Centa Gears

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

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Rockwell Automation is a global provider of industrial automation, power, control and information solutions


Features 

Hannover Fair 2011 Show Report

Visitor number at the 2011 Hannover Fair in Germany were close to pre-recession levels, spurred by the strong revival of the German manufacturing sector. There were more than 5,000 product innovations on show, some of which we describe here.


After last year’s Hannover Fair, when the disruptive effects of the Icelandic volcano contributed to a slump in visitor numbers from 210,000 (in 2009) to just 150,000, some observers wondered whether the world’s largest industrial trade show could ever recover.

So, it was with some relief that the show’s organisers reported that by the time this year’s five-day show closed on 8 April, more than 230,000 visitors had passed through the turnstiles. (They hailed this as “the best outcome in ten years” even though the 2007 show had attracted more than 240,000 visitors.)

According to Dr Wolfram von Fritsch, chairman of the show’s management board (above), the 2011 Fair has given German industry “a real boost, powering it up to drive the economic recovery”.

The 2011 Fair attracted more than 6,500 exhibitors from 65 countries and 60,000 foreign visitors – a third more than the last comparable show in 2009. “Our foreign visitors, alone, would have filled over 150 jumbo jets,” a delighted von Fritsch declared.

The resurgence of the Hannover Fair reflects the buoyant state of the German industrial sector. ZVEI, the trade body that represents the sector, is forecasting that it will expand by 10% this year (a 3% improvement on a figure it gave last December). ZVEI expects the sector to generate sale worth more than €180bn in 2011, compared to €164bn in 2010.

Despite the upbeat noises, some big names from the automation sector were missing from this year’s show – including Rockwell, Omron and Yaskawa. But these will probably be at the SPS/IPC/Drives show in Nuremberg in November which, for many companies operating in the automation sector, has become a more important and focused exhibition than the sprawling Hannover event.

But there were plenty of automation and motion engineering companies showing their wares in Hannover and over the next few pages, we will look of some of the 5,000-plus innovations that the organisers estimate were on display.                                                    

 

DRIVES AND MOTORS

The Italian motor and gearbox manufacturer Bonfiglioli used Hannover to launch a new corporate image, logo, Web site and slogan ("power, control and green solutions") on two stands. It was showing compact new ranges of IE2 motors and gearmotors which use larger optimised stators to cut copper losses without sacrificing power.

Control Techniques showcased a rig for testing hybrid and electric vehicles, using its standard Unidrive SPM modular inverters to produce DC power and to regenerate power during braking. One inverter simulates the characteristics of the EV batteries. Two regenerative drives power the EV drive system and a common DC bus recirculates energy from the EV motors back to the supply, thus minimising energy consumption.

GE Energy announced an IE3 motor range (above) suitable for extra-severe-duty applications, and rated for Zone 2 and Division 2 hazardous areas with a T3 or lower temperature code. During tests, the X$D Ultra 841 IEC motor continued to operate after one million plug reversals. It complies with IEEE 841-2009, comes with an individual test report, and has a five-year warranty.

The German drive specialist Heinzmann unveiled a third generation of motors for low-speed, high-torque hybrid drive applications. The robust, low-loss motors incorporate concentrated single-tooth windings and are cost-effective to produce even in small volumes, according to the company.

Drum motor specialist Interroll demonstrated its maintenance-free RollerDrive EC310 system, designed to replace conventional mechanical conveyor components and to cut energy use by up to 30%. The matching DriveControl rugged decentralised drives – available in IP20 or IP54 versions – interface via optically decoupled I/Os.

Lenze has developed a memory module copier (above) designed to simplify commissioning and servicing of its 9400 servodrives and 8400, smd and smv inverter drives. All of a drive’s parameters can be programmed without needing to switch it on. The copier can be used to commission a series of drives or to transfer parameters from one drive to another. It is operated using a single pushbutton.

The Korean company LSIS – formerly LS Industrial Systems – was showing two new ranges of drive: the Starvert iG7 “intelligent” drive and the Starvert iE7 “economical” drive. The iG7 covers single-phase ratings from 0.4–22kW and three-phase from 0.4–22kW (200 or 400V). It is available in IP20 or IP66 versions and offers dynamic braking, PID control and safe stop functions. The tiny (68 x 128 x 88mm), IP20-protected iE7 covers single-phase ratings from 0.1–2.2kW and three-phase from 0.4–3.7kW. It offers a choice of V/f or sensorless vector control and incorporates PID and safe stop functions.

Nord Drivesystems has announced a new top-of-the range decentralised frequency inverter with built-in PLC functions. The rack-mounting SK540E drive can control other inverters via CANopen and is Nord’s first inverter that can control synchronous motors. The company was also showing a motor-mounting inverter in ratings up to 7.5kW, with optional plug-in EtherCat and Profinet modules. Later this year, Nord plans to launch a range of IE3 motors with copper rotors.

Nord was also showing a range of “technology boxes” that will integrate its SK500E and SK200E inverters into Profinet environments. The boxes, which support real-time data transfer, can connect several inverters to one bus. An Ethernet switch, Web server and Profinet status display are built in, with fibre optic support as an option.

Parker Hannifin has produced a pair of option boards that add registration functions to its AC890 modular systems drives for shaftless printing and converting applications. The boards allow 1V sin/cos encoders to connect directly to a drive for accurate speed feedback and registration.

Parker has also enhanced its Compax3 servodrives to offer safety functions, such as safe torque off. Other safety functions can be added using an optional card. The Compax3 drives are also now available with Profinet communications ports.

Parker has broadened its range of frameless torque motors to include smaller models with simpler mechanical designs. The rugged, wear-free, brushless TK130 motors – supplied as kits with separate stators and rotors for direct integration into machines – are aimed at applications needing smooth rotation, precision and high dynamics.

Finally, Parker has extended its range of brushless, permanent magnet servomotors down to 0.45Nm. The new NX1 motors cover torque outputs from 0.45–64Nm, power ratings from 0.2–13.7kW, and speeds up to 7,500 rpm. They use ten-pole PM rotors with concentrated flux for high torque densities and motion quality.

SEW-Eurodrive announced a compact decentralised gearmotor with controls and thermal protection integrated into its terminal box, saving cabinet space and cabling. The Movi-Switch-1EM (shown above) covers the ratings range 90–250W and incorporates a brake and an electronic switch for operating the motor in one direction. It can be controlled using binary signals or an optional AS-i interface.

SEW has also expanded its Movidrive B inverter family to include regenerative power supplies and matching inverters. The MDR61B supplies, available in 160 or 250kW ratings, provide connected inverters with energy and are designed to recover energy in applications such as lowering and braking. Built-in functions include filtering, line contactors and automatic precharging of the DC link. The matching MDX62B inverters are available in 160, 200 or 250kW (300, 380 or 470A) versions. THDi is said to be less than 5%.

SEW is now offering an EtherCat interface for its Movitrac B cabinet inverters and a module (FSE24B) which can retrofit EtherCat to existing inverters.

On its vast stand, Siemens was promoting its ranges of IE2 and IE3 asynchronous AC motors in two formats: general-purpose motors with aluminium housings, outputs from 550W–22kW and shaft heights from 80–160mm; and severe-duty cast-iron versions, with ratings from 2.2–375kW and shaft heights from 100–315mm. The IE3 versions have the same shaft heights as the IE2 models, allowing direct replacement. Siemens is also producing high-efficiency EISA-certified motors for the Nafta market.

Siemens has revised its 1FK7 series of servomotors (above) which it now offers in three versions: a basic Compact model; a High Dynamic version, with reduced rotor inertia for dynamic tasks with low load inertia; and a High Inertia version, for dynamic tasks involving high load inertias. The encoders have been decoupled mechanically from the motor shaft, making the motors more rugged and easier to service. They offer efficiency levels up to 94%.

Siemens has also enhanced its 1FW3 series of water-cooled torque motors, increasing the speed range from 250 to 600 rpm (for a 280mm axis height), and adding plug-in and solid-shaft versions to the previous hollow-shaft models. The rugged, compact machines offer precise concentricity and a high dynamic response and can replace gearmotor assemblies in some applications. The solid-shaft version is available in shaft heights of 150 and 200mm, while the plug-in version adds a 280mm option. All are available in ratings from 3–380kW.

On the drives side, Siemens has upgraded the CU320 controller for its Sinamics S120 line with a new chipset, allowing more axes to be controlled. A version of the CU320-2 controller is available with a Profinet interface, and S120 drives can now be commissioned via Ethernet as well as Profibus.

The Swiss drive manufacturer Technosoft announced a new version of its IDM680 intelligent servodrive which supports EtherCat communications for multi-axis applications requiring tight, centralised control. The drives can operate as slaves supporting CANopen over EtherCat, or can be programmed to execute complex motion programs at the drive level.
 
At Hannover, the Brazilian motor and drives manufacturer WEG announced two new ranges of drives spanning ratings from 0.75–132kW: a general-purpose range for OEMs called CFW700; and the company’s first range dedicated to HVAC applications (CFW701) which offers a built-in PLC and fan and pump macros. The drives are better tailored to the European market than WEG’s previous offerings.

The CFW700 promises accurate and reliable speed and torque control, with simple start-ups, multi-speed operation, PID control, auto-configuration and overload and over-temperature protection as standard. The less expensive CFW701 models offer HVAC-specific properties such as support for Bacnet communications. WEG was also showing a new family of modular drives spanning ratings from 350kW–2MW in seven sizes.


CONTROLS

ABB has launched a safety control system for SIL3/PLe applications based on its AC500 automation platform. Existing AC500 systems can be upgraded to safety operation by plugging in certified safety modules and implementing safety software in existing programs. Safety functions can be programmed under CoDeSys using the IEC 61131-3 structured text language, as well as function block and ladder programming. AC500-S programs can be verified using a patented source code checker, simplifying TÜV acceptance. Decentralised safety and non-safety modules can be operated simultaneously on the fast, real-time Profinet bus with ProfiSafe functions.

Eaton announced a touchscreen PLC/HMI incorporating a master for its SmartWire-DT system (above), which replaces the control wiring for components such as motor starters, inverters, circuit-breakers and sensors. Previously, connecting to a SmartWire-DT system had to be done via CANopen or Profibus. There will be five versions of the new XV102 PLC with screen sizes from 3.5–7 inches and the option of Profibus DP or CAN support, for integrating devices with these interfaces into a system. Up to 99 slaves can be connected to the SmartWire-DT master, which is configured using CoDeSys.

Eaton also announced several new I/O modules for SmartWire-DT, including four-channel input and eight-channel output digital models, and several modules for analogue sensors and actuators, including: a four-input module for current and voltage signals; and a module with five temperature inputs.

Kuhnke Automation announced an EtherCat-based “intelligent” I/O motion module which can connect DC and EC (electronically commutated) drives up to 250W to a control system. The processor built into its Ventura FIO four-quadrant controller can handle motion functions normally handled by machine controllers, thus improving processing speeds. It supports positioning, rotary control, torque control and synchronous control of multiple drives.

Kuhnke has also launched a range of Windows CE-based touchscreen PCs with EtherCat connections which, it says, cost less than conventional industrial PCs. The Ventura Scout embedded panel PCs are designed to control small machines and production systems. They are available with 7, 10.4 and 12.1-inch screens with front protection to IP65. The CE operating system is complemented by a CoDeSys soft-PLC which adds visualisation functions.

Lenze’s ECS servo system can now be ordered with a clock-synchronised EtherCat interface which, when combined with its L-Force Controller 3200C, can handle demanding multi-axis motion applications.

Lenze has also extended its L-Force System 1000 family to include bus couplers for Profinet, DeviceNet and Modbus TCP (in addition to the existing CANopen, Profibus and EtherCat couplers). I/O modules can be mounted on the side of the bus couplers. There are also three new 12.5mm-wide power distribution modules (24V and 10A or 4A) that can be used to set up a separate potential area and to connect three-core sensors to the system.

Metronix was showing a servo-positioning controller that can be mounted on a motor to provide speed, torque, positioning and sequence control. The IP67-protected DIS-2 controllers offer a choice of I/O, RS-232, CANbus or fieldbus communications. Another Metronix servo controller (the ARS 2000) supports CANopen-over-EtherCat and offers a choice of star or line topologies.

Nanotec was demonstrating a controller for stepper and brushless DC motors which has RS-485 and CANopen interfaces, and a “real” closed-loop encoder input which allows a stator’s magnetic field to be controlled via a rotary encoder, as with a servomotor. The SMC136 controller’s current is adjusted continuously to match the required torque, reducing power consumption and heat output. Nanotec has also integrated a CANopen interface into its SMC112 stepper motor controller, making it one of the smallest CANbus stepper controllers available.

Phoenix Contact used the Hannover Fair to launch a range of compact embedded box PCs for harsh environments. The rail-mounting Valueline BPC Mini PCs (above) have 1.1GHz Intel Atom processors and can run Windows Embedded, CE, or Linux operating systems. They will operate on 9–36V supplies, from –40 to +70°C, and consume just 4.5W.

Rexroth was demonstrating a new version of its IndraMotion MLC system for automating hydraulic, electric and hybrid drives, which users can program using one software tool. The system uses open standards such as Sercos III for Ethernet-based real-time communication, and supports decentralised control of up to 64 axes or centralised control of 32 axes. It incorporates an IEC 61131-3 compliant PLC.

Schneider Electric launched a 5.7-inch HMI designed for tool-free mounting. The 240 x 320 pixel STU 855 HMI has serial and Ethernet interfaces and can be used as a gateway – for example, to connect drives via Modbus or to exchange data with a master controller via Ethernet. The LED-backlit HMI has a built-in Web server.

Siemens has expanded its Simatic S7-300 family of controllers and improved their performance as well as doubling their memory. A new addition, the CPU 314C-2 PN/DP, is Siemens’ first compact CPU to offer two Profinet ports with switching capabilities. The CPUs have new firmware (version 3.3) that executes user programs up to nine times faster than before, and some CPUs are half their previous widths. Bit commands can be executed in 25–100ns, compared to 50–200ns for the previous generation.

Siemens also announced a family of compact, energy-saving embedded industrial PCs in two formats: Nanobox PCs (Simatic IPC227D) which can be mounted on machines or in small enclosures and offer a choice of DIN-rail, wall, portrait or landscape mounting; and Nanopanel PCs (Simatic HMI IPC227D) with integral high-resolution, widescreen touchscreens in sizes from 7–12 inches (with larger versions to follow). The IPCs (above), powered by Atom processors, are suitable for simple control, visualisation and communications tasks in tough environments.

For more demanding applications, Siemens has a new 19-inch rack industrial PC (Simatic IPC547D) using up to four-core Intel processors with integrated graphics functions. The PCs are available with 64-bit Windows 7 operating systems and up to 32GB of DDR3 memory.  


ELECTRICAL AND SAFETY

Eaton has extended its circuit-breaker portfolio to include high-power models that operate at 690V AC. The new MZML2 offers electronic tripping to 160A, while the NZML3 goes up to 400A at 690V and has an 80kA switching capacity. The breakers can be used in motor control centres controlling up to 350A. They are designed for at least 10,000 switching operations.

At Hannover, igus announced more than 80 new products, including: a redesigned version of its E6 energy chain system that is 37% lighter, quieter and easier to install; an efficient roller chain (E2/000) for long-travel applications which is said to need 75% less driving force than previous systems; a “light” version of its E4.1 energy chain, which has more space for cables and hoses and is suitable for dynamic applications; and data cables with 30% smaller bending radii than previously possible.

Phoenix Contact has expanded its SafetyBridge system with new logic modules and safety-relevant output modules. Up to 48 single-channel or 24 dual-channel I/O are supported and there are now 14 safety modules, from emergency stops to muting blocks. The SafetyBridge system is independent of networks or control systems and can be used to network devices without a safety-relevant control system.

Pilz has launched a device for monitoring the electrical safety of insulated supplies and preventing power failures caused by short circuits. The PMD s20 (shown above) monitors the insulation resistance of unearthed AC/DC systems and can also monitor de-energised systems. Values are set using a rotary encoder and can be stored on a memory card for transfer to other devices.

At Hannover, Rittal celebrated its 50th anniversary with a slew of new and improved products. For example, it has collaborated with the German motor control specialist Trips to offer a high-availability MCC with slide-in equipment, based on its Ri4Power switchgear system. The Trimot MCC’s rack modules are suitable for motor loads up to 160kW. Up to 22 of the 75mm-high modules can be incorporated per rack space, and can be replaced even under voltage. Patented lateral contacting of the rack modules avoids accidental arcing.

Rittal also showcased several cooling technology enhancements. For basic fan-and-filter cooling, it has extended its TopTherm range to handle up to 900m3/h. The system uses electronic commutation and a diagonal fan system that combines radial and axial technologies to provide an even distribution of air in an enclosure. For enclosures with higher cooling demands, Rittal has redesigned its aluminium air/water heat exchanger technology and introduced intelligent controls for improved efficiency when cooling loads from 500–5,000W. Finally, the company has also revamped its aluminium cold-plate technology for cooling frequency inverters. In the latest version, the cooling liquid flows mainly horizontally rather than vertically, providing uniform heat dissipation and allowing water connections from either side.

On its stand at Hannover, Schneider Electric was showing a mid-range soft-start with torque control functions previously available only on high-end models. The Altistart 22 allows a linear increase in torque during the acceleration phase and a linear decrease when slowing down. In pump applications, this prevents pressure fluctuations and water hammer.

SEW-Eurodrive announced a pair of safety modules for protecting up to 12 axes to SIL3/PLe. Logic processors in the Movisafe UCS50B and UCS51B modules allow flexible linking of inputs and outputs, up to 150 digital I/O and 54 outputs. They are said to provide almost all of the safety functions in IEC 61800-5-2 and can eliminate the need for mechanical protection. Output signals can be sent to safety PLCs.

Siemens has added various communications and diagnostics functions to its Simatic ET 200S High Feature motor starter, which can switch and protect three-phase loads up to 7.5kW. For example, new Profinergy functions allows the starters to be integrated into energy management systems while the new DP V1 profile for Profibus and Profinet offers acyclic data services which, combined with expanded statistics and diagnostics data, provides extra information for plant and device monitoring. There are also three new “logbooks” for monitoring events such as tripping and device faults. 

Siemens has also added two failsafe digital modules to its Simocode pro motor management system. The DM-F Local module shuts down a motor in response to a local failsafe signal from a sensor or controller, while the DM-F Profisafe receives failsafe signals from safety controls via Profibus. Both provide safety to SIL3/PLe.

New from Wago is a failsafe Profisafe I/O module with four digital inputs and one digital output. The 75x-666 module supports Profisafe V1 and V2 and has a configurable failsafe output with two semiconductor switches (10A, 24V) and four clock-sensitive inputs. It monitors short-circuits, cross-circuits and the 24V supply for both inputs and outputs.


MECHANICAL AND LINEAR

Baumüller used Hannover to launch two new series of planetary gearboxes, said to be shorter, quieter and more efficient than their predecessors. The BPNF boxes with integrated flanges offer a backlash of less than a minute and come in 12 ratios and four sizes. The right-angle BPNA boxes (shown below) are smaller, lighter and more efficient than the earlier BPSA series and use a hypoid tooth system to reduce wear and noise. They come in four sizes and 11 ratios.

ContiTech’s power transmission group has expanded and optimised its range of industrial belts for the global market. For example, it has introduced new profiles, dimensions and power categories for raw-edged and classic V-belts, and launched a double-section V-belt range. The company has also developed a carbon-black-free range of rubber industrial timing belts for environmentally sensitive applications.

At the 2009 Hannover Fair, igus previewed a lightweight, plastics-based modular robot system designed to cut the cost of implementing robotics. At the 2011, show it announced 19 new products for the system which is driven by cables powered by drives modules located away from the movement mechanisms and tools, thus minimising moving masses. More than 100 beta testers are already experimenting with the system.

More conventional mechanical developments on the igus stand included lubrication-free polymer plain bearings that incorporate 54% of renewable materials, and high-helix nuts with a zero-backlash mechanism for low axial backlash over the nut’s service life.

KTR announced a compact, hydraulically-operated brake system which, it says, offers improved performance and reduced wear compared to earlier models. The lightweight, high-power-density KTR-Stop brakes will be available in six sizes and incorporate an “intelligent” control system for programming the braking process.

Nanotec has added an encoder option to its hybrid linear actuators, allowing closed-loop operation for error-free operation at high positioning speeds. The actuators use low-friction, self-lubricating thermoplastic nuts running on trapezoidal leadscrews – said to double the efficiency of systems using conventional bronze nuts. The actuators can provide a resolution of 0.0025mm/step and can move at 1mm/s.

Nord Drivesystems was previewing a range of two-stage helical-bevel gearboxes for washdown duties, which are due to the reach the market at the end of 2011. There will be five sizes of the compact, lightweight boxes with diecast aluminium casings and torque ratings from 90–660Nm.

Parker Hannifin is offering a delta robot for pick-and-place applications such as packaging in high-volume production environments. The 45kg robot, with carbon fibre arms, can handle payloads up to 3kg and has a working radius of 1,130mm. A fourth (rotary) axis can be added to the low-maintenance machine’s standard three axes.

Rexroth has announced a range of ironless linear motors (above) designed to position small masses accurately and dynamically. The aluminium primary of the MCL motors contains a three-phase copper winding, while the U-shaped secondary contains permanent magnets. This design results in a linear force constant with no cogging. The motors – available in four sizes delivering 20–1,700N of force – can accelerate at up to 300m/s2 and achieve a top speed of 26m/s.

Rexroth has also developed a range of planetary screw assemblies designed to move heavy loads quickly. They need less installation space and are quieter than ballscrews of a similar capacity. The assemblies are available in five sizes with dynamic load capacities to 231kN and static load capacities up to 475kN. Initially they offer screw diameters of 20, 30 and 48mm and leads of 5 and 10mm.

With the latest additions to its FAG X-life high-performance tapered roller bearings, Schaeffler claims it is offering the world’s biggest range of these components, including sizes not previously available. The bearings are said to exhibit up to 75% less frictional torque than standard products. Dynamic load ratings have been increased by 20%, efficiency has been improved, and the rating life increased by up to 70%. Schaeffler also presented three new INA needle roller bearings, promising better performance, reduced friction and smaller dimensions (with a radial section height of just 1.5mm in one case).

Schaeffler’s linear technology business is now offering complete, ready-to-use multi-axis handling or gantry robot systems, based on its modular system of linear components and actuators. The systems are said to save time and costs. They offer stroke lengths up to 30m, traverse speeds up to 10m/s and can handle masses up to 500kg.

SEW-Eurodrive has extended the helical and helical-bevel gearboxes in its X Series so that they now span torque ratings from 6.8–475kNm. The high-power-density boxes offer ratios from 6.3–450 and a wide range of modular options, such as motor adaptors and mounting flanges.

Siemens has also been enhancing its gearboxes, boasting that its new Flender SIG range of standard industrial gearboxes offer up to 15% more torque that the previous generation while being a similar size and weighing less. The first phase of the launch is focusing on two- to four-stage helical and bevel-helical gearboxes with torque ratings from 3.6–125kNm. Later, the range will be expanded to cover 20 sizes with torque ratings up to 500kNm.

 

FLUID POWER

Festo announced a Profisafe module for its CPX valve terminals (shown below) which can be used with Profinet bus nodes to disconnect voltages safely from VTSA valves. The safety function is integrated into the terminal, eliminating external wiring. The CPX-FVDA module has three digital output channels, including one that disconnects power to the valves internally.

Parker Hannifin was showing an electrohydraulic cylinder which incorporates a precision feedback transducer that allows fast, accurate electronic control. The HMIX cylinder is said to respond rapidly to control signals for position and velocity without needing mechanical resetting. The internal magnetostrictive transducer provides analogue or digital information on the actuator position. In closed-loop systems, it allows accurate position, velocity or motion control, and in open-loop applications is can act as a continuous position monitoring device. The cylinder offers stroke lengths up to 3m.

At Hannover, Rexroth announced a decentralised, integrated single-axis controller for hydraulic installations which closes control loops locally, thus reducing wiring. The controller supports Sercos II, EtherCat and Varan, allowing precise, real-time control of dynamic motion tasks, and supports both open- and closed-loop operation.

Rexroth is promising compressed air savings of over 50% (depending on the application) from a new range of cylinder valve units for decentralised pneumatic applications. The CVI series, which includes two ISO cylinder series with diameters from 32–125mm, allows tubing lengths to be reduced and flow rates dimensioned to meet exact needs. An online configurator is available to help plan installations.


SENSORS AND MEASUREMENT

Baumer has developed a magnetic encoder system for use on large shafts of almost any diameter. A flexible magnetic tape is buckled onto the shaft like a belt and can be exchanged easily. The non-contact Hdmag MGSP system (shown below) is said to be wear-free with an almost unlimited service life. The combined sensing and signal processing head has a ±5mm tolerance on axial displacement and allows airgaps up to 3mm, making it easy to align and immune from backlash and vibrations. Angular resolution is better than 0.003 degrees and is not affected by shaft expansion.

Baumer was also showing a family of hollow-shaft encoders for use in tough environments, including temperatures from –40 to +100°C, axial shaft loads up to 200N, and radial loads to 300N. The HOG-86 encoders offer a choice of connections, including terminal boxes that can be rotated through 180 degrees.
 
Beckhoff has redesigned its EL3403 EtherCat power measurement terminal to produce a new version (EL3413) which can measure up to 690V and avoids the need for a voltage transformer for currents up to 1A, thus cutting costs. Higher currents are measured via current transformers. Built-in harmonic analysis functions can be used for simple network analysis and measurements up to the 21st harmonic.

Phoenix Contact was demonstrating a family of three energy-measuring devices, designed to be easy to configure. A rail-mounting version (EMpro MA250) for cabinets has an RS-485 port for connection to Modbus and Jbus, as does the panel-mounting EMpro MA400 for use in panels up to 500V AC. The third member (EMpro MA600) is suitable for a variety of tasks in systems up to 700V AC, including current and power management, recording harmonics, spectral analyses and trend calculations. Plug-in modules are available to support various communications systems, including Web servers supporting Ethernet.

Pepperl+Fuchs says that its UMC3000 ultrasonic sensor raises performance in harsh environments to a new level. Its smooth stainless steel housing and chemical-resistant cable allows it be used in areas previously regarded as impossible for this type of device. The IP68/69K-protected device has an adjustable 200–3,000mm sensing range.

Pilz has announced an IP67-protected safe proximity switch that detects metal objects without making contact. The wear-free PSENmini switch can operate at high switching frequencies and detect objects with a high repetition accuracy. It can be connected in series with devices such as safety switches and gates, thus reducing the wiring needed.

Siemens has introduced a switched Profinet module for its PAC3200 and PAC4200 measuring devices, allowing energy values from industrial plants to be integrated into higher-level automation and power management systems via Profienergy or Profinet IO. Installation and commissioning costs are said to be minimal. The module is plugged into the back of the power-monitoring device and connected to the PAC and other Ethernet stations via a built-in Ethernet switch.

Weidmüller claims to have implemented signal splitter and sensor supply functions in 6mm-wide modules for the first time. It says that its fourth generation of devices for converting and isolating analogue signals will provide more cabinet space. The Ex Zone 2 approved ACT20M series includes one- and two-channel passive isolators, temperature transducers, DC isolating amplifiers as well as two-way signal splitters. Power can be supplied either directly or via a bus built into top-hat rails.


COMMUNICATIONS

One of Beckhoff’s Hannover launches was a device that makes it easy to connect EtherCat terminals to Profinet networks, thus giving Profinet users access to a wide range of EtherCat digital and analogue I/O. The EK9300 bus coupler acts as a Profinet RT device and integrates a simple EtherCat master, which connects EtherCat terminals using auto-configuration.

Nexans announced a series of industrial Ethernet switches with up to 24 ports for fibre optic or twisted-pair connections, with each port supporting Gigabit or Fast Ethernet data rates. The switches can be installed on a DIN rail, in a 19-inch rack or on a wall. They have two redundant power packs, and networks can be reconfigured in a few milliseconds. Up to eight connected users can be supplied with power via RJ-45 Ethernet connections.

Phoenix Contact has introduced a UMTS router with a 3G modem that can transfer data at 7.2Mbit/s. Protection is provided against unauthorised access to plants and the router incorporates a firewall and VPN connections. Six configurable switching inputs can be used to signal plant or system states via SMS or email. Four switching outputs allow sections of plant to be controlled by password-protected SMS messages. A second SIM card can be used to configure a redundant network.

At Hannover, Sercos International unveiled a new image and a new slogan “Sercos – the automation bus” to emphasise the system’s transition from a drive bus to an automation bus that can provide security, I/O communications, and other Ethernet protocols, as well as supporting drives applications. The company says that Sercos can reduce the number of interfaces needed, enabling standardised engineering and scalable functions.

Wago revealed a telecontrol module that uses GSM networks to monitor machine faults and positions. The To-Pass Mobile modules use quad-band GSM and can send messages via SMS, email, fax or phone calls, while switching outputs via SMS. Each module has four digital inputs, four analogue inputs and two digital outputs, and can receive GPS position data. Onboard memory stores up to 4,096 process images in an adjustable time cycle. One version of the module can transmit these images and GPS data to a user-selected Internet address.

Weidmüller was showing various industrial Ethernet switches including in three families: Basic Line (unmanaged); Value Line and Premium Line (managed). The Premium devices can be equipped with up to nine Gigabit or Fast Ethernet ports. Integrated ring redundancy technology boasts a recovery time of ≤20ms. The portfolio also includes Power-over-Ethernet switches that operate from a 24V supply and can supply up to 30W of power, thus eliminating the need for an extra 48V supply module.

 

SOFTWARE

Beckhoff has incorporated safety editors into its new-generation TwinCat 3 engineering environment, offering all of the functions needed for safety including: configuration; programming; diagnostics and safety performance level (PL) calculations for the revised Machinery Directive. The safety tools can be configured using a function block language or high-level C programming. There is also a software-based TwinCat Safety PLC that runs on an industrial PC. The PL calculator can access data already entered into the TwinCat environment, while external safety sensors and actuators are maintained in a database.

Eplan was promoting various aspects of its latest design software – Platform 2.0 – highlighting the fact that some of its 1,000-plus extensions are still not widely known. One innovation on show was an interface to Rittal’s new Therm 6.1 configurator for laying out and dimensioning heating, cooling and climate control systems.

A new master package for Eplan Fluid now bridges the gap between hydraulic and mechanical design, with more than 1,000 new macros speeding up and simplifying interdisciplinary documentation.  

Festo says that its FluidDraw Professional software will simplify the drawing of pneumatic and electrical circuit diagrams. The software takes users from an initial idea through to the planning of machines and systems. It manages and documents complex circuit diagrams and links electric and pneumatic symbols where this makes sense. The software, embedded in Festo’s Engineering Tools system, lists the electrical elements of pneumatics components automatically and updates the contactor and relay overview continuously, avoiding the risk of forgetting connections.

Rexroth is offering a free software package for creating complex pneumatic circuit diagrams. The D&C Scheme Editor 3.0 (above) allows symbols to be taken from a library, dragged-and-dropped onto a worksheet, and connected to form a circuit diagram. The rotatable components are aligned on a grid and parts lists can be generated for ordering purposes.

Version 6.0 of Rittal’s Power Engineering software satisfies the demands of IEC 61439-1/-2 and verifies switchgear designs and the rated currents of switching devices. Switchgear protection categories and mounting positions are taken into account and designs verified at the push of a button. The software supports Rittal’s Ri4Power modular system for LV switchgear and systems consisting of its TS 8 enclosures and RiLine60 modular busbar system. For the latter system, once an enclosure has been selected, and after entering the pertinent parameters, the busbar can be selected, positioned and configured.

SEW-Eurodrive has added energy consumption analysis and reporting functions to its Workbench software. Based on drive and application data, the software determines the energy consumption per cycle and annually, as well as the corresponding CO2 emission values. The TÜV SÜD testing organisation has certified that the methods SEW is using to determine efficiencies and power losses are correct, resulting in accurate consumption values. SEW claims it is the first manufacturer to have its energy calculations certified in this way by a third-party authority.

Siemens has announced a tool for maintaining and administering its Simatic industrial PCs remotely, allowing system or program errors to be rectified without making a site visit. The Simatic IPC Remote Manager uses Intel’s Active Management Technology, which can be used whether a system is switched on or is in standby. The software can also take over the remote PC’s mouse and keyboard functions, allowing an administrator to control the PC remotely and to set parameters.

Siemens has also released a selection tool called DT Configurator that makes it easier for users to choose a converter based on their application. First they choose the general type of application – such as motion, machining, or pumps and fans – and they are then offered possible applications in the chosen category. A further series of choices leads to suggestions of the most appropriate products for the application.



The 2012 Hannover Fair will take place from 23–27 April. It will include a new show called IndustrialGreenTec, focusing on industrial environmental technologies.


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