Author: Ken Cheng

Industrial automation systems have revolutionized manufacturing and processing industries, improving efficiency and productivity. However, with the increasing complexity of machinery, ensuring worker safety has become a significant challenge. Safe Torque Off (STO) is an essential safety feature in industrial automation system. Its key design is to mitigate risks and protect personnel and machinery.

What is Safe Torque Off

Safe Torque Off (STO) is a critical part of the overall functional safety framework compliant with international standards such as IEC 61508 and ISO 13849. The primary purpose of STO is to ensure the controlled and safe deactivation of the torque produced by electric motors. This stops the motion of machinery in a controlled and secure manner. It allows for the decoupling of the motor from the load, ensuring that it cannot generate any motion or torque.

Read More

Introduction

The under evaluating of surge protectors is not something that is exclusive to the world of industrial automation.  People tend to buy them for their multiple outlet utility overlooking their actual value.  However, surge protectors play a very pivotal role in the function and protection of our devices.  Often their importance goes unrecognized until of course disaster strikes.  In the world of industrial automation, the importance of surge protectors is just as important yet overlooked as ever.

Read More

In today’s world of automation and robotics, precise control of machinery is critical. The ability to control the position, velocity, and acceleration of moving parts with pinpoint accuracy is essential. This is regardless of whether it’s in manufacturing, robotics, or aerospace. This is where AC servo motors come into play. These advanced electric motors have revolutionized the way we control and automate complex mechanical systems. In this article, we will delve into what AC servo motors are, how they work, and their applications.

Read More

In today’s technologically advanced world, electrical equipment plays a pivotal role in our daily lives. From industrial machinery to household appliances, these devices power our world. However, the safety and functionality of electrical equipment is not just about proper installation and maintenance. It also involves understanding and implementing the appropriate protection standards. One essential aspect of this is NEMA ratings.

NEMA, or the National Electrical Manufacturers Association, is a trade association based in the United States that represents manufacturers of electrical equipment. NEMA ratings are a standardized system used to classify and define the level of protection an electrical enclosure or housing provides against environmental elements, such as dust, water, and corrosive substances. These ratings are essential for selecting the right equipment for specific applications, ensuring durability, and maintaining safety standards.

Read More

When it comes to the debate on what what is the most crucial device in industrial automation; there exists and spectrum of varying opinions. Some argue that the VFD’s (Variable Frequency Drives) play the most crucial role. Others would believe that it is the motors themselves seeing as without their power and movement nothing can get done.  Ultimately all components in industrial automaton are crucial. However unless an operator can give commands for a function, the entire process doesn’t happen.  In order to achieve this, the operator has to be able to give commands to a symphony of devices. He conducts orchestra of machinery on when and how to play.  This where the industrial control panel comes into play.

Read More

Have you ever used a dimmer on a lamp or room light and wondered how you were able to adjust the brightness of light so easily? How about a running fan in your room on a hot day? Ever wondered what it was that allowed you to change how fast the fan went? Maybe you work at an assembly plant, and see the machines moving and performing tasks with precise speed and timing. Has it ever crossed your mind as to how these giant machinations can do such complicated things and not breakdown or catastrophically collide into one another? That is the wonder known as the Variable Frequency Drive or VFD.

So WTF is a VFD?

Variable Frequency Drives (VFDs), alternatively referred to as Variable Speed Drives (VSDs) or Adjustable Frequency Drives (AFDs), constitute a fundamental aspect of industrial automation. These electronic devices are meticulously engineered to govern the speed and torque of electric motors. They achieve tha by manipulating the frequency and voltage supplied to them. By exerting control over these parameters, VFDs grant the ability to finely regulate motor speeds. This results in optimized operational efficiency and performance across a wide array of industrial applications.

In the realm of industrial automation, VFDs offer a multifaceted range of advantages. Among their most prominent benefits is the potential for substantial energy conservation. By permitting motors to operate at lower speeds when maximum power output isn’t essential, VFDs contribute to marked reductions in power consumption, thereby fostering an environment of heightened energy efficiency. Moreover, these drives contribute significantly to the realm of process control and productivity enhancement. Through the implementation of gradual acceleration and deceleration of motors, VFDs curtail mechanical stress and wear on machinery, leading to prolonged equipment lifespan and diminished maintenance expenditures. Their capacity for intricate adjustments further facilitates seamless synchronization with other processes and components, ultimately culminating in elevated product quality and consistency within the sphere of manufacturing and production.

A Brief History in VFD’s

The history of Variable Frequency Drives (VFDs) traces back to the mid-20th century. During this time advancements in power electronics and control systems set the stage for their development. The initial concept of controlling motor speeds by varying the frequency of the power supply emerged in the 1960s. However, the state of electronics at the time limited the technology. The 1970s saw the advent of solid-state devices like thyristors and later insulated gate bipolar transistors (IGBTs). These components enabled more efficient and precise control over motor speeds by allowing the modulation of voltage and frequency.

By the 1980s, the electronics industry had made significant strides, making VFDs more practical and cost-effective. Advances in microprocessors and digital control algorithms led to the emergence of more sophisticated and versatile VFD systems. These drives gained traction in various industries where precise speed control and energy efficiency were crucial. Some examples include HVAC systems, pumps, and conveyors. The turn of the millennium saw further improvements in power electronics, enabling higher switching frequencies and greater efficiency. Additionally, advancements in communication protocols and networking facilitated seamless integration of VFDs into larger industrial automation systems.

How Are VFD’s Used

Variable Frequency Drives (VFDs) operate based on the principles of pulse width modulation (PWM) and voltage-frequency control. These drives consist of three main components: a rectifier, a DC bus, and an inverter. The process begins with the rectifier, which converts the incoming AC power supply into DC voltage. This DC voltage is then stored in the DC bus, creating a stable power source. The inverter stage is where the magic happens. The VFD generates variable frequency AC output by rapidly switching the DC voltage from the bus into a series of pulses through the inverter’s transistors. The width of these pulses determines the effective voltage and frequency delivered to the motor, effectively controlling its speed and torque.

To elaborate on the concept of pulse width modulation (PWM), imagine turning a light switch on and off very rapidly. When the switch is on, the light receives full power, and when it’s off, the light receives no power. By adjusting the duration of the on and off states, you can regulate the average power delivered to the light, thus controlling its brightness. Similarly, VFDs use PWM to regulate motor speed. The width of the output pulses corresponds to the voltage and frequency applied to the motor. By adjusting this pulse width, VFDs can provide a wide range of speeds, allowing precise control over the motor’s performance.

Voltage-frequency control is another fundamental aspect of VFD operation. The relationship between voltage and frequency needs to be maintained within certain limits to prevent overloading the motor. As the frequency changes, the VFD adjusts the voltage to maintain an appropriate ratio. For example, as the frequency is reduced to slow down the motor, the VFD decreases the voltage proportionally to ensure the motor’s torque remains consistent. Conversely, at higher frequencies, the VFD increases the voltage to sustain the motor’s torque output. This coordinated adjustment of voltage and frequency ensures the motor operates within its safe and efficient operational range, enabling seamless control over its speed and performance in various industrial applications.

What Uses a VFD?

Implementing VFDs in industrial settings involves careful planning and integration to harness their benefits effectively. First, a thorough assessment of the application’s requirements and the specific motor system is necessary. This includes considering factors like load characteristics, torque demands, and desired speed ranges. Once the appropriate VFD is selected, the installation process involves connecting the drive to the motor and the power source. It’s essential to ensure proper grounding, wiring, and following manufacturer guidelines for correct setup.

After physical installation, configuring the VFD settings becomes crucial. This involves programming parameters such as motor nameplate data, acceleration and deceleration rates, maximum and minimum speed limits, and control modes (e.g., open-loop or closed-loop control). Advanced VFDs might also offer features like communication interfaces (such as Modbus or Ethernet) to integrate with larger automation systems for centralized control and monitoring. Careful tuning of these parameters ensures that the VFD operates optimally, delivering the desired motor performance while minimizing energy consumption and wear on equipment.

Implementing VFDs also requires considerations for safety and maintenance. Properly trained personnel should handle VFD installation and configuration to prevent accidents. Regular maintenance and periodic inspections are necessary to ensure the drives and associated components are functioning correctly. Monitoring for anomalies, such as overheating or unusual noises, can help detect potential issues early and prevent costly downtime. As technology evolves, the implementation of VFDs might also involve exploring predictive maintenance strategies that leverage data analytics and sensors to anticipate maintenance needs and enhance system reliability.

Conclusion

VFDs stand as a testament to synergy between technological innovation and industrial efficiency. VFDs have transformed the way we control and optimize electric motor-driven systems. Not only do VFDs empower industries to achieve unparalleled precision and performance through dyanmic controls. They also contribute significantly to energy conservation, equipment longevity, and process refinement. As industries continue to evolve and prioritize sustainability, VFDs will undoubtedly remain at the forefront of this evolution. VFDs continue to drive innovation, enhance productivity, and leading to a more efficient and environmentally conscious industrial landscape.

On the surface, The Internet of Things (IoT) may sound like tech jargon for something really complicated and sophisticated. In a way that is true when you get into the technical aspects of “how”. The formal definition of the IoT is: the interconnection via the internet of computing devices embedded in everyday objects, enabling them to send and receive data. Fundamentally however, IoT is just a really fancy way of saying all our home devices and technology are capable of connecting and talking to one another.

What makes up the Internet of Things

The Internet of Things is often characterized by different features. While all these features may not be in every device, generally all devices have more than one of these.

Devices and Sensors

Device and sensors describe physical objects equipped with communication interfaces that collect (sensors) and transmit (actuators) data. These devices can range from simple household appliances like thermostats and smart lights to more complex industrial machinery and vehicles.

Connectivity

IoT devices rely on various communication technologies to transmit data. These technologies can include Wi-Fi, Bluetooth, cellular networks, Zigbee, LoRa, and more. The choice of connectivity depends on factors like range, power consumption, and data bandwidth.

Data Processing and Analytics

The massive amount of data generated by IoT devices needs to be processed, analyzed, and interpreted to extract meaningful insights. This often involves using cloud computing resources and advanced analytics techniques, such as machine learning, to derive valuable information from the collected data.

Cloud Computing

IoT devices typically send their data to cloud-based platforms for storage, processing, and analysis. Cloud computing provides the scalability and computational power required to handle the vast quantities of data generated by IoT devices.

Applications and Services

IoT data creates a wide range of applications and services. These can include remote monitoring and control of devices, predictive maintenance of machinery, smart homes and cities, healthcare monitoring, environmental monitoring, and more.

Security and Privacy

When it comes to the collection and transmission of sensitive data, security and privacy are major concerns. In IoT, ensuring the confidentiality, integrity, and authenticity of the data is crucial.

Interoperability

The seamless interaction of various IoT devices and systems is essential for the success of IoT ecosystems. Standards and protocols ensure compatibility and smooth communication between devices from different manufacturers.

The History of Things

The Internet of Things as a concept spans back several decades. However, its development into a widespread and recognizable technology trend began in the late 20th century.

Pre-Internet Origins (1960s – 1980s)

The idea of interconnected devices predates the internet itself. In the 1960s, early computer networks like ARPANET laid the foundation for later

The Term “Internet of Things” (1990s)

Kevin Ashton, a British technology pioneer, coined the term “Internet of Things” in the late 1990s. Ashton was working on radio-frequency identification (RFID) technology, which used small chips to communicate data over short distances. He used the term to describe a system where physical objects connected to the internet, sharing data without human intervention.

Development in the Early 2000’s

 In the early 2000s, developments in sensor technology, wireless communication, and data processing began to pave the way for practical IoT applications. This decade saw the emergence of various projects and initiatives exploring IoT concepts, including smart homes, industrial automation, and RFID-based supply chain management.

The 2010’s to the Present

The proliferation of wireless communication technologies, such as Wi-Fi, Bluetooth, and cellular networks, played a crucial role in enabling widespread IoT adoption. As these technologies became more accessible and cost-effective, IoT devices could communicate over longer distances and with greater efficiency.

It also gained momentum in specific industries, such as manufacturing and agriculture. Here, sensor-equipped machinery and data analytics improved efficiency and productivity. The concept of “Industrial IoT” (IIoT) emerged, highlighting the use of IoT technology in industrial processes and automation.

By seamlessly connecting machinery, sensors, and control systems, IoT has enabled the creation of “smart factories” that operate with heightened responsiveness and optimization. Real-time data from IoT-enabled sensors monitors every facet of production, offering insights into variables such as temperature, pressure, and quality. This data-driven approach empowers manufacturers to implement predictive maintenance strategies, identifying potential equipment failures before they occur and minimizing downtime. This results in a substantial reduction in operational costs, increased productivity, and enhanced product quality, as intelligent automated systems replaced manual processes. These systems can adapt to changing conditions in real time.

Moreover, IoT’s impact extends beyond the confines of individual factories. Supply chains have become more transparent and interconnected, as IoT-enabled tracking devices provide real-time visibility into the movement and status of goods at every stage. This heightened visibility enhances inventory management, reduces delays, and allows for agile responses to market demands. The convergence of IoT with advanced data analytics and artificial intelligence offers the potential for more sophisticated decision-making. Manufacturers can optimize production schedules based on predictive demand trends, allocate resources efficiently, and even customize products in response to specific customer preferences. As the synergy between IoT and industrial automation deepens, it is reshaping traditional manufacturing paradigms and propelling industries into a future defined by intelligent, interconnected, and agile production ecosystems.

Conclusion

The IoT continues to expand its influence across various sectors, including healthcare, transportation, agriculture, and more. As technology advances, the IoT is becoming more integrated with other emerging technologies like artificial intelligence (AI) and edge computing. Edge computing allows data processing to occur closer to the source, while also reducing latency and improving real-time decision-making.

While the IoT has come a long way, challenges remain, including concerns about security, privacy, data governance, and the need for continued standardization. However, as technology continues to evolve, the IoT poises an even more significant role in shaping the way we interact with the digital and physical worlds.