How to hack programmable logic controllers
PLC cyber attacks become models for security
Since the late 1980s when the Morris worm, one of the first-ever Internet worms, was launched by a Cornell graduate student from a computer system at the Massachusetts Institute of Technology, cyber attacks have become big business.The Morris…
Heidenhain to digitally connect equipment throughout IMTS
Kuka eliminates data silos with PLM software
How connector upgrades fit into an IIoT retrofit
Recommendations for connectors in extreme environments
What to expect from distributed I/O
Whether the communication system is open or closed proprietary, choose device hardware to meet expectations
Distributed I/O can mean different things to different people and different manufacturers, but let’s discuss I/O device hardware—digital, analog or messaging device—that is connected to the primary control device using a communication system…
Control for massive foundations
How to put new legs on legacy
Simplify press maintenance and management through IIoT innovation
Make time for innovation
Panel of experts discuss a way to virtually eliminate the cost of wiring in new components in current and future retrofits
While not everyone on our panel of experts is sold on what IIoT can do for connectors today, the possibility to virtually eliminate the cost of wiring makes it as enticing as any other upgrade. As the Industrial Internet of Things (IIoT) continues…
Maintenance strategies for cable identification
When to use a cable conduit outside the enclosure
Which wire color coding standard is best?
Manufacturing’s information revolution
How Industry 4.0 can help to turn machines into data centers
As we transition from an Industry 3.0 world and its islands of automation to an Industry 4.0 world with connected automation, too many people are still failing to take advantage of its benefits. There is a revolution coming to manufacturing, and you need to ask yourself whether you are going to be part of it or are you going to be left behind.Think of Industry 4.0 as the type of disruption that the iPhone bought to our everyday life a little more than 10 years ago. Thanks to carrying a connected computer (iPhone) on our person all the time, information is instantly at our fingertips. We now have an instant connection to a world of information. Think about how your day-to-day life has changed in the past 10 years thanks to smart phones.If…
Batch-size-of-one manufacturing and digitalization take center stage
Keep systems safe and secure in a connected world
IIoT, meet the edge-gateway controller
The path forward for clean energy
Houlder creates a safe and reliable upending tool to control the lifting of immense offshore wind monopiles
A tool that picks, orients and places a part is common in machine automation. However, when it's part of a wind-farm installation located offshore, it's a rather complex and impressive piece of equipment (Figure 1).Our company, Houlder, was tasked…
Light-fidelity communication: technology in progress
The future is flooded with wireless data
What will you engineer next?
12 steps to Li-Fi implementation
Networking devices for harsh environments
Components are tested for temperature and vibration extremes at RuggedCom.
I’m a software guy, so, when I was invited to Siemens’ RuggedCom plant tour, I was intrigued, as well as excited to see what these guys were doing.
RuggedCom started as a Canadian innovation story in 2002. It grew quickly and found the eye of…
Codimag improves productivity by limiting service costs
Cybersecurity concerns continue to speckle remote-access compositions
Smart connectivity includes cybersecurity
Keeping the HMI application secure while providing remote viewing
New strategies for old components
Obsolescence is a headache that can be avoided with proper preparation
Most machine builders and integrators get to experience the joy of supporting obsolete machines and control hardware. What was easy to support and understand in the past is often difficult and somewhat annoying, if not impossible, to support…
Wastewater treatment plants can be built for small-scale applications
Temperature control helps brewery to expand its winning ways
Should I limit programming to ladder logic or use all standards within IEC 61131?
How many IEC 61131-3 languages do I actually need and does limiting help ensure maintenance techs and programmers can provide support?
A Control Design reader writes: Due to past issues with programming support of our automated machines, we have created a requirement for new equipment that the control software meet the IEC 61131 standard, and we have limited the approved controller…
How many IEC 61131-3 languages do I need?
Forget PLC vs. PAC vs. IPC
How to bridge the automation generation gap
Power supplies get out of the cabinet
By moving power supplies closer to devices, it enables modular design and reduces thermal-management issues
Moving PLCs, I/O and other control equipment closer to the input and output devices they manage has become standard practice among design professionals. It offers a number of advantages, one of which is that it allows for modular design of…
Linear power supply vs. switched
Zero-cabinet power supply
The basics of power supplies in industrial machinery
How much effect will linear power supplies’ EMI have on machine controls?
Artificial intelligence is smarter than you think
Discover how AI has moved data collection beyond finding the what and how to a more predictive and prescriptive presentation of actionable data
Artificial intelligence (AI) is all around us. Soon, AI will make decisions and take actions for you. The availability of production data gives the intelligence necessary to make it happen, but you often need to "work that data" to understand…
Get control of maintenance
Accurate fishing begins with lights-out manufacturing
Okuma machinery helps aerospace company to evolve into the reel deal
Accurate Fishing Products, in Corona, California, started as a summer work project during my college days in the early 1990s. Design and development of fishing reels in those early years led to the purchase of several Okuma CNC machines and related…
CNC’s future looks bright
Romeo Engineering leverages PC-based control to improve manufacturing speed and accuracy
Case Study: Harry Major Machine modern gantry improves plant uptime, recovery time
Absolute Machine Tools acquires distributor Machine Tool Technology-21
PC-based control yields 33% higher controller functionality while reducing cabinet and machine footprints
Edge Automation throws away the box to solve previously unsolvable engineering projects
Good things come in small packages. There is perhaps no better way to describe Edge Automation, a custom machine builder and automation solutions provider based in London, Ontario. Though our company is small—employing around 47 skilled designers,…
The IPC adapts to advanced control needs
A control system by any other name
Programming a PLC vs. industrial PC: which is best?
How will greater software capabilities and more powerful CPUs affect IPCs and EOI?
Infographic: If You Use Stepper Motors Are They Open or Closed Loop? (2014)
February 2014 Survey Results Show 53% of Respondents Use Closed-Loop Stepper Motors
An electronic survey of Control Design readers was conducted in February 2014 in order to identify usage and application trends in motion, drives and motor technology among the industrial machine builders that comprise Control Design's readership.
47% of respondents who use stepper motors use open-loop steppers; 53% use closed-loop.
Read all survey results.
How duplicating designs can build obsolescence and cost in to control systems
It's the little things that add up
As designers, we tend to try and make things as easy on ourselves as possible. One way to do this is to re-use designs when we find a good one. While good, in theory, we can quickly find ourselves behind the times because technology moves along at a…
How machine designers can integrate thermal-protection technology to prevent solid-state relay and equipment failure
Ensure machinery durability and long-term functionality
Reap the benefits of designing for mass production
Economies of scale can lead to discounts and savings that you might not have considered
An opportunity presented itself not too long ago when my company was forced to re-examine the use of some equipment in our two facilities. We package dry goods for a variety of clients using nearly 40 production lines. Such is the nature of our…
The art of designing the cabinet with maintenance in mind
Which enclosure fits my needs?
How to address the need for higher speeds and increased modularity in IPC-in-cabinet design
Safety relay or safety-rated PLC?
Safety Applications Become More Complex When More Than Three Inputs Must Be Monitored and Controlled
Machine and robot builders often need safety-rated monitoring and control, which can be accomplished with safety-rated relays or PLCs. "Many applications could use either a safety relay or PLC, but the choice depends on four main considerations: complexity, flexibility, availability and footprint," says George Schuster, senior industry specialist for the automotive team at Rockwell Automation.
SEE ALSO: Safety Relays or Better Diagnostics?
Safety applications become complex when more than about three inputs must be monitored and controlled, or when communication over a digital network is required. "Safety relays are hardwired to perform simple diagnostics and logic, and work well when the amount of safety points in the application…
Relays: Out with the old?
Simulation technology center slated for University of Cincinnati
Siemens provides PLM software and pledges up to $1 million to establish center.
Siemens and the University of Cincinnati have announced a partnership to establish a simulation and modeling center enabled with Siemens product lifecycle management (PLM) software.
Housed on UC’s main campus in its College of Engineering and Applied Science (CEAS), the Siemens PLM Simulation Technology Center will be a hub for developing and applying new methodologies and technologies in engineering education and research, according to Siemens.
Through a pledge from Siemens of up to $1 million, as well as Siemens’ staff support and additional PLM software, the partnership will provide experiential learning opportunities for students in UC’s CEAS.
“As manufacturing companies worldwide move closer to Industry 4.0, it is more…
IML announces next round of projects targeted toward small, medium manufacturers
How design software impacts development time, predictive modeling and thermal management
NIST Project to Give Design Software New Digital Threads
ECAD: Simple or Complex?
Software to enable design detail
When does control design begin?
Where does electrical CAD software stand with the digital twin?
Get me to the future
National Instruments reinvests in development to reduce time to market and nurture its collaborative community of users
Who wants to get to the future faster? In May, almost 4,000 engineers and scientists gathered in Austin, Texas, for National Instruments’ annual spotlight on its community of technology lovers and wunderkinds. The displays of innovations and…
Machine design with maintenance in mind
How IP67 and IP69K components affect machine-design decisions
The importance of IIoT in the packaging equipment industry
Permanently more efficient motors
Technology is making motors more robust and reliable, while future standards, like permanent-magnetic motors, are driving a more efficient system design
There are two things worth noting on how technology is changing motors. "One is the Internet of Things (IoT) trend," says Michael Offik, PE, director of packaged solutions at ABB. "The motors can be inexpensively monitored. The other is the…
Servo motion control makes thermoformer bigger, faster and less expensive
What is motion control?
Manufacturing quality starts with the motor
How will VSDs alter motor efficiency?
Variable-frequency drives and electromagnetic interference
How to minimize EMI in motion systems
How do you address electromagnetic interference when designing a motion system using variable-frequency drives?Tim Lusha, senior EMC engineer at DLS Electronic Systems: Controlling emissions from a VFD is very challenging. VFD efficiency comes at…
How do you provide overload protection for variable-frequency drives?
Soft starter or variable-frequency drive?
How to bore an engineer into retirement
Critical alignment really is critical
Why designers, engineers and end-users should not accept rod seal failure as normal
A critical design feature of any mechanism where moving elements interact or work in tandem with each other is the alignment of those parts in relationship to one another. Design engineers commonly specify and make notation on design prints…
How to select pneumatic valves and actuators
Why bother with energy efficiency?
The reindustrialization of America
Pneumatic use is all about the fundamentals
Hydraulic muscle, as needed
Sometimes brute force is needed, and a little hydraulic knowledge can get things moving in the right direction
There is no doubt hydraulics has unmatched muscle, compared to pneumatics or electrical power transmission in linear and rotary motion applications. While pneumatics may win the game when it comes to simple, low-cost and fast linear motion,…
Keys to specifying hydraulic power systems
6 surprising capabilities of modern hydraulics
The Straight Skinny on Linear Motion
Webinar: Preparing for Ebola in the Water Sector
Real automation bias
Key positions on encoders
Pick machines, not processes
New innovations in linear motion
The fundamentals of motion control focus on the details and theories about motor control, feedback methods and mechanical actuators
Motion control is a bit of a specialty in automated control systems, and its use is not basic, as it can provide advanced machine functionality. It provides the means to move the machine tooling or the part itself in a controlled, and often…
How do I make precision-motion machinery IIoT-ready?
Motion application drives stepper or servo selection
As machine trends change, motion requirements stay unaffected
Is a stepper or servo best for torque optimization?
3 key indicators to ensure motion-control application success
Configurators and function blocks make motion technology less technical
In this highly connected world we live in, it seems that flying cars would have made their appearance more than a decade ago. Flying cars don’t exist yet, but more capable PLC and motion drive systems do.Our customer, a major aerospace structural…
Adaptable packaging line improves speed
Once clean, dry air at the proper pressure is connected and safe, get control of the pneumatic cylinders, actuators and motors with proper valve selection and flow control.
Supplying clean, dry air is an important starting point to long and reliable valve operation in industrial machines and equipment. However, switching the air through the proper type of valve to control the cylinder, actuator or air motor is where is where fluid power is controlled.
Pneumatics are a great choice for many machine linear and rotary applications. Unless the machine requires accurate, programmable motion-positioning electric motors or the high-force capabilities of hydraulics, a pneumatic solution is often the best and most popular choice. Instead of electricity, design in some pneumatic air preparation hardware, tubing, valves, solenoids and flow controls, connect to the pneumatic cylinders, actuators and motors and get the…
November Showcase: Valves, Control Systems, Motors and More
New Wireless Application Boosts Safety at Harcros
Integrated axes crank up cold working
Speculating on Valve Futures
The future direction of control
Add vision guidance to delta robots on packaging equipment and combine it with state-of-the-art controller technology for an image of innovation and the future
Over the years, we have reinvented and repurposed JLS Automation as necessary and moved into new markets as we identified trends and opportunities. More than a decade ago, we decided to focus on hygienic packaging solutions for the food industry,…
Where machine automation and design software is heading
PLCopen Software Construction Guidelines released
Programming standardization through IEC 61131
Commission machines with the swipe of a finger
How collaborative robots can solve the labor-shortage problem
Plastic injection-molding company Tennplasco sees a return of investment in less than four months by deploying a smart robot
For a long time, automation was essentially deployed. The manufacturing process was designed around the automation. A robot was a custom implementation, which included sensors and PLCs. Bring it all together, code it and switch it on.“You were…
Congratulations, your job has just been automated
Robots reach for new heights
Maintain domain expertise
Founders Brewing monitors, captures and controls critical process variables to produce successful test brews
Well-balanced, unremarkable beers don’t attract new customers, and they certainly don’t win awards. It takes complex, in-your-face ales with huge aromatics, big body and lots of flavor to make waves in the competitive brewing industry. And you…
You can’t troubleshoot what you can’t diagnose
Smarter and more capable sensors
How does linear measure up?
Where do vision systems fit in the process?
Whether it’s assisting with assembly or improving inspection, vision systems need to be maintained
A Control Design reader writes: As a production engineer at a medical device manufacturer, I have been tasked to investigate the use of vision systems to assist assembly and to improve our quality and inspection processes, but I'm feeling…
TIM the robot monitors the health of CERN's large hadron collider
How to develop reliable vision applications
Which devices do it all for presence sensing?
How to choose between proximity sensor, photo eye and fiberoptic sensor
A Control Design reader writes: We had downtime on a production machine due to failure of a presence sensor recently. The inductive sensor that failed had a unique form factor and was embedded in a part nest. My boss was not happy; production shut…
Drive roller conveyors with AS-Interface
Do I really need a presence sensor?
See what’s new with photoelectric sensors
Hot options for temperature measurement
How to troubleshoot and calibrate 4-20 mA
How to tune PID loops
Process variables and the art of calibrating instruments
More methods for planning a safety upgrade
Seven industry experts on how to consider design, integration, testing and operation
A Control Design reader writes: I work at a packaging plant where safety upgrades to palletizing equipment excessively stopped the machine and confused multiple technicians, ultimately leading to some of the safety measures being bypassed, which…
How to plan a safety upgrade
A complete safety solution
Intrinsic safety comes with requirements
Options for HMIs in explosive atmospheres
Compliance for robots in collaborative and other applications
Finding common ground in a world of numerous environments.
Compared to traditional industrial sectors, robotics is a relatively young field with only about 40 years of deployment history in workplace environments. Technology within this field however is advancing incredibly fast, and thus compliance needs to adapt to keep pace with these rapid changes. Another challenge is how to convey the myriad facets of compliance comprehensibly to end customers and integrators for issues such as knowing when a robot system is really compliant or what the requirements to which the robot and robot system have to comply are.
The first thing, which has to be clarified for the topic of compliance, is always in what industry and for which purpose the robot system will be used. Compliance requirements differ from…
How to make the right safety and sensing decisions
How machine vision systems and robots have influenced each other
The impact non-vision sensing and robotics have on each other
Applications that will benefit from collaborative robot innovations
4 solutions to the 3 biggest cybersecurity challenges
Industrial control systems need protection, too
Cybersecurity and the threat of malicious actors make headlines every day. Boards of directors are recognizing cyber threats as one of the most significant risks. To date, this cybersecurity discussion has centered largely on IT systems; however,…
Zero day cyber threats
DOD-backed DMDII Cyber Hub for Manufacturing enables cybersecurity technology experimentation for factory floor
Technology and the future of employment
The Internet's unintended consequences
Open-source PLC and HMI library makes headway
System integrators and others add functionality, including automatic HMI object generation
Outside of industrial automation, open-source libraries have been booming for many years. Open-source code has been a fundamental pillar of computing since the start of computer software and has continued to remain relevant. You can look back at operating systems in the 1950s and 1960s when code was almost always delivered, to the success of Linux, and the more recent news in the $7.5 billion acquisition of GitHub by Microsoft.However, in an industry where everyone has competed to have the best secret sauce, the open-source movement has largely steered clear of industrial controls. Each individual end user, OEM and system integrator has created its own code base and worked hard to ensure internal secrecy to provide a competitive edge in…
3 HMI configurations for hazardous areas
How innovation drives medical production
The stack light gets brighter
22 tips to ensure control panel maintainability
Some considerations for designers and builders of control panels that will help ensure the panels' maintainability.
One of our most popular articles on control panel design comes from a 2014 article by Don Fitchett, president of Business Industrial Network, an industrial training company, on considerations for designers and builders of control panels to help ensure the panels' maintainability.
In it, he outlines a hefty list of these considerations for designers and builders. Check them out below and read the full article, "Control panel design with maintenance in mind," here.
According to Fitchett, here are some considerations for designers and builders of control panels that will help ensure the panels' maintainability:
Have an outside-the-panel PLC communication port and fused 120-V outlet.
If it's an ac-powered PLC, have the line filter on…
What’s the best way to measure, control and display?
Universal Panel Meter is configurable for measurement, display or control
Panel Meters Take on PLC Chores
Experts weigh in on best practices for control panel housings
The extreme IPC
IPCs get the job done and are right at home on the factory floor, where the office PC is a bit out of its element.
The benefits of using an industrial computer (IPC) instead of a commercial-grade PC when the application required rugged and reliable equipment are numerous. IPCs can cost three to five times as much as their commercial-grade counterparts. However,…
Vendor-supplied or open-source HMI software?
PLCs, PACs and IPCs ─ controller terminology explained
The more controls change, the more familiar they become
A variety of improved options are provided by industrial PCs
Manage alarms without being overwhelmed
Operators need different information than maintenance personnel
The most critical HMI notification, the alarm, has important information for both operators and maintenance personnel. Our panel of experts advises how to manage alarms to ensure high-severity alarms receive the attention they need.
Alarms are an…
3 alarm types to manage with HMI
The best ways to indicate alarms and to confirm proper operator action
The human factors of panel layout
Harsh environments call for more rugged components
Why and when to upgrade from indicator lights to an HMI display
Do stack lights make the most sense for my assembly line?
Consider the Need for Safety Switches
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