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Innovations 2015

1. handles base functionality gt Increased quality of machine software gt Reduced cost of software maintenance costs of the application software are reduced through the use of mapp blocks proven in thou sands of applications and maintained by BSR Extensive support Full documentation and help functions com plete the mapp toolkit And when all else fails BSR s expert support team can always be counted on Innovations 2015 z 1 EP a cs l 1 1 1 11 p 11 T b 1 1 1 E 1 V 1 me ____ 2 ar Open Standard software development in Automation Studio Extensible range of IEC 61151 functions standard Based open standards such as PLCopen Consistent look feel Fast configuration Diagnostics Easy web based diagnostics n Extensive list of functions When mapp is introduced more than mapp blocks will already be available It is therefore pos sible to design software solutions for many ex
2. Fanless design for maximum robustness in industrial applica tions Ethernet 10 100 1000 v lx USB 5 0 1x USB 2 0 24 VDC power supply Innovations 2015 Da Panel 2100 Optional interfaces RS232 CAN FRAM Automation Panel 5 7 VGA to 24 Full HD with single or multi touch Operating systems Windows 7 Professional 32 64 bit Windows 7 Ultimate 32 64 bit Windows Embedded Standard 7 32 64 bit Windows Embedded Standard 7 Premium 32 64 bit Windows 8 1 Industry 32 64 bit Automation Runtime Embedded Automation Runtime Windows CFast Combines the shape and dimen sions of CompactFlash cards with the faster SATA interface Innovations 2015 Fanless design for maximum robustness in industrial applica tions Ethernet 10 100 1000 Ethernet 2 j 10 100 1000 lx USB 3 0 5 1x USB 2 0 24 VDC power supply Innovations 2015 24 Compact performance Equipped with Intel Atom processors Automa tion PC 2100 and Panel PC 2100 systems offer scaled processing power up to Core i3 perfor mance levels The Atom processors themselves are available in five designs from single and dual core all the way to quad core processors This guaran tees the perfect match between CPU power and any application The integrated graphics engine also delivers performance above and beyond anything possible with Core2 Duo processors Another supported feature is Direct
3. Lees Del eee p ume Fem bam a ee b eap ard ume mam mam ans REGI b he Sf Serie d LUL ben Uo ui aper TUE eet Ge Fig lam ey dae ba Bi 7 oe ep ELTE All devices are structured and configured the same way in a single configuration window in Automation Studio New em ployees for example can be trained in no time XDD for optimal modularity In order to optimize manufacturers stock modu lar network devices usually consist of one main station and a number of add on modules All of these devices main station and add on mod ules are simply moved into the System Designer topology using drag and drop and configured there Full modularity is provided whether the de vices are from B amp R or any other vendor The soft ware automatically checks the plausibility of the configuration It ensures for example that manu facturer A s modules are not connected to manu facturer B s modules In the configuration window a complex device is shown in clearly structured tree form rather than an endless list of parameters This is made possi ble by the extended specification of the XDD de vice description files Innovations 2015 d Support for openSAFETY devices Modern machines and systems often combine safety componen
4. The control cabinet depiction makes it easier for the user to configure the automation system 74 software quality right from tne start There is no denying the increasing importance of software quality During the development phase it should already be up and running without er rors Automation Studio now provides a unit test ing framework a perfect solution for meeting this challenge Today s automation projects often consist of tens of thousands of lines of code Unit testing is a proven method for increasing the quality of source code as early as development it uses automatic tests to check functional units in order to ensure the basic functionality of the software Unit testing in Automation Studio One or more tests can be started at the push of a button The tests then check if the expected val ues have been output Testing is logged and the user can navigate directly to the part of the code where the error is being reported The tests are run directly on the target system so that the de veloper can continue to work on the project in the meantime These automated tests can be used to check over functions function blocks and methods Any of the 61151 4 languages can be tested as can C and C The unit tests work in simulation and on all hardware whether PLCs Box PCs or Panel PCs Error free software development In addition to unit testing other methods from the IT industry
5. ir f een LET BR 11 1 M 12 actui om p Ee ea D PU Easy to understand graphs provide information essential to good decision making pe o Egan bene 1 lug mm m reed n ii gt EI p i die EE ls fami tiem ma F 4 4 Tis Asi mii Bla mni 18 m par ERA Wadi 2 FE m 11 m m 3 im i T Individual dashboards can be easily created using drag and drop and adjusted at any time Innovations 2015 96 verification of quality Centralized acquisition of operating and process data from machines and equipment using BSR s APROL process control system is now much easi er The new APROL PDA solution has a PDA brows er PDA function blocks and a PDA visualization element Centralized data acquisition with APROL PDA en ables complete online performance monitoring and visual overviews Powerful and extremely reli able long term archiving makes it possible to track quality for the entire manufacturing pro cess Highly flexible reports with integrated anal ysis functions p
6. 44A 8 8 1 kW e kW 4 kW Single axis Double axis Triple axis ILS 5 28 8 8 A 2 5 4 5 8 8 2 2 4 4 8 8 2 0 4 5 8 8 2 2 4 5 8 8 6 kW 8 kW e kW 4 kW 4 kW 4 kW 4 kW 4 kW Single axis Double axis 52 18 11 kW 16 kW 24 kW Innovations 2015 le Homing Unce is enough With SafeMOTION Release 1 9 BSR has updated the safety functions for the ACOPOS servo drive family In addition to two new functions Remanent Safe Position RSP and Safely Limited Acceleration SLA this update also introduces machine op tions for SafeMOTION parameters and improves both system availability and user friendliness In order to obtain a safe absolute multi turn po sition homing was previously necessary each time an axis was restarted In certain situations this can require considerable effort especially for complex multi axis systems The RSP function allows SafeROBOTIC SLS SafeROBOTIC SLP and safeROBOTIC SLO to be used without homing after every power on cycle Remanent storage of the position After a controlled functional stop of the axis the Current safe position is stored in remanent non volatile memory A status bit indicates that the save operation is complete and the axis can be switched off Data verification When switched on the stored data is checked for validity The safe position can then be set to th
7. 60 safeLOGIC with an integrated 1 0 interface is introducing a new safety controller with an integrated 1 0 interface X20 modules can be add ed directly to the 20518101 SafeLOGIC controller 1 0 system integrated in the safety controller supports both safe 1 0 and all conventional X20 modules When using the 20518101 SafeLOGIC controller standalone POWERLINK bus controller becomes superfluous Ihe controller is integrated into the safety controller just like the power supply for the 0 bus system This not only saves money during installation but also optimizes the overall perfor mance and thermal efficiency of the system Blackout mode Together with the 1 0 modules the new safety controller supports blackout mode which allows the safety application to continue undisturbed even if the POWERLINK network drops out This function is especially important in applications where the safety function should remain active even in the event of CPU or network failure Innovations 2015 X20 modules can be added directly to the X208L 8101 SafeLOGIC controller Highlights gt Small footprint gt Inexpensive installation gt Safety even on network failure The X20SL8101 SafeLOGIC controller can process data from up to 300 safety nodes setting new performance standards for safety controllers At B amp R the safety controller is an integral compo nent of the overall safety architecture There
8. PERFECTION IN AUTOMATION www br automation com Motion control PC and panel systems Control technology Safety technology Software Process automation Contents ACOPOS 5 axis servo drive oi NEW safety TUNCTIONS RSP and SLA ue asas taps EE qii aem Virtual motion Realistic simulation of drives Virtual sensors for monitoring torque 24 Autotuning without an encoder simple backlash compensation safe workspace for robots _ Perfect synchronization with Generic Motion Control 0 0 Hygienic motor connectors m More compact and Servo motors The latest Intel Atom technology for industrial PCs MEM New compact Box PC Automation PC 2100 0 0 0 0 0 Panel PC 2100 in an ultra compact housing _ Windows 8 for industrial applications _ E stainless steel operator panel with IP69K Panel Designer Individually design panels and PES 00 0 0 0 A the fast lane with reACTION technology 4 2 2 22 22 Secure remote maintenance worldwide 10 years Ihe X20 2 4 X20 1 0 modules for strain gauges Pneumatic solutions integrated in the B amp R system Circuit examples for integrated safety technology 0 10 0 Operator panels with an openSAFETY interface Safety controller with an integrated 1 0 interface Processing signals from 500 safety nodes one controller _ PLCopen Function block library for press applications 2 s
9. 1 Engineers can quickly and easily develop the hierarchical struc ture of the network using the tree view in Automation Studio Innovations 2015 Highlights gt Use of custom developed controllers gt Project development in Automation Studio gt Safety for custom designed control systems A POWERLINK network can be shown in graphic form in Automation Studio providing the perfect overview of modular machine con cepts or individual developments Multi vendor components In general the solution for an automation task be gins Automation Studio where the POWERLINK network is laid out in system Designer All components are listed in the Automation Studio Hardware Catalog The use of device description files XDD XML Device Description and OSDD openSAFETY Device Description allows the net work to be expanded with components from any vendor Standardization of the device description files and their use is handled by the Ethernet POW ERLINK Standardization Group EPSC gl T ACIS rmm Erk cen Eni i rr Evia Hoe ac Em prm Tope an c4 im Caer te PTEI APCEQU Saee ME 5 erunt PEGS bresti DIG Lam lu o oe N
10. 26 Compact dynamic Motors from the 8LS series have been completely revamped and are now more powerful than ever A more compact housing optimized design and additional sizes are only some of the features that make these motors even more attractive and universal With cost effective inductive en coders safety functions can also be used with hybrid motor cables B amp R has improved the already very powerful and dynamic servo motors from the 815 series in many details For example size 2 and 5 motors with the same technical data are now much more compact guaranteeing maximum compatibility with a higher power density Size and motors are available in additional lengths thereby offering more flexibility in terms of dynamics and torque Safety included 8LS motors use new inductive encoders that deliv er extremely precise and reliable data In combina tion with the digital EnDat 2 2 interface the most common safety functions can even be used with Innovations 2015 Highlights Compact design Highly dynamic Additional lengths High power density Safety with inductive encoders Hybrid motor cable reduces costs Excellent efficiency gt gt gt gt gt gt hybrid motor cables where the encoder and motor cables are grouped together reducing wiring effort and costs The most commonly used 8LS series motors are also now available as preferred motors For our customers this means an unbeat
11. During the printing process reACTION technology can be used to quickly read and measure marks registration marks or product identification marks for example in the nanosecond range Post processing of printed material becomes faster and more precise with less waste pro duced during cutting folding stapling and collat ing In addition by allowing for a smaller trim ink consumption is also reduced Innovations 2015 50 Maintenance from afar Machines and systems are now sold in all corners of the world With regard to maintenance and ser vice of the machines this represents a challenge for manufacturers as long as service technicians have to travel to get to the machines Remote maintenance opens new perspectives Like consumer goods machines and systems are now sold all over the world Modern communica tion and transportation make it possible to cover large distances Modern production and logistics concepts are the basis for global trade But for machine manufacturers worldwide sales dont only bring advantages The situation be comes difficult if maintenance is needed that can only be carried out with the help of the manufac turer Remote maintenance is playing an increas ingly important role as it keeps service techni clans and engineers from having to fly halfway around the world 20798 Fe world wide web Data transfer WWW three letters infinite possibilities Today
12. Resistant and robust The standard X20 1 0 system from the BSR auto mation portfolio can be used in applications where other manufacturers develop specialized systems In addition to an operating temperature Ium FAS tese mogulle swale GL certified and have been tested with vibrations up to 4g The X20 system can also be used reliably ia ect n OUS ROS Ten years after its launch at the 2004 5 5 IPC Drives B amp R is still a leading innovator with the X20 system Innovations 2015 55 Precise strain measurement BSR is introducing two new analog input modules from the X20 1 0 series that are used to digitize signals from strain gauges the Al 744 with two full bridge strain gauge inputs and the Al 744 1 2or4channels with four full bridge strain gauge inputs This al gt High component density lows up to four strain gauge channels to be inte gt Perfect granularity grated in one module that is just as thin as a l channel strain gauge module The user save money and reduce the amount of space re quired in the control cabinet The Al A744 and Al B744 modules work with 4 wire Strain gauge load cell Compensation in the mea surement system eliminates absolute uncertainty in the measurement circuit such as component tolerances effective bridge voltage or zero offset The modules each have 24 bit converter resolution strain gauges detect minimal component deformations making it possible to in
13. functions In the past five years PLCopen has worked inten sively on a specification for function blocks in press applications with B amp R playing an instru mental role in this development The result is part 4 of the PLCopen Safety specification which de fines safety aspects of mechanical electrical and hydraulic presses Also defined in this specifica tion are the corresponding vendor independent function blocks for the safety application PLCopen specifications provide solutions for ma chine manufacturers that are open to all not just a few manufacturers The PLCopen Safety work group brings together engineers from leading in dustrial automation companies as well as experts from certifying institutions who work closely with safety related technology For many years now BSR has been involved in this consortium 65 Integrated safety selecting the operating mode From now on the operating mode can be safely and securely selected from the HMI application as well rendering mechanical operating mode key switches obsolete This is made possible through the use of new function blocks and certified visu alization objects The operator panel itself doesnt require safety certification for this The user can simply configure the function blocks in the secure SafeDESIGNER 4 2 editor Existing ac cess protection mechanisms such as passwords RFID tags and other technologies can also now be used when to make sure t
14. gt Quickly find errors Also fully displayed are variable values with basic data types such as integers as well as composite data types such as structures and arrays This al lows developers to directly check the program code the tooltip to determine whether all vari ables contain the correct values Powerflow in Ladder Diagram In Ladder Diagram rungs that have not yet been executed are indicated by their status on the left contact using Powerflow What is shown c the current states of the signal lines The switch ing states are collected in sync with the PLC cycle and transferred to Automation Studio as a consis tent image ee ee ee ome b eR bere eee 8 i ae 1 occ po O pH Hicr mee 2 ed Seed 1 Pee imine E lime EF ren ee aam iep oe Re RR p hid ATI TY gt 4 1 TT If the value of a variable changes several times during program execution it is sure to be detect ed Because Ladder Diagram depicts the exact position dependent states of variables and lines developers can quickly and easily discover the cause of errors au Fi mh variable values Inno
15. x Clear analysis gt Extremely customizable gt Easy to operate Market interest for solutions is growing steadily due to the ineffective reporting and analysis functionality provided by conventional ERP and MES solutions that is a strong driving force for change In addition the front end is often only useful for specialist users with IT training The individual processes Business intelligence consists of three steps col lection analysis and presentation The first step involves the collection of the data This raw data can come from an ERP system database or file for example It must then be filtered cleaned up and harmonized before it can be subjected to analysis simple analysis is possible with online analytical processing OLAP cubes Complex statistical analysis is carried out using methods associated with data mining In the third stage the data is prepared for presentation in the form of reports PDF files or dashboards The user can specify what data should currently be prepared Compil ing individual reports is as easy as using drag and drop A manager may want boiled down Summarized performance data while a process engineer can call up detailed information about an individual process pe beepiT hane jd DE OZED4 wem je dut P fea Ae FS Energy consumption 4 HN 10 1 1
16. There are also many advan tages during service work If the cable is crushed for example it is simply disconnected and re placed without having to open the motor IP69K connector The same hygienic design standards used for the motor also apply to the connector The connectors have IP6SK protection and meet EHEDG and FDA hygiene standards The hybrid cables with FDA approval and heat resistance up to 150 C exhibit a high standard of safety and reliability and there fore fit seamlessly into the B amp R environment This 1 cable solution saves time and money Innovations 2015 Highlights Easier installation Easy maintenance Stringent hygienic design 100 stainless steel Smooth rounded housing for optimal cleaning IP69K protection for high pressure cleaning Food safe and resistant to chemicals Satisfies EHEDG and hygienic requirements The smooth stainless steel housing of the motors has a surface finish of less than 0 8 um rounded corners and seamless transitions designed to eliminate undercuts and protruding screws to prevent the collection of contaminants while still allowing for simple safe and efficient cleaning With a laser engraved type plate and IP69K tection these motors are extremely suitable for efficient daily cleaning processes 24 Installation and maintenance of hygienically designed motors is considerably simplified thanks to the IP69kK rated connector Innovations 2015
17. are many different safety controllers in the SafeLOGIC family that can manage the safety oriented tasks on the real time POWERLINK network Even with the previous limit of 100 safety nodes safeLOGIC is still one of the most powerful safety solutions on the market With the 20518101 it is now possible to control up to 500 safety nodes corresponding to several thousands of signals There is increasing interest in safety solutions that can process several thousand signals rapid ly in particular for process control systems lifting platforms and building control systems i e in in dustries outside of conventional machine manu facturing As a result the 20518101 is opening up entirely new safety concepts for comprehen sive control solutions 62 P Copen Function block brary for press applications Examples of function blocks Monitoring a mechanical drum sequencer Functions for monitoring shafts for Functions for cyclic operation typical operating modes for presses Function blocks for valve control foot switches Multi operator mode with two hand operator panels Innovations 2015 With the SafeDESIGNER library for press applica tions is one of the first manufacturers to offer a complete set of the function blocks spec ified in PLCopen part 4 As a result users working with safety critical press applications will have a much easier time setting up the necessary safety
18. has to be col lected and evaluated In addition safety applica tions place high demands on network performance Machine manufacturers with custom developed control solutions reach their limits when real time capability and comprehensive safety solutions be come necessary Ihe combination of Automation studio and POWERLINK makes it possible for these machine manufacturers to continue using their custom developed control solution while integrat ing 8a powerful real time network and extensive safety solutions m EI UR E E gt i Li ir Eme i gta i ee TIE FREI FESE prer ngri ede E 8 m P bihi ambiam Sy td oe T CEPE doi DELE le LL Pa caca 5 PLIL comun amis ede SC jl m mud um wi Er ira a da Tus Erim E Flat SSP Pel 2 en Od em
19. independent and oper ates at the Ethernet layer It works for OPC UA and Process Visualization Interface as well as pro prietary protocols Bonding can be easily config ured in Automation Studio Operator station bondo ethO eth1 IP 192 10 50 42 Runtime servers jii eve Redundancy bus 0 ethO eth1 ESI systemwide redundancy all production data is communicated from the control level to the management level without risk of failure Innovations 2015 The bonding driver uses standard components with multiple physical network cards combined into one logical unit If an open line occurs due to wire break for example or a network card fails then the connection between the networked com ponents remains intact This makes it possible to implement cable redundanoy for the process bus to ensure maximum availability Universal and flexible use With process bus redundancy B amp R has added an other component to its extensive line of redundan cy solutions Customers have already been able to implement controller redundancy using standard hardware and POWERLINK redundancy for failsafe communication at the field level BSR redundancy solutions are also perfectly suited for Scalability solutions They can be flexibly com bined and enable redundant systems from the 0 all the way up to the process control level The bonding driver makes it possi
20. must be in the microsec ond range while the switching times themselves require precision in the nanosecond range In these types of applications a reACTION module can read setpoints and actual positions directly from the drive This saves the cost of an external encoder cuts back on wiring and also reduces the load on the controller For every industr gt Industry independent reACTION technology Recycling Sorting Modern sorting plants require extensive and flexi ble automation to ensure the throughput required by the recycling industry Precision and speed are particularly crucial for tasks such as evaluating sensors and controlling large pneumatic valve lines At extremely high sorting speeds compen sating for switching tolerances is also important reACTION technology can significantly boost the throughput of sorting plants and improve the quality of recycled materials reAC TIO TECHNOLOGY 4g Textiles Air weaving Air weaving is one of the most productive weaving methods he weft thread is initially blown in and then aerodynamically guided using relay nozzles These processes place very high demands on the precision and speed of the application demands that can be mastered perfectly using reACTION technology Shorter switching times and de creased dead volume considerably reduce the quantity of compressed air consumed by the main relay and stretching nozzles Print Registration mark detection
21. program every single detail Software development Traditional Base functionality They make it possible for example to put multi axis systems coupled with cam profiles electronic gears or various robot kinematics into operation in a matter of just a couple hours Also included is a web based tool for diagnostics and configuration of mapp functions With mapp it has proven possible to reduce develop ment times by an average of 67 Machine With mapp technology app Machine process process 67 faster With mapp technology machine and system manufacturers can concentrate on developing crucial machine functions Basic functions do not have to be programmed because simple configuration is all that is necessary Innovations 2015 69 FOCUS on core competencies Ay 7 ti 5 Machine or system manufacturers shouldnt have to worry about basic functions or software maintenance they should be concentrating in Stead on their core competencies as their pro cess know how is quickly turned into software The gateway hurdles usually involved in imple menting complex software are reduced to a min imum with mapp technology In addition effi ciency is increased and the total maintenance OEMs free to focus on core competencies gt Implement process know how gt Increase competitive advantage gt Bring innovations to market faster 44
22. service portal then allows authorized connections to be made bet ween the service technician and the machine and the secure VPN connection is established Machine builder Service engineer Maintenance Service Portal The Maintenance Service Portal MSP is the cen tral connection platform for the service techni cian and the machine A connection is establis hed from both sides according to the defined authorization settings User accounts authoriz ation settings and machines can be managed easily and intuitively by authorized personnel via a web portal Machine builder service provider Maintenance Service Portal MSP The MSP can be set up according to the specific requirements of the customer For example the machine manufacturer can set up its own in house portal on a server and implement their own Machine Pool Manager Customers can also take advantage of the Machine Pool Management ser vice hosted by BSR as an alternative Other exter nal service providers can also be used Safety first VPN networks firewalls and appropriate strategies for establishing a connection provide maximum protection for the remote connection This protection even extends to man in the middle and Production facility Maintenance Site Gateway MSG Site LAN Maintenance Site Gateway MSG The Maintenance Site Gateway MSG is the connection from the machine or machine network to the pla
23. such as test driven development and continuous delivery are also gaining ground in Innovations 2015 machine and system manufacturing The unit testing framework included in B amp R Automation otudio is already prepared for these possibilities Not only does it provide web services that allows these tests to be integrated into any build pro cess the tests themselves can be run also via web service and evaluated automatically Highlights Automated testing gt Increased software quality gt Faster development some functions and functions undergo automated checks at the push of a button 75 ast error localization With the increasing number of machine variants and options the amount of program code is also increasing As a result errors in the source code are becoming harder to find BSR provides mecha nisms that enable developers to quickly and easi ly determine which parts of the program are active and therefore responsible for the current behavior If development takes place using text based lan guages such as Structured Text all of the pro gram lines being executed are indicated in Auto mation Studio even within function blocks If an error occurs the developer only has to check the indicated lines Because many lines of code are often skipped over in text based programs error localization is limited to the few active areas Highlights gt Clear representation gt Exact diagnostics
24. the Internet can be accessed from the farthest corners of the earth providing the ideal connec tion between service technicians and the ma chine A prerequisite for this is secure and reliable data transmission Data must be be transmitted via secure VPN connections using highly ad vanced authentication procedures It does not matter whether the Internet uplink is set up via LAN WLAN or a mobile network Machine Pool Management Machine manufacturers have a lot of customers and even more machines in the field In order to use re mote maintenance effectively a centralized Ma chine Pool Manager must be implemented This manages the machines in the field as well as the access rights of service staff operating the individ ual machines al Possibilities gt Diagnostics using the System Diagnostics Manager in Automation Studio gt Reading logbook entries and application data gt Changing machine settings and parameters gt Updating programs and firmware Innovations 2015 92 Innovations 2015 Simple and secure During a service call a Secure connection must be established between the machine and the service technician The service technician only needs a web browser the Connect Client pro gram and an Internet connection in order to log into the portal The machine also connects to the service portal via a remote maintenance ga teway with a built in firewall The Machine Pool Manager integrated in the
25. tremely complex functions with less effort We re not about to rest though B amp R developers and maintenance specialists all around the world con tinue to expand the portfolio of mapp blocks to meet the demands of the future as well Inis tecn nologys complete integration into Automation studio means that all of the new functions will be available through a simple update Over 70 functions Single and multi axis functions CNC and robotics functions Recipe and alarm functions User management and Audit Trail Industry standards e g PackML Trend functions Extensive web diagnostics Simple configuration using a browser gt gt gt l l gt l Innovations 2015 72 Jrag and drop documentation In Automation Studio it is possible to quickly and easily move and configure hardware depicted by photorealistic images using drag and drop Ad ditional documentation features now allow devic es to be grouped together and described in text boxes This provides everyone involved in the project with a clear overview even for extensive topologies Keeping documentation up to date can be a major challenge Ideally all necessary information is collected during project configuration without having to use a separate tool Clear overview of topologies The 2D representation of the entire topology in Automation Studio already includes the majority of the documentation The developer can save additiona
26. I EOD UNE cee AP CURT eem SATs CODO Sene Eee 6555 01 15 Parr modum YT SE PEI2OHCOO M end uni 27 EREHE ADDR eal poder uni hh Sse eer may une 222 pasares peer gqoly und All components are imported into the Automation Studio ware Catalog as XDD device description files regardless of manufacturer When components are added their parameters and process variables are shown in the same structured form regardless of who built them The uniform interface makes configuration very intuitive for the user and minimizes the amount of training required Machine manufacturers can use custom developed controllers as a POWERLINK master connect slaves as required and configure the whole system in Automation Studio am Turm iFa Tie gil LED ELE 7 tombe a F mm PERLE 4 ee b amas ee ee ee ee LESE Meme seip mei fm aum ph oem cin mri
27. POS P5 can be combined with all ACOPOSmulti family products Additional space Innovations 2015 3 2 zem can be saved in the control cabinet for exam ple by using the motor mounted ACOPOSmotor servo drive or the distributed ACOPOSremote drive system No loss of energy When using an ACOPOS P4 together with an ACOPOSmulti drive it is also possible to take ad vantage of the power regeneration capabilities of the ACOPOSmulti Braking energy from the ACOPOS P5 is not converted to heat using braking resistors instead it is passed on to an 5 multi via the DC bus which can feed the energy back into the power grid Improved international capabilities The flexibility of the ACOPOS shines in this regard since it Supports the world s most com mon power mains configurations such as IN TT and corner grounded IN S systems In some circumstances only an additional line fil ter is needed to meet the necessary regula tions In addition the ACOPOS satisfies the machine and system manufacturing require ments set forth 55011 CISPR 11 and EN 61800 3 first environment category C2 12 Main supply 1 x 110V 1 x 230V 5 x 208V 2 2 4 4 8 8 A 0 5 kW 1 kW 2 kW Single axis Double axis Triple axis 8 8 A 2 o 4 5 8 8 A 8 8 A 2 o 8 5 8 8 2 2 4 5 8 8 1 kW e kW e kW e kW e kW e kW Main supply 5 x 208 480V
28. S SafeROBOTIC function can thus be configured closer to the point where there is real danger The Safely Limited Acceleration func tion is available for safeMOTION modules with an EnDat 2 2 and SinCos interface 12 safe machine options When commissioning some machines it is nec essary to make machine specific settings for certain parameters such as the homing offset or the unit system as it relates to the actual gear ratio You can now use the machine op tions function to selectively transfer the safety parameters from the functional application to a safeMOTION module Setting parameters on the panel These safe machine options can be used to up date parameters via the HMI application on the operator panel for example Because they are safe parameters configuration may only be per formed by authorized personnel and the cor rectness of the transferred parameters must be acknowledged machine options able for SafeMOTION modules with an EnDat 2 2 and SinCos interface The Safely Limited Acceleration SLA function makes it possible to configure the speed limits closer T delay time to to the actual limit without risk start SLA lt q SLA control bit SLA status bit Speed tolerance units s Safe deceleration limit for SLA units s in the negative direction Safe acceleration limit for SLA units s in the positive direction Acceleration Safe acceleration
29. Standard and Windows Embedded Standard 7 Premium Windows 8 1 is also supported Whether 52 or 64 bit all operating system versions can be used The real time operating system Automation Runtime turns PC systems into fully fledged high performance industrial controllers Ihe combination of Automation Runtime and Windows unites the open PC world with applications that require hard real time Based on multi core processor architec ture the real time operating system runs on one core while the other cores are reserved for Windows 29 The modular panel PC series provides the perfect solution for any application Highlights Intel Atom E5800 processors Up to quad core CPU performance Extremely powerful graphics Compact dimensions 2x gigabit Ethernet SDL DVI Automation PC 2100 Fanless Innovations 2015 Operating systems Windows 7 Professional 32 64 bit Windows 7 Ultimate 32 64 bit Windows Embedded Standard 7 32 64 bit Windows Embedded Standard 7 Premium 32 64 bit Windows 8 1 Industry 32 64 bit Automation Runtime Embedded Automation Runtime Windows Viv Viv Innovations 2015 Smart Display Link Single cable to easily connect operator panels compatible with all Automation Panels in the field CFast Combines the shape and dimen sions of CompactFlash cards with the faster SATA interface 4 E eal 4 4
30. X 11 which 30 Giga instructions per second Innovations 2015 makes it possible to design even more demand ing HMI software Fanless The PC architecture is designed as an extremely efficient system on a chip SoC solution Be cause this technology does away with addition al components such as the chipset it is able to reduce heat dissipation to a minimum and elim inate the need for extensive cooling systems The result Compact PC systems that can be operated with no fans whatsoever over a wide temperature range SiSoft Sandra 2011 Drystone ALU 26 Windows 8 for Industrial applications With Windows Embedded 8 1 Industry Pro Micro softs latest operating system can now also be used for machine and system manufacturing ap plications As the ideal basis for HMI applications with touch screen capabilities it also offers addi tional possibilities that increase system security BSR provides supports for Windows Embedded 8 1 Industry Pro a system tailored to industrial applications Based on the full version of Windows 8 1 Professional this new Windows technology combines embedded system charac teristics such as additional lockdown functions to make industrial PCs more secure And like Win dows 8 1 Windows Embedded 8 1 Industry Pro offers improved touch s
31. able price per formance ratio and reduced delivery times If nec essary these motors can be ready within a few hours and dispatched using express delivery ay Stall torque range Nm 12 08 0 13 45 525 54 5 5 155 Wr 190 95 ie ees MEL Me 8h 20 118 9 20 66 27 1307 ias cure 01 04 necs 05 41 09 92 Sedes 85 280 kW Max speed 9000 9000 9000 9000 9000 4500 3600 rpm Motor flange 58 913 142 190 190 240 mm B amp R has completely revamped the 8LS series of mo tors and implemented numerous improvements in the process Innovations 2015 28 Latest Intel Atom tecnnolo With an ultracompact housing that corresponds to the dimensions of a Smart Display Link receiv er the Panel PC 2100 is an extremely powerful PC system that can handle virtually any application The control cabinet variant of the Automation PC 2100 also provides a complete PC system with minimized dimensions This innovative PC design is based on Intel Bay Trail architecture whose single dual and quad core processor technology represents a milestone for embedded systems all while of fering an optimal price performance ratio The quad core processor achieves a higher perfor mance level than the Core i5 5217UE processor used in the Panel PC 900 All Automation PC 2100 and Panel PC 2100 variants have done away with internal fans Communication i
32. al and simulated machine process directly on the industrial bus The machine model can be created in different domains for example electrical or hydraulics Additional user interfaces allow parameter con figuration and monitoring of the developed pro cesses It is also possible to represent state ma chines or control processes as well as display Highlights Easily create machine models Seamlessly integrate models a B amp R controller Switch between the simulation and the real process easily seen se Hardware description m gt Pm Simulation Y ou ISG mechanical components in 3D Virtual commissioning made easy Real time processes from VIRTUOS run smoothly on a B amp R controller This is made possible by the virtuos VIRTUOS visualization VIRTUOS real time simulation BSR Runtime Windows ETHERNET POWERLINK Generating code from VIRTUOS models in Automation Studio is not just possible it s easy Switching between real time simulation and the real ma chine process is just one of the many features Real PLC Real machine Embedded CPU Industrial PC Virtual machine ETHERNET I II POWERLINK simulation allows system models created in the VIRTUOS environment to be executed on BSR runtime systems Innovations 2015 s
33. all of these chal Y lenges Their external appearance can also be de signed according to customer wishes BSR stainless steel panels can be configured individually and are still able to meet the strictest hygiene requirements Innovations 2015 Illuminated ring keys and RFID readers sumere ine panel makes It POSsiple Te and without having to deal with passwords or key operated switches Not all operating ele ments can be implemented using a touch screen sometimes an illuminated push button with a clear signal or tactile feedback is required As a result illuminated ring keys can be integrated on ioues ese keys cle 3 alte eve conventional electromechanical pushbuttons be cause they provide tactile feedback And because they are integrated directly in the panel overlay there are no edges or grooves making cleaning extremely easy Grooves and edges caused by add on control elements are not just minimized they are completely eliminated gt Approved for food production gt be operated with gloves gt Flexible swing arm installation gt Easy clean 4 Panel Uesigner A personal for your macnine Panel Designer allows all B amp R panels and the front doors of Automation PCs to be designed in dividually This web based application makes it possible to create professional designs within a few minutes without any pre
34. ated and configured automatically Device parameters can be clearly structured into groups An overview even of complex devices is possible with parameters organized into a tree like structure pe acd Feary L E 7 POWERLINK timing values are automatically optimized Automation Studio Innovations 2015 94 simple evaluation of large amounts of data B amp R has upgraded the highly advanced and flexible APROL automation platform by adding a powerful system component for business intelligence Business intelligence enables systematic analy sis of recorded operating and process data Us ers can gain valuable information for the deci sion making process with the help of standard reports personalized interactive reports and ad hoc reports Native iPhone and Android apps are available for mobile access Originating in the area of business management the term business intelligence has been in exis tence since the beginning of the 1990s refers to the procedures and processes necessary to sys tematically collect analyze and present data in electronic form Platform JasperSoft Professional Report server OLAP Server Jasper Report Designer Analysis Aggregation Designer Various modules be added to the platform to meet cific application requirements Innovations 2015 Highlights
35. ble to implement process bus redundancy on the Ethernet layer 80 Security Dy Design Communicating via SSL TLS In line with the security by design approach strongly emphasizes the importance of secu rity during development New systemwide func tions include encrypted SSL TLS communication secure user authentication and authorization based on username and password and technolo gies such as RFID The ever increasing use of network communication in production plants is placing new security chal lenges on automation solutions increasing the need for integrated solutions In addition to access from external locations for remote maintenance for example it is also necessary to ensure Secure communication within the production area for things like operator panels and MES systems Complete security Modern production plants require all encompass ing security concepts New functions for encryp tion authentication and authorization are central components of the PLC operating system They can be used for standard protocols such as FIPS HTTPS or OPC UA as well as proprietary systems using libraries Machine manufacturers Innovations 2015 Highlights gt Complete security solutions gt Easy maintenance during runtime gt Ready for expansions can thus design and implement access manage ment in Automation studio as a complete solution for their customers User administration made eas
36. brak ing distance Diagnostic function blocks there fore allow validation of the safety related parameters during commissioning without hav ing to change the safety application Innovations 2015 EC Perfect synchronization with beneric Motion Control As processes in production lines continue to be synchronized to conveyor belts the division be tween material handling and production is disap pearing Highly complex control solutions used to be necessary to ensure the great degree of preci sion and speed needed for these processes With B amp R Generic Motion Control GMC conveyor belts and robots can now be easily synchronized with a high degree of precision Production lines with conveyor belt tracking have an advantage since they prevent production pro cesses from stopping thereby achieving higher production volume The complexity of these sys tems is constantly increasing with the presence of robots becoming more and more common heir tasks range from simple sorting to complex prod uct processing on running conveyor belts Freedom with PLCopen BSR provides easily configurable PLCopen func tion blocks that are tailor made for these tasks They can be used for all types of robot kinematics and even allow robots to be synchronized with multiple conveyor belts The interfaces are also ideally suited for integrating machine visualiza tion systems The robot can move freely during Innovations 2015 the synchroniza
37. can be used for compensation if the frequency response is too high The PID controller can then be set up much more effectively Once a controller has been set up diagnostics are possible in the frequency domain If simple Closed loop control blocks Pid PWM Tuning ete Signal filtering gt Low pass high pass notch etc Setpoint generation gt Position generator etc Statistical functions gt Mean value standard deviation etc Lookup tables gt 1Dand 2D tables etc The basic closed loop control packages in Automation Stu dio provides plenty of preprogrammed solutions for closed loop control tasks Innovations 2015 PID controllers are not sufficient additional blocks can also be set up in the frequency do main This allows the desired controller to be set up for specific behavior Additional library functions are also provided that round off the advanced package Adding intelligence to controllers The added value of the functions in the advanced package is the ability to add intelligence to con trollers This allows them to be set up in a more targeted manner during commissioning while also simplifying diagnostics The blocks are processed directly on the real time control system allowing the implementation of intelligent closed loop controllers For example they can adjust themselves to changing machine behavior in different operating conditions by identifying dynamic behavio
38. complex especially in light of the increasing mass customization of products Purely mechanical solutions make it hard for ma chine builders to keep up with these new demands And even though the software required for these 6 types of projects will continue to become more complex more extensive and more individualized than ever before there will nevertheless still be those functions that will always recur This not only includes things like controlling single or multi axis systems but also general administrative functions Such as recipe management Just ensuring basic functionality of the software requires a consider able investment in both time and money With the modular mapp function blocks the programmer no longer has to deal with these basic functions The shift in development disciplines Mechanics Electronics 1980 Over the last few decades the proportion of software development involved when designing new machinery and systems has skyrocketed Software 2000 2010 Source VDMA ITQ Innovations 2015 2020 68 Development time reduced by 67 Many thousands of field proven B amp R applica tions from all over the world provided the bench marks needed to develop the mapp function blocks and seamlessly integrate them into the Automation Studio environment What sets mapp function blocks apart is that they are ex tremely easy to configure and relieve the devel oper of having to
39. creen support for an in tuitive user interface Individually configure devices The lockdown functions in Windows 8 1 Industry Pro make it possible to individually configure the device while making the system more secure at the same time In addition to locking certain functions in the operating system Microsoft has also included the unified write filter capabilities from Windows Embedded Standard including Innovations 2015 Highlights gt Optimal touch screen support gt Individually configure devices gt Write protect data storage media gt Hide dialog boxes if desired gt Multilingual operating system Write Filter File based Write Filter and 5 try Filter These features can be used to config ure a flash drive for read only access for exam ple or to allow only certain registry keys to be accessed Any changes made to the registry are thus redirected to RAM As a result the system always starts with the same configuration after rebooting Existing data storage media such as 550 or CFast can be write protected With the dialog box filter windows and dialog box es can be suppressed at the process level Such dialog boxes can occur for example if virus scan ners are updated network connections fail or the Windows Security Center shows warnings These dialogs can be hidden if so desired Large number of languages Like Windows 7 Ultimate Windows Embedded 8 1 Industry Pro is multilin
40. d axes This makes it possible to develop and test se quential control and complex processes without requiring the physical drive unit and the machine Coupled axes can also be analyzed at the same time which makes it possible to assess their in fluence on the overall performance of the ma chine or on the performance of an individual axis With this type of simulation the process the be havior of the motors and the behavior of the drives are simulated on the controller The configuration of various complex process models is supported by PLCopen model components which are made available in libraries be jn A 4 em _ Print cylinder Backing roll Thrust bearing Simulation on the controller Simulation on the PC Simulation on the PC is the most comprehensive type of virtual motion simulation It provides a real istic picture of the overall system without any actu al machine hardware being used Sequential con trol systems and their impact on the machine are simulated and analyzed directly in B amp R Automation Studio enabling faster product development with out any loss of quality ord Simulation on the PC Innovations 2015 16 Virtual sensors for monitoring torque Motor torque shaft torque and load torque play an important role in condition monitoring for open loop control drive sys
41. des in the network Network traffic CPU performance In a conventional control solution each 1 0 signal must be sent CPU load over the network to the central controller where it is processed and then returned to the 1 0 module Controller 1 0 with N pU DU 1 Ultrafast 1 0 responses For both low end and high end systems Fully integrated Open IEC 61151 technology With reACTION technology time critical subprocesses are exe Centralized software management cuted directly on the 1 0 module which removes the limiting Decentralized program execution factors of conventional control solutions from the response time equation Innovations 2015 46 frequencies The selection of reACTION function blocks is con stantly growing with new blocks available in the field by upgrading the firmware Users can also assemble their own custom function blocks from the reACTION library to improve the clarity of com plex programs For example new encoder and counter function blocks can be developed and used to process input signals with frequencies higher than 1 MHz Internal signal processing in the reACTION mod ules runs at a much higher clock rate than the reACTION program itself Qutputting high frequen cy signals is also possible using the PWM function block for example 20 ns resolution When reading digital inputs a reACTION program can determine exac
42. directly measure acceleration torque weight pressure and much more Innovations 2015 56 Pneumatic system Solutions with BOR In cooperation with partners Festo ASCO Numat ics and Aventics B amp R has created the perfect solution for seamlessly integrating pneumatic solutions in an automation system Customers benefit from extremely easy handling high clock accuracy throughout the system and freedom of choice Valve terminal families can easily be integrated in the BSR engineering environment using a device description file Proven functionalities graphical display simple component configuration auto matic firmware downloads and easy to use diag nostics features are available for valve terminals just as they are available for other BSR products This shortens commissioning times maximizes productivity by increasing system performance and reduces downtime to an absolute minimum ETHERNET MEN EN POWERLINK Innovations 2015 POWERLINK The key to success One of the things that characterizes the POWERLINK communication protocol is its high performance in terms of cycle time and clock accuracy The inte gration of pneumatic solutions into the B amp R auto mation system allows high speed response times in the field of pneumatics as well Machine se quences can be more precisely coordinated open ing up entirely new machine concepts Highlights Seamless integration gt Increased productivity
43. e remanent safe position after confirmation by the user The RSP function is available for SafeMOTION modules with an EnDat 2 2 interface Using the Remanent Safe Position RSP function al lows a safe multi turn position to be received after a restart without having to perform a homing procedure de Q Power OFF Power ON Position Safe encoder range y Position acknowledged by DOS ee m NE user homing with RSP POS stored p s stored Safe position set up internally POS 0 S Apos TOL ower ON Invalid range for encoder position at power on Time xo 5 Overflow encoder SM lt Tue Qr position cO NS C XS safe position valid 69 SS c ee Safe position N S Encoder position Innovations 2015 Highlights gt Repeated homing procedure not necessary gt Safe operation closer to the limit gt Increased availability Closer to the limit The Safely Limited Acceleration 51 function monitors the acceleration or deceleration of an axis If the limit being monitored is exceeded the safeMOTION module goes into an acknowledgeable error state and power is no longer applied to the axis Using the SLA safety function for coupled axes for example makes it possible to signifi cantly reduce the maximum remaining distance an axis will move in the event of an error The speed limit set in the SL
44. ealing mate rials The range of available panels extends from simple touch screen visualization termi nals to operator panels with integrated control and drive technology Fully fledged Panel PCs are alSo available Because these panels were designed to be especially slim they do not need additional handles In addition to an IP65 rated USB interface on the back of the panel it is also possible to mount these sys tems on any conventional swing arm system Innovations 2015 Highlights 9 Projected capacitive multi touch 15 6 HD to 24 Full HD DVI SDL SDL3 IP65 USB interface Touch screen technology Reliable and intuitive All stainless steel panels are equipped with multi touch screens that can be operated eas ily and intuitively Since touch screen technolo gy is firmly anchored in everyday life time con suming training can be kept to a minimum Operational safety is increased by ensuring that only sensible options are displayed on the screen which minimizes the chances of unin tentional operations being carried out The ap plication determines which operating condi tions can be selected Users are also reliably guided step by step through complex process es The touch screens themselves have a smooth surface so that their integration in the operator panel allows them to continue meet ing strict hygienic requirements The special structure of the screens increases robustness and also provides shatter p
45. eamless integration of ANSI C code in Automation studio The user can choose whether the real time model should run on a separate B amp R controller or directly on the machine controller s target system This solution can be used for all machines and systems that would benefit from virtual commis sioning through visualization of the process for example production and packaging systems or robotics applications In addition to code generation from MATLAB Simulink Automation Studio Target for Simulation V4 4 also sup ports Simulink models structured using model referencing External mode 89 Quickly generate large amount of code BSR has vastly reduced the time required to gen erate code from large Simulink models This is made possible with Automation Studio which supports code generation from MATLAB Simulink 2014b as well as Simulink models that have been structured using model referencing Version 4 4 of Automation Studio Target for Sim ulink not only allows code to be generated from MATLAB Simulink 2014b it also supports Sim ulink models that have been structured using model referencing MATLAB Simulink ANSI C C Automation Studio i2 Target for Simulink Compile and download Up to 100 times faster Model referencing makes it possible to reuse oimulink models allowing a large Simulink mod el to be created by linking several sub models together Simulink and Automation Studio also support st
46. ecision with a minimum sampling time of 50 us for the entire controller cascade The ACOPOS P4 is offered as 1 2 5 drive and covers a power range from 0 6 to 24 kW or 1 2 to 48 amps And because the housing of the Innovations 2015 axis drive is as compact as a conventional sin Gle axisaiivemimie DOSSible to reduce the amount of space required in the control cabinet by 6996 Highlights gt 69 smaller footprint gt 50 ys sampling time gt Virtual sensors gt Use anywhere in the world Innovations 2015 08 ETHERNET B POWERLINK High availability Maximum security A new dimension in virtual sensors The short cycle time of 50 us for current speed and position control opens up new opportunities for drive control using the ACOPOS P5 For highly dynamic and precise processes like those in the printing and packaging industry high speed pre cision control of movements is a must his is not a problem with the short cycle times achieved the 5 and the bandwidth and precision of the POWERLINK real time Ethernet network Reduced energy consumption Machine manufacturers are being forced to move to lightweight construction to meet demandas for increasing productivity while decreasing energy consumption at the same time To meet these de mands moving mass and mass moment of inertia must be reduced This results in reduced rigidity and increased elasticit
47. electing the operating mode via Develop software 67 faster with mapp technology s Create documentation for automation products quickly and easily 2222 Unit testing in Automation Studio Quickly find source code errors Vendor independent communication witn OPC UA Process bus redundancy with bonding drivers Security by Design Communicating via SSL TLS solution packages for control tasks _ Exact movement of crane loads Hardware in the loop simulation on the real time Fast code generation for large Simulink models Manufacturer independent engineering in Automation Studio Business intelligence for APROL Recording operation and process data in a central location in APROL 2202 Easier online parameter management with APROL 0 00000000 05 04 12 _ 14 16 18 20 22 24 __ CO _ 28 50 ae OC 48 4 44 50 55 56 58 2 od __ 60 61 62 68 J __ 74 5 45 78 80 _ 86 88 89 _ 90 _ 94 96 Ne 99 Innovations 2015 standard for drive technoloc nnova 2015 5 Servo drive With the ACOPOS P3 BSR is setting new standards for motion control This 5 axis servo drive offers a power density of 4A per liter making it one of the most efficient servo drives with integrated safety functions on the market It also provides previ ously unmatched dynamics and pr
48. esponse tests on the controlled system are available Using additional functions from the advanced package The advanced package offered by BSR includes additional methods that go beyond the basic package These advanced functions are based di rectly on the functions in the basic package and can be directly connected to them making it pos sible to identify control and if necessary trou bleshoot applications OscillationTuning SetValue TO Limiter pem PID Model ActValue CtrlTask LowPass SimMod PID LowPass and OscillationTuning from the basic closed loop control package are ready made blocks with clear and simple interfaces These blocks can be used to implement a single loop PID controller with built in tuning Innovations 2015 84 To use basic function blocks with a PID controller and two filter blocks on the controlled system for example the transfer behavior is defined using an identification block from the advanced package All of the function blocks in the basic package provide information about their transfer behavior via a compatible interface This information allows a tuning block from the advanced package to de termine the PID controller parameters for specific controller behavior Specifically defining controller behavior The frequency response of the identified system is displayed which allows the user to design an optimized controller For example a notch filter
49. gt Fast response times 22 NUMATICS 5 Valve terminals from Festo ASCO Aventics be seamlessly integrated in BSR control solutions Innovations 2015 58 ine right answer to all wiring questions Version 1 90 of the Safety user s manual now includes extremely useful connection examples to make connecting and configuring safety com ponents easier than ever before gt Wiring examples with assessment of the category B amp R products and integrated safety functions are gt Information regarding compatibility of optimally matched to one another Unlike hard sensors and actuators wired safety technology there are a lot of aspects Examples of configuring parameters and that users have to worry much less about such making connections as wiring safety products achieving a specific per formance level configuring parameters during maintenance and much more Extensive documentation with connection exam Light curtain Input device ples an assessment of the category that can be achieved and information regarding the compati bility of safety sensors and actuators provide us ers additional guidance when using safety compo gt Input nents that go beyond BSR s product portfolio Input gt Input gt Input gt The users manual includes many connection examples including one for a light curtain Innovations 2015 In respon
50. gual and covers all major languages including those with Arabic and Chi nese character sets Arabic Finnish Korean Bulgarian French Croatian Chinese Greek Latvian Danish Hebrew Lithuanian German Dutch Norwegian English Italian Polish Estonian Japanese Portuguese Windows Embedded 9 Pindustry provides support for these languages Romanian Russian swedish serbian slovak Slovenian Spanish Windows 8 Thai Cech Turkish Ukrainian Hungarian 99 Hygienic stainless steel operator panels with protection The pharmaceutical biomedical engineering and food industries place particularly high demands on machines HMI systems must be free of wear and have no open grooves in order to meet strin gent hygiene requirements BSR s stainless steel panels provide IP69K protection and are perfect ly suited for use in these conditions Hygiene is becoming more and more important in the processing industry In the food processing and packaging industries it is necessary to keep the materials being processed free of impurities This issue is of course no less important in the pharmaceutical and biomedical engineering in dustries Here it is also necessary to protect em ployees against infections and diseases Smoothed stainless steel BSk stainless steel panels feature a hygienic design and use especially resistant materials such as smoothed stainless steel a high qual ity polyester overlay and special s
51. hat the operating mode is selected safely Existing approaches to user au thorization can simply be integrated as is Highlights gt Renders mechanical switches obsolete gt Easy to manage existing authorization approaches gt Can be adapted to individual situations Safe temperature monitoring Visualization objects also make it possible to monitor temperature or pressure safely and se curely through the editing of parameters These safety functions are primarily integrated in the process or plant automation technology With this new solution B amp R has considerably simplified the work involved when using operating mode switch es It used to be the case that a physical operat ing mode switch with key function had to be in Stalled if changing the operating mode led to a reduction in the machines safety level open NI SAFETY Innovations 2015 revolution In automation software Innovations 2015 Innovations 2015 66 revolution In automation software is revolutionizing the development of appli cation software for automation with mapp tech nology These modular software blocks simplify the development of new programs and reduce the development time for new machines and sys tems by an average of 67 At the same time mapp solutions are much more convenient to service and maintain When it comes to engineering new machines and systems software development is becom ing a
52. iguring this data can result in a great deal of work due to the large number of variables and OPC UA nodes To provide optimal support to the user Automation Studio offers over 1 000 standardized units that can be quickly and easily assigned to the nodes using drag and drop Ihe end result is simplified con figuration and accelerated development Effective use of data resources when transferring alarms Process relevant variable values are normally transferred to a remote system such as an HMI application or SCADA system This communica tion often results in large amounts of data which places a heavy load on both the network as well as the control hardware OPC UA offers intelligent solution whereby the server only transfers active alarms dramatically reducing total data volume BSR provides the option of implementing the OPC UA server directly on the controller Changes to alarm states can therefore be be detected and evaluated in real time which also ensures that the alarms are displayed in the correct chronolog ical order The machine operator can then easily recognize causality so that problems can be found and corrected quickly Highlights Efficient engineering OPC UA server and client alarms and conditions OPC UA historical data access OPC UA data model Access to historical data The server also seamlessly records all produc tion data to prevent lost data due to network problems Data can be
53. ith regard to velocity orientation and workspace All 14 safety functions are completely network based and can be used dynamically in the system thanks to openSAFETY 09 Safe Torque Off A Safe Torque Off single channel 4 Safely Limit Speed Safe Maximum Speed Safe Stop 1 Safe Direction Safely Limited Increment Safely Limited Acceleration Innovations 2015 10 iia scalable Ae mem Lean automation with Scalability The compact design of the ACOPOS is not the only factor in reducing the space required for an automation solution Together with other com ponents from the BSR automation product range it is possible to implement an extremely lean au tomation solution A Power Panel operator panel and controller ACOPOS 5 and X20 1 0 are that is needed for a complete and powerful auto mation solution Because this type of system is completely modular and scalable it can be up graded and expanded as needed guaranteeing maximum reusability of software that has already Deen engineered safety included It is even possible to integrate a complete safety solution in a minimized system of this type The safeLOGIC X virtual safety controller runs on an ordinary PLC and offers the reliability B amp R cus tomers have come to expect without requiring a dedicated safety controller Completely compatible The ACO
54. l information directly in a topology sim ilar to a control cabinet Text boxes with corre sponding comments can be added to individual modules motors or assemblies This makes it possible for machine variants to be indicated and described directly in the engineering tool for example Team collaboration is made easier as each devel oper quickly gains an overview of the current de velopment status Projects can also be better maintained since all relevant information can be quickly accessed Innovations 2015 Highlights gt Quick overview of large topologies gt 2D representation of components gt Documentation in a virtual control cabinet Easy alignment of components A large part of the documented information is de rived from the position of the hardware In order to make it easier to arrange components existing modules are automatically aligned on a grid or line When moving modules or module groups scrolling also allows the components to be posi tioned outside the visible workspace Keeping it all together Text boxes can be added to mod ules motors or assemblies This provides visual cues for highlighting machine vari ants for example d a d eres m raa m 3 dod 3 3 RA BE gH eoa es E mi i11 GAB
55. l load position Highlights gt Increased positioning precision Simple configuration gt Fast compensation for mechanical play Motor position in units 10 Load position error in relation to the motor position Performance level pl Innovations 2015 With PBC Without PBC 20 a 20 A safe workspace for robots has updated the functions available for safe robot control Users now have access to the mon itoring functions SafeRC SLS SafeRC SLP and SafeRC SLO in Safe Designer These SafeROBOTICS functions are based on easy to configure func tion blocks that not only provide safety applica tions the flexibility to easily be adapted to envi ronmental conditions but also to be validated as well In addition to monitoring the speed at the tool center point and at all joints of a general ized serial robot SLS it is now also possible to safely monitor the workspace SLP and the ori entation of the tool mounting flange BSR s ACOPOS servo drive provides the safe axis posi tion using integrated safety functions to calcu late the Cartesian positions of all joints the tool mounting flange the TCP and additional moni toring points Safely Limited Position SLP Position In order to monitor a safe workspace 51 rotat ing cuboids or planes are defined either as a workspace WS o
56. limit for SLA units s in the negative direction Safe deceleration limit for SLA units s in the positive direction Innovations 2015 14 Virtual motion Realistic simulation of drives Carrying out tests on real machines requires time and money Simulations are becoming increasing ly important to a large degree due to the creasing complexity of machines and systems With virtual motion B amp R offers the possibility of realistically simulating machine behavior for cer tain configurable environmental conditions while still in the development phase in order to obtain an accurate representation of how the machine will behave when it is finished Virtual motion allows the simulation of a single drive system with hardware in the loop functionality as well as the simulation of complex machine elements or even entire machines There are two main areas of application for virtual mo 2 55 Simulation on the PC Simulation on the controller Virtual motion allows simulation on three different levels Innovations 2015 Highlights gt Faster development gt More precise configuration gt Damage avoided tion One is realistic simulation of the behavior of the machine before it is even built which allows possible weaknesses to be detected and correct ed early on The second is fast and convenient configuration of the drive c
57. ly implement closed loop control functionality special closed loop control packages are offered in three categories basic advanced and expert In addition technology packages containing li brary functions for specific areas of technology such as hydraulic axes or temperature zones are also available Simulation ON OFF Automation Studio lets the user decide which programming language to use An extremely wide range of external tools including simulation can be integrated into the software Innovations 2015 Ga Technology software e E T ricis 2229 _ Mantesoft Extensive solution packages These library functions are available in two vari ants as software blocks and as solutions for typ ical tasks A solution package consists of gt Library functions for the respective closed loop control task gt Atemplate that shows how the functions are used for a typical application gt Aready to use version for commissioning and diagnostics gt One or more simulation models that reflect the behavior of machine component gt Simple and easy to read help documentation A solution can be selected from a menu and im ported into Automation Studio where it can be Technology packages e vie hydraulics Temperature Winders Print Wind Process Closed loop control packages Basic Advanced Expert executed immedia
58. mportant system or machine data d7 2 Sirsa ne LIRE d The status of individual production jobs and individual products can be checked and tracked at any time rea a M APROL PDA provides a wide range of options for displaying and presenting data Several machine HMI applications can even be grouped together in a dash board without problems Innovations 2015 98 More UA in APROL 26 Users of B amp R s APROL process control system can now enjoy more of the benefits provided by OPC UA An OPC UA server and OPC UA client are now available directly on APROL s Linux based runtime servers to allow allow open vendor independent communication All APROL variables that make the OPC UA server available to other OPC UA clients via read or write access can be defined through a simple selec tion process All data points that should be linked can be easily selected via integrated browser functionality for the OPC UA client Important at tributes such as read or write access are made available automatically Through the integration in the CaeManager engi neering tool BSR uses OPC UA to provide a totally new dimension of ope
59. n all directions The Panel PC 2100 integrates the most import ant interfaces including 2x gigabit Ethernet as well as 1x USB 2 0 and 1x USB 5 0 Interface modules can also be added in order to take advantage of fieldbus technology such as POWERLINK and CAN For data storage MLC Dased CFast cards are available that can store up to 60 GB or more Maximum flexibility All 2nd generation Automation Panels whether single or multi touch can be transformed into a complete PC system with the Panel PC 2100 since the Panel PC 2100 is no larger than the omart Display Link receiver it does not increase Innovations 2015 the system s physical depth Connecting cables to the Ethernet and fieldbus interfaces is also extremely user friendly since they are all acces sible on one side of the Panel PC 2100 Maximum graphics performance The graphics engine used by Intel Atom proces sors is derived from Core i technology and pro vides powerful processing This is also the first time that support for DirectX 11 has been pro vided in this segment opening up even more possibilities for enhanced graphic capabilities in SCADA and other HMI systems All resolutions and screen sizes up to 24 0 Full HD are sup ported Operating systems Automation PC 2100 and Panel PC 2100 tech nology closes the gap between open and real time operating systems In addition to Windows Professional and Ultimate it is also possible to run Windows Embedded
60. n communication Easy to use functions for data access support the config uration of gateway variables The entire process image for the system is available to the OPC UA server and client via read and write access based on the runtime server process data Motor management and control units compact OPC controllers and other devices can directly ex change all important operating service and diag nostic data with the OPC UA client In addition an OPC UA server can be used to connect any number of HMI panels or SCADA systems to the APROL process control system Innovations 2015 Communication can also be set up between APROL runtime servers This is not only possible within a project but also between different APROL systems with a different software version Highlights gt Integration on the runtime server gt Direct data exchange gt Flexible communication SCADA Operator station 101 m Operator station 201 system 1 system 2 Runtime server 2 OPC UA OPC UA server Runtime server 1 Real time Real time database client OPC UA OPC devices 7 TU E jme 229592 OPC UA makes it possible to easily monitor and control systems from various manufacturers via B amp R s process control system 99 Frasie
61. n increasingly significant time and cost factor Nevertheless the lion s share of this work is spent on programming basic functions like loading recipe data Concentrate on the essentials mapp eliminates these recurring programming tasks for developers by providing preconfigured blocks that are easy to use and already exten sively tested Programmers can then concentrate Innovations 2015 Highlights gt 67 faster development time gt Reduced investment risk gt Increased machine availability gt Lower maintenance costs on their main task implementing machine or sys tem processes in the application software Increased machine availability mapp blocks are seamlessly integrated into 8 automation software landscape This means that any developer who works with Automation Studio can implement mapp blocks to make their work easier and their application software clearer The end results speak for themselves increased ma chine availability lower maintenance costs and much easier team collaboration 100 90 80 70 60 96 50 40 50 20 10 0 1970 ma TECHNOLOGY The increasing importance of software Over the last few decades the proportion of soft ware development involved when designing new machinery and systems has skyrocketed from gt to over 50 percent and it shows no sign of slowing The production processes themselves becom ing more and more
62. n of spindle drives with and without backlash can be increased through compensation without requiring an extra encoder on the load side Control quality can also be significantly improved in other applications with mechanical play using pitch and backlash compensation PBC Compared to conventional handling of mechani cal play in the setpoint generator spindle pitch and backlash compensation provides substantial benefits With condition based closed loop con trol backlash that occurs on a changing edge is overcome quickly and reliably and the transition to the new edge is as smooth as possible A smooth transition reduces the likelihood of dam age to the mechanical components caused Dy continually changing edges Simple configuration The entire control loop can be configured as if there were no backlash This can be achieved us ing the new closed loop control approach for sta bilizing the speed controller for the motor position Feed forward Position setpoint Position controller O Speed controller gt Drive control for spindle drive with slope error and backlash 19 within the range of mechanical play A further ad vantage of spindle pitch and backlash compensa tion is that the currently displayed position corre sponds to the actual position of the load All that is necessary is to carry out a reference measure ment that defines the relationship between the motor position and the actua
63. nge is monitored here Free selection of the direction vectors in combination with the possibility of multiple instances of the monitor ing function block in the safety application al lows many different possible applications For example the monitored limit angle for tool orien tation can be defined in relation to the current TCP position Exceeding the specified limit angle in space is also indicated by a status output Monitoring passive joints for added safety New features have also been added to the ex isting monitoring function for speed 515 For example it is possible to configure and monitor additional monitoring points that move with the robot Passive joints on serial robot can also be monitored The joint axis position of these joints is composed of a linear combination of the ac tive joint axes positions further increasing the number of serial robots that can be configured Safely Limiled Speed Validation using a diagnostic function block In addition to parameter and safety function blocks special attention was also given to dating the parameters used in the safety appli cation For this diagnostics function blocks are available to the user that not only allow valida tion of the robot s configuration but also of the parameters relevant to the monitoring function some of the things that can be output include the Cartesian position and speed of all kinemat ic objects the angle of orientation and the
64. nt LAN and further on to the Internet built in firewall is integrated in the MSG In order to avoid security conflicts with plant firewalls communication to the Internet is handled using firewall compatible encrypted Web protocols Machine network Tm a E E Simplified depiction The MSG only has to be installed once If it be comes necessary to replace the gateway all parameters are transferred from the machine controller to the new gateway When the gate way logs onto the service portal for the first time one time authentication is all that is necessary oj Innovations 2015 54 10 years ne X20 system In 2004 BSR set new standards with the intro duction of the trendsetting X20 1 0 and control system The three part modularity of this product series together with its compact and robust de gt Three part modularity sign is particularly innovative gt Extremely compact gt Highly reliable With up to 16 channels and status LEDs in a unit gt Robust design that is only 12 5 mm wide 2 je tremely compact making it possible to reduce the amount of space required in the control cabinet to a minimum B amp R was the first manu facturer to produce this type of three part mod ularity where the bus module electronics mod ule and terminal block exhibit such compact dimensions The result is a simple design faster installation and easier maintenance
65. ontroller for already existing drive systems Avoiding damage to the machine During simulation it is easy to change system parameters and test the behavior of the machine at its limits Damaging the machine is not possi ble and the influence of external forces can be Clearly depicted Virtual motion can be used on three different lev els to simulate the motor and load to simulate the drive motor and load and purely soft ware based simulation that runs entirely on the computer Complex multi body systems and drive systems can also be simulated in the design or prototyping phase just like completed machine elements where all that remains is to provide them with an optimal configuration Simulation on the drive The first level of virtual motion is simulating a single axis The behavior of the motor and the load that corresponds to the axis is simulated This simulation mode is particularly useful in an alyzing the behavior of the drive controller The result of changing system parameters can be in vestigated as well as the behavior with different loads In addition it is also possible to make per formance estimates in relation to the controller configuration dim 7 Simulation on the drive including load simulation Simulation on the controller simulation on the controller offers the possibility of replicating large processes with a high degree of complexity or processes with couple
66. r can be reduced and there are no components that may require maintenance BSR drives are based on the principle of field oriented control The location of the rotor is used for commutation speed and position control This information is usually supplied by a position sensor mounted on the motor shaft If a virtual sensor is used a phys ical sensor is not needed Reliable support The use of a virtual sensor changes the dynamic behavior of the controlled system The field prov en autotuning function takes this fact into ac count and provides reliable support for the user when commissioning the machine Current setpoint opeed setpoint Position setpoint setpoint generator Position controller Actual speed Actual position opeed controller Highlights gt Field proven autotuning gt Smaller motor gt Reduced maintenance Magnitude dB 10 10 10 10 Frequency Hz Frequency Hz Frequency response of speed controlled system for physical encoder blue and virtual encoder orange Performance level Torque and current control Virtual encoder Standard controller cascade in servo drives with virtual encoder Innovations 2015 setpoint generator simple backlash compensation The standard controller cascade for the BSR 05 servo drive family now provides compensation for spindle pitch and backlash The positioning preci sio
67. r during operation and recalculating the controller parameters system Identification MTFilterBiQuad MTBasicsPID MTFilterLowPass ActValue Controller Control input ADVANCED BASIC The blocks in the basic and advanced packages provide users with the tools they need to create optimized control loops 85 Features such as troubleshooting within the fre quency domain are integrated in the control sys tem so they can also be used during commission ing or maintenance work gt Easy to master Fast commissioning Complete freedom for mechatronic development gt Possible to further develop machines In Automation Studio the user can decide if the individually control software should be programmed in ANSI C C or any of the IEC 61131 languages External tools developed by companies like MathWorks MATLAB Simulink or MapleSoft Maple MapleSim can also be connected in order to develop control algorithms and integrate them in a machine proj ect using automatic code generation Complex software components can be dynamically tested and verified using simulation In Automation Studio 4 this is done at the push of a button Signal processing gt FFT compensation curves Identification Frequency response transfer function E Linear algebra gt Matrix and vector calculations e Le Autotuning gt Model based processes frequency domain Vir
68. r online parameter management with APR L has integrated powerful and easy to use line parameter management features in the APROL DisplayCenter The many online parameters 5 points limits PID parameters etc that are changed when commissioning measurement cir cuits and control loops for identical or similar sys tems can be copied using drag and drop In addi tion all online parameters are an integral part of the engineering project and therefore directly traceable using version management information Online parameter management is available to both commissioning engineers and plant operators The faceplate view measuring points online pa rameters and control module view online param eter groups are available to clearly display and easily edit online parameters Starting up the ap plication software is simplified by a list view that allows missing parameters runtimes delays etc Highlights gt Clear representation Simple commissioning gt Transferring parameters with drag and drop to be easily entered in addition to enabling the Inhibit flag for multiple control modules at the same time New dialog boxes allow all parameters for a mea surement point to be displayed at the same time as well as a comparison of several measurement points Existing online parameters can also be transferred to other measurement points using these dialog boxes When importing the online paramete
69. r safe space 55 Special func tion spaces that control position dependent ac Innovations 2015 Highlights gt Improved safety gt Increased flexibility gt Simpler engineering tions in the safety application round out the range of functions of the SafeRC SLP safety function Calculating braking distances The possibility to calculate braking distances is now available This allows the braking distance for each kinematic object to be determined de pending on the current speed and position of the robot If stopping the robot before reaching the workspace limits is no longer possible ac cording to the defined braking deceleration this is indicated by a status output This makes it possible to minimize the overrun distance in the event of a workspace violation and the workspace limits can be more precisely matched to the robot s operating area A reduction in the space requirements is the result Depending on the application the robot can be stopped by triggering a Safe Torque Off STO function for all joint axes for example Calculat ing and specifying the positional tolerance en sures that the status output is set before a workspace violation safe orientation monitoring oafe orientation monitoring is used to monitor the orientation of the tool mounting flange in space Ihe angle in space between a fixed direc tion vector and a direction vector that moves safely Limited Orientation with the fla
70. responding physical unit including scaling and the value range for a normal operating state It is possible for example to include the unit C and the re quired scaling with the measured temperature SSS Automation Studio makes it cin em Pecan Q4 HL Vt yr J Herera oe i 3 j X ae Ee 1 a wa 2 Mura El um Wo rer x musa is Fd a hrs toma bo Pli mm WT r dam mr a ali ore arem LF ig Hmi rdum mi arme D ml am bid T arm ere ee i TIRE eee um L sir aum adam ia x prr tage hra 1 pa ee TE rugis pm meri E gt IT k 4 The units of the variable can be assigned using drag and drop easy to choose the desired units using filters Tool supported configuration of data points An automation project can contain several thou sand variables with attributes such as scaling or unit of measurement Conf
71. retrieved in blocks at any point in time CERTIFIED 3 Copri PLCopen Eur MEE HM Lc Bob c T n OPC UA Unified Architecture Innovations 2015 78 Seamless traceability processes B amp R provides a systemwide redundancy solution spanning everything from 1 0 up to the process control system The bonding driver allows cus tomers to set up a redundant process bus on the Ethernet layer ensuring fail safe communication of all production data from the control level to the management level An increasing number of manufacturing compa nies are starting to document all process data during production This provides added security in the event of a warranty or product liability claim and also satisfies consumer wishes for more de tailed information about products such as proof of authenticity or the CO footprint Operator station bondo ethd 1 IP 192 10 40 41 bondo 0 1 192 10 50 50 bondo 0 1 In order to seamlessly and accurately record all process data large amounts of production related data must be transferred from the controller to the higher level acquisition system Process bus re dundancy must be implemented in order to ensure that all of this critical information is recorded Cable redundancy for the process bus The bonding driver offered by BSR is a standard ized solution for process bus cable redundancy This solution is protocol
72. rotection Touch screens can also be used with gloves or a suitable stylus pen Hygienic panels gt Diagonal inch Resolution px Touch Orientation SDL SDL3 Panel PC 2100 E Stop illuminated ring keys RFID 59 Lum DEE Ki Low eed 1 1 1 9AP99D 156B B60 SAP93D 185B B60 5AP99D 185B B60 5AP99D 215C B60 SAP93D 240C B60 185 185 21 5 24 185020702 ISIE Hiss 1920 x 1080 121050 ALT ACT AGT PICT Landscape Landscape Landscape Landscape Landscape v v v v v v v v v v v v v v Y Innovations 2015 40 Individual solutions These standard stainless steel panels can be Individual design options adapted to meet special requirements at any time Manufacturing candy has different requirements Illuminated ring keys and environmental conditions than processing E stop switch meat while filling highly salty or sugary liquids has RFID reader different requirements than pressing and packag Custom design ing pharmaceutical products Changes in lifestyle Industrial PC integration and the resulting booming market for ready made meals is another challenge Aseptic processing of products provides many additional benefits to consumers including reducing or doing away with the use of preservatives and increasing product shelf life BSR operator panels can be specifically SN and individually adapted to meet
73. rovide support for production op timization The combined display of ongoing data alarms and events in the IrendViewer makes it easy to trace cause and effect The new browser provides read access to data points on B amp R controller without requiring the Automation Studio project that is on the con troller The new PDA function blocks make it very easy to define the required data archive in a sim ple block language The pin layout of a scalable function block is used to automatically define a table structure on the APROL SQL server DisplayCenter provides the new AprolVncViewer and VncViewer visualization elements for embed ding in a process graphic With VncViewer multi ple VNC visualization applications can be grouped in overview images at the same time This allows multiple machine visualizations to be shown in a process graphic at the same time and with any scaling for example regardless of the respec Innovations 2015 Highlights gt Integration on the runtime server gt Direct data exchange gt Flexible communication tive platform A web widget is also available that allows web pages to be embedded for example for HMI applications based on HTML 5 IP cameras and business intelligence reports gt Alarm system b gt Trend system Cui gt Reporting ees APROL PDA ensures that the user always has an overview of the most i
74. rs into the project created in BSR s Cae Manager engineering tool a new version is auto matically created with the version comment 0 line parameters imported New dialog boxes allow all parameters for a measurement point to be displayed at the same time as well as a comparison of sev eral measurement points Engineering database Real time server rr database losys VIL www VIL www mea E Controller 6 1 Controller 5 1 0 n Online parameter management has proven to be extremely helpful to commissioning technicians and system operators in very extensive plants Innovations 2015 integrated automation olobal presence olid partnership ETHERNET PE POWERLINK BSR Corporate Headquarters Bernecker Rainer BSR Strasse 1 45 7748 6586 0 Industrie Elektronik Ges m b H 5142 Eggelsberg Austria f 43 7748 6586 26 open s SAFETY office br automation com www br automation com Your local contact www br automation com contact 10 2014 by All rights reserved worldwide MM E01442 188
75. ructuring using Simulink libraries which can also be used to reuse or encapsulate functions In addition model referencing can precompile each subsystem individually If a subsystem has not changed it does not result in compilation time during automatic code generation For large models for example the model of a wind turbine model referencing can save anywhere from 50 minutes to 50 hours Large models can be created in Simulink by combining several smaller models Model referencing can precompile each sub system individually Testing in the real time process since 2007 B amp R has offered the possibility of in tegrating closed or open loop control algo rithms or process models that were developed directly in MATLAB Simulink in Automation Studio using automatic code generation The interface in Simulink is easy to operate and makes it pos sible for users to run tests from Simulink in the real time process Innovations 2015 90 Vendor independent engineering in Automation studio has made it significantly easier to engineer POWERLINK networks in Automation Studio Ex panding custom developed control systems to include POWERLINK and configuring them in Automation Studio is no problem at all When needed openSAFETY functionality can also be easily added to the system The level of automation in production plants is constantly increasing which is causing a rapid in crease in the amount of data that
76. se to multiple customer requests B amp R is now offering operator panels with an integrated openSAFETY interface for transferring safety re lated data Hard wired emergency stop operating mode and start buttons are no longer needed settings up operator panels with several hard wired switches and buttons by threading count less cables up through the swing arm system is nothing but a headache openSAFETY operator panels on the other hand only require a bus and power connection This means that these sys tems can be placed exactly where they are need ed without having to deal with unwieldy cable harnesses Commissioning and service are also simplified saving additional money in these areas as well The E stop button is just as reliable as its hard wired counterparts oxen 660 49 Reliability without hard wiring Highlights gt Reduced cabling gt Faster installation gt Easier placement Arrange buttons and switches as needed These customized operator panels can be tailored exactly to any application In addition to different display sizes and ratios it is also possible to choose between various touch technologies Just as configurable are the number and arrangement of buttons switches and the E stop button The oper ator panels are also available in housings rated up to IP65 And to round it off BSR offers solutions for specific industries such as food and beverages Innovations 2015
77. t changeover times with a resolution of 20 ns in addition to the current input states at the start of the cycle The changeover times for digital outputs can also be controlled at this resolution Highlights gt Encoder counter function blocks gt PWM function block gt Signal resolution 20 nanoseconds Innovations 2015 a eee or mk a 48 Wide range of applications Food industry Bottling To guarantee high production quality and speed filling machine valves and analog sensors must be synchronized in real time with an extremely high degree of precision With reACTION technology filling valves and flow sensors be synchronized at an unbeatable resolution of lt 200 ns which allows filling machines to be set up with extremely low tolerances Not only does this minimize wasted raw materials it also allows possible delays resulting from activation times for example to be calculated automatically by the system reACTION technology maximizes prod uct quality regardless of controller performance and network settings Innovations 2015 Metalworking CNC laser cutting To increase productivity modern CNC laser cutting machines switch the laser on and off while in mo tion This must be performed with a high degree of precision and tightly synchronized with axis posi tioning Delays between CNC position setpoints and axis positions must also be compensated The laser on off cycles
78. tely The user can immediately start working with or test the machine model the technology component The simulation can be adapted to the real behav ior of the specific application by defining parame ters such as mechanical dimensions addition the simulation can be expanded or replaced using Custom made machine models These solutions are ideal starting points when developing ma chine applications Ready made blocks PID control with step tuning is an example of one solution included in the basic package PID Low Pass or OscillationTuning are ready made blocks with clear and simple interfaces These blocks were designed for a single loop PID controller with built in tuning The SimMod model represents a controlled system with pro nounced low pass behavior as is the case for a temperature system The included simulation configuration allows the two programs to imme diately run in the simulation environment on the development system 85 Expanding or changing solutions as needed The closed loop controller can be integrated in the control system for the actual machine using drag and drop The user can extend or change the solution by adding functions from the libraries included in the basic package for example It is also possible for users to develop their own closed loop controllers using pre programmed ba sic functions Simple tuning functions for setting up a PID controller using oscillation and step r
79. tems Nevertheless only motor torque is usually known With virtual sensors B amp R now offers the possibility of pre cisely determining shaft and load torque even in dynamic applications And this can be done with out the need for additional physical sensors Existing and easily measurable values are used as the basis for virtual sensing and this includes motor speed and position If the torque control loop provides sufficient dynamics and accuracy relatively accurate motor torque value can also be determined If drive dynamics can be described mathematically and the necessary system pa rameters such as rigidity drive shaft damping and moments of inertia are known a virtual sensor can be used to determine the difficult to mea sure shaft torque and load torque Avoiding damage One of the ways to monitor torque is through the use of a virtual sensor In this way torque and Load torque Motor torque Drive system measured Virtual sensor Highlights Easier measurement gt additional hardware gt Damage avoided force are determined virtually and used to esti mate the mechanical stress on a drive shaft for example If this is too high mechanical damage will occur sooner or later This danger can be de tected at an early stage using torque monitoring making it possible to change parameters or switch off the drive before damage occurs Motor torque Shaft torque Load torque ohaft torq
80. tion phase which also enables complex product manipulation A special feature of GMC is that the conveyor belt is fully integrated in the application external sensor that sup plies information about the current position of the conveyor belt is all that is needed Hardware independent GMC is hardware independent which allows the use of different drive systems with different kine matics to be used application can be created quickly and easily upgraded at a later time The robot can be replaced or the conveyor belts can be upgraded at any time without a significant amount of application engineering work A large portion of the software can be used as is Highlights gt Hardware independent gt Simple programming gt Unlimited number of conveyor belts gt Unlimited expansion possibilities gt Can be used for all kinematics 23 Innovations 2015 24 Hygienic connections Stainless steel motors from B amp R meet strict hy gienic design standards and are now easier than ever to use Employing a special connector the motor can be connected and disconnected in the field This connector meets the same strict hy gienic design standards as the previous variant with a fixed mounted cable Motors are much easier to handle using this new connection technology since the machine can be wired without the motor being connected to the cable In addition these cables can be easily as sembled in the field
81. tomation With the addition of new function blocks the range of applications that can bene fit from reACTION technology has been expanded significantly reACTION program is created in Automation Studio like any other control program using function blocks in line with IEC 61151 specifications The reACTION program is then assigned to one or more reACTION modules in the module configuration Simulation on the controller Application data is stored centrally on the con troller and transferred to the reACTION modules as Innovations 2015 needed where it is stored in remanent memory As an alternative to having one program perma nently assigned to a module it is also possible for the controller to dynamically transfer and activate a variety of reACTION programs even during run time A reACTION program can also for be executed directly on the CPU for simulation purposes Slow motion so to speak As with regular 1 0 modules cyclic data is trans ferred using data points whose number and data type can be set in the module configuration With cross communication mapping these cyclic data points can be exchanged between reACTION mod ules independently of the controller This also means that reACTION modules can just as easily communicate directly with regular 1 0 modules 1000 us Response time 45 Controller Conventional approach Response time depends on Network performance Number of no
82. ts from different vendors to cre gt Extended XDD format ate a safety solution With Automation Studio any gt Modular POWERLINK devices openSAFETY device be seamlessly integrated gt Vendor independent and configured in SafeDESIGNER the Automation gt Standardized studio editor for safety applications using the OSDD format Configuration tool POWERLINK master Binary configuration file XML device description file After the POWERLINK devices have been configured the configuration data for the POWERLINK master is generated when the build process is started Innovations 2015 do open Integrated safety solution gt OSDD device description files gt Vendor independent Simple engineering Automatic optimization gt Timing value calculation gt Timing value configuration gt Optimized system performance Automatic configuration of network timing Pen To optimize overall system performance the net work timing parameters be tuned to the mE S cific requirements of an application Traditionally ee these values have been calculated using a Ear spreadsheet or pocket calculator This is a time consuming process even for a mid sized appli ne ee cation In Automation Studio on the other hand ELI the optimal timing values are calcul
83. tual sensors gt System observation The functions the advanced closed loop control package make it possi ble to create intelligent control loops In different operating situations for example they are able to respond flexibly to changing machine behavior Innovations 2015 86 Fxact movement of crane loads Loads that are moved using cranes can be subject to uncontrolled oscillation which increases load ing times and reduces the efficiency of the crane system With its anti sway solution B amp R provides a way to make sure that loads are precisely guid ed to their destination Throughput time plays an essential role in all plants where goods are transported since it determines the profitability of the facility If a gantry crane is used to move suspended loads uncontrolled oscil lation of the load can occur These oscillations in crease throughput time are potentially dangerous for personnel and can damage materials Compensating for oscillation in the drive concept BSR compensates for the tendency of the load to oscillate in the drive concept and ensures the exact movement of the load using high level closed loop control This technology solution includes gt Software library in Automation Studio with corresponding functions sample implementation Freely configurable simulation model for a gantry crane gt HMI application gt This solution is ideal for gantry cranes as well as for full
84. ue refers to the torque transferred via the drive shaft whereas the load torque refers to the torque acting on the drive system At a standstill motor torque shaft torque and load torque are equal in dynamic applications they can differ significantly depending on the mechanical design of the system Motor speed shaft torque virtual Load torque virtual A virtual sensor can be used to precisely determine shaft and load torque in dynamic conditions Innovations 2015 iy Virtual sensors can be used to prevent motor damage weit 210 Unknown load peu ip t p tJ 0 Mathematic models make it possible to replace physical en coders with virtual encoders Shaft torque Nm N ZA La 5 Acceleration Const speed Deceleration Stop If the shaft torque exceeds the defined limits then parameters can be changed to prevent damage Innovations 2015 18 Autotuning without an encoder The autotuning function in the standard control ler cascade for the ACOPOS servo drive has been upgraded to also work on axes without a dedicat ed position encoder This makes it possible to also use autotuning to reliably and accurately ad just servo axes without an encoder Encoderless control of axes is sleek and reliable since it doesn t require the use of an encoder en coder cable or evaluation unit The size of the mo to
85. vations 2015 76 Vendor independent communication with UA has extended the OPC UA functions available in Automation Studio Users can implement ven dor independent communication from controller to controller configure data points using tool as sisted methods and much more For production processes the current trend is to move away from self contained standalone con trollers in order to implement controller groups that allow the individual controllers to exchange data with each other even between different manufacturers With these new function blocks BSR controllers can assume the role of an OPC UA client or OPC UA server for communication allow ing users to flexibly manage communication not just to higher level systems SCADA for example but within the controller group as well Srd party client 1 1 pc server 3rd party server When it comes to communication BSR controllers can take on the role of an OPC UA client or OPC UA server Innovations 2015 CERTIFIED Reliable interpretation of data To ensure that the client can correctly interpret all data on the server a uniform data model must be in place Ideally all attributes can be inter preted without ambiguity A large share of the optional attributes are therefore also supported in Automation Studio and on the OPC UA server making it possible to specify the cor
86. vious experience To create a design simply select the hardware and then arrange the colors shapes and text as needed External graphics can also be easily loaded into the program and added to the de sign Panel Designer immediately shows how the finished product will look allowing HMI de vices to be perfectly adapted to the respective cooperate design When the design is ready it is simply stored in file that can be used during production With Panel Designer it s easy to create an individual design for your machine Display selection Highlights gt Fast Easy gt Individual design Link to Panel Designer http paneldesigner br automation com Panel Designer video http youtu be MxVXzrUtW30 Display selection With Panel Designer BSR HMI devices can be designed quickly and easily Innovations 2015 43 ix ELS f i 2 Panel sefection Display selection Power Panel T C Serias 57 Design Aperta ZIW SPPCILOSZL 208 0571 2 187 42757 05 228 2 FL 218 20 057 Panel Designer be started web browser Innovations 2015 44 in the fast lane with technology reACTIONZ TECHNOLOGY With the ability to realize response times of 1 us using standard hardware B amp R has certainly shaken up the market when it comes to ultrafast au
87. y Seamless integration of SSL TLS and user role systems simplify their use during development and allow an initial set of users and roles to be created Users can also be managed directly from the machine via the operator panel Clear separation of users and roles only roles can be assigned rights makes it easy to manage users during runtime Centralized management of access for all users and roles in the system paves the way for future expansions such as connecting to higher level management systems via LDAP 81 SAIS wh mm m m m m m Tn 7 on i Are the username and password correct LUN Does the user have authorization to perform the action User authentication Authorization via the roles to which the user is assigned User management a i A W Safe access with SSL and user management Innovations 2015 82 Fast and easy Implementation of closed loop controllers Automation Studio provides pre programmed solutions for closed loop control applications in the form of continually maintained library functions that can be used for specific tasks These solutions reduce the implementation time required for closed loop controllers and are suitable for non specialist engineers and experts alike BSR customers can use the technology functions provided in Automation Studio to quickly and eas i
88. y Virtual sensors make it possible to control these elastic systems with a high level of quality and without having to use ad ditional position measurement systems at the process intervention point Lag error compensation Virtual position encoders can be used in the mo tor eliminating the need for a motor position en coder cable and evaluation unit in the servo drive while increasing availability There are also further additions to the standard controller cascade for Innovations 2015 ACOPOS P3 servo drives This includes repetitive control for example which makes it possible to predict and compensate for lag errors The result More precise control improved performance and increased product quality Maximum safety Due to machinery directives in the EU and similar legal regulations other parts of the world the safety functions automation components are becoming increasingly important The ACOPOS P3 provides many safety functions that satisfy SIL 5 PL e Cat 4 requirements A new function Safely Limited Torque SLT checks whether the maximum permitted torque has been exceeded SafeMOTION Combining various safety functions such as SLS and SLI makes it possible to achieve shorter changeover times ensuring increased machine availability SafeROBOTICS The Remanent Safe Position RSP safety function is also new This safe position data allows the safe monitoring of all serial kinematic chains for robots w
89. y automatic rail based or rubber wheeled trestle cranes Ship to shore cranes can also be optimized using this solution This technology is fully functional and can be quickly and easily ad apted to individual requirements Innovations 2015 Large number of functions available B amp R offers a large number of functions for this new technology solution They allow the user to position a load manually or automatically with the ability to decide whether the load position should be measured or not avoid collisions it is possible to define areas that may not be crossed VN 27 uncontrolled oscillation of a load This behavior reduces the efficiency of the crane system B amp R compensates for the tendency of the load to oscillate and ensures the exact movement of the load 88 VIRIUOS simulations Complex system models can be created in the VIRTUOS modeling environment developed by ISG Using hardware in the loop simulation models can run on the real time system by connecting hardware to this environment With the VIRTUOS modeling environment users can model simulate and perform diagnostics in the real time process It is also possible to switch between the re

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