Tag: Controllers

A PLC installed alongside other components

What Is a PLC (Programmable Logic Controller)?

Ben Wayand Leave a comment

What Does “PLC” Stand For?

A Programmable Logic Controller, abbreviated as “PLC” is a computer used to address the issues of a particular assembling process. These devices come in a wide range of shapes and sizes, with numerous alternatives for computerized and simple I/O, as well as protection from high temperatures, vibration, and electrical noise. The invention of the PLC allows for computers to be streamlined into the industrial automation process.

A PLC can be a solitary device figuring and executing operations, or a rack of various modules utilized to meet whatever your automation system requires. A portion of the extra parts include processors, power supplies, additional IO, interfaces, and more. Each part cooperates to have the option to run open or shut circle activities that are appraised at fast and high accuracy. Take a CNC machine for instance; a PLC would be utilized to control positioning, motion, and torque control. These devices are popular since they are inexpensive in relation to the amount of power and lifespan they possess. PLCs can run for hours on end. 

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Kawasaki E3/E7/E9 Controllers

Joe Kaminski Leave a comment

Being a leader of the robotics industry for over 50 years, Kawasaki has developed one of the most complete lines of e-controllers on the market. All of these controllers are suited with a wide array of features including:

  • High powered CPU performence
  • Large, easy to use LCD Display
  • Optimized key layout
  • Easily accessible safety switches

The E76/77 family of controllers are very compact and used for smaller robot arms. One of these arms are the RS003N Robot, which has a maximum payload of 3kg and has horizontal and vertical reaches of 620mm and 967mm, respectively. The controllers with these robots specialize in assembly and material handling applications.

The E9 family of robotic teach pedants are also built very compact, however these devices are typically used in medium-duty applications. Unlike the other two families of controllers, the E9 family features an open structure system with a direct cooling system. However, like the E7 and E3 families, the enclosed structure with indirect cooling is an available option. The E9 family takes full advantage of the digital servo drive powering it to have a maximum payload capacity of 40kg.

E30/32/33/34 controllers at their base are very alike the E76/77 controllers but with more power. These devices are not as compact as the previous devices we have discussed, however the reason being they are highly expandable and are easier to maintain. Features such as Kawasaki’s K-Logic sequencer software allow the addition of up to 16 total controllable axes. The E3 family of Kawasaki e-controllers are able to handle the following maximum payloads:

  • E30 – 145 kg
  • E32 – 180 kg
  • E33 – 195 kg
  • E34 – 180 kg

If you are interested in learning how to purchase the robot arm, the controller, or any other part/device that goes into an industrial robotic set-up, please call MRO Electric and Supply at (800)691-8511 or email us at sales@mroelectric.com and we will help you get what you need.

3HAC028357-001

ABB Robotics 3HAC028357-001 Teach Pendant

Joe Kaminski Leave a comment

The 3HAC028357-001 is a modern ABB Robotics Teach Pendant designed to be used with the IRC5 Industrial Robot Control, one of the most popular robotics controls on the market. Also known as the “FlexPendant”, the 3HAC028357-001 is characterized by its clean, color touch screen-based design and 3D joystick for intuitive interaction.

The 3HAC028357-001 TPU (or teach pendant unit) is a hand held operator unit used to perform many of the tasks involved when operating a robot system: running programs, jogging the manipulator, modifying robot programs and so on.

The FlexPendant is designed for continuous operation in harsh industrial environment. Its touch screen is easy to clean and resistant to water, oil and accidental welding splashes.

ABB FlexPendant

The 3HAC028357-001 replaces the legacy 3HAC023195-001 teach pendant.

The standard cost for a new ABB 3HAC028357-001 direct from the manufacturer or authorized distributor is typically in the $6000-7,000 range. MRO Electric is able to supply these pendants at a much lower price point, and we warranty all of our robotics parts for 12 months.

If you would like a free quote on a replacement ABB 3HAC028357-001, please email us at sales@mroelectric.com or call 800-691-8511.

Motoman Teach Pendants And More

Brian Hughes 2 Comments

Yaskawa Motoman, an American subsidiary of Yaskawa Electric Corporation, was founded in 1989 and since then have been able to get over 380,000 industrial robots, 10 million servos, and 18 million drives into automation systems around the world. Robots are the wave of the future and Yaskawa Motoman is at the top of this market. Using an automated robotic system in your work space will allow you to free up many other costs and resources that may not have been available before.  The key to efficiency is simplicity and using  Motoman Teach Pendants to give instructions to your robot makes that possible.

Teach Pendants are non-tethered devices that allow your robot to be controlled remotely. These devices are crucial for industrial robotics as they are not only used for assigning operations but they are able to edit commands, emergency stop commands, and even view past operations. Motoman Teach Pendants are split between the older models(ERC, XRC, MRC) and the newer models(DX and NX Series’).

MRC

The older models such as the MRC, which came out in 1994, were able to increase the workload of an industrial robot by up to 300%. This was also the first time ever that a single teach pendant was able to control two robots at the same time. Four years later when the XRC model was released, it was a huge improvement as Motoman was able to add control of more axes and even up its synchronous control of two robots to four industrial robots.

nx100

Later in 2004, the NX series of controllers was released. These devices featured Windows CE with a high-power processor, back-lit color touchscreen, built-in ethernet, and a huge amount of memory. A single teach pendant can control up to 36 axes and 4 separate robots. It’s Advanced Robot Motion control allows for the most accurate results. For information about the DX series, please visit one of our previous blog posts featuring the DX200 controller and Yaskawa’s new ArcWorld project.

Looking inside the ArcWorld 6000 and DX200 Controller

Brian Hughes Leave a comment

Yaskawa’s ArcWorld 6000 line of robotic welding systems offer the most cost efficient and powerful solution to your welding needs. ArcWorlds are pre-built, easy to install, and ready to run immediately after installation. The units can configured with multiple robots, a heavy duty positioner or servo controlled external axes. The 6000 line can handle payloads from 755 kg to 1255 kg over a 2 or 3 meter span.  There are many other cool benefits to running the ArcWorld over a traditional welding system:

  • All controllers and power sources are installed and shipped on the frame for minimal setup
  • The world class MA1440 arc used for welding can be combined with multiple robots to cut cycle time by 15%
  • Twist locking connectors for all cabling
  • Fully compliant with most recent robot safety standards (ANSI/RIA R15.06-2012)
  • A standard workcell is only documented and supported by Yaskawa Motoman

arcworld 6000

The RM2-Series Positioners are are powered with three AC servo motor drives and have a payload capacity of 1555 on each side. With a 6.5 second rapid indexing time, the positioners have a part length between 3000mm and 3500mm. Convenient slip ring built for  the fixture of utilites such as Ethernet and DeviceNet. The positioner uses MotoMount mounting technology inside of the Yaskawa ArcWorld Unit.

Typically used inside of the ArcWorld 6000 line is the DX200 controller. These controllers can coordinate motion between 8 robots with up to 72 axes. Its Advanced Robot Motion control gives the ArcWorld unit the ability to use the arc’s at their peak performance with pinpoint precision. DX200 controllers are available with Cat 3 Functional Safety Unit. Maintenance is hardly necessary as these controllers efficiently use energy and use top of the line prevention methods for most types of failures. Contact Yaskawa Motoman right now to inquiry on price options for different ArcWorld models and make your automation system perform at its best.

dx200

KUKA teach pendant

KUKA Teach Pendants

Joe Kaminski Leave a comment

MRO Electric and Supply distributes a variety of KUKA Teach Pendants for KRC1, KRC2, and KRC3 controls. We also can supply the new KRC4 smartPAD. The smartPAD pendant  is the latest type of KUKA teach pendant, designed to allow users to perform even the most complex operating tasks with ease – even those with little experience.  It features an 8.4″ display size with a industrial touch screen.

KUKA smartPAD Teach Pendant

The ergonomic design of the KUKA smartPAD creates a pendant with reduced weight and an anatomically comfortable operation. It can be used to operate all KUKA robots that have a KR C4 controller. Its 6D mouse allows for movement and reorientation of the robot on all axes.

All smartPADs are programmed using the KRL – KUKA programming language. This easy to learn robotics language is very intuitive, and can be used to create customized robotic motions with ease. You can also synchronize your programming with up to 6 KUKA robots. The other major benefit of the smartPAD teach pendant is that  it can be hot swapped at any time from a KR C4 controller – just simply plug it in and use.

Legacy KUKA Teach Pendants

MRO Electric also distributes a number of legacy KUKA teach pendants. We recognize that there are still a variety of older KUKA controllers still in use today. Rather than having to upgrade your control system when one of your pendants fail, we can ship you a replacement pendant to minimize any downtime.

If for some reason our stock is depleted, we can usually repair your KUKA pendant in as little as 3-5 days. Visit our main KUKA product page to see all the KUKA teach pendants that we can supply or repair.

For more information or to request a quote on a replacement pendant or panel, please call 800-691-8511 or email sales@mroelectric.com.

plc

How to maintain a PLC (Programmable Logic Controller)

Joe Kaminski 2 Comments

Updated: June 2024

Proper maintenance of Programmable Logic Controllers (PLCs) is crucial to ensuring they continue to function efficiently and reliably. Routine PLC maintenance involves tasks such as checking for wear and tear, replacing defective components, and consistently updating the software. This proactive approach not only extends the lifespan of PLCs but also helps in avoiding unexpected downtimes and costly repairs. Additionally, maintaining PLCs plays a key role in predictive maintenance, leveraging data and analytics to foresee potential equipment failures and schedule timely interventions. By adhering to a consistent maintenance routine, industries can enhance their operational efficiency and safeguard their investments in automation technology.

Why is PLC Maintenance Important?

PLCs (programmable logic controllers) are such an integral part of the automation world, and in turn a major contributor to the industrial market. Downtime can be incredibly costly, and finding parts for legacy units can be difficult and time consuming. (MRO Electric sells many legacy and discontinued automation components, from top brands) Therefore, properly maintaining your PLC can avoid unnecessary headaches and get the most life out of your units.

Pre-Maintenance Checklist

Before starting preventative maintenance on your PLC, make sure to do the following:

  1. Back up your PLC program prior to getting your hands dirty (it’s also a good idea to always keep a master copy of operating programs on hand).
  2. Follow proper lockout/tagout procedures.
  3. Remove power from the system. Power should always be off and unplugged during maintenance.
  4. Audit all parts in use.

PLC Maintenance Procedures

This is a good guidebook to use when performing preventive PLC maintenance:

  1. Check environmental factors / operating conditions. Humidity, temperature and other factors play an important role in the longevity and proper operation of your components. Be sure that these factors are consistently within the range of your PLCs optimal operating conditions.
  2. Clear debris, dust, and buildup from your units. A clean working environment for your PLC is a great way to prevent downtime. Also, dust getting to the circuit boards could cause a catastrophic short circuit.
  3. Clean or replace all filters installed in enclosures. This allows your PLC to get the maximum airflow and ensures consistency.
  4. Check all your connections for a tight fit, especially I/O modules. This is a very simple way to make sure everything is working smoothly. Also, a loose connection may cause lasting damage to your components.
  5. Inspect I/O devices for proper adjustments.
  6. Check LED battery indicators on the RAM memory module in the CPU. If the OK LED is on or flashing, replace the battery ASAP.

Other Things to Keep in Mind

  1. Calibrate circuit cards with process control analogs every 6 months.
  2. Service devices such as sensors every month.
  3. Never place other pieces of equipment that produce lots of noise or heat close to your PLC.

How to maintain a PLC (Programmable Logic Controller)

As many of us know, PLCs (programmable logic controllers) are staples in the factory automation world. In order to have them running optimally and as efficiently as possible, routine maintenance is imperative. Generally, manufacturers produce PLCs to endure strenuous, unsterilized environments. By adhering to an adequate maintenance schedule, PLCs operating timeframe can be lengthened.

Protect your PLC

Always be on the lookout for corrosive and conductive contaminants that have the potential to become a detriment to a PLCs’ components. By completing visual inspections for black dust and blowing airborne particles from the PLC’s vicinity, you are lowering the likelihood of contamination.

Is power flowing?

A PLC will not operate correctly without adequate power. To avoid any operation bugs, remain vigilant of any surges or shorts.

Calibrate Analog Components

Always refer to the preventative maintenance schedule for any analog input device. Analog inputs need to be cleaned regularly and calibrated as accurately as possible.

Take EMI into consideration

EMI (electromagnetic interference) is known to cause horrible issues for PLCs without clearly indicating what the specific issue is or how to go about fixing it. To remain ahead of the game, many perform an audit of the local wiring to pinpoint potential EMI sources before they interfere with the operation of your PLC. Lower-level components and high-current wires often interfere with each other, which wiring designs must take into consideration.

Additional PLC Maintenance Tips

By creating a PLC maintenance checklist and adhering to it strictly, operating errors can likely be avoided. The space between the PLC and the machine it’s controlling should be minimal.

MRO Electric and Supply has new and refurbished Modicon PLC parts available here. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.