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White Papers: In Depth Research

Five Critical Factors for Selecting Fieldbus Valve Manifolds
Author: Numatics, Enrico De Carolis
Posted: 05/12/2011
In today's highly automated machines, fieldbus valve manifolds are replacing conventional hardwired solutions. They more easily perform vital functions by integrating communication interfaces to pneumatic valve manifolds with input/output (I/O) capabilities. This allows programmable logic controllers (PLCs) to more efficiently turn valves on and off and to channel I/O data from sensors, lights, relays, individual valves, or other I/O devices via various industrial networks. The resulting integrated control packages can also be optimized to allow diagnostic benefits not previously available.

Fieldbus valve manifolds from manufacturers such as Festo, SMC, and Numatics find wide utility in packaging, automotive/tire, and material handling applications, as well as in the pharmaceutical, chemical, water, and wastewater industries. They are specified for purchase by controls engineers at original equipment manufacturers (OEMs) who design and develop industrial automation solutions - as well as by end users in relevant industries.

This paper presents controls engineers, specifiers, and buyers with new insights into five crucial factors they must consider before selecting pneumatic fieldbus valve manifolds - commissioning, distribution, modularity, diagnostics, and recovery - while also outlining some shortcomings of conventional approaches. Finally, it highlights new designs that offer substantial improvements in the application, performance, and maintenance of these valve manifolds from the end users’ and OEMs' points of view.

Understanding Cable Assembly Molding
Author: Mike Levesque, Shawn Young & Brock Richard, C&M Corporation
Posted: 04/05/2011
While a molded cable assembly can offer significant advantages over a similar product of a mechanical construction, the art of insert molding remains somewhat of a mystery to cable assembly consumers. While attracted by the potential for a more aesthetically pleasing product that can be sealed from the environment and rendered 'tamper proof', the complexity of the insert molding manufacturing process is often over looked.

Many cable assembly engineers who are consumers - but not producers - of molded assemblies are familiar to some degree with conventional molding. In this environment, the goal is the maximization of process speed which translates directly to bottom line financial performance. Manufacturing lot sizes are often characterized by long runs, where the same part is produced continuously over a considerable amount of time. The molding machines are usually horizontal in construction, use a closed cavity approach with auto-ejection of the finished parts, and operate at much higher injection pressures and speeds than an insert molding process. Additionally, the often uniform nature of the parts relative to wall thickness, balanced runner systems, and sufficient draft on the molded parts being produced serve to support consistent quality in the face of maximum manufacturing speed. The ability to optimize tool cooling, standardize mounting, and implement automated processes are also major differentiators between the conventional horizontal molding and vertical insert molding approaches. The result, all things equal, is a much higher production rate for finished parts in a conventional molding process.

What then are the challenges of the insert molding process used to manufacture cable assemblies, and, more importantly, how are they met by the manufacturer? At a high level there are four major areas of consideration when discussing the intricacies of insert molding. These include the operator, tooling, equipment, and the process itself. Let's examine each of these in more detail.

Operator: As with any non-automated process, it is the operator who is often the most important component of the success or failure of a manufacturing lot. This is especially true in cable assembly molding. In addition to knowing the basics of machine operation, the operator has several variables to properly monitor and control if he or she are to produce parts that meet the established design and quality guidelines. In light of some of the equipment and component variability discussed earlier, some of these operator focused considerations include...

Improving SCADA Operations Using Wireless Instrumentation
Author: Control Microsystems
Posted: 06/29/2010
The purpose of this paper is to explore the particular ways in which operators can tightly integrate wireless instrumentation networks with SCADA and realize.

Integrating wireless instrumentation with SCADA systems can drive operational efficiency and reduce deployment costs.

The use of wireless instruments in pipelines and gas production operations has been gaining momentum over the past few years. Driven by cost cutting measures and the need to gain more operational visibility to meet regulatory requirements, wireless instruments eliminate expensive trenching and cabling while providing access to hard-to-reach areas using self-contained, battery-powered instruments. However, SCADA engineers and operators are facing the challenge of integrating wireless instrumentation networks with other communication infrastructure available in the field. Managing and debugging dispersed wireless networks presents a new level of complexity to field operators that could deter them from adopting wireless instrumentation despite the exceptional savings.

This paper will look into the particular ways in which operators can tightly integrate wireless instrumentation networks with SCADA and realize the full benefits of such an integrated solution.

High Slip Braking Software
Author: Mike Rucinski, Yaskawa Electric America
Posted: 05/17/2010
HIGH-SLIP BRAKING SOFTWARE PUTS THE BRAKES ON TRADITIONAL LOAD-BRAKING METHODS WITHOUT EXTERNAL EQUIPMENT
The techniques for braking of high inertial loads to a stop traditionally involved either Dynamic Braking or DC Injection Braking technology.

This article examines a new load-braking alternative called High-Slip Braking (HSB). We identify the different aspects of HSB, look at what it does, how it works, and how it is different from other braking methods. We also provide examples of "real world" successes, and discuss the new technology's cost effectiveness.

WHAT DOES HSB DO?
High-slip braking allows the stopping of larger inertial loads without the need for expensive and bulky braking options such as Dynamic Braking packages. Inertial loads involve only inertia and friction and given enough time, will tend to stop on their own when power is removed. HSB is most effective in applications involving infrequent stopping of inertial rotating loads where speed control during stopping is not required. Typical applications of this sort include; laundry equipment, centrifuges, large commercial fans, punch presses, blowers and mixers. Do not use HSB on overhauling static loads like; hoists, winches, elevators, product lifters, and similar applications. HSB is applicable only for complete stopping of the load and not as a means of braking for speed changes.

The HSB feature has proven to cut braking times in half without requiring extra equipment. The overall stopping time, however, does depend on the inertia of the load being stopped and the characteristics of the motor. HSB can achieve braking torque of more than 100% of the full motor torque.

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