.

The Sound and Vibration Measurement Suite 2011 provides

several new features, including a ready-to-run data logging

virtual instrument that makes it possible for engineers to save

data continuously or based on specific criteria such as trig-

gers or time. Engineers can easily configure the data logger

and run it as long as necessary for a variety of sensor types

including accelerometer, tachometer and proximity probes.

The measurement suite also includes the Sound and

Vibration Assistant, a stand-alone software module for

quickly acquiring, analysing and logging acoustic, noise

and vibration data. Additionally, the software provides easy-

to-use application examples for impact test and swept

sine analysis. These enhancements for the 2011 version

add superior flexibility and high-performance capabilities

to a variety of sound and vibration measurement projects.

By integrating with LabVIEW, the software helps en-

gineers increase test throughput with advanced parallel

processing capabilities, among many other advantages

of LabVIEW.

National Instruments Australia


CLEANROOM ROBOTABB has launched an ISO 5 (Class 100) clean-

room version of its smallest multipurpose industrial

robot, the six-axis IRB 120. It is designed to eliminate

the potential for contamination of the manufacturing

area and the components being processed.

The IRB 120 Cleanroom variant has been indepen-

dently tested and certified by the Fraunhofer-IPA

institute in Europe as cleanroom ISO 5 (Class

100). This robot, with specially painted smooth

surfaces, has high accuracy while performing

very short cycle times. It can also be mounted at

any angle, either in a cell, on top of a machine

or close to other robots on the manufacturing

line, making it suitable for material handling and

assembly applications.

The robot comes with the ABB IRC5

compact control which includes user friendly

FlexPendant programming, RobotStudio of-

fline programming, flexible RAPID language and

powerful communication capabilities.

ABB Australia Pty Ltd


http://www.daanet.com.au/movie


MakingAir Technology

co-located with

Register to visit >> nationalmanufacturingweek.com.au

zone partnerzone sponsor

N M W_ A D 1 7 . p d f P a g e 1 1 3 / 0 2 / 1 2 , 4 : 0 1 P M

WIDESCREEN HMI PANELSAdvantech has launched a range

of widescreen 4.3 to 10.1″ HMI

industrial panels for controlling

a wide range of programmable

logic controllers.

Designed for harsh industrial

environments, the NEMA4/IP66

WebOP-2000 industrial panels

feature 128 MB of onboard flash memory and a MicroSD card

slot for additional applications to run from and store data on. The panels

features over 300 drivers and the company will also custom design

drivers to meet customer needs.

The panels are supplied with WebOP Designer which is an easy-to-use,

object-orientated programming application that enables users to create

their own application, saving both time and development costs. Once

the developer has written the application and compiled, it can then be

installed via the serial, ethernet, USB or MicroSD ports.

Advantech Australia Pty Ltd


THERMAL FLOW SWITCHThe Series TDFS thermal flow switch

indicates whether the flow rate is above or

below a user set flow rate with NO and NC NPN outputs.

Setpoint is easily field set, just tap the included magnet

on the setpoint target three times at the desired flow rate

and it's done. Incorporated into the unit are two LED status

indicators on opposite sides of the unit providing visual

switch indication - green when the flow is above setpoint,

red when the flow is below setpoint.

The TDFS uses an impulse thermal dispersion measure-

ment technique to measure the flow rate where the probe is

heated above the process temperature and then is allowed

to cool down to the process temperature. Empty pipe is

not a problem with the TDFS unlike some competitor units

that may overheat. Thermal flow switches can offer better

long-term reliability and life expectancy than mechanical

flow switches.

Benefits of the TDFS over mechanical flow switches

include: no paddles or vanes to break off into the flow;

no jams or material stopping the paddle movement; no

seals on movement assembly to wear or leak; low pres-

sure drop, only needs to be 10% into the flow (eg, 1/8″

for 3/4″ schedule 40 pipe).

Dwyer Instruments (Aust) Pty Ltd


NEWPRODUCTS

http://www.nationalmanufacturingweek.com.au


DIGITAL PANEL METERThe Red Lion PAX2D digital panel meter is a single

package featuring a dual counter and dual rate meter,

with a third counter and rate display that allows the user

to perform math functions. With universal features and

versatile programming capabilities, this single meter can

suit virtually any digital pulse application.

Line one consists of an 18 mm high, 6-digit LCD that

can be programmed to show counters A, B or C; rate A,

B or C; or the high or low values. The main display also

offers three programmable, easy-to-read colours: red,

orange and green. The colour change can be linked to

programmable setpoints. This feature provides the op-

erator with a visual display of changing conditions, even

when they are not close enough to read the meter value.

A second display line is a 9 mm high, 9-digit, green

LCD that can also be programmed for any of the line one

parameters. The 9-digit display accommodates totalising

applications that exceed normal 6-digit displays. The

meter also offers a programmable custom unit indicator

for both displays.

In addition to the dual displays, the PAX2D offers

features allowing users to stock a single meter for

numerous applications. The meter accepts inputs from

proximity sensors, magnetic sensors, photoelectric sen-

sors, encoders and simple switches. A universal power

supply accommodates both AC and DC inputs.

Optional plug-in cards allow users to configure the meter

for present applications, while allowing easy upgrades

to accommodate future needs.

Control Logic Pty Ltd


NEWPRODUCTS

http://www.pca-aus.com.au


AS I SEE IT

Printed and bound by Webstar +61 2 9748 0020Print Post Approved PP255003/00198ISSN No. 0819-5447

All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them.Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick Farrow P/L does not quantify the amount of local content or the accuracy of the statement made by the source.

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Chief Editor

Janette Woodhouse

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Sept 2011 total CAB audited circulation (Aust + NZ)7,451 readers (92% personally requested)

ENERGY SAVING HAS BENEFITS BEYOND COMPLIANCEDino Alessio, CAPS Australia Pty Ltd

Starting out as a me-chanical engineer, Dino Aless io i s now the National Sales Manager of CAPS Australia. He has more than 20 years’ experience with com-pressed air applications

and is known in the industry for being customer focused - providing the best solutions in terms of reliability, efficiency and low lifetime cost to organisations both large and small.

Australia’s new carbon price is increas-ing demand for compressors with the greatest energy efficiency. We see

Australian companies putting greater emphasis on the benefits of premium-quality compres-sors over budget equipment than ever before.

The carbon price calculation is included in the federal government’s Clean Energy Future Plan and will be based on the National Green-house Energy Reporting (NGER) data submitted via the scheme’s OSCAR (Online System for Comprehensive Activity Reporting - NGER Reporting Tool) system. Two key elements of the plan will be a ‘price per tonne’ carbon tax and encouragement of energy efficiency. The plan is designed to encourage industry to develop proactive plans to mitigate any environmental impact of its operations.

It is regularly reported that approximately 15% of all electricity consumed by industry is used to compress air. With the carbon pric-ing regime soon to be implemented, we’ve noticed a definite trend towards purchasing premium two-stage VSD compressors instead of lower-cost alternatives. This stems from the marketplace placing greater emphasis on reducing power costs and lowering emis-sions. Quality compressors can deliver greater efficiency and improved running costs when compared to cheaper alternatives.

More companies are looking to identify the real underlying value of their decisions and not just looking for short-term paybacks. Australian companies are adopting a longer-term view and can see both the energy and emission benefits to be gained by investing in premium equipment.

To achieve peak efficiency and reduce operating costs, a two-stage compressor uses less energy to compress a given volume of air when compared to a single-stage con-ventional compressor. Combining this with advanced synchronous motor technology, such as a hybrid permanent magnet, allows these types of compressors to run at 95% operating efficiency throughout their entire speed range. The motor is controlled by variable speed

inverters that match compressor output to demand at all times. They are designed to produce the most air using the least amounts of energy - and continue to do this down to loads as low as 20%.

Energy consumption can represent 80% of the life cycle costs of compressed air genera-tion in a typical manufacturing plant. Significant savings in operating costs and improvements in bottom line profits can be made by simply upgrading an inefficient compressed air system.

Businesses must find a balance between strong financial outcomes and the responsibil-ity for sustainable energy consumption and reduced carbon emissions. Changes made in processes to facilitate sustainability should be viewed as a long-term proposition that rewards with more than just regulatory compliance.

Premium compressors are a great place to start looking for savings because they are remarkably efficient, reduce energy usage, help offset rising electricity costs and can also help companies achieve their internal carbon and emissions reduction targets.

With many tender documents now asking companies to declare their environmental and carbon footprint reduction policies, and then to report on how they are meeting those targets, installing a premium VSD compressor into the correct application will help users achieve both their energy and their emission reduction targets.

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36 WHAT'S NEW IN PROCESS TECHNOLOGY - MARCH 2012

Providing tried&true label print and apply solutions for over 25 years.

Featuring quality modular design for simple operation and maintenance, the M-Series is hard to beat. With the flexibility of 80 tamp arm options and built in bar-code scanners, the M-Series is packaged into durable cabinets for OH&S and environmental protection considerations.

Simple integration allows for easy management and setup, including IO and Ethernet capabilities, with an intelligent controller taking the complexity out of integration. Add to that insignia’s tailored agreements for technical support options and over 25 years experience - it’s no coincidence that the Domino M-Series is world class.

The Domino M-Series printer applicator range is reliable, adaptable, and has proven 99% up time.

Contact us to find out more about the Domino range.

Phone: 1300 467 446 | Email: [email protected] | Web: www.insignia.com.au

http://www.insignia.com.au

Documents

What’s New in Process Technology Mar 2012