Pneumatics

As an engineer, the responsibility to adopt not just the latest, but the safest technologies, never goes away. Protecting people and machinery has become, quite simply, industry’s number one priority. Safety first. Always.

Factory automation is certainly no exception. Here, major advances have fuelled greater focus on smarter controls and increased integration of smart devices and safety componentry. Included in this are the latest pneumatic solutions, which nowadays form a core part of safety controls for implementing the preventative technical measures needed to ensure machine safety, including clamping, blocking, exhausting and holding equipment in place.

But hold on a moment, what actually classifies a product as a safety component? Well, as with all things related to machine safety, the best place to find out is the Machinery Directive, which states that a product is deemed to be a safety component when it is tested and verified to provide specific safe function for a pre-determined period of time in a given state. 

The Machinery Directive also offers clear distinction between safety devices and standard pneumatic components deployed in a safety circuit. Notably, the term ‘safety component’ does not imply the actual reliability or safety level of the component. Those products offered as safety-rated must undergo stringent requirements for certification, testing and approval. As a further point, the Machinery Directive does not prescribe the use of safety-rated componentry, it merely provides a description of the conformity assessment procedures to market a product as safety rated. 

So, how is it best to determine what level of safety is required? The answer: perform a risk assessment. Three steps are involved here: analysis, evaluation and reduction. The first step, risk analysis, also requires engineers to estimate risk and determine the performance level required (PLr). 

After the PLr is established the performance level (PL) will need to be calculated based on safety categories that are established in line with factors such as a measure of diagnostic capabilities (DC) for the control system, the meantime to dangerous failure (MTTFD) and common cause failure (CCF). In combination, these inputs will define the level of a given safety function.

In tandem with the strategy set out here, peace-of-mind can, of course, be found by specifying safety-rated products from a reputable supplier. After all, as machine builders will be well aware, the price of non-compliance can be extremely costly.

To discover more about Parker’s factory automation solutions, please see our guide "A Comprehensive Guide to Machine Safety".

Article contributed by Linda Caron, global product manager for Factory Automation, Pneumatic Division.

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Industrial Ethernet (IE) is growing at a startling rate. In fact, the latest estimates put the annual growth at a staggering 22 percent, which means some 52 percent of the connectivity market is now commanded by IE, putting it ahead of traditional fieldbus networks for the first time.

There are many reasons for this. In our opinion, these include the widespread accessibility of several IE protocols, a good degree of backward compatibility and the availability of rugged components (hardwired) that are typically protected from electrical noise. And it is important to not overlook the emergence of cloud technologies, as well as the pure and simple demand for more connected devices as part of industry’s smart factory evolution.

Smart factories look to eliminate downtime and enhance productivity, which is why the systems and equipment in such facilities must be far more intelligent, flexible and dynamic.

Data collection and analysis is at the core of this effort, an activity that is intended to aid faster and more informed decision making. It’s perfectly clear why all of you production managers out there would want to make decisions based on accurate reporting of what’s actually trending on the shop floor.

From a technical perspective, analytics can be accomplished in different ways. Data can be stored and retrieved as needed (acyclic data) or returned through the network in real time for immediate attention (cyclic data).

In either case, as already mentioned, there are numerous IE protocols which can help communicate this data, not least familiar ones such as Profinet, Ethernet /IP and EtherCAT. And each has its own set of attributes, but regardless of which best suits a given application, the proliferation of these protocols has made IE a major fixture in control systems around the globe.

While our industry is without doubt seeing more take-up of IE, the goal for automation equipment vendors has been delivering IE connectivity in a cost-effective and straightforward manner. For this reason, Parker has been busy developing a high-capability, high-reliability IE network node: the P2M node.

Designed with advanced factory automation in mind, Parker’s engineers have created the node so that it’s both easy to configure and cost-effective. The result is that the company’s H Universal ISO Series valve, Moduflex valve and H Micro valve families can now connect to the IE network. In fact, we can now offer a large range of IE connectivity options, including EtherNet/IP, Profinet IO, EtherCAT, Ethernet PowerLink, Modbus TCP/IP and CC-Link IE protocols.

Adding further to the options for easier and more cost-effective network connectivity is our H Series Network Portal, which delivers on-machine flexibility for IE applications. The portal handles machine digital or IO-Links I/O's, eradicating the necessity for extra PLC input and output cards or other remote I/O modules. Offering full configurable IO-Link channels on the valve manifold via the network portal facilitates straightforward and cost-effective centralised machine application, even in caustic, wash-down or hazardous areas and even where extreme temperatures are present.

Ultimately, the reality of low-cost connectivity with integrated diagnostics has at last arrived, serving to further reduce complexity and cost at the machine, while simultaneously meeting the requirements of smart factories and Industry 4.0. The IE compatibility of critical automation components such as pneumatic valves is paramount if industrial users are to leverage the full benefits that total and reliable connectivity can bring.

If you’d like to discover more about Parker’s P2M IE network node, please watch the video below:

Article contributed by Patrick Berdal, EMEA product manager for control devices, Pneumatic Division Europe, Parker Hannifin Corporation.

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Careful and correct sensor installation is vital if accurate and reliable information is to be measured and communicated from the sensor. 

What all engineers want when it comes to sensor installation is a simple, secure and rapid assembly process, without complicated processes such as the need for additional mountings. 

The P8S proximity sensor offers universal use, flexible integration and excellent form. Its square design is also suitable for rapid installation in industry-standard T-slots, regardless of cylinder profile or brand. The upshot of this direct, drop-in design – as opposed to ‘turn-in’ or ‘slide-in’ concepts – is a significant reduction in installation time. 

Among the innovations with the P8S are retaining ribs on the side of the sensor body that enable simple mounting, including hard-to-reach locations or overhead assemblies. These ribs ensure the sensor conveniently holds its position in the T-slot even before the screw is tightened.

To begin the installation, simply slide the sensor into the T-slot. When in the desired position, a quarter-turn of the eccentric stainless steel screw is all that is required to secure the sensor. To further simplify mounting, the screw head design is such that it accepts either a flat-blade screwdriver or Allen key. The mounting screw even features a knurled head that helps to withstand shock or vibration.

Of course, not all cylinders have T-slots. With P8S sensors this is not a problem as they also mount externally to cylinders. As a result, fitment to round, tie rod and profile cylinders are straightforward.

To make life as simple as possible, every P8S sensor is delivered with a specific adaptor to suit dovetail grooves. Also available are special brackets for round and tie-rod cylinders. The concept is to provide one sensor for all actuator types and brands - not just Parker units.

Cables are be supplied in three or 10 metre lengths (flying lead) or 0.3 metres with an M8 rotating plug, as standard. 

Ultimately, automation demands excellent functionality and precision, which in turn requires solid expertise and knowledge at all levels, including best-practice installation. 

To discover more about Parker P8S sensors and benefits they can deliver, watch this video:

This article was contributed by Franck Roussilon, product manager, Pneumatic Division Europe, Parker Hannifin Corporation.

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We are witnessing the increasing take-up of IE (Industrial Ethernet) as engineers continue leveraging the benefits of network connectivity over traditional hardwired networks. The trick, however, has been achieving IE connectivity in a cost-effective and simple way. For those tasked with finding a cost-effective means of connecting valve systems to IE, Parker's new network node can provide a solution.

The need for connectivity largely results from the potential for real-time control of manufacturing processes, which in turn captures and generates data to aid the implementation of predictive maintenance strategies and make decisions based on shop-floor trends. Several IE protocols such as Profinet, Ethernet /IP, EtherCAT and others are introduced and widely adopted due to their advantages over traditional fieldbus networks. You will probably not be surprised to learn that IE protocols are today the fastest growing deployed network type in new industrial installations with an annual growth rate of 22 percent.

IE become popular thanks to the availability of several protocols, broad market acceptance, a good degree of backwards compatibility and the availability of rugged components (hardwired) which are typically protected from electrical noises.

Parker’s global focus on factory automation means has resulted in an extensive range of network connectivity options with the addition of a cost-effective IE node. The new P2M IE node provides an inexpensive means of connecting Moduflex Valves, H Series ISO valve and H Micro valve families to IE. P2M IE node is intuitive, and easy to use, install and maintain. Moreover, the network node is safe-power capable, meaning auxiliary valve power can be supplied by a safety device in support of the European Machinery Directive. This capability allows for test-pulse (OSSD) compatibility and can be supplied with auxiliary power from a safe output device, such as a safe relay or a remote safe DO module.

With the P2M IE node, simple diagnostic input data is provided over the network for easy troubleshooting and predictive maintenance. There are useful diagnostic flags in process (cyclic) data for easy access, including voltage and temperature warnings, communication error and solenoid short-circuit error. This is complemented by detailed diagnostic information in parameter (acyclic) data, such as voltage readings, configuration options and cycle count for each solenoid.

Low-cost connectivity with integrated diagnostics is at last a reality, further reducing complexity and cost at the machine, while aligning with the needs and objectives of smart factory and Industry 4.0 objectives.

Today Parker offers a full range of IE connectivity options, including EtherNet/IP, Profinet IO, EtherCAT, Ethernet PowerLink, Modbus TCP/IP and CC-Link IE protocols.

Find out more about Parker's P2M network mode and the benefits it can bring to your project. 

Article contributed by Patrick Berdal, EMEA product manager for control devices, Pneumatic Division Europe, Parker Hannifin Corporation.

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As Industry 4.0 and the Industrial Internet of Things (IIoT) continue to grow and evolve, they promise numerous benefits for a leaner enterprise. In the realm of machine tools, the IIoT can certainly offer chances for improvements in monitoring and maintenance. There are, however, some concerns that must be addressed before this becomes a reality.
 

Machine tool manufacturers seek to use such components to make their products more reliable and productive, without increasing initial machine cost. This situation is driving a trend of increased cooperation between end users, machine design engineers and their engineering partners in electro-mechanical and pneumatic motion components. 

The end goal is to offer useful information to factory managers who can act on the data that machines collect. Considering this, all partners must work together to set up effective IIoT-capable systems. End users know what information they need for their businesses. Machine designers know the unique concerns and opportunities present in a particular application. Automation component suppliers know how to get data from edge devices to factory software and the internet. Together these engineers can create systems that help factories achieve a leaner, more automated business.

These alliances work to find automation solutions that cost-effectively incorporate better connectivity, control and intelligence into machine tools. Engineering partners can make sure that all collected data is accurate and that it represents important parameters relevant in the real world. They can specify which components to use and which communications protocols make sense for a given application.

Take, for example, a pneumatic tool used to grasp blank parts and load them into position on a cutting machine. Its pneumatic valves are controlled by solenoids, and the voltage of the coils can be monitored for signs of impending failure. To make this data actionable, machine designers need a means of acquiring that information. Open-standard protocols such as IO Link provide affordable serial communication with low-level edge devices, connecting them to motion controllers which in turn connect to the factory network and, if desired, to an internet gateway. Motion component manufacturers are starting to offer IO Link modules for their pneumatic valves, providing an easily integrated, cost-effective solution.

Rather, it is an approach that allows the collection and effective interpretation of data. So far, the status quo in industrial equipment and machine tools has been to monitor one or two aspects of a system, such as position or speed. However, tracking the number of cycles could supply business managers with data that is important for measuring production, service life and total cost of ownership. 

Other parameters such as thermal warning may allow engineers to spot when equipment is not operating correctly or as efficiently as it could. Managers can then schedule maintenance predictably and prevent small problems from becoming big headaches.

A good example is a motor that powers the position of a cutting tool. In the past, the motion controller or PLC received only speed and position information from the motor and its encoder. Now it must be able to receive information about errors, temperature and power factor. Most PACs (programmable automation controllers) are able to handle these inputs and provide the logic that determines when to send a maintenance alert. Some PACs even have internet gateways as part of their embedded HMIs (human-machine interfaces). This greatly simplifies the programming required to connect machines to the internet.

As industry continues to move into the 21st century, the demand for automated, intelligent equipment and controls is sure to expand into machine tool applications, as well as transportation, energy, food and beverage, and life sciences. 

Each of these applications has its own set of unique requirements. For example, food and beverage applications require absolute cleanliness and frequent, periodic maintenance, whereas transportation applications require long operating times and harsh, continually varying environments. For machine tools, the approach marries the muscles of machines with intelligent motion control, and then shares information about machine health and production with the entire enterprise.

As mentioned, the IIoT is a highly integrated approach to industrial applications, machine tools and operations. It requires collaboration on many levels between machine tool builders, motion control suppliers, sensor manufacturers, infrastructure vendors and machine end users. When each partner offers the essential expertise needed, then machine intelligence can be applied to many different kinds of processes and business goals.

As a concept, right-sizing is inherently linked to smart machine design, which brings about rewards such as optimised space, considerable savings on components and installation, inherent safety by design and, oh yes, that all-important future-proofing against ever-changing requirements.

Of course, the design engineers need a sound understanding of standard machine components, as well as knowledge of current machinery safety standards and a firm grasp of the desired outcome in terms of machine function. Meeting all of these requirements when selecting products is a process known as right-sizing. In pneumatic applications right-sizing can impart considerable benefits, especially with regard to valve manifolds.

Valves are generally sized by cylinder bore, actuation speed and required pressure. In the past, the entire valve manifold would be sized based on the largest force/speed requirements to ensure enough flow was present in the pneumatic system, or by splitting between two manifolds (low and high pressure/flow). However, this methodology results in waste, both in terms of compressed air and the expense and size of the manifold, not to mention the labour needed to install two manifolds.

Today, right sizing is achieved by selecting the correct valve for each actuator on one manifold based on speed and bore size for a given flow requirement. In addition, we are pleased to report that some ISO valve manifolds, such as Parker’s H Series, offer a broad range of flows (0.55 Cv up to 3.0 Cv) on one manifold for ease of right-sizing.

Here’s a practical application to consider. Assume a machine that needs the following: four actuators requiring <0.5 Cv; four actuators requiring 1 Cv; and two actuators requiring 2 Cv. This application can be sized several different ways based on the highest flow requirements (solution 1), by splitting the application into two different manifolds for varying flow (solution 2), and by right-sizing each valve to the corresponding actuator (solution 3).

In this example, a cost estimation was produced for a collective hard-wired system and a networked (Ethernet) system in all three solutions. Right-sizing each valve to the corresponding actuator (solution 3), proved to be the most cost effective for both. Beginning with hard wiring, right-sizing saved $92 against solution 2, and $656.60 against solution 1. Similarly, for the networked system, right-sizing produced savings of $552 compared with solution 2 and $656.60 when pitched against solution 1. In addition, labour is not included in these estimations, which would be a particular cost for solution 2, where two manifolds have to be installed.

We can say with certainty that right-sizing works for a number of reasons. Aside from certain valve manifolds offering a broad range of flows, buying just one manifold means purchasing fewer overall components. In addition, the cost of smaller valves is less, installation costs are reduced and less space is consumed within the machine.

Think smarter, lighter and faster.

If you would like to find out more about Parker’s H Series valve manifolds, and the benefits they can bring to machine-building projects, read the white paper "Why Right-Sizing Matters".

Article contributed by Linda Caron, product manager for Factory Automation, Pneumatic Division 

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