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Mitsubishi GX Works Communications Setup

Image by Paul Hunt

In today’s article I’ll explain how you setup communications in the Mitsubishi Programming Software, GX Works.

For those coming to GX Works 3 from GX Works 2 (or earlier,) finding the right area to modify the parameters is the first step. (see figure 1)

Figure 1 -GX2 on Left, GX3 on Right. Image by Paul Hunt

As you can see above, there is a different look and feel between the two software packages. There are many similarities too, but I think the overall feel is much more intuitive (especially in parameter settings) in the newer GX Works 3 software.

Once you have your IP addresses chosen for your components, it may also be handy to have associated connection documentation (if available) that may be specific to each vendor in front of you. In this case, I also have a camera system that works with Mitsubishi and has step-by-step guidelines to get connected that are protocol specific.

Once the controller’s own IP configuration is set, you will need to access the Ethernet port parameters in the software by going to the “External Device Configuration”.  This will be visible on the right side in the “Setting Item” window after double-clicking either the “Module Parameters” in GX Works 2, or the “Ethernet Port” in GX Works 3, as shown in Figure 2.

Figure 2 – R04 (left) and FX5 (right) Image by Paul Hunt

Then click on the “Configuration Access Button” (ellipsis,) on the right.

In Figure 3 below you can see what these connections look like after being setup for both the FX5 (right) and the R processor (left).

Figure 3 R-Series (left) FX5 (right.) Image by Paul Hunt

Note: In my system above, the “Active” connection module is a Moxa Nport, the “SLMP (UDP)” connection module” is a Camera (Vision) Controller, and the “MELSOFT” connection module is an HMI.

To add your devices, you drag and drop connections from the “Module List” window on the right side of the software, and then drop them in the main config window on the left. Next, step through each of the white fields at the top and enter in all of the required parameters:

Figure 4 Populating Communications Config from Module List. Image by Paul Hunt

When complete, be sure you press the button on the top of the window that says to “Close with Reflecting the Setting” or else the settings will be lost.

Figure 5, “Close with Reflecting the Setting.” Image by Paul Hunt

Once set, the next step is to get these parameters downloaded to the processor, and I’ll cover those steps in detail in my next article.

Author’s Note: The PLC in the above application connects through a lightly managed switch to a Serial Controlled Unit (via a Moxa Nport Ethernet to Serial server), an Ethernet Controlled Camera (Vision) System, and an HMI.

This is a little more advanced than just starting with a typical PLC and HMI that would connect quickly, easily, and somewhat seamless. But I thought showing a more complex system was a good way to demonstrate the flexibility, intuitive setup, and ability of having the multiple devices set up in the same configuration window.

Written by Paul Hunt
Senior Automation Engineer and Freelance Writer

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

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Paul Hunt
 


S7 – How To Add Profinet I/O & Drives (S24)

Image courtesy of Siemens

In this week’s episode of The Automation Show, John DeTellem walks us through how to add PROFINET (Ethernet) I/O and Drives to an S7-1500 using TIA Portal:

For more information, check out the “Show Notes” located below the video.




The Automation Show, Episode 24 Show Notes:

Special thanks to John DeTellem at Siemens for sharing this video with us!

Related Articles and Videos:

Support Shawn’s work on TheAutomationBlog.com/join!

You can now support Shawn’s work on The Automation Blog and Show with a small monthly pledge! To become a Patron, visit us at https:// TheAutomationBlog.com/join.

You can also purchase the entire season for a one time donation of $15 at https://vimeo.com/ondemand/theautomationshow.

Thanks in advance for your support!

Vendors: Would you like your product featured on the Show and Blog? If you would, please contact me at: https://theautomationblog.com/contact

Until next time, Peace ✌️ 

If you enjoy this episode please give it a Like, and consider Sharing as this is the best way for us to find new guests to come on the show.

Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt

Automation In Agriculture Increases Efficiency

Images courtesy of Case IH

The agriculture industry has come a long way in the last hundred years. Gone are the days of working from sunup to sundown, planting, weeding and harvesting all your crops by hand.

Photo by Nicolas Veithen via Pexels.

The advent of machinery made it possible for farmers to plant and harvest large swaths of land, which wouldn’t have been possible just a few decades before.

Now automation is set to change the agriculture industry again. How is automation increasing efficiency in the agriculture sector?

Seeding

Using traditional farming techniques, seeding acres of farmland could take days or weeks, depending on the crop. Farmers plowed the ground by hand or with animal-driven plows, then sowed each seed manually.

Now, with advances in agricultural automation, farmers may find themselves completely out of the loop.

The Case IH Autonomous Concept Vehicle was the star of the 2016 Farm Progress Show in Iowa. This self-driving tractor can move from its parking space to the field and back without a driver, and can also carry out various farm tasks, including seeding, without any interference from a human. Users can also control this tractor remotely via tablet, but it’s not necessary.

Images courtesy of Case IH

Irrigation

If you’re not relying on rainwater to irrigate your crops, irrigation is a necessary part of the agriculture industry. Without automation, watering the crops comes down to guesswork, and if you skip a day or two, the effects could be disastrous.

Automating your irrigation can be as straightforward as using timers, sensors or computers to control when and where a field gets watered. Pairing the system with moisture sensors in the soil can prevent you from over-watering the crops and potentially damaging the roots.

Crop Maintenance

Weeding, fertilizing and using pesticides or herbicides are all parts of crop maintenance that used to be manual. Trying to apply fertilizer or other chemicals to an entire field could take days, and by the time you reached the end, it was time to start again at the other end of the farm.

Today, new advances in automation have streamlined the process of crop maintenance. One such robot, called Bonirob, can navigate through the field autonomously, thanks to GPS, video cameras and LiDAR.

Researchers are teaching it to automatically identify weeds before removing them. Eventually, robots like Bonirob could replace human workers entirely, at least when it comes to weeding and other crop maintenance.

Harvesting

Finally, at the end of the season, it’s time to harvest the hard-earned crops. Even with machinery, and the crew to run it, harvesting an industrial-sized farm can take days — and that’s assuming there are enough people on hand to make the effort successful.

Automation is helping to make the job of harvesting a crop more straightforward by reducing the need for a human crew.

One example is the harvesting of nuts, where farmers would traditionally use tractor-mounted “tree shakers” that would vibrate the nuts free from the trees, so nut harvesters can pick them up from the ground and separate them from dirt and pebbles.

Today, self-propelled tree shakers are the most popular option. Automation may, in the future, remove the need for human operators, allowing these devices to operate autonomously.

Images courtesy of Case IH

Drone Use

Unmanned aerial drones might seem like toys or tools for photographers, but they’re starting to prove their worth in the agriculture industry.

These autonomous robots can monitor crops, taking pictures, thermal imagery or more depending on their equipment. With agricultural consumption expected to increase by 70% by 2050, farmers will need every advantage they can get to keep the world fed.

As drone technology continues to advance, these devices will start to adopt more responsibilities, from seeding and weeding to taking soil samples for analysis. There are some limitations to our technology, but with as far as we’ve come in the last two decades, the future is looking bright.

IoT

The Internet of Things is a broad term for networked devices capable of sending and receiving information. IoT sensors in agriculture can collect data about everything from cattle health to crop growth to soil nutrients, and transmit that data back to a central hub for collation into useful data points.

Having all this information at your fingertips lowers production risk and makes it easier to succeed as a farmer, in spite of the ever-changing state of the industry.

The Future of Agriculture

Unless the global infrastructure collapses, we won’t be relying on human-powered tools or manually operated equipment for much longer. Automation is set to change the entire agricultural industry from the ground up — literally in some cases.

It’s exciting to contemplate how far we’ve come, and what advances will continue to revolutionize farming in the years ahead.

Written by Megan R, Nichols
STEM Writer and Freelance Blogger

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

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Paul Hunt
 

Mitsubishi iQ-R PLC Overview (P48B)

In part two of this week’s episode of The Automation Podcast, Jeff Brown from Mitsubishi provides us with an overview of the iQ-R line of PLCs:

For more information, check out the “Show Notes” located below the video.

Watch the Podcast: Why Mitsubishi @ 1:27, Presentation Start @ 2:14



The Automation Podcast is also available on most Video and Podcasting platforms, and direct links to each can be found here.


Listen to the Podcast:


The Automation Podcast, Episode 48 Part 2 Show Notes:

Special thanks to Jeff Brown at Mitsubishi for for taking the time to review the Mitsubishi line of PLCs with us!

Related Links
Mitsubishi PLC Product Link
Part One of Episode 48


Vendors: Would you like your product featured on the Podcast, Show or Blog? If you would, please contact me at: https://theautomationblog.com/contact

Until next time, Peace ✌️ 

If you enjoy this episode please give it a Like, and consider Sharing as this is the best way for us to find new guests to come on the show.

Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt

Mitsubishi iQ-F FX-5 PLC Overview (P48A)

In part one of this week’s episode of The Automation Podcast, Jeff Brown from Mitsubishi provides us with an overview of the iQ-F line of small PLCs:

For more information, check out the “Show Notes” located below the video.

Watch the Podcast: Why Mitsubishi @ 1:27, Presentation Start @ 2:14



The Automation Podcast is also available on most Video and Podcasting platforms, and direct links to each can be found here.


Listen to the Podcast:


The Automation Podcast, Episode 48 (part 1) Show Notes:

Special thanks to Jeff Brown at Mitsubishi for for taking the time to review the Mitsubishi line of PLCs with us!

Related Links
Mitsubishi PLC Product Link
Part Two of Episode 48 – Coming October 3rd


Vendors: Would you like your product featured on the Podcast, Show or Blog? If you would, please contact me at: https://theautomationblog.com/contact

Until next time, Peace ✌️ 

If you enjoy this episode please give it a Like, and consider Sharing as this is the best way for us to find new guests to come on the show.

Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt

HMI and SCADA Performance and Optimization

“These displays take forever to load!”

It’s a common and very audible frustration I’ve heard in many control rooms over the course of my career. And I have to admit, these complaints are often quite valid.

I’ve personally observed it taking thirty seconds or more for an operator to call up a display simply due to a lack of cleanup of the HMI/SCADA piece of a control system.

To avoid issues like these, from time to time we must evaluate our control systems to ensure they’re not performing at a level far less than what they’re capable of.

Image by Brandon Cooper
Image by Brandon Cooper

Based on my own experience, I believe that it’s important to address errors found in HMI and SCADA graphic displays at least on a yearly basis.

Over time, errors can be introduced by programmers deleting tags or points in the control system, but not following through with removing those same tags from the HMI and SCADA displays connected to that system.

And when an operator calls up display with missing tags, in most systems timeout errors are generated in the background, which in turn slows down overall performance and page load times of the HMI and SCADA system.

In addition, scripting errors created by someone looking for enhanced automation can decrease performance as well. Taking the time to call up each graphic display and monitoring the system logs to help you correct the errors will save your system from performance issues and frustrated operators down the road.

Another thing to consider is when was the last time you evaluated your system alarms?

That I/O Module that repeatedly generates errors even though it is working fine, could be telling you that failure is coming.

The PLC that you removed from the system during the outage last month still has the SCADA channel active and is consistently generating timeout errors.

These types of system issues can easily add up to becoming a nightmare for operations and you can guarantee it will be in the middle of an upset condition when the issues are exposed.

The key to system cleanup is being proactive and not letting errors build until the system becomes a tool that is difficult to work with. Both system monitoring and cleanup can be a KPI that can only be measured by the lack of system issues that you are facing in your facility.

“Details Matter” is an Understatement

One request I was given at the start of a new job was that operators were simply asking for a larger mouse pointer in the control system operating displays.

They had difficulty visually locating the pointer, and it would take frustrating seconds of shaking the mouse at their stations every time they needed to use it.

After modifying the domain policy and changing the mouse pointers on each operator station to a much larger font, you would have thought that I had added more air conditioning to the control room.

Image by Brandon Cooper
Image by Brandon Cooper

They praised me for the next year about what seemed to me like the easiest request I could have been given.

It was something they had asked for several years before it could be completed, so to them it was a big deal.

Even though it was a simple request, these details matter to the people operating your facility.

In conclusion, by maintaining and optimizing our control systems to operate at the highest performance obtainable, we help our operations team achieve the greatest potential for the facility’s stability and ability to meet production goals.

Operations also benefit from an environment that contains less frustration and stress due to control system issues, which is definitely an ingredient in the recipe for success.

Written by Brandon Cooper
Senior Controls Engineer and Freelance Writer

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

First Time Using A Siemens Basic Panel (S23)

In this week’s episode of The Automation Show, I connect a Siemens KTP-700 Basic Panel to a S7-1200 for the first time:

For more information, check out the “Show Notes” located below the video.




The Automation Show, Episode 23 Show Notes:

Special thanks to Siemens for sending us the S7-1200 with KTP-700 starter pack!

Related Articles:

Support Shawn’s work on TheAutomationBlog.com/join!

You can now support Shawn’s work on The Automation Blog and Show with a small monthly pledge! To become a Patron, visit us at https:// TheAutomationBlog.com/join.

You can also purchase the entire season for a one time donation of $15 at https://vimeo.com/ondemand/theautomationshow.

Thanks in advance for your support!

Vendors: Would you like your product featured on the Show and Blog? If you would, please contact me at: https://theautomationblog.com/contact

Until next time, Peace ✌️ 

If you enjoy this episode please give it a Like, and consider Sharing as this is the best way for us to find new guests to come on the show.

Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt

Connecting PLCs and Sensors to the Cloud

Life would be so easy if there were only one PLC manufacturer, one Communication Protocol, and just one Cloud Solution.

Unfortunately, since this is not the case you’ll want to find a solution that will cover as many different “constellations” as possible.

What do you need, and why should it be a Cloud solution?

Sensors, Meters, and PLCs provide a variety of data which today we want to monitor, record and display to users in the form of dashboards.

In fact, today’s consumers expect to be able to use their smartphone or tablet to access important data from anywhere. They also expect push notifications to be sent if something goes wrong, as well as beautiful-looking data analysis to only a few clicks away.

All of this can be developed on-premises with great effort, or we simply use an existing Cloud solution that provides these capabilities out-of-the-box.

How do I get my data into the cloud?

Option A: Using a standardized protocol

There are not many standardized cloud protocols, however MQTT seems to be ahead in the race between MQTT and AMQP. These are both very simple protocols that enable the communication between sensor and broker.

MQTT requires low network bandwidth and is easy to understand. But since the payload of a “topic” is not clearly specified, many Cloud Applications will interpret these messages differently.

And for PLCs, MQTT is not very easy to develop, and if the connection fails the data cannot be recovered.

Option B: Using a Cloud Adapter

Typically, an IoT gateway is required whenever data is to be retrieved over a local field bus protocol, like Modbus, OPC-UA, BACnet, M-Bus, etc. These are not suitable for direct communication to the Cloud because they are master-slave protocols, and we never want to open a communications port in our firewall to enable a Cloud Communication.

Thus, a Cloud Adapter serves as a Data Collector on-site, establishes an encrypted connection to the cloud, and transmits the data without requiring a large amount of network bandwidth.

And if the Internet connection fails, all the data is buffered locally.

Option C:

When we program a PLC, we can also implement a direct connection from PLC to Cloud. For this we can use the mentioned standard protocol MQTT.

Siemens now offers a solution here. CODESYS also offers a library for this, but unfortunately it’s not very cheap.

And a free alternative is the AnyViz Cloud adapter by Mirasoft (the company I work for.)

Demo case: Connecting different devices to one cloud

I’m with a customer who has an old Siemens controller installed in production. I’m extending the system with several Energy Meters (via Modbus) and installing another PLC that supports the more modern OPC-UA protocol.

OK, that does not sound easy, but I’m here to implement the Cloud Solution my company offers (AnyViz) because it supports all these protocols.

And for cost reasons I’m using a Raspberry PI as my Cloud Adapter, which nowadays are available in industrial enclosures.

Step 1: Installing Cloud Adapter on Raspberry PI

This step is explained quickly. Log in via SSH and execute this command:

Then I can open my browser and navigate the web interface of the cloud adapter.

Step 2: Collecting data locally

Since this application is using three different protocols, I have to create three connections in the web interface of my cloud adapter.

The fastest way to do this is with OPC-UA, because here I only have to specify the URL. For Modbus and Siemens I have to specify the register addresses (or block address) of each data point, which does take longer but after a few minutes this is done.

Step 3: Creating my data visualization

After registering in the AnyViz portal, I have to enter the project number in the Cloud Adapter and confirm the password. Afterwards, all data points of my local components will be listed in the Cloud Portal.

Using drag and drop, the data points can be configured into different visualization elements, and after about half an hour I’ve configured the following dashboard.

Push messages and emails are sent when any failure occurs, and the monthly report that the customer wants is also done quickly.

Conclusion

The internet offers us a variety of Cloud Solutions that make our lives easier. And we have the option of choosing between Standardized Protocols or Ready-Made and Optimized Solutions which I covered in the demo.

Written by Thomas Hepp
Passionate automation specialist at Mirasoft.de
Edited by Shawn Tierney

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

How To Connect IoT Devices To PLCs With No Programming Knowledge

pccc input node configuration fig. (2)

Connecting PLCs to IoT devices like the Raspberry Pi in order to read and write data to a PLC generally requires the programming knowledge needed to develop communication drivers.

But in today’s article I’ll show you how you can connect and communicate with a PLC without any programming knowledge.

The case for IoT to PLC communications

Those not familiar with industrial automation applications and Programmable Controllers might be wondering why you wouldn’t just connect your Raspberry Pi directly to sensors and eliminate the PLC?

While it’s technically possible to do this, in most applications sensors are already installed and connected to a PLC that is also controlling the system.

In those situations, there’s typically no provisions built into the equipment that would allow you to install additional sensors for a second device.

And while some might suggest connecting the Microcomputer to the same sensors the PLC is wired to, since most sensors only have a single output this would often require adding additional devices like signal splitters or converters.

In practice, the most convenient way to collect all the data coming from existing sensors that are already wired into a controlling PLC is to collect that data from the PLC itself.

Pros and Cons of IoT to PLC Communications

There are definitely advantages to setting up communications with a system’s PLC, as apposed to reading the system’s sensors directly.

The most obvious of which is that you also gain the option to write data back to the PLC. This means the data your analytics provide can actually be sent to the PLC to effect the control of the process.

One disadvantage of communicating with the PLC is that you’ll typically need to purchase the specific PLC’s communications driver software. And since most PLC vendors use their own unique communications protocols (Ethernet/IP, ProfiNet, etc.) you may find you need to purchase multiple drivers from multiple vendors.

But in this article I’ll walk you through how to avoid the cost of commercial driver packages by showing you how to setup communications from your Raspberry Pi to an Allen-Bradley  PLC using a free PLC driver.

Test bench with Raspberry Pi computer connected to an Allen-Bradley MicroLogix 1400 – Image by Nilesh Soni

How our journey began…

When we started our journey to connect the plant floor to our ERP systems, our team didn’t really have any PLC knowledge as our team was comprised of several mechanical and software engineers.

In fact, most of us hadn’t even seen an actual PLC before starting on this journey.

What we did have was a requirement that we connect our ERP system with the PLC’s in our facility, and with that in mind we started searching for solutions.

After trying several different solutions, we settled on the Rasberry Pi micro-computer as our IoT device, with Node-RED as our development environment, and the PCCC-Contrib driver for our IoT to PLC communications.

In the rest of the article, I’ll explain how we setup our Raspberry Pi to communicate with our first PLC, which happened to be an Allen-Bradley ControlLogix.

Raspberry Pi IoT Communication Setup for A-B ControlLogix PAC

As I stated above, our system used a Raspberry Pi as our IoT device, and on it we installed Node-RED, a visual development environment.

Node-RED was originally developed by IBM as a programming tool for connecting hardware devices together, and provides a “web browser based” flow editor where you can just drag and drop different components and then wire then together.

  • Tip: Use this link to get started using Node-RED for Windows
  • Tip: Use this link to get started using Node-RED on Raspberry Pi

While there are several drivers you can use to connect to an Allen Bradley PLC, after trying many of them we found the node-red-contrib-pccc to be the best because of its simple structure and efficient functionality.

  • Tip: Use this link to learn more about node-red-contrib-pccc

To add node-red-contrib-pccc nodes to your Node-RED workstation, first install Node-RED onto your Raspberry Pi computer.

Next, run the Node-RED server and go to http://localhost:1880 to access your Node-RED Flow Editor from your browser.

From here select “Options” (found on the top right of the page,) then go to “Manage Palette.” Then on the “Install” tab search for PCCC. Now find node-red-contrib-pccc in the search results and install it:

Add pccc nodes to your Node-RED environment fig. (1) – taken by Nilesh Soni

Note: Contrib-pccc gives you two nodes: One is “pccc-in” to read the values, and the other is “pccc-out” to write the values.

Next, in your “Input Nodes” find the pccc input node, and drag and drop it into your project’s work-space where you’ll be prompted to enter in the details like the IP Address of the PLC, and Variables Details whose values you want to read or write:

Pccc input node configuration fig. (2) – taken by Nilesh Soni

Note: The pccc input node also has a feature where it only provides an output when the value of PLC’s variable changes. This greatly reduces unnecessary server calls for the same value, improving the efficiency of the system.

Now physically connect your Raspberry Pi to your A-B PLC via Ethernet, and then connect the pccc communication node to a debugger in Node-RED to see the PLC values:

Pccc input node connected to debugger fig (3) – taken by Nilesh Soni

With that done, we’ve proven the communications from our PLC to our IoT device are working using Node-RED and pccc nodes.

In future articles I plan to cover the details of how you use this setup to transfer real-time data from the PLC to the Server so you can run analytics on it with AWS IoT.

Written by Nilesh Soni
Provider of custom ERP solutions and Freelance Writer
Edited by Shawn Tierney

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

Flex I/O – How to add on ControlNet to ControlLogix (S22)

In today’s article (and video) I walk through how to add ControlNet Flex I/O to a ControlLogix system:

NOTE: This article is not a comprehensive ControlNet tutorial, so if you’re not already familiar with ControlNet you’ll likely want to learn about it prior to reading this article.


Step 1) To start, open your RSLogix 5000 or Studio 5000 project and find your ControlNet communications module under I/O Configuration.

Once you find it, expand it by clicking on the plus sign (+) so you can see the “ControlNet” network underneath it.

NOTE: While some CompactLogix controllers have ControlNet port(s) built-in, ControlLogix controllers will require you to add one to your project before you can add Distributed ControlNet I/O like Flex I/O.

Step 2) Next, right click on “ControlNet” and select “New Module”:

Step 3) Now in the “Select Module Type” window, type in the part number of your Flex I/O ControlNet Adapter, then select it from the list and click on “Create” (in this example I’m using a 1794-ACN15):

Step 4) In the “New Module” window, check the default “Revision” and “Chassis Size” to see if they match your actual Adapter and application. If not, click on “Change” to edit either or both fields:

Note: If your Adapter is already powered and wired to the network, you can check it’s revision by first finding it in RSLinx and then right clicking on it and selecting “Device Properties”:

Step 6) If you need to make a change to the module definition, click on the “Change” button and update the “Revision” and/or the “Chassis Size” to match what you have installed and then click on “OK.” Note that most Flex I/O Adapters support up to 8 modules, which is a chassis size of 8:

Step 7) After your “Module Definition” matches your physical hardware, you’ll need to “Name” your adapter and give it an “ControlNet Address” before clicking on “OK”:

NOTE: It’s important to understand that your Flex I/O Tags will show up in Controller Tags using the name you give your adapter. In our example we used the name, “CFIO.”

Step 8) Once you’re finished adding all your ControlNet adapters and other devices, click on “Close”:

Step 9) With your Flex I/O ControlNet Adapter added to the I/O Configuration, the next step is to add your Flex I/O Modules to the Adapter. To do this, click on the plus sign and then right click on the Adapter’s Flex Bus and select “New Module”:

Step 10) Now find and “Create” each of the Flex I/O modules connected to the Adapter:

Step 11) Just like with the Adapter, you can also find a module’s “Revision” in RSLinx Classic by right clicking on the module and selecting “Device Properties”:

Step 12) As you add each module, confirm the “Module Definition” and “Slot” is correct before clicking on “OK”:

Step 13) Once all your modules have been added, you’ll find their I/O Tags under “Controller Tags” using the “Name” you gave your Flex I/O Adapter.

In this case we used “CFIO” as our adapter’s name, and below you can see our new “CFIO” Flex I/O Tags:

NOTE: With ControlNet I/O we have the additional step of “Scheduling” the network. While there are many ways to do this (and many considerations you must make prior to doing it,) below we’ll walk through the simple steps we took in our project to schedule our I/O.

Step 14) The first step was to find the ControlNet Module in our I/O Configuration and right click on it to access its “Properties”:

Step 15) Next we selected RSNetworx on the left, and insured there is either a ControlNet file listed, or that you enter a new ControlNet file name:

Note: For the following steps to work you’ll need to have RSNetwox for ControlNet installed.

Step 16) Next we select “Schedule the ControlNet Network”:

Step 17) And finally we click on the RSNetworx Icon:

Step 18) At this point RSNetworx for ControlNet will launch, and you may be prompted to choose between online and offline data:

Step 19) One final note on scheduling a ControlNet network:

All Controllers on the same ControlNet Network which also have Scheduled I/O on that same Network MUST be put into program mode for the Network’s schedule to be updated in each and every Controller.

Put another way, there is only one (1) Network Schedule per ControlNet Network, so if multiple Controllers have I/O that’s part of that Network’s “Schedule,” then those Controllers need to be put in the Program Mode so they can receive and begin using the updated copy of the Network’s Schedule:

Step 20) Once our network was scheduled, and our controller was returned to “Run,” our ControlNet Flex I/O worked as expected:


The Automation Show, Episode 22:
Adding ControlNet Flex I/O To ControlLogix


I hope you found today’s article (and video) about how to add ControlNet Flex I/O to your ControlLogix helpful!

If you have any comments or questions, please don’t hesitate to post it using the “comment” link found below my signature.

Until next time, Peace ✌️ 

If you enjoy this episode please give it a Like, and consider Sharing as this is the best way for us to find new guests to come on the show.

Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt

Maintenance Management Of Programmable Controllers

Programmable Controllers are the brains behind high industrial performance today.

And because they are so critical to the operation of so many facilities, it’s very important to do what you can to avoid unplanned failures of your Programmable Controllers.

Maintenance Management Of Programmable Controllers

But because Programmable Controllers rarely develop faults, most companies only learn how devastating these faults can be when the effected machine or process goes down.

Unfortunately, it’s even common to see situations where the potential causes of faults (and the means to avert them) are completely ignored.

To avoid finding yourself in that situation, below I’ll recommend several ways your can actively manage the maintenance of your Programmable Controllers.

Programmable Controller Audit

An audit of your installed base of Programmable Controllers should provide you with an overview of all the Programmable Controller models, types, spare parts, program backups, and installation details at your site.

To carry out the Audit Process, you simple open every electrical panel, and write down the Programmable Controller brand, model, machine or area name, Programmable Controller Program Name, Network Node Address, Network Name and Details, available Spares, Date the program was last backed up, Descriptors copy of program if available, Programmable Controller EEPROM or Flash Memory (non-volatile memory) status, as well as the last date the Program was changed, EEPROM/Flash was updated, and Battery was changed.

After recording all this information, analyze it to develop an action plan based on your own risk analysis of were failures could result in bottlenecks or other production issues in order to asses priorities.

Availability of Trained Personnel

Having your technicians adequately trained on maintaining and troubleshooting your installed base of Programmable Controllers will cost the company in the short term, but pay dividends in the long run.

That said, I’d propose that the training should focus on topics in this order:

  1. How to safely troubleshoot electronic components in electrical panels
  2. In person training by Installers or OEMs currently (or soon to be) deploying new systems
  3. Scheduled hands-on training with Programmable Controllers and Programming Software
  4. Create a space with PLC equipment and software, and then encouragement employees to use it to continue their self-education and practice their skills
  5. Create a library of training books, DVDs, and computer based training as another option for employees to continue learning.

Company Policy and Procedure

Companies should include the following Programmable Controller maintenance management in their policies and procedures:

  1. All personnel responsible for working on a particular Programmable Controllers will be trained on that Programmable Controller
  2. Backup copies of the Programmable Controller programs should be made every 6 months regardless of change status
  3. Changes to a Programmable Controller program should be documented in software copy, printed copy, and in CMMS program.
  4. Copies of Programmable Controller programs should be stored on CD, USB, etc.
  5. Copies should be disseminated to relavent PCs, including the maintenance laptop, manager’s PC, and any other relevant locations (engineering server, etc)
  6. If available, the non-volatile memory (EEPROM, Flash Memory Card) also needs to be updated every time a program is changed
  7. Forcing inputs and outputs on or off shall be treated as a Safety issue.
  8. Forcing Inputs and outputs on or off should be done with clear understanding of complete effect on Programmable Controller program and a second opinion.
  9. If forces are installed, they shall be removed within 24 hours and a more permanent solution found.
  10. All forces should be documented in software and a written log before being enabled.
  11. Online programming is somewhat of a safety risk; normal procedure is to change offline and download to the PLC.

In addition to the above, equipment purchase procedures should including the following requirements:

  1. All equipment which include Programmable Controllers should come with the PLC brand and models the plant has standardized on
  2. OEMs are required to provide a full, un-protected/un-locked copy of all PLC programs, and those programs need to include descriptors in the customer’s native language
  3. All Programmable Controllers with 110v Control Voltage will have a line filter on it
  4. All Programmable Controllers will also have a backup EEPROM or Flash Memory Card with the final “as deployed” code loaded

Conclusions

Because Programmable Controllers are critical to many facilities, it’s important that those facilities prioritize PLC maintenance management to avoid unplanned downtime.

Common steps that can be taken to do so include performing an audit of installed PLCs, evaluating what PLC training employees have and need, as well as implementing updated policies and procedures to insure future systems will fall in line with the plant’s existing standards.

Written by Emmanuel Okih
Automation and Control Systems Engineer and Freelance Writer
Edited by Shawn Tierney

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

Regaining Control Of Your Control Systems: Begin With Housekeeping

Photo by Pixabay from Pexels


Have you ever ventured into a server room or opened a control panel which contained mission critical equipment, and just looked right past legacy equipment that hasn’t been used in years?

Like old parts propped up in a corner, and cabinets full of cables that aren’t connected to anything?

Maybe you inherited these “opportunities,” or maybe you created them? Either way, the fact of the matter is that to get to where you want to be in your facility, you cannot accept this as the normal any longer.

In my experience I’ve come to firmly believe that the first step in regaining control of your control systems takes root in housekeeping.

Photo by Brandon Cooper

Take a look at the picture above and ask yourself this question: Do I accept this level of disorganization in my facility’s panels and cabinets?

From personal experience I can assure you that some of you do.

But in a world that’s growing more competitive, most companies are seeing decreasing profit margins, which makes downtime and time to troubleshoot even more costly.

How competitive can “Facility A” really be when they have disorganized panels and cabinets like the above, with no drawings or documentation, and workers who are always in “firefighter” mode?

How well will “Facility A” compete against “Facility B” which has organized and documented its control and network panels with up to date documentation and drawings, as well as labeled all the critical components, connections, and ports?

In this scenario, “Facility B” measures their troubleshooting in seconds instead of hours or even minutes, running like a world-class facility and operating as good as the control systems behind them.

Now some may be asking themselves, does it really hurt to leave legacy equipment lying around and cluttering up panels, cabinets, and storerooms?

Well, while unused equipment and cabling may not be actively taking your systems down, it may well dictate the level of acceptance for clutter and poorly documented systems in the rest of your facility, resulting in more of the same from your staff and outside contractors who work on your systems.

With that in mind, it becomes obvious that rooms, closets, cabinets, panels, and enclosures should be clean, clear of clutter, with critical systems well documented. Your servers, network, and control equipment depend on it.

Ideally, they should be organized so that any engineer who needs to troubleshoot your systems can make decisions in seconds, instead of having to spend hours tracing through an uncharted sea of cables and wiring without up to date labels and documentation.

Changing from “Opportunities” to “Ownership”

If I were to inherit this equipment, the first thing I would do is clean up what can be done quickly, since taking ownership is the first step in moving towards being a world class facility.

So start by removing the legacy equipment and anything else that doesn’t belong.

Next, create a plan for the next outage or opportunity to organize and document everything down to the last detail.

Everything should be labeled and documented while unused cables and equipment should be removed (when possible,) and all other cables and wiring should be neatly organized.

Photo by Pixabay from Pexels

While this is just a part of the puzzle, it can be a substantial part depending on the level of effort you put into it before a problem arises.

When you create an atmosphere in your server rooms and control panels that demand respect, you’ll also promote an atmosphere for others in your facility to follow.

If we want to be world-class, we must carry ourselves exactly that way. If we accept less, complacency may soon lead to loss of opportunities and profits.

Written by Brandon Cooper
Senior Controls Engineer and Freelance Writer

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

Things To Consider When Planning An IIoT Implementation


One topic that is taking over many conversations, and decisions involving control integration, is that of the rapidly growing Internet of Things (IoT).

This has been expanded to IIoT (Industrial IoT) which some celebrate as a major part of the 4th Industrial Revolution (Industry 4.0.)

In this article I’d like to pass on what I’ve learned about this hot topic, and layout some thoughts and key points to consider when integrating IIoT into new and existing control systems and processes.

Honestly, the chosen name can be a little strange if you’re hearing it for the first time.

Even after many seminars, webinars, expos, and college IT courses, I’m still asking, “why did they choose ‘things‘”?

Here is a brief description of what the ‘things‘ are using an excerpt from Wikipedia:

Kisi Smart Lock by Kisi

“…vehicles, home appliances, or any other device that contain electronics, software, sensors, actuators, and connectivity which allows these things to connect, interact and exchange data” – Source: Wikipedia

With the use of IoT, there’s the ability to monitor all of these devices. From your truck, to your car, to any device inside your home.

Some IoT devices can also learn, connect in multiple ways, and even learn where and how to connect. This is typically accomplished through mobile apps and open-source software.

Here are some key points to consider when reviewing the hardware needed to integrate new or existing controls into the web that is IIoT and/or MES.

Image By Kevin Ku
  1. Communications:
    • How many different protocols (gateways) are needed?
    • What is the distance or area being covered
    • What are the total number of connections
  2. Levels to encompass:
    • Control Systems (i.e. PLCs)
    • SCADA
    • MES
    • ERP
    • Cloud
  3. Data Storage (local, remote, size, ease of expansion, cost)
  4. Type of analytics and control (Dashboards, SQL)

Beyond these points, security needs to be at the top of your to-do list when deciding on an implementation. And security becomes more and more important as the number of devices that are connected and communicating grows over time.

Manufacturing Execution Systems (MES) and Enterprise Resource Planning Software (ERP) may also be part of the discussion when delving into the IIoT realm, and they will have their own considerations which need to be addressed.

These include Data Storage and Cloud Access (let’s add Big Data to the keywords here). And these are also tied heavily into security as well.

And as always, planning is essential in order to maintain a focus on the key features and functions you need.

Depending on what you determine are the most important aspects of your system, you may have to design from “storage availability” backward to the “plant floor,” or vice versa.

Also be sure to build-in expandability options, leaving yourself plenty of room to grow to meet future needs.

And finally, when it comes down to the implementation phase, in many cases it’ll make the most sense to start with a single process, line, or building, especially if you have many that you will be adding to your system.

Taking a “phased” approach like this often simplifies the initial startup, as well as allows for easier “tweaking” of the system to work around unforeseen technical issues prior to rolling the system out to the rest of your facility.

And the efficiency gains and cost savings achieve from the initial phase could be used to justify or even fund the expansion of the system.

Written by Paul Hunt
Senior Automation Engineer and Freelance Writer

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

Flex I/O – How to add on Ethernet to ControlLogix (S21)

In today’s article (and video) I walk through how to add Ethernet Flex I/O to a ControlLogix System:


Step 1) To start, open your RSLogix 5000 or Studio 5000 project and find your Ethernet communications module under I/O Configuration. Once you find it, expand it by clicking on the plus sign (+) so you can see the “Ethernet” network under it:

NOTE: While some CompactLogix and ControlLogix controllers have Ethernet port(s) built-in, most will require you to add one to your project before you can add Distributed Ethernet I/O like Flex I/O.

Step 2) Next, right click on “Ethernet” and select “New Module”:

NOTE: While you may be tempted to try to add or “Discover” Flex I/O “Online,” this is not supported as shown below:

Step 3) In the “Select Module Type” window type in the part number of your Flex I/O Ethernet Adapter. In this example I’m using a 1794-AENT:

Step 4) Next, select your Adapter from the list and click on “Create”:

Step 5) In the “New Module” window, check the default “Revision” and “Chassis Size” to see if they match your actual Adapter and application. If not, click on “Change” to edit either or both fields:

Note: If your Adapter is already powered and wired to the network, you can check it’s revision by first finding it in RSLinx, and then right clicking on it and selecting “Device Properties”:

Step 6) If you need to make a change, click on the “Change” button and update the “Revision” and/or the “Chassis Size” to match what you have installed and click on “OK.” Note that most Flex I/O Adapters support up to 8 modules, which is a chassis size of 8:

Step 7) After your Module Definition matches your physical hardware, you need to “Name” your adapter and give it an “Ethernet Address” before clicking on “OK”:

NOTE: It’s important to understand that your Flex I/O Tags will show in Controller Tags using the name you give your adapter here. In our example we used the name “EFIO.”

Step 8) Once you’re finished adding all your Ethernet devices, click on “Close”:

Step 9) With your Flex I/O Ethernet Adapter added to the I/O Configuration, the next step is to add your Flex I/O Modules to the Adapter. To do this, right click on the Adapter and select “New Module”:

Step 10) Now find and “Create” each of the Flex I/O modules connected to the Adapter:

Step 11) Just like with the Adapter, you can also find a module’s “Revision” in RSLinx Classic by right clicking on the module and selecting “Device Properties”:

Step 12) As you add each module, confirm the “Module Definition” and “Slot” is correct before clicking on “OK”:

Step 13) Once all your modules have been added, you’ll find their I/O Tags in Controller Tags with the “Name” you gave your Flex I/O Adapter.

In this case we used “EFIO” as our adapter’s name, and below you can see our new “EFIO” Flex I/O Controller Tags:


The Automation Show, Episode 21:
Adding Ethernet Flex I/O To ControlLogix


I hope you found today’s article (and video) about how to add Ethernet Flex I/O to your ControlLogix helpful!

If you have any comments or questions, please don’t hesitate to post it using the “comment” link found below my signature.

Until next time, Peace ✌️ 

If you enjoy this episode please give it a Like, and consider Sharing as this is the best way for us to find new guests to come on the show.

Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt

What’s New At The Automation Blog And School, Summer 2019 (Article & Video)

It’s been a busy summer here at Insights In Automation, and I thought I’d take a moment to review what’s new at The Automation Blog and School!

You can either watch the video version here, or scroll down for the text version below the video:



What’s new at TheAutomaitonBlog.com

1. Recruiting Freelance Writers

First up, we’re now actively recruiting Freelance Writers to submit articles for publication here on The Automation Blog.

We’re doing this with one goal in mind: To broaden our audience by publishing articles on industrial automation topics which lie outside of my own areas of expertise, including products made by vendors other than Rockwell, as well as Rockwell products other than PLCs, HMIs, and SCADA.

We’ve already had a few people sign up, and you’ve probably noticed their posts over the last couple of weeks.

So if you’re interested in joining out team, please submit the contact form on this page and I’ll get in touch with you next week.

2. Submit a News Tip

Now that our forums are up and running to handle reader Q & A, I’ve brought back the “submit news tip” link to the top of the site for those of you who want to shares news about products and happening with us.

The new form offers you the choice of submitting the news tip anonymously or with credit given.

3. TheAutomationBlog.com/join and TheAutomationExchange.com now part of TheAutomationBlog.com

For those who might not be aware of this change, over the summer we migrated the above two sites into this one.

We also attempted to migrate every product, user, order, and receipt from the store at TheAutomationExchange.com to the new store at TheAutomationBlog.com, so any previous orders you’ve made at the old site should now show up here.

4. Looking to trade a ControlLogix Course for an RSLogix 5 license

As you’ve probably seen on The Automation Show, we’re hard at work putting together our product backboard in Studio B.

One product we’d like to fully integrate with the rest of the equipment is our PLC-5, however Rockwell has formally rejected our request to purchase their PLC/HMI Toolkit by telling us we just don’t qualify.

Not wanting to waste money on an expensive toolkit full of products we’ll never use, we’re thought we’d reach out to our readers and connections to see if any of them would be willing to trade us a license of RSLogix 5 for a ControlLogix course from The Automation School.

So if you have a license of RSLogix 5 you no longer need and would be willing to transfer to us, please contact me using this form here.

5. Become a member, get free stuff!

We’re very thankful to those individuals who’ve been backing our site, some as far back as 2014!

In order to show them our appreciation, we’re in the process of updating our membership program so that all our backers will be able to browse our site Ad Free, as well as get access to free download too!

We’re not ready to release the details as of yet, but stay tuned as we plan to roll it out shortly!

What’s new at TheAutomaitonSchool.com

1. Last Chance Sale for Compact (Logix) Basics

I’m prepping to film the very last chapter of my CompactLogix course, Compact Basics, and wanted to let everyone know that my “Last Chance” sale ends on September 30th!

So if you (or someone you know) would like to learn all about the CompactLogix line, then please head over to TheAutomationSchool.com/courses/compact-basics-course/ to save 20% off this course and get if for just $119!

2. All Contact Links in One place

In our recently updated “top menu,” you’ll now find all of our contact links in one place!

These include links to our pre-sales questions, group enrollment questions, returning student discounts, upgrade coupon requests, and general contact link.

3. Recruiting Instructors

Last but not lease, we’re always on the lookout for instructors who’d like to join me in teaching over at The Automation School.

So if you either already have a course or would like to create one, please contact me about teaching at The Automation School by using this link.


Well that’s it for our Summer 2019 update!

If you have any comments, questions, or suggestions please don’t hesitate to leave them below 😉

Until next time, Peace ✌️ 

If you enjoy this episode please give it a Like, and consider Sharing as this is the best way for us to find new guests to come on the show.

Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt

Troubleshooting A Tension Application: Knowing Your Components

I was recently involved in troubleshooting a machine that I’d originally built and programmed for some prototype work, and which was later moved into production.

Unfortunately, it had developed an issue that caused it to run unsteadily, and of course production needed it fixed a.s.a.p.!

Sound familiar?

The issue seemed to be related to the closed-loop tension for one of the servos.

In this particular system, the PLC receives a load cell value from a signal conditioner that is powered by 24VDC. This signal is an analog signal of 0 to 10vdc.

Like many signal conditioners, the one used had a setting to allow selecting different input ranges (typically in the millivolt range for load cells). The output is then sent to the PLC where it has specific programming and/or hardware to handle the input signal (common ranges include 0 to 10VDC, 0 to 5VDC, andr 4-20mA).

As I saw it, I needed to determine if the issue was (a) the load cell setup, (b) the servo system itself (improperly sized?), or (c) a problem within the PLC code.

I started troubleshooting by stepping through the measurements and setup for the analog input, hoping to eliminate both the load cell configuration and the PLC’s code. Then if needed, I’d inspect the servo system.

Photo by Bill Oxford on Unsplash
Photo by Bill Oxford on Unsplash

When designing a servo system, the user needs to consider the speed of the motor, inertias, and the torque needed for the final system to work. So I thought it doubtful that at this stage it would be the design that was the problem since the machine had run successfully for over a year.

However, remember that this system was created as a prototype to test a process, I had to concede that the process of specifying parts and how they would be used was not done in a typical way.

Also, another unfortunate point about moving a prototype machine into production is the fact that when you’re asked to put together a prototype on a limited budget, it’s common to make use of used equipment already on hand, as well as not design the system with longevity in mind.

Back to the troubleshooting of the machine, the first step I took was to take a detailed look at the load cell.

The process engineer was using three different load cells that are swapped out depending on the load of the material in the machine, and the range of tension needed.

Intuitively I knew that could pose a problem, but luckily all three outputed a standard 21mV signal. Upon reviewing the design and specifications of each load cell, I found they were also all the same resistance and had the same nominal excitation voltage (10VDC).

So at that point I eliminated that part of the system as being the cause of the problem.

Next I focused on the signal conditioner, which had a series of dip switches used to set the starting and ending input values from the load cell (in this case, 0 to 21 millivolts.)

The signal conditioner also had a bank of switches that set the output signal discussed above.

But something I did notice was that the switches were NOT at the default settings for this unit. This is something I knew I needed to double check, but after I did I found that they all looked good.

Next, I moved on to reviewing the PLC parameters in the analog hardware setup.

This system is controlled by a Mitsubishi FX5, programmed with GX Works 3, which is one of the nicer software packages I’ve worked with (more on that in a future article.)

For some reason, I found non-default parameters set in the scaling, shift, and clip settings, which seemed odd?

So I decided to download the defaults, but found the issue still there.

But when I combined the defaults with a control function that would force a fixed tension (used for debug purposes,) the unstable condition completely went away?

Not only did it go away, the system was much more stable with lower values of tension, which meant the issue is definitely not what I originally thought.

To be absolutely sure, I ran through the below testing process several times:

  • Start the machine
  • Begin with a fixed output for tension.
  • Switch over to PID controlled tension after a short period.

Each and every time the system would now run perfectly smooth.

I discussed the issue with some of my colleagues and found that some of the other machines with similar controls would also startup at a fixed tension before switching to PID control after several seconds, confirming what I was seeing.

With that issues resolved, we’ll now be adding this additional tension switching functionality into not only this machine, but also future machines which we are getting ready for production.

So in summary, the solution to the issue was different than what I expected. In the end the system just needed to stabilize first with fixed tension setting prior to into PID control. Once this was discovered, a simple process change was all that was needed.

So when analyzing a system to resolve issues, you have to keep an open mind as to what the issue might be, as well as understand how the different components of the system interact as well as how peripheral equipment can affect them.

Written by Paul Hunt
Senior Automation Engineer and Freelance Writer

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

How IOT works

How IOT works, from an ERP perspective.

Definition:

Simply put, IOT (Internet Of Things) is a system where machines talk to each other without the need for users to get involved.

It’s used to provide next-generation automation by identifying the state of a system with the help of various devices and sensors, and today major applications for IOT include monitoring and analysis.

A typical IOT system comprises of 4 components:

  • Data Source
  • Data Transfer Medium
  • Data Processing
  • Client (User interface)

Data Source:

It is the source that generates/collects data from the environment, and it can be any type of sensor (temperature sensor, pressure gauge, flow meter, etc.), any type of machine (weighing machine, CNC machine, etc.) or any type of PLC controllers.

The basic function of this source is to generate data about the state of the system, for example: A steam turbine system consists of many temperatures, pressure, and flow sensors, this sensor understands the state of a steam turbine and generates data about the temperature and pressure of turbine.

Data Transferring Medium:

This component’s main function is to fetch the data from the data sources and send data to the cloud then this data goes for further processing.

This data can be sent to cloud by several mediums like: Cellular, Ethernet, Satellite, etc. Which medium is used completely depends upon the availability and compatibility with the source of data.

For example: For one of our applications we used a Raspberry Pi computer as data transferring medium to connect with a PLC, and it fetches the data via. a Python Script and sends that data to a server.

Data Processing:

This component compares the data through some conditions and performs the actions accordingly. This action can be either monitoring, alarming, performing tasks like shutting down the system or activating another process, and typically is comprised of algorithms that contain if-else statements.

In my experience, the most popular platform for IOT data processing has been AWS IOT (Amazon Web Services IOT.) AWS IOT provides a platform that uses the MQTT protocol for data transferring, allowing users to develop their own algorithms and define custom actions that meet their requirements.

For example: In one of our applications we monitor the temperatures and pressures of a Steam Turbine. In applications like this, users can define a certain range for temperatures and the actions to take if temperature crosses that range.

Client (User Interface):

It’s the component that shows the processed data to the user in a presentable form, and typically makes use of bar graphs, pie charts, and other graphical objects. It also shows notifications of alarms and messages, and provides a user interface to respond to these back to the data source.

For example: In our Steam Turbine system, if blades temperature crosses the given range, our Turbine needs to trip immediately. Hence we made an alarming system that sends alerts via notification and messages, and with the help of user interface users can now send trip signals to the PLC.

Summary:

In summary, from my perspective as an ERP Solutions provider, utilizing IoT not only makes interfacing with automation systems easier, but it also adds an extra layer of safety to the system by integrating alarming and emergency trip systems.

Written by Nilesh Soni
Provider of custom ERP solutions and Freelance Writer
Edited by Shawn Tierney

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

Tips to Optimize Your Smart Factory for Maximum Efficiency

Photo by Dids

Whether you already have a smart factory or are creating one, you undoubtedly want to operate it at peak efficiency. Doing so helps you increase worker productivity while keeping clients happy. Here are some tips for success.

1. Use Data to Inform Your Process Improvements

One of the top advantages of smart factory equipment is that it continually collects data to inform plant operators about operations. However, many people who run smart factories realize they have data available, but don’t know how to use it effectively.

Some analysts say there are four data-driven evolutionary phases for smart factories. In the earliest stage, companies have data to use, but it’s hard to access. But, the final one encompasses action-oriented data. Then, companies have large, validated data sets and feel confident enough in them to make decisions based on the results.

There are no quick processes to make better use of your data. But, once you believe you’re in the last data evolution stage, dig into the information and use it to guide what you do next.

2. Get Employee Feedback About the Tech

When companies make their factories smarter, they can often do the same amount or more with a smaller workforce. However, you’ll almost certainly have workers that directly work with smart factory machines. They should ideally be the first points of contact as you assess what’s working well and what isn’t.

Ask them what they like best about the smart factory as well as any frustrations they have about the inefficiencies that remain. Moreover, be aware that making your facility more efficient may require adjusting your workforce so that it has the know-how to take your factory into the future.

A survey from PwC found candidates with four-year or advanced degrees get three-quarters of non-factory-floor jobs at smart factories. Furthermore, the most common way to upskill workers to meet advanced manufacturing needs is to train them in-house.

After speaking with your factory floor employees about the new tech, you may learn the workforce has skill gaps to address. If so, internal training could fill them.

3. Update Your Factory Layout Every Year

Your smart factory almost certainly has features that assist with inventory management. For example, workers might use handheld scanners as they move around the facility floor to retrieve or restock items. Or, your factory might have autonomous vehicles that safely transport products to the proper places.

Photo by Dids

In any case, you’re probably not selling precisely the same products now as you were this time last year. That’s because successful businesses grow and change with time. One way to boost efficiency is to adjust the factory layout annually and ensure your most-sold products are in the most accessible sections of your inventory storage areas.

The layout update may indicate you need new equipment to accommodate the changes. In that case, always take the time to give employees the training they need to feel confident about the new layout and equipment.

4. Consider Implementing Predictive Maintenance Technology

Unplanned downtime due to maintenance negatively affects both profitability and profits, and the outcomes tend to get worse the longer a stoppage persists. When Intel investigated what manufacturers do to improve their smart factories, they talked to company representatives about their most prominent pain points. Nearly a quarter of respondents cited equipment maintenance and upkeep as being problematic.

But, if smart equipment has predictive maintenance features, it’s easier to spot issues before they become severe enough to stop production. If you already use predictive maintenance tech on some machines, improve it by seeing if other pieces of machinery tend to have unexpected breakdowns more often. If so, focus on adding predictive maintenance sensors to those things, too.

When machines run more consistently, your facility should quickly become more efficient. The predictive maintenance tools used may also inform you of process deficiencies you should change because they make parts wear out more rapidly than normal.

5. Ensure All Efficiency Improvements Connect to a Larger Strategy

It’s tempting to see inefficiency in a factory and address it immediately without making sure it supports your overall strategy. Research from Capgemini found 56% of the participants surveyed invested at least $100 million into their smart factories. But, only 14% of them said they felt satisfied with their success levels so far.

That’s not to say you should hold off with any planned smart factory enhancements. But, whether the upgrades relate to efficiency or something else, spend time thinking about how you’ll measure success and align it with a strategy.

Help Your Smart Factory Grow

These tips will help you achieve better efficiency in your smart factory. Then, you’ll be in a better position to excel.

Written by Megan R, Nichols
STEM Writer and Freelance Blogger

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

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Paul Hunt
 

Troubleshooting 101: Not always what you think, but how you think

Photo by Chandler Denise on Unsplash

Not many people spend their entire career in one place or the same position.

Photo by Nikita Kachanovsky

As you move up and on to different positions and other seemingly brighter opportunities, as most do for much of their career growth, the ability to step back and look at an issue becomes increasingly important.

You may be the last in line on the frontlines to get something running or the one that everyone else is looking to for ideas.

Either way, there are a few steps or guidelines I feel that can be kept in mind to make any automation troubleshooting experience go smooth and hopefully end with a successful result.


1. Previous Knowledge

Take advantage of the knowledge from the technician, the operator, and the maintenance personnel that deal with the issue every day. This is key. Every one of these positions involved has a unique perspective on the equipment or system.

Communication becomes more and more crucial in troubleshooting (just as most daily activities) especially as technology continues to move forward and continue to make the face to face interactions less and less common.

2. Understand & Review

Review and know what you are looking at. Whether it’s a system or a single piece of equipment, know what you are looking at. Understand the problem at hand. Keep in mind too that diving way in-depth with technicalities may not be the best initial approach.

Take your time in reviewing and being sure something less technical or simple to fix could have been overlooked. Might be best to just find what it is supposed to do when the failure happens and work backward.

Sometimes a situation just needs a set of fresh eyes to help expose the issue.

3. Keep calm

Photo by Chandler Denise

Regardless if you have an entire afternoon or a few seconds to look over the code in the robot between items as they come down the assembly line (been there…not fun), keeping a cool head will ALWAYS be more beneficial to the troubleshooting process than getting frustrated or angry (at yourself or other people involved).

4. Take Notes

Do what you can to document steps taken previously and along the way. This is important when trying to be as efficient as possible and not trying the same thing more than once.

Good records will help with future issues on this equipment or similar equipment to determine if the same fix needs applied or something else needs to be looked at.

This can be as simple as Notepad notes in a text file or screen capture (with software or Alt + PrtScn). No such thing as too much information…ever!

5. Stumped?

Step back…take a walk…check postings (or post a question) in forums… come back tomorrow if you can. The key is to rest your thought process.

Sometimes, you will be surprised to see that the answer will just appear as if magic.

Be ready for a delay though. Sometimes this epiphany won’t happen until you are fast asleep. Maybe it will wait until in the morning starting your shower and getting ready for the day.


Though these steps are good points to follow, I think the key is to stay calm and let your mind work.

Even though you may have the most advanced knowledge of the equipment or process, often it comes down to the thought process in finding the cause more than knowing the system like the back of your hand.

Written by Paul Hunt
Senior Automation Engineer and Freelance Writer

Have a question? Join our community of pros to take part in the discussion! You'll also find all of our automation courses at TheAutomationSchool.com.

Sponsor and Advertise: Get your product or service in front of our 75K followers while also supporting independent automation journalism by sponsoring or advertising with us! Learn more in our Media Guide here, or contact us using this form.

Paul Hunt
 

TIA Portal, S7-1500 – Create, Download, and Test your first PLC Program (S20)

In this week’s episode of The Automation Show, John DeTellem of Siemens walks us through how to create a new program for a Siemens S7-1500:

For more information, check out the “Show Notes” located below the video.




The Automation Show, Episode 20 Show Notes:

Special thanks to John DeTellem for sending in this video!!

Related Articles:

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Until next time, Peace ✌️ 

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Shawn M Tierney
Technology Enthusiast & Content Creator

Eliminate commercials and gain access to my weekly full length hands-on, news, and Q&A sessions by becoming a member at The Automation Blog or on YouTube. You'll also find all of my affordable PLC, HMI, and SCADA courses at TheAutomationSchool.com.

Paul Hunt