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CCW – v12: What’s New in Connected Components Workbench

By
Shawn Tierney
-

Earlier this week Rockwell released version 12 of Connected Components Workbench.

Below I’ll summarize the new features as documented in the release notes:

New CCW Features:

  • Support for new products including the Micro870 with AC Inputs, Spectrum Controls MicroSD plug-in module (2080-SDMEMRTC-SC,) and new Electronic Overload Relay (193-E200-PCM)
  • Support for FactoryTalk Linx in addition to RSLinx Classic
  • Trending of Micro800 variables as well as PowerFlex drive parameters added

New Micro800 Features:

  • New Micro850 simulator added (Standard Edition simulator only runs for a short time in order to demo feature.)
  • Micro870 support for customizable module scan interval
  • New instructions including SCL (scale), COM_IO_WDOG (external comms watchdog), AFI (always false), and NOP (no operation.)
  • Disable/Enable Modbus TCP server
  • Feature Pack v11 integration, including Copy/Paste of ladder logic between CCW, Studio 5000, and RSLogix 500.

New PV800 Features:

  • Integrated v11 Feature Pack
  • Can now start applications from PC after download
  • Simple object animation (size and screen location)
  • Auto-updating tag names based on controller tag name

Enhanced features:

  • Data Log/Recipe features now available for Micro830, 850, and 870 (see Spectrum module above) including export and import

Functional changes:

  • When you open a project from an older version of CCW, the software will now automatically create a backup of the older project prior to upgrading the project.
  • You can now choose not to download Micro800 source code when you download your project.  Doing so speeds up building and downloading, however it also disables the ability to go online with the controller (unless the project is already open in CCW.) It also disables uploading and discovering the controller.
  • With the addition of several new instructions, additional reserved words have also been added in v12. Older programs using those reserved words will no longer build in v12 until the reserved words are no longer used.

Learn about other releases:

Check out our coverage of other releases of CCW below:

Find out more:

If you would like to view the Connected Components Workbench 12.0 release notes, head over to Rockwell’s Product Versions webpage and search on Connected Components Workbench.

From the resulting list, under Connected Components Workbench select “Versions,” and then from the versions page click on the “PDF Document” icon under version 12.00.00:

So, what do you think of the new features of Connected Components Workbench 12?

Will you jump in and install v12 right away because of the added features or hardware support?

You can share your thoughts and opinions by clicking on the “post a comment or question” link 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.

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S7-1200, Basic HMI – Starter Kit (S11)

By
Shawn Tierney
-

In this week’s episode of The Automation Show we open a brand new Siemens S7-1200 PLC and Basic HMI Starter Kit:

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


The Automation Show, Episode 11 Show Notes:

Siemens PLC and HMI Starter Kit Details:

Description from the Siemens Industry Mall: S7-1200+KTP700 Basic starter kit Consisting of: CPU 1212C AC/DC/relay, HMI KTP700 Basic, input simulator, STEP 7 Basic CD, manual CD, information material, SYSTAINER.

Link to product: 6AV6651-7DA01-3AA4

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.

NOTE: 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.

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Automation Q & A for March, 2019 (qa190328)(s10)

By
Shawn Tierney
-

In this week’s episode of The Automation Show we answer viewer questions on a wide range of automation topics:

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


Note: Automation Q & A is a member/supporter perk. Learn more about our membership/supporter options here.

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.

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Alias Tags – Do you use them (Q&A)

By
Shawn Tierney
-

One limitation of legacy programmable controllers like the PLC-5, SLC-500, and MicroLogix, was the inability to save “address names,” known as “symbols” in the aforementioned products, directly to the controller.

And since these “symbols” could only be saved with the offline project, in order to display them while online required that you match-up the correct offline file with the one already in the controller.

Offline with RSLogix 500: Tag names, known as “Symbols” in RSLogix, can be seen here highlighted in green above tag addresses.

But thankfully for Allen-Bradley users, with the release of the ControlLogix in 1999 Rockwell switched from using “Data Tables” to a user created Tag Database that was also downloaded to the controller along with the user’s program.

This change enabled programmers to create their own custom named Tags for any supported data type, which resulted in what Rockwell called “self documenting” code.

That said, Logix controllers still automatically assigned Tag names to Physical I/O based on the module type and slot.

With this in mind, Rockwell included a feature known as Tag Aliasing which allows users to assign their own Tags as “aliases” to the Physical I/O Tags (or to any other Tag for that matter.)

And while many find using Alias Tags to be quite useful, they do have one fairly big limitation, which is that a Tag’s alias definition can’t be edited online.

Even using the old v20 version of RSLogix 5000, Alias Tags that are currently in use in the program can be renamed Online in the Run mode

That’s not to say you can’t create new Tags online, or rename Tags online, or even alias new Tags to I/O online. You can do all three, even in older versions of RSLogix 5000.

But what you can’t do is change or edit a Tag’s Alias online.

For most this isn’t an issue because you typically don’t change which I/O terminals your I/O devices are wired to while your system is running.

And even if you did, you can still rename old Alias Tags and replace them with new Alias Tags while your online and in run mode.

But that said, I recently found out that quite a few of my connections don’t use Tag Aliases at all.

Actively Avoiding Aliases

I received this feedback when I asked my connections how they were handling migrating programs from the 5370 to 5380, which I discuss in a previous article here.

The response wasn’t at all what I was expecting, as nearly all of the respondents said they’ve been avoiding Alias Tags completely.

Many shared that instead of using Alias Tags, they used a dedicated Routine to “map” Physical I/O Tags to user created Tags.

The thought process being that, while Tag Aliases can’t be edited online, Routines can be.

You still can’t edit Alias Tag definitions online even while in program mode using v30 of Studio 5000 and a 5380.

Now as you might imagine, creating a “one to one” relationship in code for hundreds of I/O points can be quite a task.

So I wasn’t surprised to hear that for many Structured Text was the language of choice to accomplish the mapping.

But there is a downside to that approach; many end users don’t have a version of RSLogix/Studio 5000 that can view Structured Text routines.

And if you can’t view the routine that does the I/O to Tag mapping, you’re at a huge disadvantage when it comes time to troubleshoot the system.

In fact, this was one of the major issues using ControlNet and DeviceNet with some legacy PLCs, as you couldn’t tell where each node’s I/O was mapped without first purchasing an expensive copy of RSNetworxs.

It is possible to avoid the Structure Text licensing issue by mapping your I/O to Tags using Ladder Logic.

But in all but the most basic systems you’ll end up with a rung (or branch) for every Discrete I/O Point in your system.

So while I do see the wisdom and flexibility of using a routine to map I/O to Tags, at the same time it seems like there should be a better solution twenty years after the Logix controller came out.

What do you think?

Should features which don’t support online edits, like Alias Tags, Produced and Consumed Tags, and Add-On Instructions, be avoided?

Or do you use these features with the foreknowledge that like rewiring physical I/O you’ll need to take the system offline to make changes to Alias Tags, AOIs, and Produced and Consumed Tags?

I’d love to hear your thoughts on this, and you can share with us by clicking on the “comment” link 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.

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MicroLogix 1400 – Memory Module: Field Report on Issues with New Models

By
Shawn Tierney
-
MicroLogix-1400-Expansion-IO-with-Expansion-IO

Today I’d like to share a helpful “field report” that was posted in our forums recently.

The report came in from Bill Hosay of DataVisual Controls, LLC, and if you’d like to see his original post you can read it here.

Bill’s story starts back in July 2018, when he sat down with Rockwell’s product manager and OEM specialist to discuss details of the changes to the MicroLogix 1400 Series C.

At the time he was assured that commissioning and recovery methods would be same between the series B and C, with only the location of the password changing.

MicroLogix-1400-Front-OpenA quick check of the current versions of Rockwell’s MicroLogix 1400 Release Notes and User Manual provide the very same information (As of today, 3/12/19, the latest version of each document is July, 2018.)

For those who don’t know, Memory Modules are used to hold a backup of the PLC’s program, and can be set to automatically load on power-up, or if the PLC’s program is missing or corrupt.

While many End Users use memory modules as a means of safely backing up PLC programs, OEMs often use them to quickly commission identical controllers, as well as to provide end users with updated PLC code that can be loaded without the need of a PC and Programming Software.

With that in mind, understanding how the implementation of passwords changed in the MicroLogix 1400 with Series B FRN 21 and Series C, is important to those End Users and OEMs who have implemented password protection.

As Bill put it in his post, “if you’ve been using latest MicroLogix 1400 Series C (or B with v21) and you’re using the MM1 module with ML1400 password set, STOP doing this! I verified with Rockwell a few weeks ago that an MM1 with a password WILL NOT COMMISSION a NEW or USED MicroLogix 1400.”

At the core of the problem is the fact that you can’t use a passworded MM1 in these newer 1400s unless the 1400 already has the same password… not very likely if you’re replacing a failed unit with one out of the store room, or off a vendors shelf.

As Bill put it, “This means OEMs would need to provide end-users with a spare MicroLogix 1400 pre-loaded with the OEMs passworded program, OR a blank program with the same password as the OEMs program, in order for them to use a pre-configured and passworded MM1.”

Not very useful.

So what’s the workaround if you find yourself in this position? Thankfully Bill shared one with us.

According to Bill, you first need to change the MicroLogix 1400 Processor in your Series Bv21 or C program to the, “NON-ENHANCED PASSWORD SECURITY version, which is currently the middle selection of MicroLogix 1400s available (ML1400 Series B):”

“This will make the series C hardware function like B, with 3 passwords that can be used. Note that you can’t actually flash your series C to series B, but you should have no issues changing the processor type from ENHANCED PASSWORD SECURITY back to B in RSLogix:”

Bill also provided some additional notes which I’ll include below:

– The MicroLogix 1400 Series C stores password in the HARDWARE, which prevents ONLINE Access & Downloads.

– The MicroLogix 1400 Series B stores all passwords in the offline .RSS file, which can be viewed if one knows how.

– Another workaround this issue is to use a SUBROUTINE password for code protection, as this password is stored in the offline file in both Series B and C, and if “encrypted” is checked it will prevent offline file hacking from relieving the password. Another reason for recommending SUBROUTINE passwords is that anyone can view a password SERIES C file offline since the Series C password is stored ONLINE.

In summary, Bill points out (and I confirmed) that nowhere in Rockwell’s manuals or documentation does it state that you don’t need to use MM1 memory modules with password protection to protect your program if you’re using MicroLogix 1400 Series C.

Bill also shared one final note, saying that while this issue effects password protected MM1’s, if you’re not using passwords the MM1 still works as advertised in the Series C (or Series B FRN 21) MicroLogix 1400.

If you’d like to see Bill’s original post you can read it here, where you can also add your own comments.

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.

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Fun Automating Virtual Factories (SG1)

By
Shawn Tierney
-

In this week’s episode of The Automation Show, we take a look at “Automation In Gaming” by learning how to automate a virtual factory in the game Factorio:

NOTE: You can purchase Factorio and support a charitable cause for free by using our game show’s Humble Store affiliate link.


NOTE: Special thanks to the folks at Factorio.com for sending us a review key so we could review their game on our blog and show.

If you’re a vendor and would like us to review your product on The Automation Show and Blog, 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.

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Automation Talk: Thoughts, Impressions, and Goings-on for March 6, 2019

By
Shawn Tierney
-

I’m very fortunate to be able to catch up with so many connections, blog readers, and forum posters each week.

Often our discussions go in some interesting directions, many of which I think our readers here would also enjoy hearing about.

So with that in mind, today I’m starting a semi-regular series to share some of our discussions as well as goings-on here at Insights In Automation.

Rockwell and Siemens Programmable Controllers

As I continue with plans to expand TheAutomationBlog.com‘s coverage to include additional vendors, I’ve been hearing from many of you about your experiences migrating to Siemens PLCs.

S7-1200 and Basic Panels (picture courtesy of Siemens)

The messages and conversations I’ve had with first time users have all indicated that the biggest challenges of moving from Rockwell to Siemens is learning a new programming environment.

Whether it’s end users, integrators, or instructors, the common theme was that, while TIA Portal is powerful, it’s not easy for the average RSLogix/Studio 5000 user to transition to.

TIA Portal (picture courtesy of Siemens)

In fact, some have compared it to trying to use CCW to program a Micro800 for the first time.

That’s a comparison that I, as someone who has used RSLogix since version 1.0, can totally relate too!

So, as I begin my journey to learn more about Siemens programmable controllers, I hope I’ll also be able to share some helpful “how to” content for first time users here on TheAutomationBlog.

In the meantime, if you have a Siemens story or tip you’d like to share with us, I invite you to comment on this article using the link at the bottom of the page.

Or if you prefer anonymity, you can drop me an email at News@TheAutomationBlog.com.

First Impressions Programming with 5069 I/O

Having been a fan of Rockwell’s modular programming techniques for quite some time, I’ve always appreciated the value of aliasing “Module Tags” to actual I/O Module DINTs, and then aliasing individual “Device Tags” to sub-elements of “Module Tags.”

By doing this, if I ever needed to relocate a module or change controller platforms, all I needed to do was re-alias my “Module Tag” to the new I/O module, and all my “Device Tags” would continue to work as is.

This concept served me well until I started using a 5380 in my new “Compact Basics” CompactLogix training course.

What I found was, for some unpublished reason Rockwell changed the data format of 5069 I/O modules.

Below you can see an example of what I’m talking about. On the left you’ll see my 5370 I/O module tags, and on the right you see the same project in a 5380 with the first three input tags expanded:

As you can see, this change results in the actual I/O points no longer being grouped together as member “BOOLS” of a Data “DINT”

Which in turn that meant that (for the first time in over a decade) I had to manually re-alias all of my individual “Device Tags” to these new I/O Module Tags.

This was not a good use of my time.

Around the same time I ran into this issue, I also started hearing from some of you that you’re actually avoiding the 5069 I/O line.

In some cases it’s due to the fact that the modules aren’t readily available. For others, it’s the lack of availability of third party modules.

And for one reader it’s because 5069 I/O is apparently incompatible with third party DCS systems, which eliminated it from being used anywhere in his plant.

With all that said, if you’d like to share your thoughts on this topic I’d love to hear from you!

You can either comment publicly on this article using the link below, or drop me your anonymous comments via email at News@TheAutomationBlog.com.

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.

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CompactLogix – 5370: The Fourth Generation

By
Shawn Tierney
-

The fourth generation of CompactLogix controllers began with the release of the L1, L2, and L3 back in 2012.

While 2012 might have been a bad year for Myan doomsayers, in was a banner year for the CompactLogix as Rockwell released not one but three new models.

While each model was physically different, unlike previous iterations all three shared a large number of features.

The 5370 Family of Small Programmable Automation Controllers:

One of the first things users noticed was that all three 5370 models had a USB 2.0 (Type B) programming port in place of the Channel 0 RS-232 port found on earlier CompactLogix controllers.

USB was not only more convenient than RS-232, it was also up to 15 times faster when flashing the controller’s firmware.

Similar to the L4x line, all of the 5370 controllers used an internal capacitor in place of a battery, and they all had a button that could be used on power-up to erase the current program.

But unlike previous models, 5370 controllers had a Run Mode ‘toggle’ switch in place of the classic ‘key’ switch.

Also gone was the CompactFlash card slot found in the L3x and L4x, replaced with the more robust Secure Digital (SD) format. And unlike L3x and L4x models, all 5370 controllers actually came with a 1GB memory card.

5370 controllers also included a single Ethernet channel connected to a built-in, two port 10/100 Mbps Ethernet switch supporting star, linear, and ring typologies.

These new Ethernet channels had a substantially increased connection count (256 CIP, 120 TCP,) which was a boon to users who needed to connect multiple HMIs to a single CompactLogix.

Along with the additional CIP and TCP connections came a new, simpler means of determining the number of Ethernet I/O Nodes each model was capable of controlling.

Users no longer needed to ‘total up’ the required connections of each I/O device as 5370 controllers had a ‘hard limit’ to the number of I/O Nodes each could control.

These features, along with the fact that all 5370 were were roughly twice as fast as previous models, made them an instant hit with most of the existing user base.

And for the who were using the L4x series in motion control applications, that fact that select 5370 controllers (ERM models) also included support for motion over Ethernet made them a more cost effective option in most applications.

Good things come in threes. Well, at least when it comes to CompactLogix:

As previously stated, the 5370 family came in three unique lines: The L1, L2, and L3.

The L1 was the smallest of the three, reminiscent of the L23 but much smaller and with only Digital I/O built-in.

It was also the first controller to use 1734 Point I/O for local I/O Expansion.

Initially, three models were released:

Catalog Number Memory Built-In I/O (24vdc) Local 1734 I/O Modules: Ethernet I/O Nodes CIP Motion Axis
1769-L16ER-BB1B 384KB 16 DI, 16 DO 6 4
1769-L18ER-BB1B 512KB 16 DI, 16 DO 8 8
1769-L18ERM 512KB 16 DI, 16 DO 8 8 2

The L2 on the other hand was a direct replacement for the L23.

It came in both Digital Only, and Combination Digital and Analog versions like the L23, however its analog offered much higher resolutions as well as universal inputs.

The L2 was also 40% smaller than the L23, and all models supported up to four 1769 Compact I/O Expansion Modules.

Catalog Number Memory Built-In I/O (24vdc) Local 1769 I/O Modules: Ethernet I/O Nodes CIP Motion Axis
1769-L24ER-BB1B 750KB 16 DI, 16 DO 4 8
1769-L24ER-QBFC1B 750KB 16 DI, 16 DO, 4AI, 2AO, 6 HSC 4 8
1769-L27ERM-QBFC1B 1MB 16 DI, 16 DO, 4AI, 2AO, 6 HSC 4 16 4

The L3 controllers launched as a direct replacement for the L3x line, supporting all of the 1769 I/O, Power Supplies, and Cables previously used with the popular L32E and L35E controllers.

The L30ER model brought a new, lower cost option to the line, while the ERM models added motion control (CIP Motion) support:

Catalog Number Memory Local Expansion I/O Modules Ethernet I/O Nodes CIP Motion Axis
1769-L30ER 1MB 8 in 1 bank 16
1769-L30ER-NSE 1MB 8 in 1 bank 16
1769-L30ERM 1MB 8 in 1 bank 16 4
1769-L33ER 2MB 16 in 2 banks 32
1769-L33ERM 2MB 16 in 2 banks 32 8
1769-L36ERM 3MB 30 in 3 banks 48

16

Even though it’s been several years since the 5370 controllers were released, I still think of them as the pinnacle of the CompactLogix line.

Fast, easy to configure and use, and coming in multiple form factors, it has to be one of the most successful product launches in programmable controller history.

Well, that’s how I feel… what do you think?

Have you used any of the 5370 controllers, and are you still using them? Or have you moved on to the newer 5380?

You can share your thoughts and opinions with us by clicking on the comment link 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.

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Poka Yoke in Manufacturing

By
Ying Zhang
-

Humans make mistakes, and these mistakes can cause defective products.

Poka Yoke, also known as mistake-proofing, is a technique for avoiding simple human errors at work. The idea was originally developed in the 1960s by Shigeo Shingo who was one of the IE engineers at Toyota.

Poka Yoke’s are mechanisms used to eliminate errors by effectively making it impossible to make mistakes in a given process. And they can be used everywhere.

To give an example of Poka Yoke design – filing cabinets could fall over if too many drawers were pulled out at the same time. For some cabinets, opening one drawer now locks all the rest, reducing the chance of the cabinet tipping. Another example of Poka-Yoke device – many elevators are equipped with an electric eye to prevent doors from shutting on people. They are also equipped with sensors and alarms to prevent operation when overloaded.

Why Poka Yoke?

Manufacturing defective products can be very costly. Some customers will return a whole batch of parts if they find just one of them to be defective. And some products are manufactured for safety critical applications in motor vehicles, aerospace and oil exploration etc.

A failure in these areas can have very serious consequences and potentially cause loss of life.

So let’s see the relationship of defects and human errors.

Human error should be nipped in the bud before they become bigger issues. Poka Yoke focuses on reducing or eliminating human errors, which cause defects.

Principles of Mistake-proofing/Poka Yoke

Mistake-proofing/Poka Yoke is based on 6 principles. Listed in order of preference in fundamentally addressing mistakes:

  1. Elimination (“don’t do it anymore”) is to eliminate the possibility of error by redesigning the product or process so that the task or part is no longer necessary.
  2. Prevention (“make sure it can never be done wrong”) is to design and engineer the product or process so that it is impossible to make a mistake at all.
  3. Replacement (“use something better”) is to substitute a more reliable process to improve consistency.
  4. Facilitation (“make tasks easier to perform”) is to employ techniques and to combine steps to make work easier to perform.
  5. Detection(“notice what is going wrong and stop it”) is to identify an error before further processing occurs so that the user can quickly correct the problem.
  6. Mitigation (“don’t let the situation get too bad”) is to seek to minimize the effects of errors.

Elimination, Prevention, Replacement and Facilitation are to avoid the occurrence of mistakes. Detection and Mitigation are to minimize the effects of mistakes once they occur.

Prevention vs Detection

Ideally, Poka Yoke’s ensure the process is designed so that mistakes can be prevented before they occur; preventing defects from occurring in the first place. Where this is not possible, Poka Yokes perform a detective function, correcting and eliminating defects in the process as early as possible.

A Prevention-based Poka Yoke system acts before a defect occurs. The Poka Yoke mechanisms sense an abnormality that is about to happen and then signal the occurrence.

A Detection-based Poka Yoke signals the user when a mistake has been made. The system does not allow continuation of the process so that the user can quickly correct the problem.

In many situations it is not possible, or economically feasible to prevent defects, particularly where the capital cost of the Poka-Yoke mechanism, far exceeds the cost of prevention.

For these situations, defects are detected early in the process, preventing them from flowing into downstream processes.

There are two approaches for Poka Yoke devices:-

Control Approach: This approach senses a problem and stops a line or process so that corrective action can take place immediately, thus avoiding serial defect generation.

Warning Approach: This approach signals the occurrence of a deviation or trend of deviations through an escalating series of buzzers, lights or other warning devices. However, unlike the control method, the warning method does not shut down the process on every occurrence.

Poka Yoke devices consist of three effective methods to ensure detection and prevention of mistakes: 1.Contact method 2. Fixed-Value method 3. Motion-step method; Each method can be used in Control approach or Warning approach.

Contact method detects any deviation in shapes, dimensions, forms, position or other physical characteristics through mechanisms that are kept in direct contact with the part. Contact method can be used in situations of rapid repetition, infrequent production or environmental problems such as poor lighting, critical temperature, dust, noise and so on.

Fixed value method is used in operations, where the same activities is repeated several times. The method employs automatic counters or optical devices and controls the number of moves, rate and length of movement as well as other critical operating parameters.

Motion step method is useful for processes requiring several different activities performed in sequence by a single operator. The method ensures that the operator dose not mistakenly perform a step that is not part of the normal process.

Commonly Implemented Poka Yoke Devices in Manufacturing

Good Poka Yoke devices should be simple and inexpensive. They need to be cost-effective towards the process. They should be integral part of the process, implementing what Shingo calls “100%” inspection. They should be placed close to where the mistakes occur, providing immediate feedback to the workers so that the mistakes can be corrected.

Examples of Poka Yoke Used in Manufacturing/Assembly Process (Projects by RNA Automation Ltd):

Fuel Tank Poka Yoke Assembly with flash testing & leak testing

Poka Yoke is crucial to the assemblies and critically controlled within the whole production process. Mistake proofing techniques including Proximity sensors, custom designed fixtures, vision system, pins, pressure sensors, barcode reader, warning lights and dot marking are used to prevent errors committed by operators. They allow the mistake to be corrected and solved without delay.
  Carpet Gap Hider Poka Yoke Station

  • Poka Yoke clamp and vision sensor.
  • The workstation is dedicated to apply the correct label to two products which are too similar to each other in size and in colour
Robotic Clipping & Welding System

  • Poka Yoke in fixture designs; Poka Yoke in Process Design
  • Mistake proofing fixture ensures proper clipping and welding
  • Dot marked for ‘good’ product assuring traceability
Laser Drilling Process Cell

  • Poka Yoke walking beam fixture; Poka Yoke vision inspection
  • The fixture fixes the position of the product, ensuring the laser drilling the correct size hole in the desired position
  • The integrated vision inspection provides 100% inspection on position, entry hole size and exit hole size

Above are just a few examples of Poka Yoke devices. There are many other types of devices that reduce human errors without requiring a heavy investment.

How to Implement

First, Get the right people together to discuss and review the product and the manufacturing and assembly process. Then identify and find out sources of defects. From the design perspective, review the features of the parts and how they are assembled. A simple change in product design may make a huge difference. Have Poka Yoke expert in these conversations, great ideas for improvement will come out due to their experience. Effectiveness of Poka Yoke technique should be reviewed continuously. Continue to maintain and improve the processes and measure the success.

Poka Yoke is the fastest way to zero defects and acts as a key enabler for efficient manufacturing. Poka Yokes are a science and also an art. Searching for creative solutions to avoid or detect errors for close to zero investment is what invites innovation.

Written by Ying Zhang of RNA Automation Ltd

About the author:

Ying Zhang
RNA Automation Ltd
Website: http://www.rnaautomation.com
Linkedin: Ying Zhang

Marketing Manager at RNA Automation, a leading automation supplier of parts handing and special purpose machines to a variety of industries. Ying has over 11 years of B2B marketing experience in the engineering and automation industry, and her passion lies in driving awareness on what automation solutions best serve manufacturers improving their productivity and success.

Editors Footnote:

I want to thank Ying and RNA Automation for reaching out to us and offering to post their article on The Automation Blog.

If you’ would like to join Ying as a guest blogger here on The Automation Blog, let me know using the contact form here.

Sincerely, Shawn Tierney of The Automation Blog.

Reference:

  1. “The Use of Poka Yoke with Medical Device Design and Manufacturing,” Jim Shore, Product and Process Improvement Leader, Dynisco, 17 May, 2011. mastercontrol.com.
  2. “Mistake Proofing/Error Proofing”, Retrieved from https://quality-one.com/mistake-proofing
  3. “Error Proofing and Poka Yoke Techniques”, Marc Smith, Error Proofing and Poka Yoke discussion threads in the Elsmar Cove Forums, 5 Auguest, 2004. elsmar.com
  4. Dhon G. Dungca. “Poka-Yoke”. Retrieved from https://slideplayer.com/slide/4471730/
  5. Ramzi Hammani. “Poka Yoke”, Introduction to Supply Chain Management. Retrieved from https://www.slideshare.net/Aditya…
  6. Anthony Inman. “Poka-Yoke”. Encyclopedia of Management. Retrieved from https://www.referenceforbusiness.com/management/Or-Pr/Poka-Yoke.html
  7. vigneshwari. “Total quality management”, Benchmarking and poka yoke. Retrieved from https://slideplayer.com/slide/12134070/
  8. Harry Robinson. “Using Poka-Yoke Techniques for Early Defect Detection”. Retrieved from https://pdfs.semanticscholar.org/6069…
  9. “Six Principles of Mistake Proofing, “ Tim McMahon, A Lean Jorney, 20 July, 2016. http://www.aleanjourney.com/2016/07/six-principles-of-mistake-proofing.html
  10. “Mistakeproofing the Design of Construction Process Using Inventive Problem Solving”, Final Report for CPWR Small Study No. 16-3-PS. Retrieved from http://www.elcosh.org/document/4306…
  11. “A Strategy for Performance Excellence”. Retrieved from https://slideplayer.com/slide/6998/

CompactLogix – L4x: The Third Generation

By
Shawn Tierney
-

The third generation of CompactLogix controllers began with the release of the L43 back in 2006.

Designed to bring ControlLogix performance and select features to the CompactLogix line, internally the L4x series shares the same architecture as the 1756-L6x controllers.

As such, the L4x was the first CompactLogix controller to support motion control (via 1768 Sercos modules,) and was also the only CompactLogix controller to support ControlNet and Ethernet networks simultaneously.

The L4x Family:

1768-L4x controllers came with a built-in “Channel 0” RS-232 Serial Port, a front facing CompactFlash memory card slot, as well as support for 16 concurrent tasks and local 1769 Compact I/O.

And like all previous CompactLogix controllers, the L4x could be programmed through its serial port via a “Null Modem” Cable (1747-CP3 or 1756-CP3.)

L4x controllers also had a “Mode” Key Switch like previous controllers, but unfortunately it used a hollow “plastic” key that wasn’t nearly as durable as previous keys.

Unlike the L3x controllers, the 1768-L4x controllers didn’t have a second “Channel 1” communication port, and the battery was replaced with a capacitor paired with additional system memory.

In place of a second communications port, L4x controllers had a new “left hand” bus which supported 1768 Ethernet, ControlNet, and Sercos modules.

In fact, all L4x systems start with a 1768 power supply as the left most device, followed by any optional 1768 modules, and ending the 1768 bus with the L4x controller itself.

And while these third generation controllers had a “default communications” button, it now supported two functions.

If the “default communications” button was pressed while the Controller was already powered on, just like with previous CompactLogix controllers the user’s “Channel 0” settings would be replaced with the defaults.

However, if the button was held down as power was applied, the user’s program in the L4x controller’s memory would be erased.

This new function was added as the L4x no longer had a battery which could be removed to erase the user’s program.

A tale of two controllers, networks, and Sercos modules:

The L4x line included two controllers options.

The 1768-L43 controller came with 2MB of user memory and support for two 1768 modules, four position axis, and up to 16 local 1769 Compact I/O modules across two banks.

The 1768-L45 controller came with 3MB of user memory and support for four 1768 modules (limited to a maximum of two Sercos and two comm. modules,) up to eight position axis, and up to 30 local 1769 Compact I/O modules across three banks.

For those looking to add Ethernet to their 1768 system, they had a choice between the 1768-ENBT and 1768-EWEB communication modules.

While both the ENBT and EWEB supported peer to peer communications (programming, HMI, SCADA,) the ENBT could also be used as an I/O scanner, while the EWEB supported custom Webpages and Tag Access via a built-in website.

And as far as ControlNet was concerned, users had the choice between the standard 1768-CNB with a single BNC connector, and the 1768-CNBR redundant media version with two BNC connectors.

So, do you have any L4x systems in your plant, or did you design any systems that used the L4x?

If so, what do (or did) you think of them?

You can share your thoughts and opinions with us by clicking on the comment link 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.

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CompactLogix – L23

By
Shawn Tierney
-

The first all-in-one CompactLogix controller, the 1769-L23, released back in 2008.

While the new, lower cost packaging was appreciated by those with smaller applications, the fact that L23 had no removable, non-volatile memory meant it wasn’t suited for many OEM applications.

L23 Models:

All L23 models came with 512K of battery backed (1769-BA) volatile memory, as well as 16 24vdc Digital Inputs and 16 24vdc Digital Outputs.

Each also came with a pre-installed 1769-ECR end cap, and supported at least two local 1769 Compact I/O expansion modules.

The L23 had the same “Run Mode” key switch found on first and second generation CompactLogix controllers, as well as a 9 Pin D-Sub “Channel 0” isolated RS-232 Serial Port.

Like previous generations, the L23 could be programmed through its “Channel 0” port via a standard “Null Modem” serial cable (including the 1747-CP3 or 1756-CP3 cables.)

And also like previous generations, the L23 had the same “default communications” button which replaced (i.e. erased) the user’s “Channel 0” settings with the controller’s defaults when pressed.

In fact, aside from the missing CompactFlash Slot, and limit of 3 Tasks and 4 Programs, the L23 was nearly identical to the L3x controllers it was based on.

Three Options:

The L23 line included three controllers with unique I/O and communication options.

The 1769-L23-QBFC1B included a second, non-isolated, DF1 only “Channel 1” RS-232 Serial Port. And in addition to the above mentioned 16 DI & DO, it also came with 4 low resolution Analog Inputs, 2 low resolution Analog Outputs, and 4 High Speed Counter Inputs.

The 1769-L23E-QBFC1B replaced the above model’s second serial port for a 10/100 Ethernet port, while retaining the same mix of analog and digital I/O.

The third and final model, the 1769-L23E-QB1B, included the same “Channel 1” 10/100 Ethernet port and 16 DI & DO as the previous model, but did not include any Analog or High Speed I/O.

This 1769-L23E-QB1B was also the only model to have its local Expansion I/O limit expanded from 2 to 3 modules later in life.

In the end, while many customers appreciated the cost savings of a Package Controller like the L23, the fact that it left users at the mercy of the “battery backed” volatile memory resulted in many avoiding it

Thankfully, with the release of the L1 and L2 controllers in 2012, Rockwell addressed this issue by insuring future “package” CompactLogix controllers did include a removable, non-volatile memory card slot and 1GB SD card as well.

So, do you have and L23 controllers installed in your facility? Or have you worked on them in the past? If so, did you find the lack of non-volatile memory an issue?

Let us know your thoughts and opinions by clicking on the comment link 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.

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CompactLogix – L3x: The Second Generation

By
Shawn Tierney
-

The second generation of CompactLogix controllers began with the release of the 1769-L35E back in 2003.

It was the first CompactLogix to be released with Ethernet communications, and came out nearly two years before the first MicroLogix with Ethernet, the MicroLogix 1100.

But unlike the MicroLogix 1100, the CompactLogix L35E could also control distributed I/O devices like the Flex I/O and PowerFlex VFDs.

The L3x Family:

Each L3x controller in the CompactLogix’s second generation included a 9 Pin D-Sub “Channel 0” isolated RS-232 Serial Port, support for local 1769 Compact I/O in up to three banks, and a front facing memory card slot for CompactFlash cards predominately used as removable non-volatile memory.

And just like it’s predecessors, L3x controllers needed to be the “left most” device in the first bank of a 1769 system, located within four modules of a 1769 power supply.

All L3x controllers had a “Mode” Key Switch (same as SLC-500 and ControlLogix,) could be programmed through “Channel 0” via a Serial “Null Modem” Cable (1747-CP3 or 1756-CP3,) and had battery backed volatile memory (1769-BA.)

To access the battery compartment, users simply slid the left side of the controller forward to reveal the battery connector and clip.

These second gen CompactLogix controllers also had the same “default communications” button as the L20 and L30, which replaced the user’s “Channel 0” settings with the controller’s defaults.

Three Options:

The L3x line included controllers with three different memory and communication port options.

The smallest of the three was the 1769-L31 controller with 512K of memory, support for 16 local I/O modules and 4 concurrent tasks, and a physical 9 Pin D-Sub non-isolated RS-232 Serial Port.

The next size up was the 1769-L32x controllers with 768K of memory, support for 30 local I/O modules, and support for 6 concurrent tasks.

The L32x also came in two versions: The 1769-L32E had an RJ45 “Channel 1” Ethernet port, while the 1769-L32C had an RJ45 “Channel 1” NAP (Network Access Port) port that was tied internally to a single, bottom facing BNC ControlNet port.

The largest of the L3x family was the 1769-L35x controllers with 1536K of memory, support for 8 concurrent tasks, and a total local I/O capacity of 30 modules.

Like the L32, the L35 came in two versions: The 1769-L35E had a RJ45 “Channel 1” Ethernet port, while the 1769-L35CR had a RJ45 “Channel 1” NAP port that was tied internally to redundant, bottom facing BNC ControlNet ports.

The “Channel 1” port on both the L32 and L35 controllers could not only be used for programming and peer to peer communications, but also supported controlling distributed I/O.

In the end, this second  generation of CompactLogix controllers proved to be extremely popular, and became the mainstay of the CompactLogix family for nearly a decade.

So, do you have L3 controllers installed in your facility? Or have you worked on them in the past? If so, what did you think of them?

You can share your thoughts and opinions with us by clicking on the comment link 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.

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PlantPAx Process Objects – Using Library AOIs in RSLogix/Studio 5000 (S08)

By
Shawn Tierney
-

In this week’s episode of The Automation Show, we walk through how to download and use PlantPAx Process Library AOI’s in RSLogix/Studio 5000:

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


The Automation Show, Episode 8 Show Notes:

Free Sample Download:

To get the file created in today’s show for free, click HERE, then add the item to your cart and enter coupon code “TASH008” and check out for $0.00!

NOTE: 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.

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Merry Christmas from The Automation Blog!

By
Shawn Tierney
-

Wishing you and yours a very

Merry Christmas!

Logix Instructions – Using The Sequencer Output (S07)

By
Shawn Tierney
-

In this week’s episode of The Automation Show, we walk through what it takes to use the Sequencer Output Instruction in RSLogix/Studio 5000: (starts at 3:00)

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


The Automation Show, Episode 7 Show Notes:

Free Sample Download:

To get the file created in today’s show for free, click HERE, then add the item to your cart and enter coupon code “TASH007” and check out for $0.00!

NOTE: 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.

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Logix, View – AF2018: What’s New with Logix and View from Automation Fair 2018 (S06)

By
Shawn Tierney
-

In this week’s episode of The Automation Show, we take a look at What’s New in Logix and View based on the Automation Fair 2018 presentations:

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


The Automation Show, Episode 6 Show Notes:

NOTE: 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.

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View – AF2018: What’s New with View at Automation Fair 2018

By
Shawn Tierney
-

One of my favorite Automation Fair Technical Sessions is “What’s New in View,” and in today’s article I’ll highlight the slides that caught my attention as I reviewed this year’s presentation.

First up was several slides about the PanelView 5000 series, but before we get into them I wanted to share a little about this product line.

For those who don’t know, the PanelView 5000 is Rockwell’s “next generation” of HMIs, and uses development software (View Designer) that is bundled with Studio 5000 Logix Designer.

The PanelView 5000 as shown at RSTechED 2012Note: I use to tell my students that View Designer was included with Studio 5000 Logix Designer at no charge. But, since View Designer’s release the price of Studio 5000 has increased by over 60%! So it now appears it would be more accurate to say that cost of View Designer is included in the price of Studio 5000 Logix Designer.

While “next gen” features may be the long term plan for the PV5000 product line, today both the PanelView 5310 and 5510 lack many of the basic features found in Rockwell’s existing PanelView Plus 7 HMI, even though the new “PV5000” HMIs only work with the latest Logix controllers (5×70 and 5×80.)

So unless you need a feature unique to the PanelView 5000 line, or you just prefer View Designer over View Studio, you may find that the PanelView Plus 7 provides more options and functionality for the same price

Now, back to the presentation 😉

The first few slides covered details about the PV5310 series, including these details:

  • Touchscreen models available from 6″ to 12″
  • Program using View Designer v4+
  • 100 Screen Limit, 1000 Alarm Limit
  • Single Controller Limit
  • Controller must have firmware v27 or greater
  • Equipped with a single 10/100 Ethernet Port
  • Has two USB ports: One host, one device
  • Built-in SD Card Slot
  • Rated IP65/Nema 4X, 0-50c
  • Available in DC Power only

Based on the fact that the PV5310 HMI only supports a single Logix PAC with v27 or greater firmware, it appears the focused market of the 5310 is the newest Logix applications with an HMI only needs to communicate with a single controller.

Next up are details about the new PV5510 series which is replacing the original PV5500:

  • Touchscreen models available from 7″ to 19″, with optional Keypad on select sizes
  • Program using View Designer v4+
  • 100 Screen Limit, 1000 Alarm Limit
  • Four Controller Limit (as of the release of v5)
  • Controller must have firmware v27 or greater
  • Equipped with Dual 10/100 Ethernet Ports supporting DLR
  • Has three USB ports: Two host, one device
  • Built-in SD Card Slot
  • Rated IP66/Nema 4X, 0-55c (except 19″ which is 50c)
  • Available in DC Power only

The added support in v5 for up to four controllers is much welcome news for the more expensive 5510. That, along with the new View Designer features which we’ll cover next.

First, Rockwell reviewed the new features found in the last released version of Studio 5000 View Designer, which was version 4:

  • Terminal Emulator (aka offline testing)
  • Remote Access via VNC
  • Real-Time Trending
  • Local Data Logging
  • Device Faceplates
  • Loading Applications from Removable Media

Then Rockwell detailed what’s new and planned for the next release, version 5:

  • PDF Document Viewer
  • Support for Logix Tag-Based Alarms (introduced in v31)
  • Automatic Logout support
  • Four “Logix” Controller Support with 5510
  • Bindable Popup Captions

NOTE: While the above new features are all welcomed, keep in mind equivalents have existed in the PanelView Plus line for many years.

Moving on from the PanelView 5000, Rockwell’s presentation then covered its Thin Manger and Industrial Computer offerings prior to providing an update on the PanelView Plus 7.

According to the slides, coming this May (2019,) Rockwell will be releasing a much requested new option for PVP7 9″ and 12″ units: IP69K rated bezels with NFS Certification for Food and Beverage applications.

PVP 6 NOTE: On a related note (while no public announcement has yet been made) word on the street is that PanelView Plus 6 production will be coming to an end in the next 24 months. This change should only effect new orders for PanelView Plus 6 units as Rockwell often supports existing customers who own discontinued products with repairs and exchanges for ten or more years.

Finally, towards the end of the presentation Rockwell highlighted what’s new in FactoryTalk View version 11.

Machine Edition is said to be getting these new features:

  • Application Manager will show .MER and .APA version in tool
  • Separate Version ID also will be available

Site Edition is said to be getting these new features:

  • New support within Asset Centre (backup, compare, etc)
  • TrendPro support for Asset Centre Audit Logs
  • TrendPro enhancements to Alarm plotting and configuration saving
  • TrendPro new features including plotting related actions along side time-series data
  • TrendPro support for configuration with an ISA-101 “look and feel”
  • RecipePro+ enhancements including current recipe viewing and refined audit log
  • New FT Diagnostic Object with customizable filter
  • Updated E-Signature functionality on Command Buttons, and Numeric and String Inputs
  • New VBA Interface for HMI TagDB (enables reusing of more RSView32 VBA)
  • FT Event added in Alarm and Events, severity of 0 to separate from Alarms
  • Removal of HMI Tag Alarms, migration tool installed with v11

Well, those our my highlights from this year’s, “What’s New in View” presentation from Automation Fair.

If you’d like to see the entire presentation, head over to the downloads page covered in this article, and search for presentation T52.

And if you think I left something out or would like to share your own thoughts and comments, I invite you to do so by clicking on the “comment” link 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.

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CCW – v11: Feature Pack – Does it make CCW look more like RSLogix / Studio 5000? (S05)

By
Shawn Tierney
-

In today’s episode of The Automation Show, we take a look at the Automation Fair 2018 presentation on what’s new in CCW v11, and then take a first hand look to see if the Feature Pack makes CCW look more like RSLogix:

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


The Automation Show, Episode 5 Show Notes:

NOTE: 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.

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DF1 to Ethernet Bridge, Message (MSG): Send Data Between DF1 and Ethernet Devices using 515RTAENI (S04)

By
Shawn Tierney
-

In today’s episode of The Automation Show, we walk through how to message between DF1 and Ethernet devices using the 515RTAENI from Real Time Automation.

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


The Automation Show, Episode 4 Show Notes:

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

I want to send a huge Thank You out to the folks at Real Time Automation for sending in the loaner 515RTAENI-N34 featured in this episode of The Automation Show.

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.

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Logix – AF21018: What’s New with Logix from Automation Fair 2018

By
Shawn Tierney
-

One of my favorite Automation Fair Technical Sessions is “What’s New in Logix,” and in today’s article I’ll highlight the slides that caught my attention as I reviewed this year’s presentation.

First up was a slide promoting the coming release of the 5380 Compact GuardLogix:

Schedule for release sometime in Mid-2019, this unit is designed to support SIL CL3 up to PLe, and includes the same dual Ethernet ports found on the standard 5380 controller.

Next up was a slide about a new line of 1756 Safety IO modules :

The initial release in planned for 2019, and the line will eventually include both Analog and Digital input and output modules, rated from SIL 2 PLd to SIL 3 PLe

Not to be left out, this March the 5069 line also receives new Safety I/O modules, with the 5069-IB8S and 5069-OBV8S supporting PLd and PLe applications:

With all the new products and options, Rockwell thankfully included this very helpful chat comparing CompactLogix and ControlLogix Standard and Safety controllers in the 5×70 and 5×80 families:

Note: For a full size version of this chart, get a copy of Rockwell’s T13 presentation by following our instructions here.

Also covered was the new Compact I/O Serial module, the 5069-ASCII, which currently supports generic ASCII, MODBUS RTU and ASCII in v31 of Studio 5000:

Rockwell also stated that it has plans to add the DF1 and DH-485 protocol in the future.

The Flex 5000 I/O (5094) line also had a spot in the presentation announcing the new SFP Ethernet adapter shown on the right side of the below image:

And the last items in my list of highlights are the new features planned for Studio 5000 Logix Designer v32.

First we have these new Extended Data Types being added to support 64 Bit Math:

  • Unsigned Short Integer: USINT
  • Unsigned Double Integer: UDINT
  • Unsigned Integer: UINT
  • Unsigned Long Integer: ULINT
  • Long Real Number: LREAL
  • Long Integer: LINT

Next we have Tag-based Alarm enhancements including the ASO (Alarm Set Operation) instruction.

This instruction provides a way to programmatically issue a specific operation (like “Acknowledge”) to all alarm conditions in a set.

And finally, for the 5×80 series of controllers we have some new optimized FBD instructions which replace existing ones:

These new instructions not only require less space and no backing tag, they also simplify diagrams by being smaller and using more intuitive “symbol-based” instruction blocks.

Sadly (as noted above,) these enhancements only work with the 5380, 5480, and 5580 Controllers.

Well, those our my highlights from this year’s, “What’s new in Logix” presentation from Automation Fair.

If you’d like to see the entire presentation, head over to the downloads page covered in this article, and search for presentation T13.

And if you think I left something out, and would like to share your own thoughts and comments, I invite you to do so by clicking on the “comment” link 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.

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