Yaskawa is a world-leading manufacturer of inverter drives, servo drives, machine controllers and industrial robots.

Centa Gears

Renold Chain

ABB Drives and Motors


Features 

Hannover Fair 2009 Show Report

Despite the economic downturn, more than 4,000 new products were launched at the 2009 Hannover Fair – a record, according to the organisers. In this report, we look at some of the new arrivals.


Before the recent Hannover Fair, there was intense speculation about how the world’s largest industrial show would be affected by the economic downturn. In the event, the organisers must have been relieved to be able to report that the numbers of exhibitors and visitors were only slightly down on the figures for 2007 – the last time the show included the MDA (Motion, Drives & Automation) event, which occupies more than six halls.

In 2007, the Fair attracted more than 240,000 visitors and 6,400 exhibitors. This time, the organisers say that around 210,000 visitors made the trip to Hannover, where they could see 6,150 exhibitors from 61 countries. But the exhibitor numbers were boosted by hundreds of small stands occupied by companies from China, India, Taiwan and this year’s “partner country”, South Korea. Between them, these countries accounted for almost 950 stands – more than 15% of the total – but just 7.5% of the total floor area.


The Fair, opened by the German chancellor Angela Merkel (above), painted a mixed picture of the state of the automation and industrial equipment industry in Germany, Europe and the wider world. Although some well-known names were missing – among them Hitachi, Omron, Rockwell, Schneider, Sick, Schaeffler and Yaskawa – many of those that did attend seemed to make an extra effort.

For example, the plastics specialist igus launched its largest ever number of new products (more than 80), while Pilz had its biggest stand ever.

In his end-of-show analysis, Wolfram von Fritsch, board chairman of the organiser, Deutche Messe, put a positive spin on the event. “Rather than dwelling on the crisis and agonising over its causes,” he said, “this show was about finding the most promising ways forward.”

Another optimist is Friedhelm Loh, president of the German electrical industry trade body, ZVEI. “The mood at the show has been far more positive that figures currently being reported by the electrical engineering industry,” he said at the end of the five-day event. “There is ample reason to hope the crisis may soon bottom out, with some initial signs of recovery on the horizon for the second half of 2009.”

According to the organisers, more than 4,000 new products were launched at the fair – a record number. Many of these products were probably under development before the downturn struck, but some companies are seeing the recession as being an opportunity to innovate, so that they will be in a strong position when the upturn arrives. Phoenix Contact, for example, is planning to launch around 2,600 new lines this year.

 

DRIVES AND MOTORS

ABB’s main drives focus at Hannover was on its new drives targeting water industry and fan/pump applications. It was also promoting its IP66-protected machinery drive and ACS850 drive modules first seen at the SPS/IPC/Drives show last November.

Baumüller was demonstrating an extended range of synchronous torque motors with higher power densities, a wider range of speed and torque ratings, and improved price-to-performance ratios. The DST range (above) includes a 400-frame motor offering rated torques to 20kNm and maximum torques up to 32kNm.

Beckhoff has added six new models, with ratings from 60–170A, to its AX5000 family of Ethercat-based servodrives. Motion control functions can be handled by a central PC-based controller, simplifying commissioning and maintenance. Beckhoff has also expanded its AM3000 series of synchronous servomotors with models that offer standstill torques from 80–150Nm.

On its stand, Danfoss was promoting its newly-released  range of low-harmonic drives rated from 132–710kW which combine frequency converters with active mains filters. As well as reducing harmonic loads and improving mains power quality, the VLT Low Harmonic Drives minimise reactive power consumption.

Danfoss was also previewing a range of safety modules which will allow users to add safety functions to its VLT Automation Drives, chosing only those functions that they really need. The modules are due to be launched by the end of 2009.
GE was showing a range of compact inverters rated from 0.75–475kW (or 400kW for high-overload applications). The VAT300 drives offer V/f or vector control (open or closed loop) and can control permanently excited synchronous servomotors as well as asynchronous motors. Built-in functions include a PLC, a configurable PID controller, multi-pump control, and dynamic braking (up to 22kW).

Lenze unveiled a range of three-phase AC motors rated from 0.12–45kW in the new IE1 (standard efficiency) and IE2 (higher efficiency) classes. Dimensions are the same for both classes of the L-force motors (shown above), making it easy to upgrade the efficiency of an application. The modular motors can be adapted to applications using encoders, resolvers, brakes, and plug-in connectors.

The Korean manufacturer LS Industrial Systems (formerly part of LG) was highlighting its iS7 family of open- or closed-loop vector control drives in ratings from 0.75–160kW. Functions include: automatic torque balance droop control; slip compensation; and kinetic energy buffering for safe shutdown after power failures. Options include a PLC card and various communications cards.

Miniature motor specialist maxon revealed several new ranges including a small (25mm diameter, 84mm long), high-speed (61,600 rpm), efficient (above 93%) 250W drive with a nominal torque rating of 42mNm.  It also had a couple of sterilisable drives for applications up to 90,000 rpm.

Moeller used Hannover to preview a range of drives in ratings from 0.55–200kW (230, 400 and 575V) aimed mainly at HVAC applications. The H-Max drives (above), due to reach the market later this year, are a companion to the smaller M-Max drives launched at the SPS/IPC/Drives show in November and use the same removable keypad. The drives, developed jointly with Moeller’s parent, Eaton, will be available in IP21 and IP54 versions, and will support option modules for functions such as I/O and communications.
                                                                                               
Nord Drivesystems was showing a range of sensorless vector inverters covering ratings from 0.25–22kW in six sizes. Standard features on the SK 500E inverters include brake management, filters and PID control. Nord has also developed distributed inverters (SK 225E and S235E) with AS-i connections built in to simplify wiring. The 235E model incorporates a Safe Stop function, allowing connected motors to be restarted without needing to shut off the power.

Parker Hannifin announced a range of robust, high-torque, low-speed, frameless servomotors, supplied as kits consisting of separate stators and rotors with large inner diameters. The brushless TK motors (above) are designed to be integrated into the mechanical structure of a machine with the load connected directly to the moving part. They can deliver continuous torques from 100–7,000Nm at up to 1,000 rpm and can be water-cooled or ventilated naturally.

Parker was also showing a range of drives for sensorless control of brushless permanent magnet AC motors which, it says, could make compact, efficient PM motors affordable in general-purpose applications. Only a few motor parameters are needed to set up the AC650S drives for most applications, while a free configuration tool fine-tunes the drive for demanding applications.

SEW Eurodrive’s bustling stand contained several additions to its portfolio including: an extension of its Movidrive inverters up to 315kW; new sizes (71, 80 and 100) for its CMP family of synchronous servomotors, taking peak torque ratings up to 179Nm; and a range of IP69K stainless-steel gearmotors with output torques up to 200Nm for use in areas subject to frequent cleaning. SEW also had a high-speed fieldbus gateway for use with its Moviaxis multi-axis servo amplifier system.

On its vast stand, Siemens was demonstrating an IP65-protected decentralised drive for simple materials-handling applications. The low-profile Sinamics G110D (above) has built-in AS-i communications for parameterisation and diagnostics, and accepts inputs from up to five sensors for local processing. It incorporates a quick-stop function and brake controls.

Siemens also has a new controller for its Sinamics G120 inverters, designed for pump, fan and compressor applications. The CU230P-2 controller incorporates PID and flying restart functions. Another new control module (CU240S DP-F) is aimed at chemical industry applications and includes an Atex-certified PTC evaluation function.

Stöber was demonstrating a remote servicing facility for its new Posidyn SDS 5000 range of servo drives. The facility ensures that safety is maintained and requires a responsible person at the client to initiate a service request via the drive. The drives, which cover ratings from 0.75–45kW, use a self-configuring integrated bus that allows every drive in a network to transmit data cyclically at the same time as accessing other network data. Networks of up to 32 drives are configured and synchronised via a pair of RJ-45 connectors on the front of each drive.

Taiwanese manufacturer Teco was promoting a combined drive and permanent magnet servomotor that spans outputs from 0.2–37kW and offers a high power density.


WEG’s stand at Hannover was dominated by a large motor from its high-efficiency W22 range, which it plans to offer in three IE efficiency classifications: IE1 (Eff2); IE2 (Eff1); and IE3 (Premium). The motors have an aerodynamic frame designed to increase airflow for improved efficiency, fewer hotspots and higher reliability.

WEG was also showing an IP54 version of its CFW-11 drive, which includes a patented “optimal flux” technology designed to minimise losses in TEFC motors, especially at low speeds. Another WEG development is an IP65-rated version of its CFW-08 inverter in single-phase ratings from 0.75–3.7kW and in three-phase versions up to 15kW. The CFW-08 Wash inverters (above) incorporate “space vector modulation” technology for optimised motor control and quiet operation.


CONTROLS

New from Beckhoff is an embedded PC with a 32-bit, 400MHz processor and a fieldbus slave, with interfaces for Profibus, CANopen, Profinet, Ethernet I/P, EtherCat and Ethernet. EtherCat or Bus Terminal I/Os can be mounted next to the CX8000 CPU and extra Ethernet interfaces with switch functions can be used to create daisychains without additional hardware. A capacitor UPS allows data to be saved if power is lost.

Another Beckhoff innovation is an EtherCat terminal (above) that accepts inputs from sensors used to monitor machinery vibrations. The signals can be analysed by a connected PC to warn of wear or damage before a breakdown occurs, thus providing a cost-effective form of condition monitoring.

Korea’s LS was showing a redundant PLC system which, it claims, boasts the industry’s fastest CPU and processing speed (42ns). The XGR PLC (below), based on a custom chip, incorporates a ring topology and synchronises master and standby CPUs via 1Gb/s fibre optic cables. A hot-swap function allows modules to be replaced during operation, while the accompanying programming tool supports offline simulation to cut commissioning times.

maxon motor has developed a card-based positioning controller for use by OEMs in single- and multi-axis applications. The plug-in Epos2 Module 36/2 can control brushed DC motors or brushless EC (electronically commutated) motors and can control speed or current as well as position.

Rexroth was demonstrating an IP67-protected fieldbus connection module that connects sensors and other automation components via Profibus DP. The VT-ZBUS module incorporates an innovative PWM technology for applying 24V voltages to switching solenoids which, it claims, can shorten switching operations by up to 60%, cut energy consumption by up to 66%, and extend solenoid lives. The modules have eight M12 sockets with 16 digital ports, and several can be cascaded using one power supply.

New from Siemens are two embedded industrial PCs – one in a compact box format, the other built into an HMI – which use Intel Core 2 Duo processers, giving them twice the performance of their predecessors. The fanless Simatic IPC427C Microbox PC and IPC477C Panel PC (above) are designed for continuous, maintenance-free operation in temperatures up to 50°C. There is also a similarly upgraded 19-inch rack PC.

Users of Siemens PLCs would also have been interested in two Speed7 PLCs on the Vipa stand, which use the Step7 programming language but are claimed to be much faster than Siemens PLCs. The CPU 314SX model is said to update its analogue I/O up to 25 times faster than rival compact CPUs, with a delay of just 40µs between a signal change at the analogue or digital I/O terminal, and access within the code. The CPU’s analogue I/Os have a 100kHz sampling rate.

Vipa’s second new arrival is a low-cost (€498) CPU that is pin-compatible with Siemens controllers, but is said to be up to 30 times faster. The 314SE CPU can use either S7-300 or S7-400 instruction sets and has a memory that can be expanded to 512kb.

Wago has squeezed an intelligent positioning controller into a field bus node with its 750-636 module, which can control DC motors rated at up to 5A. Three 24V inputs detect limit switches and a preset signal, while an incremental sensor interface acquires values from 5V or 24V sensors. The module can compensate for gearing backlash.


ELECTRICAL AND SAFETY

Beckhoff used the Hannover Fair to preview a Safety PLC that will run on any industrial PC without needing extra hardware. The system, due to be launched at the end of 2009, is based on software integrated into Beckhoff’s TwinCat system. Communications between the PC and distributed safety components – such as sensors, I/Os and drives – is achieved using the Safety-over-EtherCat protocol.

ETA Circuit Breakers has introduced a rail-mounting electronic over-current circuit breaker for 24V DC control circuits and load currents from 1–12A. The 12.5mm-wide ESX10-T breaker provides active current limitation to 1.5 or 1.8 times its rated current.

Euchner was showing various safety products including a combined safety switch, bolt and door-locking mechanism (above) which, it says, can protect almost any safety door in accordance with EN ISO 13849 and EN 1088. The modular MGB (multifunctional gate box) system is based on an “evaluation” module, available with functions such as integrated controls or emergency stops, that the user chooses to suit an application.

GE has launched a digital soft-starter for asynchronous motors up to 690V AC and 1.4kA. In addition to standard functions – such as overload monitoring, adjustable ramps, current limiting and kick-starts – the Astat XT starter can phase in sequence with motor windings, reducing currents and allowing a smaller starter to be used. It also offers a soft, time-controlled torque ramp for running motors up and down with an almost linear coasting speed ramp to prevent stalling.

GE also had various circuit breakers, including a space-saving MCB called Unibis (above), which combines two poles in one module. The range spans versions from 3–10kA, with two to four poles, in housings that are a maximum of two modules wide.

The Swedish safety specialist Jokab unveiled a three-position enabling device with a built-in capacitive sensor hand detector. To produce an output signal, it has to be gripped by a human hand and two three-position pushbuttons have to be pressed to the middle position. When the switch is released or pressed to the third position, a double stop signal is generated. The JSHD4 device also supports AS-i and needs just two connections.

Jokab has also produced AS-i versions of its unique Safeball device (above) – which needs to be gripped with two pushbuttons depressed before a machine will start – and its Smile emergency-stop button.

The Lapp Group has developed talcum-free versions of its Ölflex connection and control cables, that allow the internal wires to slip against the outer sheath without the problems of traditional talc-filled cables, such as dust getting into machinery when the cable is stripped, causing skin irritations and making it difficult to read numbers on the cores.

Moeller was showing a range of motor-protection circuit-breakers with wider current setting ranges than bimetallic breakers, reducing the number of variants needed by up to 75%. The modular PKE breakers have a control section that plugs into a base, allowing functions to be changed without disturbing the wiring. The networkable breakers generate up to 85% less heat than bimetallic versions, cutting energy consumption, and offer selectable trip classes for current and overload protection.

Moeller also unveiled a compact range of air circuit-breakers for rated currents from 630–1.600A. The IZMX16 ACBs are 32% smaller than their predecessors and two can fit next to each other in a 600mm-wide section. 

New from Phoenix Contact is a range of compact, modular surge protection devices that can protect up to four 6.2mm-diameter signal wires. Multiple Linetrab modules can be installed using bus adapters.

On its busy stand, Rittal unveiled several additions and extensions to its portfolio, including: a new busbar system for its Ri4Power range of LV switchgear, which takes the maximum rating up to 5.5kA; new isolator sections for Ri4Power with a 100kA short-circuit resistance; new fused isolators for the RiLine NH series, in sizes 00–3; and a 2kW version of its Cool Efficiency cooling system (launched last year in a 1kW version), which uses up to 45% less energy than conventional systems. 

Schaffner announced 300A, 400A and 600A versions of its FN 3280 EMC filters which, it claims, make four-wire filters available for high-power applications for the first time. The filters are designed for large machines and plants with numerous motor drives or long motor cables.

Safety specialist Schmersal claims to have developed the world’s most compact Cat 4 light curtain. The SLC Curtain (above), available from its Safety Control subsidiary, has a cross-section of 12 x 20mm and a range of 300–3,500mm, and is available in eight protection heights from 236–1,804mm.

Other new arrivals from Schmersal include: a new generation of safety mats with a lifetime of more than 1.5 million operations; a version of its MZM 100 solenoid interlock that allows the latching force to be adjusted in eight steps from 30–170N; and a variant of its AZM 200 solenoid interlock with extra locking bars.

Siemens announced two ranges of motor starters offering a choice of communications technologies. The IO-Link version of its compact Sirius 3RA6 starter allows up to four starters to be mounted side-by-side with IO-Link replacing conventional control wiring to transmit operating and diagnostic data, thus saving space and costs. Siemens’ distributed, IP65-protected M200D starters incorporate AS-i communications, again reducing wiring. The direct or reversing starters in ratings up to 5.5kW can be installed outside control cabinets, close to the motor.

Steute has developed a command switch which generates energy when its pushbutton is pressed to power a brief radio transmission, thus avoiding the need for control or power wiring. The BF 72 RT device, which can transmit an actuation signal over a distance of 300m outdoors or 30m indoors, can be mounted onto any surface, and can be moved easily from one position to another.

Weidmüller was demonstrating two new surge suppression ranges: the 17.8mm-wide, pluggable Varitector SPS system (above) offering protection, indication and remote signalling; and the 6mm-wide Varitector SSC in the form of a modular terminal block which combines connection and protection functions. The company has also announced a fourth generation of its Stripax wire-stripping tool incorporating several user-suggested improvements, including a “unique” partial stripping function which leaves the separated insulation on the conductor, preventing its from fraying and making it easier to insert into ferrules and other terminals.

Wieland was promoting a plug-in DIN-rail terminal block system (Fasis Con) consisting of feedthrough and earth blocks that can connect wires up to 4mm2 for rated currents up to 32A. The company also had a new range of emergency stop buttons (SNH) in seven sizes for applications to Cat 4 / SIL 3.


MECHANICAL AND LINEAR MOTION
   
ContiTech, now owned by Schaeffler, has developed a “green” V-belt, called Conti-V Pioneer, made from natural ingredients such as vegetable oil and cotton yarn, and eliminating the usual carbon black. It is also expanding its Conti Synchrochain range of timing belts to encompass more than 55 different sizes, thus opening up new applications.

Plastics specialist igus launched 80 products at Hannover – a record number – including a range of plain bearings using a new “nano” plastic material, called iglidur X, which is said to be up to six times more wear-resistant at 250°C than earlier materials, as well as being easier to press-fit and more resistant to chemicals. The company also showed a new range of lubricant- and maintenance-free, push-fit plain bearings (RJMP) which cost less than the previous RJM series and have similar dimensions to recirculating ball bushings.

igus has also developed a cable-protecting energy tube which, it claims, is 100% chip-proof – nothing will stick to it, from the tiniest to the coarsest particles. The RX tube (above), aimed at machinery applications, offers an interior height of up to 52mm and is said to be completely airtight.

The couplings manufacturer KTR unveiled an all-steel gear coupling with a crown-shaped spline that accepts high radial displacements. The torsionally rigid Gearex coupling (below) comes in 12 sizes covering a torque range of 930–135,000Nm. KTR has also developed a compact, backlash-free shaft coupling for encoder and tacho drives which is claimed to compensate for any possible displacement in a tiny space. The aluminium-hub Countex coupling has a nylon-toothed cage and can transmit torques up to 1Nm via positive locking. Finally, KTR has reduced the price of its torsionally flexible Rotex jaw couplings by splitting the traditional spider into individual two-tooth segments.

Nord claims to be the only company in the world to offer industrial gearboxes larger than 90kNm in single-case housings that resist axial and radial loads. At Hannover, it announced models rated up to 200kN that eliminate any sealing surface that could deflect under load, or allow lubricant leakages. Nord has also produced three new sizes (7 to 9) of its Nordbloc.1 aluminium gearmotor boxes, which have overlapping bearing offsets and can handle high thrust and overhung loads. 

Parker Hannifin has announced a new generation of servomotor gearheads with higher radial load capacities and longer service lives. The Stealth Gen II gearheads cover frame sizes 60, 90 and 115mm.

SEW Eurodrive unveiled a linear “electric cylinder” which, it claims, is the first of its type to need almost no maintenance. The servomotor-driven, IP65-protected CMS63S cylinder (above) uses an oil-bath lubrication system which improves efficiency, minimises lubricant losses, reduces friction and heating, and avoids the stick-slip effect. It can deliver a peak force of 10.5kN and speeds of up to 450mm/s.

Siemens has expanded its Flender range of high-torque gearboxes up to a maximum rating of 1.4MNm. The two- to four-stage spur and bevel-spur boxes cover ratios from 1–450 and have a modular design using standard components, avoiding the need to custom-build high-torque gearboxes.


FLUID POWER


Although Festo is increasingly becoming involved in electrical actuation, it hasn’t forgotten is pneumatic roots and at the Hannover Fair announced a new controller for its CPX-MPA valve terminal which supports the autonomous control of complete sub-systems and the pre-processing of diagnostic data on the valve terminal. In this way, the CPX-CEC-C1 controller (shown on the extreme left, below) reduces the amount of traffic on the field bus.

Festo is also offering a range of soft-start valves (VABF) for use with its VTSA terminal that ensure a slow, controlled build-up of pressure so that downstream cylinders and other devices travel slowly to their initial positions, reducing potential hazards.

Another innovation from Festo is a self-adjusting cushioning system for pneumatic cylinders which avoids the needs for manual adjustments and is claimed to be cheaper and more robust than shock absorbers. The PSS system, now available for Festo’s DSNU cylinders, is claimed to ensure optimum cushioning every time, even if friction or pressures change. It also reduces acceleration forces, wear and vibration, and set-up times.

Parker Hannifin has launched a centralised plug-in valve island for building compact pneumatic systems. The Isys Micro system has a metal sub-base onto which up to four valves can be fitted. There are four valves in each 42mm-wide slice, offering up to eight functions per module. No individual wiring is needed and the system supports industrial Ethernet and field bus communications. 

Rexroth used the Hannover Fair to launch two new valve terminal systems, as well as a version of its LS04 terminal with an IO-Link interface. The modular CDO1/02-PI terminal system can hold up to 16 valves in two formats: the 26mm-wide CDO1 valves with flow rates up to 1,350 litres/min; or the 18mm-wide CDO2 version with a 650 l/min flow rate. The two types of valve can be combined.

The HF04-XF (extended functionality) terminal system (shown above) can control up to 32 valve coils and simplifies the integration of pneumatics into machines by using a rotatable sub-base connection for aligning the air supply connections. Pressure valves can be used instead of directional control valves, allowing the outlet pressure to be adjusted to lower operating costs.


SENSORS AND MEASUREMENT

Festo has developed an inductive proximity sensor which, it claims, is the first to fit into an 8mm T-slot on a pneumatic cylinder to allow flush mounting. The SIES-8M sensor, which can also be used to detect the position of metallic objects or the fingers of pneumatic grippers, incorporates a patented twin-LED indication system which can be seen at all times.

The sensor specialist ifm electronic had several new arrivals on its Hannover stand, including “the first industrial 3D sensor that can detect scenes and objects in 3D at a glance”. The efector pmd 3d sensor (above) has a 64 x 48 pixel matrix with each pixel evaluating its distance to an object using a time-of-flight technique, resulting in 3,072 distance values. From this, 3D images can be generated, and volumes, levels or surface areas evaluated. A single chip performs the measurements and time-of-flight calculations.

The German sensor manufacturer Kubler used Hannover to announce “the first multi-turn optical encoder without gears and 100% magnetic insensitivity”. The Sendix F36 encoder has far fewer parts than conventional encoders and is designed to minimise wear and ageing, resulting in a long service life. It needs no battery and accommodates an 8mm hollow shaft or a 10mm blind hollow shaft in its 36mm size. A single chip provides the intelligence for single- or multi-turn operation with a resolution of up to 41 bits.

New from Moeller is a range of energy measuring and communication modules for monitoring circuit breakers and switch-disconnectors from 1.5–630A, 35–690V. The MCx modules can be used to calculate: phase and neutral conductor currents; rms voltages; active, reactive and apparent power; and power factor. They include an IP54-protected display.

On its stand, Parker Hannifin was demonstrating a portable instrument for commissioning, preventive maintenance and troubleshooting duties. The Service Master Plus (above) is designed mainly to measure rotational speed, pressure, temperature and flow, and incorporates automatic sensor recognition and parameterisation. Up to 16 sensors can be connected via two CANbus networks, with the option for ten more.

Pepperl+Fuchs’ sensor portfolio now includes a magnetic incremental, rotary encoder with intelligent diagnostic and adjustment functions. The compact, IP67-protected MN140 sensor offers a resolution of up to 3,200 pulses/rev, and is said to be unaffected by dirt, oil or water.

P+F has also redeveloped its pulse-based distance-sensing technology, allowing it to be used in sensors of all sizes. The technology, which measures time of flight directly, is claimed to be superior to indirect processes such as phase correlation, and to produce unambiguous, reproducible results, regardless of variations in surface quality, colour or extraneous light. There are various versions available with ranges from 6–300m. One new model operates at temperatures down to –30°C with an accuracy of 0.5mm and a resolution of 0.1mm over a range of 150m.

Siemens has developed a power monitoring device that collects and records up to 200 values such as voltage, current, and active power and energy, to an accuracy of 0.2%. The Sentron PAC4200 (above) records more than 4,000 events and can be used to analyse network quality, including factors such as distortion current intensity, phase angles and 3rd to 31st odd-order harmonics. Average values for apparent, active and reactive power are stored as load profiles for 40 days.

Siemens also had several new sensors including: a flush-mounting inductive proximity switch for precise measuring of distances up to 3mm from metal objects; a three-size family of ultrasonic proximity switches with ranges of up to 10m, and built-in IO-Link support, allowing simple device replacement, sensor monitoring, and automatic parameterisation; and a magnetically mounted speed sensor for belt-driven conveyor pulleys, suitable for belt speeds up to 2m/s.


COMMUNICATIONS

B&R has expanded its X20 hub system with a fibre optic module that increases the potential distance between decentralised remote modules up to 2km (compared to 200m for copper connections). The Austrian company has also added a four-channel IO-Link module to X20, providing connections to intelligent sensors and actuators.

Festo is supporting the Wisa wireless data transmission developed by ABB for short-distance communication between controls and I/O modules. It expects the main applications to be where controllers need to communicate with moving or rotating components which would normally need slip-ring connections for standard wired field buses. Wisa allows several hundred devices in a plant to communicate simultaneously.

Harting reported progress on its Fast Track Switching technology, announced at the SPS/IPC/Drives show, which will allow deterministic, time-critical communications to run on standard Ethernet cables and hardware, and will bring industrial Ethernet down to the field level. Prototypes have been tested and Harting expects the first products to emerge in the autumn of 2009.

HMS Industrial Networks has added an OPC server to its Anybus X-gateway family (above), allowing OPC-supporting applications to connect via standard Ethernet networks and X-gateway to any major field bus network. The free OPC connectivity function is available for 19 Ethernet to field bus versions of X-gateway. It will allow and PC-based OPC application to access data from field devices without needing a PCI field bus card.

New from ifm is a module that combines the AS-i wiring system with IO-Link communications, providing a data connection and a power supply for two IO-Link devices. Sensor settings can be saved centrally and transferred via the module to new sensors. Status LEDs indicate AS-i and IO-Link operating states.

The energy chain specialist igus has developed a range of twistable fibre optic cables (above) designed to withstand continuous 3D movements in energy chains. The two-core cables have survived more than four million cycles on a testbed, involving torsional twisting through ±180 degrees, without affecting their data transmission capabilities.

For the first time, the Lapp Group is offering active field bus components, in addition to the passive components in its Unitronic series. The new devices support all the main field bus systems and are designed for quick and easy installation of sensors and actuators in decentralised automation systems. Lapp has also launched quick-fit devices for networking AS-i sensors and actuators. A locking mechanism allows tool-free connections to AS-i cables.

Moeller was demonstrating the latest developments in its SmartWire-Darwin technology (above) for networking switching devices without using conventional control wiring or I/O modules, thus saving cabinet space. Data is transferred via gateways to PLCs using standard field buses, and up to 99 modules can be connected to a network over distances of up to 100m. Connections to switchgear are made using function modules fitted to contactors. Software is available for planning SmartWire-Darwin networks.

Phoenix Contact unveiled several communications developments, including an adapter that allows automation devices to be integrated into wireless LANs. The IP65-protected FL WLAN EPA adapter can be connected directly to the Ethernet port of an automation device and incorporates a circularly-polarised antenna to provide reliable communications in industrial environments.

Phoenix also has a new range of GSM modems for communicating with remote Ethernet networks. As well as dial-up GSM connections, the modems support TCP/IP-based GPRS connections at data rates of up to 210 kbit/s. At Hannover, Phoenix also launched a range of lean managed switches that can connect copper-based Ethernet devices or network segments to any type of fibre optic Ethernet network.

Another company that has been busy on the communications front is Siemens. It has developed a pair of communications processors for connecting PCs and its S7-300 PLCs to Profibus and industrial Ethernet networks. The Simatic Net CP 5711 adapter links PCs, via their USB ports, to Profibus at speeds of up to 12Mbit/s. The Simatic Net CP 343-1 ERPC module connects S7-300 CPUs with databases via industrial Ethernet.

In addition to several new ranges of Ethernet switches, Siemens also announced a network management software package for planning, simulating, and configuring industrial networks. The Sinema Server software diagnoses and visualises Ethernet networks and logs network activity data. It can also help users to react quickly to network faults.

Vipa was demonstrating a Teleservice Module that provides remote communications with control systems via Ethernet or GSM/GPRS. The modules can gather and transmit machine data and send this in the form of graphs, tables or text files. They can also be used to configure controllers remotely, and can raise an alarm – by email, text message or SNMP – if preset parameter limits are exceeded.

Weidmüller is using the Bluetooth technology in a new range of wireless modules for short-range communications with sensors and actuators. The IP67-protected SAI Bluetooth gateways (above) act simultaneously as Profibus DP stations and Profibus slaves, communicating with up to six slaves. Up to 31 “piconets”, each comprising a gateway and six slaves can be created, to support installations of up to 186 Bluetooth modules.


SOFTWARE

At Hannover, Baumüller was demonstrating its ProMaster Engineering Framework software (below) for automation system engineering, based on Microsoft’s .Net technology. Data and programs from individual devices are contained in a project-dependent XML structure. Editors for individual sub-disciplines have the same look and feel, reducing complexity and boosting efficiency. Drag-and-drop functions are used to create projects and applications, as well as EtherCat and CANopen bus topologies. The software also allows safety functions to be integrated into automation engineering.

Beckhoff has integrated robotics, motion control and PLC functions in a software package it calls TwinCat Kinematic Transformation. It says that the software will eliminate the need for dedicated CPUs for robotics, as well as reducing engineering costs. Because complex communication between CPUs is no longer needed, performance and accuracy will be improved, Beckhoff predicts.

Rittal subsidiary ePlan was promoting the latest service pack for its PPE system, which supports planning processes from rough system designs though to detailed documentation including schematics. Service Pack 1 offers extended plant structure display options that provide all project participants with an overview. ePlan has also been working with the cable processing machinery specialist Schleuniger Automation on an interface between ePlan’s Cabinet software and Schleuniger’s Easy ProductionServer to produce ready-cut and labelled cables for use in cabinets.  

A drive system design tool originally developed by Lenze for internal use, is now being made available to external customers. The Drive Solution Designer (DSD) tool (above) analyses complete systems including motors, drives and mechanical components and can be used to compare alternative configurations on both cost and performance criteria, including energy consumption.

Parker Hannifin’s Legris subsidiary has produced a software tool which calculates the volume of air wasted through leaks and pressure losses in compressed air networks, and estimates the costs associated with these losses. The Transair Energy Efficiency Calculator shows users where they could be making savings and produces lifetime payback calculations.

The next Hannover Fair will be held from 19-23 April 2010, with Italy as the partner country.

 
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