We get technical
Smart Manufacturing | Volume 17
How smart motor controls can maximize resilience and uptime How SMEs can use an industrial metaverse to explore and deploy robotic solutions rapidly What support products does it take to maximize the impact of using VFDs and VSDs?
Savoring success: efficient motion for OEMs in food and beverage
we get technical
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How smart motor controls can maximize resilience and uptime
How miniature safety laser scanners can maximize protection and productivity
How SMEs can use an industrial metaverse to explore and deploy robotic solutions rapidly
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What support products does it take to maximize the impact of using VFDs and VSDs? - Part 1
Special feature: retroelectro Automation Revolution
What support products does it take to maximize the impact of using VFDs and VSDs? - Part 2
What are some key considerations when selecting industrial automation equipment?
Savoring success: efficient motion for OEMs in food and beverage
How new IO-link masters can balance the benefits of cloud connectivity and local control in industry 4.0 factories
Smart manufacturing
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Editor’s note Welcome to the Smart Manufacturing eMagazine Volume 17, where we delve into the rapidly evolving world of industrial automation and the technologies shaping the future of manufacturing. In this issue, we explore a range of solutions designed to enhance productivity, safety, and sustainability across industries. We’ll explore smart motor controls that maximize resilience and uptime, and how miniature safety laser scanners are revolutionizing safety while boosting productivity. We will also dive into how small and medium enterprises (SMEs) can harness the power of the industrial metaverse to explore and deploy robotic solutions with agility. As always, we bring you practical insights into the selection and optimization of key equipment, from maximizing the impact of variable frequency drives (VFDs) and variable speed drives (VSDs) to key considerations when choosing industrial automation equipment. We also shine a spotlight on OEMs in the food and beverage sector, offering solutions for efficient motion that drive operational success. Lastly, we look ahead at how new IO-Link masters are bridging the gap between cloud connectivity and local control, enabling manufacturers to achieve a balanced approach to Industry 4.0. We hope these articles provide valuable insights and inspire you to consider how these innovations can help unlock the full potential of your operations.
How smart motor controls can maximize resilience and uptime
By Jeff Shepard Contributed By DigiKey's North American Editors
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Smart motor controls are needed that can maximize resilience and uptime of machinery in the next generation of Industry 4.0 manufacturing, metals and basic materials processing, mineral extraction and mining, and critical infrastructure like drinking water and wastewater plants. The motor controls in these applications must be able to control and protect motors between 75 horsepower (HP) and 700 HP. Comprehensive protection, including overload protection, ground fault protection, and phase imbalance protection, is needed to support resilient operation. They should also include self- diagnostics for contact wear and coil over/under voltage detection with visible indicators to support predictive maintenance and have modular designs for faster servicing to maximize uptime. Compliance with National Electrical Code (NEC), UL, and International Electrotechnical Commission (IEC) short circuit current rating (SCCR) is needed to ensure electrical equipment can withstand high currents without damage and that it’s safe. These motor controls must also comply with IEC 60947- 4-1, which covers the safety of electromechanical contactors and starters, including motor protective switching devices (MPSD), instantaneous-only motor protective switching devices (IMPSD), and actuators of contactor relays.
Figure 1: SCCR calculations begin with individual component ratings (yellow boxes), move up to determine the SCCR of branch circuits (red dashed box), and then consider the SCCR needs of the completed control panel (grey rectangle). (Image source: Schneider Electric)
This article begins with an overview of SCCR requirements. It then takes a deep dive into a recently developed family of smart motor controls from Schneider Electric, including modular contactors and overload relays detailing the operation of the protective functions and how self- diagnostics is implemented. It looks at how those overload relays meet the requirements of IEC 60947-4-1 and presents how the modular design speeds preventative maintenance. It closes by looking at how two contactors
can be used to assemble a reversing assembly, enabling bidirectional control of AC motors. The SCCR is an essential characteristic when specifying a control panel that contributes to overall dependability. It’s used when sizing power components like contractors and conductors. IEC 60947-4-1 details three phases for calculating the SCCR (Figure 1):
1. Identify the SCCR of each protection and/or control
component and each block and element in the distribution system.
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How smart motor controls can maximize resilience and uptime
TeSys Giga contactors can be supplied by an alternating current (AC) or direct current (DC) control voltage and have built-in surge suppressors. There are two versions of contactors, standard and advanced. Standard contactors are designed for general usage. Examples include: ■ LC1G1154LSEN, 4P for AC-1 loads. Rated for 250 A with a 200- 500 V AC/DC wide-band coil ■ LC1G225KUEN, 3P for AC-3 loads. Rated for 225 A with a 100- 250 V AC/DC coil Advanced TeSys Giga contactors have additional features like a greater selection of coil voltages, lower coil power consumption, a programmable logic controller (PLC) input, and a cable design that enables maintenance without removing cables or busbar connections. Advanced models are also compatible with the optional Remote Wear Diagnosis (RWD) module discussed in the next section. Examples of advanced contactors include: ■ LC1G115BEEA, 3P for AC-3 loads. Rated for 115 A with a 24-48 V AC/DC coil ■ LC1G800EHEA, 3P for AC-3 loads. Rated for 800 A with a 48- 130 V AC/DC coil
2. Determine the SCCR of each branch circuit. Based on the values of the components in the circuit. 3.Determine the SCCR of the complete control panel. Based on the values of the circuits. TeSys giga contactors TeSys Giga contactors are available with ratings from 115 to 900 amps (A) in both 3-pole (3P) and 4-pole (4P) configurations. They have SCCRs rated up to 100 kiloamps (kA) and 480 volts (V), with the specifics for various protection devices and ratings listed in a table on the side of the contactor. Additionally, the 4P contactors show the AC-3 and HP motor ratings. These contactors are available for two load categories: ■ AC-1 – This applies to AC loads where the power factor is more than 0.95. These are primarily non-inductive or slightly inductive loads, such as resistive loads. Breaking the arc results in minimal arcing and contact wear. ■ AC-3 – This applies to squirrel cage motors with breaking during normal running of the motor. On closing, there’s an inrush current of up to seven times the rated full load current of the motor. On opening, the contactor breaks the motor's rated full load current.
All TeSys Giga contactors include a Diagnosis LED on the front panel for quickly evaluating fault conditions (Figure 4).
Figure 2: Typical TeSys Giga contactor showing the Diagnosis LED in the top center of the unit. (Image source: DigiKey)
TeSys Giga contactors have several integrated diagnostic functions to improve reliability and support preventative maintenance, including:
Contact Wear Diagnosis and RWD
Contacts experience wear every time they break the current in the power circuit. A contact failure results in loss of motor control. The
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contact wear algorithm in TeSys Giga controllers continuously calculates the remaining service life of the contacts. When the remaining life is below 15%, an alert is issued, enabling preventative maintenance to be scheduled: ■ A local alert is visible on the Diagnosis LED on the front of the contactor. ■ An optional RWD module can be used with advanced contactors.
1.05 x Ir
1.2 x Ir
1.5 x Ir
7.2 x Ir
Class Time to trip from a cold start
10A >2 hrs
<2 hrs
<2 min 2 s < to < 10 s
20
>2 hrs
<2 hrs
<2 min 2 s < to < 10 s
20
>2 hrs
<2 hrs
<2 min 2 s < to < 20 s
30
>2 hrs
<2 hrs
<2 min 2 s < to < 30 s
Table 1: Examples of thermal overload relay classes based on rated current (Ir). (Table source: Schneider Electric)
Control Voltage Diagnosis
The control voltage monitors for undervoltage and overvoltage conditions. The diagnosis indication is remotely available on units with part numbers ending in LSEMC using an optional remote device management (RDM) module. An undervoltage is defined as a supply voltage below 80% of the minimum specification, and an overvoltage is defined as greater than 110% of maximum.
amount of time it takes for the relay to open when there is an overload. There are also differences between North American and IEC trip classes. For example, class 10 is a North American trip class that trips the overload within 4-10 seconds of detecting 600% of the overload current setting. Class 10A is an IEC trip class that trips the overload within 2-10 seconds of detecting 720% of the overload current setting (Table 1). Trip classes 10A and 10 are suited for normal-duty motors. Class 20 is recommended for heavy-duty motors to avoid nuisance tripping. Class 30 is used with a very long starting motor.
use of MPSDs is also an important consideration to ensure maximum productivity and availability. In IEC 60947-4-1, MPSD refers to a device designed with a delay to protect a motor from overload conditions. A second type of device, an IMPSD, is a specific type of MPSD that trips immediately upon detecting an overload. IMPSDs are not usually associated with AC motor protection. Depending on the application, motor starting can take a few seconds or several tens of seconds. The MPSD must be specified to meet the application requirements for safety while avoiding nuisance tripping. To satisfy specific application needs, IEC 60947-4-1 defines several classes of overload relays. The trip class indicates the maximum
Internal Functioning Diagnosis
Continuous blinking of the Diagnosis LED indicates any internal malfunction of the control circuitry.
Motor protective switching devices Smart motor controls like TeSys Giga contactors are an important part of Industry 4.0 installations. The
TeSys giga overload relays
TeSys Giga thermal overload relays are highly flexible and designed
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How smart motor controls can maximize resilience and uptime
value in another phase is greater than 0.8 Ir, the overload relay triggers within 4 ±1 seconds. Phase loss protection cannot be disabled and must be reset manually.
Phase imbalances
Phase imbalances cause overheating of an asynchronous motor. Common causes include:
■ Long main supply line
■ Defective contact on the incomer switch
Figure 3: The front panel of TeSys Giga overload relays includes status LEDs and protection adjustments. (Image source: DigiKey)
■ Imbalanced network
When the imbalance ratio exceeds 40%, the overload relay triggers in 5 ±1 seconds. Phase imbalance protection must be reset manually.
for use with AC motors. Settings for ground fault protection, phase imbalance protection, and trip class (5, 10, 20, and 30) are configurable on the front panel. The front panel also includes alarm and status LEDs. They have wide adjustable thermal overload protection ranges that enable four overlapping models to handle applications from 28 A to 630 A (Figure 3): ■ LR9G115, adjustable from 28 to 115 A ■ LR9G225, adjustable from 57 to 225 A ■ LR9G500, adjustable from 125 to 500 A ■ LR9G630, adjustable from 160 to 630 A
Thermal overloads
Thermal overload protection is used with single-phase and three-phase asynchronous motors. The current level for thermal overload protection can be adjusted based on the model of the overload relay being employed. In addition, the trip class and associated delay are adjustable. Thermal overload protection can be set for automatic or manual resetting.
Ground faults
Ground-fault protection is used to protect three-phase asynchronous motors. A ground fault occurs when the insulation on the load circuit becomes ineffective due to vibration, moisture, or other factors. The overload relay monitors the ground current (Ig). When the Ig exceeds more than 10% of Ir, the relay trips in 1 ±0.2 seconds. Ground fault protection must be reset manually.
Phase loss
Phase loss protection is used to protect three-phase asynchronous motors from overheating. The overload relay continuously monitors the current in each phase. When the current value in one of the phases is lower than 0.1 of the rated current (Ir), and the current
Modularity
The modular design of TeSys Giga contactors can be especially useful if excessive contact wear
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is experienced or if an overload or other abnormal operating conditions damage the controller. Control modules can also be replaced to adapt to different coil voltages, and the switching module can be switched out to replace worn-out poles. A cable memory function can be implemented with an optional kit to facilitate rapid maintenance. Once installed, the control or switching module can be replaced quickly without removing the cables. Going in reverse Reversing contactors are used to change the direction of rotation of AC motors in applications like conveyors, elevators, and packaging lines. They work by reversing the polarity of the connections, causing the motor to rotate in the opposite direction. A reversing contactor can be made using two mechanically interlocked standard contactors.
The contactors have ratings from 115 to 900 A in 3P and 4P configurations. They have SCCRs up to 100 kA 480 V, and their modular design speeds maintenance. The programmable overload relays have wide operating current ranges, enabling a small number of devices to satisfy the needs of many applications. Finally, bidirectional motion control can be realized by connecting two TeSys Giga contactors with a mechanical interlock system.
■ DZ2FJ6, contactor lug kit
■ LA9G3612, spreaders
■ LA9G3761, reverser bars
■ LA9G970, mechanical interlock
Summary TeSys Giga contactors and overload relays are highly versatile devices that can maximize resilience and uptime in a wide range of applications.
The interlock prevents the contactors from turning on simultaneously (Figure 6).
For example, the following components can be used to build a reversing contactor rated for 200 HP at 460 V with a 100-250 V AC/DC coil (Figure 6): ■ LC1G265KUEN, TeSys Giga motor controller, two required
Figure 4: Two TeSys Giga contactors interlocked to form a reversing contactor for AC motors. (Image source: Schneider Electric)
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How miniature safety laser scanners can maximize protection and productivity
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By Jeff Shepard Contributed By DigiKey's North American Editors
The increasing complexity of Industry 4.0 factory and logistics automation requires new approaches to system design that simultaneously maximize safety and productivity. The flexible nature of Industry 4.0 operations means that the placement and extent of hazardous operations can change occasionally, and safety systems must adapt quickly. A reconfigurable, programmable, and flexible safety system is needed. The ability to establish warning zones to alert workers approaching a hazardous area before they get too close can be a big plus. It prevents workers from accidentally entering the hazardous area, tripping a safety device, and turning off a machine. That enhances uptime and productivity. This article begins with a brief review of international standards for safety mats and safety laser scanners, then moves on to comparing application considerations for safety mats and safety laser scanners, looking at factors like contact versus non- contact operation, warning field protection, and adjustability. It closes by presenting examples of miniature safety laser scanners
from SICK and how they meet the requirements of several
applications, along with installation and configuration options, including how the scanners are easily replaced if they become damaged. Key safety performance standards include International Electrotechnical Commission (IEC) 61508, “Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems (E/E/PE, or E/E/PES),” International Organization for Standardization (ISO) 13849, “Safety of machinery — Safety-related parts of control systems,” and IEC 61496, “Safety of machinery — Electrosensitive protective equipment.” Safety mats and safety laser scanners meet various parts of those standards. For example, IEC 61508 defines a series of safety integrity levels (SILs). Safety laser scanners meet SIL 2 requirements. So do some, but not all, safety mats. Some safety mats only meet the requirements of SIL 1, which is an order of magnitude less stringent than SIL 2. SIL 1 safety devices are intended for use with low-risk applications where the consequences of a failure are not severe, like basic machine guarding, non-critical processes, and simple alarms. SIL 2 safety devices are
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How miniature safety laser scanners can maximize protection and productivity
designed to mitigate risks that could result in serious injuries or significant environmental damage, but not necessarily catastrophic events. Using similar concepts to SILs, ISO 13849 defines performance levels (PLs). Safety mats typically qualify for a PLc certification, while safety laser scanners must qualify for the tougher PLd certification. Some safety mat installations can also meet PLd performance requirements. To become certified, a safety laser scanner must meet SIL 2, PLd, and IEC 61496-3, specifically covering active optoelectronic protective devices responsive to diffuse reflection (AOPDDR, or laser scanners). The implications of the various safety certifications for safety mats and safety laser scanners are important, but they are just the start when maximizing protection and productivity. More to consider Properly specified safety mats and safety laser scanners can both meet the IEC and ISO safety requirements. But that’s not the end of the story; there’s more to consider in Industry 4.0 factory and logistics automation applications. A safety mat is a matrix of mechanical switches. When a weight, like a person stepping on the mat, closes one or more of
Figure 1: Safety mat operation requires physical contact and can be compromised by accidents and environmental hazards. (Image source: SICK)
the switches, it sends a signal to the mat controller that stops the operation of the protected system. The mechanical nature of safety mats can be a cause for concern. First, for the mat to operate, there must be direct contact with a person walking across the mat. Second, the mats are subjected to wear and (sometimes literally) tear. People can drop heavy and/or sharp tools on the mat, damaging it (Figure 1). Or a forklift may drive across the mat and damage it. Environmental factors like spills of corrosive materials can also compromise the mat.
There are different sizes and mat configurations for specific installation requirements. That can present challenges in Industry 4.0 factories and logistics operations that are subject to reconfiguration as process demands change. Making changes to safety mat- based systems can require the acquisition of a new mat, extending the time needed for the changeover to become operational. That can negatively impact machine availability and overall productivity. One way to minimize the impact is to keep various replacement safety mat sizes on hand. That can speed changeovers and the replacement of mats that become damaged. But it’s also expensive. It can also require keeping a variety of safety mat
Adjustability
Safety mats are inherently fixed installations and are not adjustable.
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controllers on hand since not all mats are compatible with all controllers.
These issues can be addressed by using safety laser scanners.
Safety laser scanners are not based on mechanical switches; they are electronic devices that can be adjusted for various application needs. Safety laser scanners are a non- contact technology that use an infrared (IR) laser to scan the surroundings in two dimensions. They emit short pulses of IR light. If a pulse of light strikes an object, it’s reflected to the scanner. The distance to the object can be determined with a high degree of accuracy based on the time interval between the moment of transmission and the time the reflected light returns. The ability to determine the distance to obstacles enables safety laser scanners to establish a series of warning and protective fields based on the nearness of an object. Some safety laser scanners can have dozens of defined fields. That can be useful for applications like navigation for an autonomous mobile robot. The S300 Mini Standard safety laser scanners from SICK are optimized for safety applications that need three defined fields — a protective field and two warning fields — to be active simultaneously. Their compact dimensions of 102 x 116 x 105
Figure 2: Size comparison of the S30 Mini Standard safety laser scanner and a soda can. (Image source: SICK)
millimeters (mm) (w x h x d) make them suitable for applications like robotic work cells and automatic guided vehicles (AGVs) (Figure 2). S300 Mini Standard scanners have a 270° scan angle to cover a wide area and a selectable resolution for hand, leg, or body detection. These scanners support warning field ranges up to 8 m and are available with three maximum protective field ranges:
from configurable safety laser scanners. The detection zones can be modified as needed to suit changing protection needs. Setting multiple warning fields can be especially useful for preventing people from getting too close and shutting down a machine. The warning signal devices can include a simple flashing light if the first warning field is breached and a warning siren or horn if the second warning field is entered. There are specific rules for calculating the size of protection fields. Safety distance calculations ISO Standard 13855, “Safety of machinery – Positioning of safeguards with respect to the approach of the human body , includes guidelines for calculating
■ One meter, model 1058000
■ Two meters, model 1050932
■ Three meters, model 1056430
Dynamic environments
Dynamic environments, where the layout or operational conditions change or where AGVs move around, can benefit
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How miniature safety laser scanners can maximize protection and productivity
are used to detect obstacles. That can limit the speed of travel for the AGV, and the strips or bumpers can experience physical damage, requiring replacement and taking the AGV out of operation for a period. To maintain safety, flexibility, and maximum availability, AGVs can replace switching strips and bumpers as the primary safety devices, and they can include a laser safety scanner to detect obstacles and safely stop. The small size of the S300 Mini facilitates integration, even in the smallest AGVs (Figure 4). Using two safety laser scanners can provide an expanded protected area. If the scanners are mounted on the front corners of the AGV, the protected area extends to the front and both sides of the vehicle. Suppose the scanners are mounted diagonally opposite each other on the front and rear of the vehicle. In that case, the protected area will surround all sides of the AGV, enabling safe movement in both directions. Configuration, installation, and maintenance Configuration and diagnostic software (CDS) from SICK can be used to define protective and warning fields using a PC or laptop. The software includes an intuitive interface for application design and implementation. The
the minimum safe distance required to stop a machine when a person approaches it. ISO 13855 applies to several types of safety devices, including safety laser scanners, safety light curtains, pressure- sensitive devices, safety mats and floors, and more. It can be useful when calculating the size of safety fields for safety laser scanners (Figure 3). A common formula for calculating the safe distance, S, is S = (K × (TM + TS)) + ZG + ZR + CRO, where: ■ K = Approach speed (1,600 mm/s, defined in ISO 13855) ■ TM = Stopping time of the machine or system
■ TS = Response time of the safety laser scanner and the downstream controller ■ ZG = General supplement = 100 mm ■ ZR = Supplement for reflection- related measurement errors ■ CRO = Supplement to prevent reaching over Automated guided vehicles Automated guided vehicles (AGVs) move items quickly and efficiently without human intervention in Industry 4.0 factories, warehouses, and distribution centers. In some AGVs, switching strips or bumpers
Figure 3: ISO 13855 guidelines can be used to calculate the sizes of safety fields (red) for safety laser scanners like the S300 Mini Standard. (Image source: SICK)
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the programmed safety tasks, no reprogramming or manual downloading of configuration data. It’s a plug-and-play process that minimizes machine downtime.
Summary S300 Mini Standard safety laser scanners provide a robust alternative to safety
mats in Industry 4.0 factories, warehouses, and distribution centers that simultaneously maximize safety and productivity. They meet IEC 61508, ISO 13849, and IEC 61496 safety standards and are suitable for fixed installations and mobile platforms like AGVs. Finally, S300 Mini Standard safety laser scanners support flexible and rapid configuration, installation, and maintenance.
Figure 4: The compact size of S300 Mini Standard safety laser scanners enables them to be mounted on small AGVs. (Image source: SICK)
software also calculates and saves all configuration and diagnostic data for quick commissioning and/or efficient troubleshooting. Configuration and diagnostics can be implemented during commissioning or maintenance. SICK also offers a choice of mounting kits for physically attaching the S300 Mini safety laser scanners. Kit 1a, model 2034324, is the basic mounting bracket without a protective cover for the optics, and kit 1b, model 2034325, includes optics protection (Figure 5). In addition,
supplemental mounting brackets, including kit 2, model 2039302, and kit 3, model 2039303, can be added to align the scanners in two planes. The maximum adjustment angle is ±11° in both planes. The mounting kits also support quick replacement of damaged scanner heads. The replacement scanner head attaches to the system plug, which is permanently mounted on the machine. The replacement head immediately downloads the configuration data from the system plug and assumes
Figure 5: Mounting kit 1b includes optics cover protection. (Image source: SICK)
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Article Name
How SMEs can use an industrial metaverse to explore and deploy robotic solutions rapidly
By Jeff Shepard Contributed By DigiKey's North American Editors
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Robots and collaborative robots (cobots) are on the leading edge of factory automation technologies. Digital twins and virtual reality (VR) are on the leading edge of design and development tools. Combined, they can be leveraged to create an industrial metaverse that delivers higher productivity faster, even for small- to medium- sized enterprises (SMEs). Designers at SMEs can benefit from a simple and intuitive interface that combines a digital twin, a highly detailed virtual model of a physical object like a delta, linear, or multi- axis robot, and a 3-dimensional (3D) VR environment to enable direct execution and checking of the robot’s movement sequences.
Using these features supports fine-tuning and optimization of the automation system even without any physical hardware and enables rapid exploration of multiple solution possibilities. This article first reviews the distinction between a mathematical, data-described digital twin and a visual digital twin (VR twin) and how both are needed to create the industrial metaverse. It then presents a robot control system and related software from Igus that can be used to simulate a robot on a 3D interface (visual digital twin) without using any physical hardware, along with compatible delta, linear, and multi-axis robots that can be used to realize the optimized solution.
Digital twins and VR are complementary technologies using different visualization forms, interactions, and hardware. Digital twins are data-based models of physical objects, systems, or processes. They are designed to be used over the entire lifecycle of the item being modeled from initial conception to decommissioning and recycling. VR is an immersive, visually based technology that also uses digital models. In a VR environment, it’s possible to simulate the relationships and interactions between objects, like a robot performing a task. So, while both technologies can be used for design and simulation, digital twin
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How SMEs can use an industrial metaverse to explore and deploy robotic solutions rapidly
technology is focused on overall lifecycle considerations, and VR focuses on interactions between physical objects. A metaverse combines digital twins and VR into a purpose-built virtual environment that supports real-time interactions between the digital objects and people. It’s often associated with gaming but is increasingly applied to business and industrial activities. Welcome to the iguverse Igus has developed the iguverse metaverse to support engineering interactions in industrial environments, such as developing and deploying robotic systems. The iguverse can be implemented through Igus Robot Control (iRC) software. This free and license-free application enables users to control various types of robots, including delta robots, cobots (robot arms), and gantry robots. It provides users with a 3D interface and over 100 sample programs. System requirements to implement iRC include a PC (minimum of an Intel i5 CPU) with Windows 10 or 11 (64-Bit) with 500 MB of free disk space and Ethernet or wireless networking connectivity.
this is a three-axis linear gantry robot like model DLE-RG-0001- AC-500-500-100 with a workspace of 500 x 500 x 100 mm or a two- axis xy actuator like model DLE- LG-0012-AC-800-500 with an 800 x 500 mm workspace (Figure 1). Designers can define movements with a few mouse clicks and use the 3D model to ensure the required movements are feasible, even before purchasing the robot. In addition to the iRC software, the robot controller is a key element in the iguverse development environment. For example, the model IRC-LG12-02000 is for 48 V motors, has seven inputs and seven outputs, and has a 10 m cable for connecting to the robot. The IRC controllers include motor drive modules for various sizes of bipolar stepper motors and are available configurable or preconfigured.
It also has several interfaces for system integration, including: ■ Programmable logic controller (PLC) interface for control via the digital inputs and outputs, especially for easy starting and stopping of programs via a PLC or pushbutton
■ Modbus TCP interface for control via a PLC or PC
■ Common Robotic Interface (CRI) Ethernet for control and configuration using a PLC or PC ■ Robot Operating System (ROS) interface for operating the robot using ROS ■ Interface for object detection cameras ■ Cloud interface for remotely monitoring the robot’s state
The software's core is a 3D digital twin of the robot being programmed. An example of
Figure 1: Example of a 3D VR digital twin of a three-axis gantry robot in the iguverse. (Image source: Igus)
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Supported kinematics
A variety of kinematics (basic motions) that define the controlled movement of the robot are supported in the iguverse. In addition to the preconfigured kinematics, up to three more kinematically independent axes can be configured in IRC. Preconfigured kinematics include:
■ 2-axis and 3-axes delta robots
■ Gantry robots,
■ 2-axis (X and Y axis)
Figure 2: The “Jogging” tab (bottom left) in the iguverse immersive development environment can be used to enter motion profiles. (Image source: Igus)
■ 2-axis (Y and Z axis)
■ 3-axis (X, Y, and Z axis)
■ Robot arms (cobots),
A 3-button mouse or a gamepad can move and position a robot in the iguverse. With the IRC software, a user can freely move all axes of the digital twin in the 3D interface. A teach-in function supports the development of robot control software, even without a physical robot being connected. To implement teach-in, the user manually moves the virtual robot to the required position and defines how it moves there. The process is repeated until the complete motion profile has been created. The tool center in the IRC software allows users to add matching end effectors, like grippers, easily and automatically adjusts the tool center point on the robot. In addition, a connection to a higher-level industrial control system can be added.
The process begins by activating the robot using the “connect,” “reset,” and “enable” buttons as needed in the interface. The status LED on the IRC should become green, and the status should indicate “No Error.” The motion profile can now be entered using the “Jogging” tab (Figure 2). Gantry robots Gantry robots, like those included in the preceding examples of the iguverse, consist of two base X-axes, a Y-axis, and an optional Z-axis. The Y-axis is attached to the two parallel X-axes and moves back and forth in two-dimensional space. The optional Z-axis supports a third dimension of movement.
■ 3-axis (axis 1, 2, 3)
■ 3-axis (axis 2, 3, 4)
■ 4-axis (axis 1, 2, 3, 4)
■ 4-axis (axis 2, 3, 4, 5)
■ 5-axis (axis 1 to 5)
■ 6-axis (axis 1 to 6)
■ 4-axis SCARA robot
Easy programming for low-cost automation
Igus robots and the IRC are designed to support low-cost automation. That would not be possible without an easy-to-use programming interface.
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How SMEs can use an industrial metaverse to explore and deploy robotic solutions rapidly
Gantry robots from Igus have self-lubricating plastic liners that slide and roll smoother and quieter than traditional ball-bearing-based designs. The new design is lighter weight, corrosion-resistant, and maintenance-free, which are important qualities for SMEs. Also crucial for SMEs, these robots cost up to 40% less than traditional gantry robots, providing a quicker return on investment (ROI). These robots are suited for two classes of applications: low speeds with high loads or high speeds with low loads. Representative applications include packaging, pick and place, labeling, material handling, and assembly operations. They are offered in a range of sizes. Available accessories include couplings, end effectors, and motor flanges. Examples of medium-sized gantry robots include: ■ DLE-FG-0006-AC-650-650 is a two-dimensional flat gantry with a 650 x 650 mm workspace. This robot can handle payloads up to 8 kg and has a dynamic rate of up to 20 picks per minute. ■ DLE-RG-0012-AC-800-800-500 is a three-dimensional gantry with an 800 x 800 x 500 mm workspace. It can handle payloads up to 10 kg with a dynamic rate of up to 20 picks per minute.
Figure 3: Palletizing is a common and important activity in manufacturing and logistics operations and can be automated using a gantry robot. (Image source: Igus)
Palletizing prowess
Delta robots Like gantry robots, delta robots are available with two or three axes. Delta robots have a dome- shaped work envelope mounted above the workspace. They have exceptionally high speeds and are often used for material handling and parts placement. Examples of Igus’ delta robots include: ■ RBTX-IGUS-0047 is a three- axis design with a workspace diameter of 660 mm. It has an accuracy of ±0.5 mm, a maximum payload of 5 kg, a maximum speed of 0.7 m/s, and can perform up to 30 picks per minute. (Figure 4). ■ RBTX-IGUS-0059 is a 2-axis design with a workspace
Palletizing products for shipment is an everyday activity in manufacturing and logistics operations. The newest and largest member of the iguverse is the XXL large gantry robot with a working space of 2,000 x 2,000 x 1,500 mm, well-suited for palletizing applications up to 10 kg. Custom designs with working spaces up to 6,000 x 6,000 x 1,500 mm are available. These gantry robots can pick parts weighing up to 10 kg, transport them at a speed of up to 500 mm/s, and place them on a pallet with a repeatability of 0.8 mm (Figure 3). The Igus palletizing robot solution costs up to 60% less than comparable systems.
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Figure 5: Articulated arm cobots with 4 DOF (left) and 6 DOF (right). (Image source: Igus)
Figure 4: Example of a three-axis delta robot next to an Igus iRC (left). (Image source: DigiKey)
diameter of 700 mm. It also has an accuracy of ±0.5 mm. Its maximum payload is 5 kg, its maximum speed is 2 m/s, and it can perform up to 50 picks per minute.
±1 mm, a nominal working range of 400 mm and can perform a minimum of 7 picks per minute with a linear speed of 200 mm/s. The 6 DOF model has a maximum payload of 2 kg and a maximum reach of 664 mm. The 4 DOF model has a maximum payload of 3 kg and a maximum reach of 495 mm (Figure 5).
to run locally on a PC without a cloud connection. It can be used to develop and test robotic solutions without a robot being present. It supports a wide range of kinematics in delta robots, gantry robots, robot arms (cobots), and SCARA robots. The IRC includes an array of interfaces to support automation and operational needs, including PLC interface, Modbus TCP/IP, CRI Ethernet, ROS interface, an interface for object detection cameras, and a Cloud interface. The iguverse, the iRC, and related robots from Igus have been optimized to support the low-cost automation needs of SMEs.
Articulated arm cobots
The iguverse also supports articulated arm cobots. Cobots can have from two to 10 or more axes, also called degrees of freedom (DOF). They generally have large work envelopes and can perform complex tasks in collaboration with a person. Igus model REBEL-6DOF-02 has 6 DOF and model REBEL-4DOF-02 has 4 DOF. Both have an accuracy of
Summary
The iguverse immersive industrial metaverse combines digital twins and VR to provide tools that enable rapid development and deployment of robotic solutions. It’s free, license-free, and designed
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What support products does it take to maximize the impact of using VFDs and VSDs? - Part 1
By Jeff Shepard Contributed By DigiKey's North American Editors
Part 1 of this article series looks at what to consider when selecting motor connection cables, output reactors, braking resistors, line reactors and line filters. Part 2 continues by looking at the differences between VSDs/VFDs and servo drives, reviewing uses for AC and DC rotary and linear servo motors, considering where soft start-stop units fit into industrial operations, and Looking at how DC converters are used to power peripherals like sensors, human-machine interfaces (HMIs), and safety devices. Using variable speed drives and variable frequency drives (VSDs/ VFDs) is necessary to maximize industrial operations' efficiency and sustainability, but it’s not sufficient. To get the maximum benefit from VSDs/VFDs, additional components like high-performance cables, braking resistors, line filters, line reactors, output reactors, and more are needed. Cabling is ubiquitous and critical. A poorly specified cable connecting the VSD/VFD to the motor can significantly degrade system performance. Other elements like braking resistors, filters, and reactors vary from installation to installation and can be very important to a successful deployment. For example, some systems operate in areas where it’s necessary to control electromagnetic interference (EMI) and can benefit from using line filters that meet EN 61800-3 Category C2. Applications where rapid deceleration is required will need braking resistors. Line reactors can
improve the power factor and boost efficiency, and output reactors can enable the use of longer cables. This article begins with a look at some considerations when selecting motor connection cables and presents typical cabling options from LAPP and Belden. It then reviews factors that impact the selection of output reactors, braking resistors, line reactors, and line filters, including representative devices from ABB, Schneider Electric, Omron, Delta Electronics, Panasonic, and Siemens. Motor cables are available in various configurations to meet specific application requirements. They typically have three main power conductors, often insulated with cross-linked polyethylene
(XLPE). Some have uninsulated grounding wires. There can be various signal wires and numerous braided and foil shielding choices. The entire assembly is encased in an environmentally rugged outer jacket (Figure 1). Even basic cables like Belden Basics part number 29521C 0105000 are complex assemblies of conductors, shielding, and insulation. These cables have three 14 American Wire Gauge (AWG) (7x22 strands) copper conductors covered with XLPE insulation and three 18 AWG (7x26 strands) uninsulated copper ground wires. These six wires are surrounded by dual helical tape shields that provide 100% coverage, and the
Figure 1: VFD motor cables come in a wide range of configurations. (Image source: Belden)
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What support products does it take to maximize the impact of using VFDs and VSDs? - Part 1
entire cable assembly is encased in a polyvinyl chloride (PVC) jacket for environmental protection. Belden Basic cables are suited for use in class 1 division 2 hazardous locations as defined in the National Electrical Code (NEC). Class 1 refers to facilities for handling flammable gases, vapors, and liquids. Division 2 specifies that these flammable materials are not ordinarily present in concentrations high enough to be ignitable. Some cable series, like LAPP's ÖLFLEX VFD 1XL, are available with and without signal wires. Applications that benefit from having signal wires can turn to LAPP’s 701710 cable. It includes three power conductors, a ground conductor, and a pair of signal wires. The power conductors are 16 AWG (26x30 stranding) with XLPE (plus) insulation. The signal pair are individually foil shielded. The entire assembly is shielded with barrier tape, triple-layer foil tape (100% coverage), and tinned copper braid (85% coverage). The outer jacket is a specially formulated thermoplastic elastomer (TPE) resistant to disinfecting solutions and is typically used in the food, beverage, chemical, and related industries. In addition to reliably and efficiently handling power and signals, VFD cables need to be able to handle high
Figure 2: Uncontrolled high voltage spikes can pierce the insulation and result in cable failure. (Image source: LAPP)
voltage spikes and electromagnetic interference (EMI) noise levels resulting from the drive's high- frequency operation. While VFD cables are designed to contain and manage high voltage spikes and EMI, they have their limits (Figure 2). That’s when load reactors reduce high voltage spikes and EMI. For a more detailed discussion of VFD cable selection, see “Specifying and Using VFD Cables to Improve Reliability and Safety and Reduce Carbon Emissions.” Load reactors Load reactors, also called output reactors, are connected close to the drive's output to reduce the
impact of high voltage spikes and EMI, and they protect wire insulation in both the cable and motor. VSDs/VFDs produce a high- frequency (usually between 16 and 20 kHz) output. The high-frequency switching results in voltage rise times of a few microseconds, causing high voltage spikes that can exceed the motor’s peak voltage rating, resulting in insulation breakdown. Depending on the type of motor used, load reactors are often recommended if the VFD cable length exceeds 30 m (100 ft.). There are exceptions; for example, if the motor meets the NEMA MG-1 Part 31 standard, it may be possible to have a 90 m cable (300 ft) without using a load reactor.
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Regardless of the motor type, a load reactor is generally recommended if the cable length exceeds 90 m. If the distance exceeds 150 m, a specially designed filter is usually recommended. In EMI-sensitive environments, using a load reactor for all applications is usually good practice. Load reactors are often designed for use with specific drive models. For example, the Omron model 3G3AX-RAO04600110-DE load reactor is rated for 11 A and 4.6 mH and designed for use with 400 V three-phase 5.5 kW motors driven by the company’s 3G3MX2- A4040-V1 VFD. Braking resistors and thermal overloads In addition to a load reactor, a braking resistor and thermal overload shutdown device can be essential additions to the output side of a VSD/VFD. Braking resistors enable maximum transient braking torque by absorbing the braking energy. Most braking resistors dissipate the energy, while some are used as part of a regenerative braking system that captures and recycles the energy. Dissipative braking resistors are rated for specific applications. The Schneider Electric VW3A7755 8
Figure 3: Definition of percentage of energy dissipation (ED%). (Image source: Delta Electronics)
Ω braking resistor can dissipate up to 25 kW, while the Delta Electronics BR300W100 100 Ω braking resistor is rated for 300 W. Braking resistor applications are defined using a percentage of energy dissipation (ED%). The defined ED% ensures the resistor can effectively dissipate the heat generated during braking. ED% is defined relative to the peak dissipation, the braking interval (T1), and the overall cycle time (T0) in Figure 3. Depending on the severity of the braking, ED% is specified to ensure adequate time for the brake unit and brake resistor to dissipate the heat generated by braking. If the brake resistor heats up due to inadequate thermal dissipation, its resistance increases, reducing the current flow and the brake torque absorbed. Braking resistors can be defined by various dissipation cycles like: ■ Light braking, where the braking power is limited to 1.5
times the nominal torque (Tn) for 0.8 s every 40 s. Used with machines with limited inertia, like injection molding machines ■ Medium braking, where the braking power is limited to 1.35 Tn for 4 s every 40 s. Used with machines with high inertia, like flywheel presses and industrial centrifuges ■ Severe braking where the braking power is limited to 1.65 Tn for 6 s and Tn for 54 s every 120 s. Used with machines with very high inertia, often accompanied by vertical movement, like hoists and cranes In addition to a braking resistor, most systems include a thermal overload unit connected to the brake resistor as a safety precaution, like the ABB Control TF65-33 thermal overload relay. The thermal overload unit protects the resistor and drive system from too frequent or too strong braking. When a thermal
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What support products does it take to maximize the impact of using VFDs and VSDs? - Part 1
limitations for industrial, scientific, and medical equipment, and IEC/EN 61800-3, which relates specifically to adjustable speed drives. VFDs/VSDs are available with and without integrated line filters. If they have a filter, it may be Class A or Class B. Depending on the environment and installation factors like cabling lengths, even a drive with an integrated filter may require additional filtering. A drive rated for operation in Class A environments can also be used in Class B environments with the addition of an optional filter. IEC/EN 61800-3 defines EMC requirements based on Environments and Categories. Residential buildings are defined as the First Environment, and industrial installations connected to the medium-voltage distribution network through their transformers are the Second Environment. The four Categories defined in EN 61800-3 include: ■ C1 for drive systems for rated voltages < 1000 V for unlimited use in the first environment ■ C2 for stationary drive systems for rated voltages < 1000 V for use in the second environment and possible use in the first environment
overload is detected, the drive is turned off. Turning off the braking function only could result in serious damage to the drive. Protection on the drive input Line reactors and filters on the drive input limit low-frequency harmonics and high-frequency EMI, respectively (Figure 4). Line reactors help reduce harmonic distortion of the AC input power caused by the drive circuitry. They can be especially useful in applications that must meet the requirements of IEEE-519, “Harmonic Control in Power Systems.” Line reactors also smooth out disturbances on the mains power like surges, spikes and transients, increasing operating reliability, and preventing overvoltage shutdowns. Examples of line reactors include the DV0P228 2 mH inductor rated for 8 A that’s part of the Minas family of three-phase drives and accessories
from Panasonic and Siemens’ 6SL32030CE132AA0 2.5 mH
inductor rated for drives up to 1.1 kW that draw up to 4 A of input current and operate from 3-phase 380 V AC -10% to 480 V AC +10% power.
Line filters
Line filters are required to support electromagnetic compatibility (EMC) and provide EMI protection in most applications. Depending on the specific environment, two classifications of EMI filters, Class A and Class B, are used in industrial
and commercial (building) environments, respectively.
Class B demands a higher level of filtering than Class A because commercial environments (offices, administration, etc.) generally include electronic systems that are more sensitive to EMI. The relevant EMC standards include EN 55011, which details emissions
Figure 4: Line filters limit high-frequency EMC, while line reactors limit low- frequency harmonics. (Image source: Siemens)
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