Tag: process improvement

Industrial Event Camera VOC for Installation Monitoring– from Pepperl + Fuchs

Posted on by Rick Morgan

Within a modern intralogistics business automated high-bay warehouses with stacker cranes are a central element to their smooth and efficient operation. Allowing quick storage and retrieval of products and materials and optimising the available warehouse space. When installed in deep-freeze storage facilities their components must also be able to withstand the demanding requirements and extremely low temperatures. An uninterrupted cold chain has to be guaranteed throughout the movement of the goods stored there.

The Height of Reliability

Reliability, throughput, high precision, and high speed are the prerequisites of a stacker crane installation and failures and downtimes have to be avoided at all costs as any delay can trigger an expensive cascade of issues.

As you can imagine, most of the locations in the high-bay warehouse can be both difficult and dangerous for engineers to access for inspection. It would be ideal if the fault situation could be analysed before taking any further action, such as readjusting the crane.

As well as being ideal for Stacker Crane applications the VOC event camera also enables reliable monitoring of sensor-secured access areas, and if a machine or system is stopped by the access guarding, the recording of the trigger event is available for remote access.

The clever design engineers at Pepperl + Fuchs, a leading manufacturer of industrial control and automation product solutions, have created the ideal Industrial Event Camera solution, available to purchase from Kempston Controls today. Below we explore its abilities in this short write-up.

Industrial Event Camera VOC for Industrial Applications

The Pepperl + Fuchs Industrial Event Camera, for example, can be mounted directly on to a stacker crane, monitoring the storage and retrieval processes performed during its shift. The event camera continuously records the last 60 seconds of the video livestream in its integrated circular buffer. Faults or defined events in the sequence act as triggers for the camera to transfer cached data to permanent storage on an appropriate SD card.

These recordings last for up to 60 seconds before and after the event, enabling them to be used to identify the cause and the current status. Only relevant events are recorded and the image sequences can be used for immediate fault analysis or long-term process optimisation.

Unlike a continuous video sequence, event-oriented storage not only handles data streams economically, but also allows direct access to recordings. The date, time, and error message are displayed in the text overlay of the recording. A digital hardware input can record trigger signals that come directly from the control system or a trigger sensor.

Industrial Event Camera Benefits at a Glance

  • Event-driven video recordings up to 60 sec before and after the trigger signal
  • Fast analysis – recording of relevant events with timestamp and additional text
  • Easy integration into IT systems via REST API and to standard HMI displays with RTSP
  • Flexible use due to large viewing area, high operating temperature range
  • High efficiency – reduced network load through optimised local data storage
  • IP65 degree of protection makes it impermeable to dust and water jets.
  • Targeted image information for fault analysis and process optimisation
  • Easy integration without additional PC hardware
  • Access via web browser or individually programmed user interface

Technical Features

  • HD livestream via Real-Time Streaming Protocol (RTSP)
  • Large field of view, can be mounted 0.5 to 10 Metres from view area
  • Digital hardware input for trigger sensor or trigger signal
  • Internal circular buffer for video sequences 60 seconds
  • SD card stores up to 10,000 sequences
  • Quick and easy classification of the relevant recording
  • REST API for comprehensive integration into IT systems
  • Temperature range –30° C to +50° C

The password-protected user interface can be displayed on any web browser and provides a live image in HD quality, enabling the event camera to be easily configured. There is no need for additional PC hardware for integration and storage. An optional integrated heating system is available for use in cold storage and outdoor areas, resulting in an operating temperature range from –30° C to +50° C. Whatever your application, the Pepperl + Fuchs Industrial Event VOC camera will ensure you and your process is ready for any eventuality, reducing possible downtime and optimising your installation.

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SLT Smart Light Tower from SICK – Industry 4.0 Signalling Made Easy

Posted on by Rick Morgan

In automated industrial production processes, signal towers, light beacons and signalling lamps are utilised for a wide variety of applications and are located on individual machines or conveyor belts and workstations. Signalling towers provide a visual operational status or alert for machine users informing them that their attention is required, or an issue has occurred.

All of these different tasks can be solved with just one signal tower, the capable, robust and reliable SLT Smart Light Tower from SICK with its built-in industry 4.0 ready IO-Link interface.

Available to order today from Kempston Controls – call us today on +44 (0) 1933 411 411 to discuss your requirements.

 

The SICK SLT Smart Light Tower Offers a Host of Benefits

  • Different operating modes – Signal light, Level meter or Animation
  • Industry 4.0 capable thanks to IO-Link
  • Parameter changes during operation
  • Bright LEDs in 21 different colours
  • 20 independently configurable colour segments
  • Only 18-30 Vdc operating voltage
  • Optional Buzzer module for acoustic alarms
  • Visualise physical variables such as temperature states or fill levels
  • The graphic user interface makes it exceptionally easy to configure
  • Maximum flexibility with just one signal tower
  • Quick device replacement if the lamp fails or is defective
  • Uniform wiring concept with unshielded standard cables
  • Dimensions – HxWxD – 306 x 60 x 60 mm

SLT Smart Light Tower – Hundreds of Applications

The SICK SLT Signal Tower can be used in a huge array of applications, such as those found in mechanical and plant engineering and in other areas such as logistics, facilities or building technology. This dependable signal tower makes it easy to monitor the statuses of machines, visualise cycle and clock times on conveyor belts, and provide information in the event of downtime or waiting time. Signal Towers alert machine operators that they need to replenish material supplies or to indicate the fill level of a processing vat.

SLT Smart Light Tower

The SLT Smart Signal Tower can be utilised in the field of mobile automation, such as in Automated Guided Vehicle systems (AGV), where the signal lamp transmits information for action. The differing colours and signal patterns are utilised to make the operational status of complex machines easy to see, even from a distance.

The SLT can be adapted to any application thanks to the built-in IO-Link, and this is all without the need for the time-consuming fitting of different coloured modules, reducing the variety and storage of the component parts.

Industry 4.0 Future Proof Communication

Thanks to IO-Link technology, the signal tower is easy to customise. Parameterisation of properties including continuous light, flashing, different colours, brightness or melodies can be performed at any time. The signal tower is connected to the control level via an IO-Link master, providing maximum flexibility without the need for mechanical conversion. IO-Link system advantages include standardised and reduced wiring, increased data availability, simple device replacement, and advanced diagnostic options.

SLT Smart Light Tower

SLT Smart Signal Tower Applications

  • Visualisation of fill levels and operational statuses of machines
  • Display of machine downtime
  • Monitoring and visualisation of temperatures in manufacturing processes
  • Representation of cycle times in work processes
  • Visualisation of the process steps of conveyor belts

 

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BN Series Control Devices from Pizzato, Capable, Versatile & Easy to Install

Posted on by Rick Morgan

Pizzato Elettrica is one of the world’s leading manufacturers and suppliers of position switches, microswitches, foot switches, safety devices and control devices. Their comprehensive industrial automation solution portfolio contains the versatile range of BN series control devices, capable modular products that are the perfect control solution for many industrial process control applications. Kempston Controls has access to the entire Pizzato product range, so whatever you need we can get it for you at the best possible price.

BN Series – Simple to Install

The primary feature of the BN series control device range is their easy installation, the in-line holes make it simple to fit and wire and being plug-and-play, all you have to do is plug the connector in. In case the unit develops a fault or is damaged they can be replaced immediately thanks to their monolithic design, without the need for rewiring helping the user avoid any possible errors.

BN Series Control Devices

Versatile, the BN Series control device units are designed with rotatable modules that provide various installation options when mounting on the machine. After loosening the fixing screws, the upper and lower modules can be turned 90 degrees to the desired configuration. Another advantage is that the fixing modules cannot be detached from the device body.

Ingress Resistant

Disassembly of the individual parts is not necessary and there is no risk of losing parts or reassembling them incorrectly. The fixing screws are protected by push-in caps, which not only prevent dirt from accumulating, but they also block access to the screws and make it less likely someone will tamper with them.

BN Series Control Devices

The BN series control device unit is available in various configurations, designed to cater for a wide variety of installation applications: for standard applications, configurations with 3 or 4 devices are ideal, while configurations with 6, 7 or 8 devices are available for more complex applications, providing the user with more control and signalling devices in the same location.

Protected against accidental damage

Featuring recessed control devices in the outer housing means they’re protected from accidental knocks and damage leading to a longer operational life. They only protrude a little from the front face, so the BN series remains within a maximum width of just 40 mm.

BN Series Control Devices

In all of the BN series device configurations, a variety of control devices can be installed and also illuminated by integrated LEDs. The buttons feature lenses that can be laser marked for a resistant, indelible engraving, allowing the user to customise the lenses with a wide range of text and symbols

The Pizzato Elettrica BN series of modular control device units have the same shape and dimensions as the RFID safety switches with lock belonging to the Pizzato NS series, giving machine manufacturers who already use the NS series the chance to create a uniform installation that is aesthetically pleasing.

 

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LOGO! 8 – Small Easy to Install Powerful Logic Modules – from Siemens

Posted on by Rick Morgan

LOGO! 8 mini controllers, manufactured by Siemens, are a comprehensively designed family of logic modules for use in industrial automation and control applications, ideally suited for smaller scale control tasks.

Easy to install, with minimal wiring and user-friendly programming, it’s simple to implement small automation projects using the LOGO! Soft Comfort Software. These intelligent logic modules  can help you save on control cabinet space, helping save on outlay.

Interfaces such as Ethernet, USB or via the Cloud (with the 8.3 software update), are used for connecting to the IoT, for programming, data transmission, predictive maintenance and power monitoring. Using expansion modules from the LOGO! family means existing installations can be retrofitted, helping to expand your application whenever you need.

Advanced IoT Connectivity with LOGO! 8.3 Soft Comfort Software

LOGO! 8.3 software helps future proof your installations, opening-up the world of IoT. This  capable engineering software offers not only familiar operation in single mode but also easy operation in network mode. Automatic configuration and the ability to open as many as 3 programs at once, and you can drag and drop to easily transfer signals from one program to another.

A wizard helps to set up a cloud connection in LOGO! Soft Comfort in just a few steps, and the web server can be configured by the user to enable control of automation components via mobile devices.

LOGO! 8 Logic Module Features

  • Eight basic units for all voltages, with or without a large display
  • Ethernet port and connections that are backwards compatible
  • 7 digital modules and 3 analogue modules
  • 6-line display with 16 characters per line
  • Maximum configuration: 24 digital inputs, 20 digital outputs, 8 analogue I/O
  • Temperature range–20 °C and +55 °C
  • Choice of white, orange, and red backlighting
  • Time synchronisation between LOGO! basic units
  • LOGO! 8 as SIPLUS extreme for use in especially harsh conditions
  • Conformal coating for added environmental protection
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Ethernet made easy

Integrated Ethernet interface for the entire product family means the logic modules communicate with each other and the SIMATIC S7 systems via Ethernet Modbus TCP/IP for LOGO! 8.1 or higher, allows modules to act as either a client or a server. The CSM add-on module Ethernet 4-port switch, expands the  interfaces local Ethernet networks still further.

Integrated web server

The integrated web server found in the LOGO! basic units is ideal for monitoring and control via WLAN and the Internet, it’s password-protected and suitable for all conventional browsers. The web server is easy to configure with no HTML programming knowledge required. LOGO! 8 can also be operated using a smartphone, tablet, or a PC. The self-configured display has the option of designing web pages for mobile devices using your own pictures, logos and icons. Data can be stored on a micro-SD card and projects can be further processed in HTML if required.

LOGO! Basic Modules

The perfect choice as a fast, uncomplicated and space-saving solution for basic control tasks. LOGO! has long been a constant as an intelligent logic module for small automation projects.

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LOGO! Expansion Modules

A wide range of expansion modules allows the user to set up a flexible LOGO! Configuration with a maximum of 24 digital inputs, 20 digital outputs, 8 analogue inputs and 8 analogue outputs possible.

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LOGO! Power

The mini power supply devices designed like LOGO! modules offer great performance in the smallest space: The excellent efficiency over the complete load range and the low performance loss during idle times guarantee efficient operation.

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LOGO! Inrush Current Limiter

As a ballast unit for SITOP power supplies, SITOP inrush current limiters reliably reduce currents like those caused by the rectifier circuit on the input side with capacitor charging, as in the case of pulse-controlled power supplies.

 

 

 

 

LOGO Communication

The LOGO! family offers many communication options. In LOGO! 8, the connection to the communication modules is done via Ethernet. This means the entire address range of the inputs/outputs remains available for digital and analogue signals.

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Operator Devices

LOGO! TDE and SIMATIC Basic Panels offer simple operator control and monitoring possibilities. The external text display TDE provides an affordable interface for machine operators and with their sophisticated HMI basic functions, SIMATIC HMI Basic Panels are the ideal entry-level series for simple HMI applications.

LOGO! 8 Starter Kits

Six LOGO! 8 Starter Kits – individually equipped to suit your application. Utilise these kits to learn more about the advantages and possibilities of the logic modules in a quick and easy manner.

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Versatile Terminal Blocks you can depend on from Elmex

Posted on by Rick Morgan

Elmex has established itself as one of the leading manufacturers of electrical wire termination technology solutions, designing and manufacturing a wide range of versatile terminal blocks suitable for industrial and commercial applications. Elemex’s range includes single and multilevel terminals  feedthrough terminals, earth terminals with screw clamp, spring clamp, push-in type terminals and more for low and high-current applications.

Effective electrical wire termination plays a vital role in the overall performance and function of an industrial automation and control installation. Always innovating, Elmex likes to push their designs to the limits, upgrading and enhancing their products to cater to the demands of the modern workplace on a regular basis.

Screw Clamp, Push-in and Spring Clamp

For typical installation, Push-in, Screw Clamp and Spring Clamp terminals help improve wiring efficiency by not only reducing assembly time with easy-to-access and secure terminals, but by also sharing terminal accessories such as multi-way shorting links. Labelling provisions are also provided on some models to aid identification during wiring. The extensive range of terminal blocks they offer caters to just about every installations needs.

Elmex Terminal Block Features

  • Common accessories – jumpers, endplates, labels, helps reduce inventory
  • Easy access guided wire entry points
  • Simple interconnection between terminals
  • Top marking label provision (model dependant)
  • Vibration resistant connection in a compact design
  • Tool-free wiring (push-in)
  • Spring clamp, Push-in, Spring Clamp terminals amongst others

The extensive range of Elmex terminal blocks has been designed to cater to a wide spectrum of industrial and commercial wiring applications, such as feed-through, disconnection, multi-level, multi-output, fused and grounding tasks. Uniform in design and compact, these capable and versatile terminal blocks provide improved stacking density and appealing aesthetics.

Below we take a quick glimpse at some of the Elmex terminal blocks you can purchase from Kempston Controls today.

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Feed Through Terminals

Feed Through Terminal blocks by Elmex

 

Feed Through Terminals suitable for all manner of control and power applications with high contact force. Easy to use and DIN mounted, the offer created by Elmex covers a wide range of conductor sizes. Constructed from high-grade materials to ensure reliable and dependable operation.

Earth Terminals

Earth Terminal blocks by Elmex

 

Earth Terminal Blocks have been designed to replace the traditional bus-bars that are utilised for earthing in your average electrical installation. These green and yellow coloured terminal block utilise the DIN mounting rail as an earth point via its retaining clamp.

Multi-Level Terminals

Multilevel blocks by Elmex

 

Multi-level Terminals are the ideal solution for applications with limited space and high-density wiring demands. These terminals are offered in a range of level types such as the DS8L 8 level models, with 8 levels for marshalling. The range covers a spectrum of conductor sizes to suit numerous applications, with dependable hardwearing conductors.

Fuse Terminals

Fused Terminal blocks by Elmex

 

Control and Automation applications typically require fuse protection, the Elmex range of terminal blocks with built-in fuse lever are designed to accommodate a cartridge fuse. Alternatively a solid link can be installed turning it into a disconnection terminal block, ideal for a wide range of circuit protection and disconnection tasks.

There are hundreds of different Elmex Terminal Blocks available from Kempston Controls  which have been designed to suit whatever your specific application demands. Be sure to give our dedicated sales team a call or speak to our technical teams for more specific information using the numbers below.

View the Range

 

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Ethernet IO Modules with Integrated IO-Link Master – the best in Industrial Communication

Posted on by Rick Morgan

Pepperl+Fuchs’ Ethernet IO modules offer an array of innovative features. With a versatile multi-protocol capability, they provide optimum efficiency for standardizing manufacturing facilities. IO-Link and comprehensive diagnostics are important for maintaining and troubleshooting your machines. These innovative, high-performance ethernet communication modules can help optimise your installations.

Managing the Demands of Modern Industry and Beyond

If industrial process control sensors are to manage the demands of the future manufacturing processes, they need to do more than simply deliver process data to a PLC. An industrial process control sensor must be able to communicate with multiple receivers and send and receive data to and from higher-level information systems efficiently.

Ethernet IO modules

The Pepperl + Fuchs Ethernet IO modules with integrated IO-Link master deliver first-class communication between system management and process sensors and actuators as they assume a gateway function between Ethernet and IO‑Link. With these capable ethernet modules up to 8 IO‑Link devices may be directly connected, with 4 channels available for sensors and 4 channels for actuators.

The ICE1 series IO-Link master enables integrated diagnostics and parameterisation from the control level right down to the process sensor level, and commissioning times will be  reduced primarily in large production plants. Ultimately, this means that Ethernet IO modules with integrated IO-Link master can be incorporated into the requirements profile of innovative machine and plant manufacturers easily, forming a crucial component of Sensorik4.0.

Ethernet IO modules

Sensorik4.0 is the next generation of interconnected sensor solutions from Pepperl + Fuchs that helps bring Industry 4.0 to life. The integrated Ethernet IO-Link masters bring the concept of Sensorik4.0 to reality. IO-Link sensors and actuators can be easily connected across all technologies creating a whole range of possibilities for the user, ranging from parameterisation to diagnostics down to actuator/sensor level and simplifying maintenance, paving the way in the digitalisation of factories of the future.

IO-Link Masters with OPC UA Interface, Dependable Information Exchange from Field to Cloud

In addition to the ICE1 masters, designed for PLC-based applications, two other modules are available for use in cloud-based and hybrid systems: the ICE2 (EtherNet/IP) and ICE3 (PROFINET) IO-Link master series.

These 2 ethernet modules support industrial protocols such as EtherNet/IP, PROFINET, and MODBUS TCP, and provide an OPC UA (Open Platform Communication Unified Architecture) interface in addition to real-time fieldbus protocols.

Ethernet IO modules

The open architecture of OPC UA allows cross-vendor, platform-independent, and the interoperable collaboration of machines in processing environments and makes communication between machines and computer or cloud-based systems possible, both in closed networks and via the internet.

Both IO-Link masters come with web-based configuration for setting all module parameters and all connected IO-Link devices (web IODD operation).  When replacing or expanding modules, all the module settings can be saved as a separate file and transferred to a new device using the module cloning function. OPC UA ensures a constant exchange of information across all levels so that plant processes can be designed more efficiently.

IIoT Starter Kit—Connecting Factory Floor Sensors to the Cloud

With the IIoT starter kit and the user-friendly IO-Link masters from Pepperl+Fuchs simple visualisation and analysis of sensor data becomes a reality. Discover the advantages of IO-Link and experience the seamless integration of IO-Link sensor data into your Industry 4.0 application.

The kit includes among others:

  • An IO-Link master, (3) IO-Link sensors, an Ethernet switch, a power supply, RFID tags and all the necessary cabling to get started
  • A quick start guide for connecting the IO-Link master and IO-Link devices
  • Connections for various platforms such as AWS, PTC, AVEVA

Connect your software dashboard via OPC UA or MQTT for easy interpretation of real-time data and start the digital transformation of your installations now with the IIoT starter kit, available from Kempston Controls.

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