Measurement and

Automation Systems
Experts in Data Acquisition
 iba America

The expert in data acquisition

and analysis systems
It is our mission to bring transparency to the world of automation with our measurement system
solutions. By means of an iba system, the user can understand and master the growing technological
complexity of automated processes and mechanical systems. As with a flight recorder, all essential
system and process data from various signal sources, field buses, and automation systems are
recorded continuously and synchronously. We have developed powerful tools for analyzing this data,
which comfortably support interactive work as well as automatic information generation.

Metals Oil & Gas

Down-to-earth and international Communicative

Our parent company, iba AG, is a medium-sized and A main characteristic of our hardware and software
still owner-managed company which has its head- products is the distinct connectivity to many different
quarters in the metropolitan area of Nuremberg, automation systems. Various manufacturers and
Germany. iba sets high standards in sustainability, system generations are taken into account. Even leg-
n not only when choosing technical concepts but also acy systems can be integrated: This is a clear benefit
isitio Da in the field of corporate development. They manu- in the life cycle of the plant.
u ta
Energy cq R Mining facture our hardware products in cooperation with
A

Areas of application long-term partners from Germany. In contrast, our Versatile

ec
ta

customers can be found all over the world.

or
iba products are always first choice when it comes to
Da

Troubleshooting

din
the following:
Process analysis In addition to the headquarters in Fuerth, iba is

g
ƒƒ Improve the up-time of production plants by en-
well-positioned worldwide with branch offices, sales
Quality documentation hancing troubleshooting capabilities.
partners and regional sales representatives. Thus,
Condition monitoring we can provide our customers everywhere with com- ƒƒ Tracking and optimizing the quality of production.
I n fo

petent advice and on-site service at short notice.

Fault recorder ƒƒ Making maintenance schedules based on condi-
rm

Automation of test benches tion-based monitoring.

Cutting edge
a ti

is

Retrofit For more than 30 years, our area of expertise has ƒƒ Assuring the reliability of supply of electricity.
on

ys

et been the development of high-quality systems for

al

An ƒƒ Combining measurement technology and automa-

R

Packaging rie Transport data acquisition and analysis, signal processing, and
va l a
D at automation. tion in test benches.

iba is one of the few manufacturers who has mas- Customer-focused

tered the whole technology chain from hardware
through software to database technology. Only those
manufacturers who understand their products in
detail can foster innovations and provide competent
advice and support to customers.
Automotive Paper & Fiber
iba maintains an intensive and long-standing re-
lation with all customers. The excellent customer
service of iba through technically-competent support
and experienced consulting is very important to us.
This is exactly why many market leaders rely on iba.

2 3
 Autonomous, modular, scalable

The iba system

The iba system for process data acquisition and analysis consists of perfectly-adjusted hardware and Advantages at a glance
software components for acquiring, recording, analyzing and processing measurement data. Due ƒƒ Enhance productivity ƒƒ Prevent critical site conditions
to modular design and ease of configuration, the iba system can be adapted comfortably to various ƒƒ Reduce downtime ƒƒ Root cause analysis
tasks and is scalable in size at any time. Thus, numerous areas of application can be covered: from
ƒƒ Improve and document product quality ƒƒ Wide range of connectivity
the portable system with 64 signals, up to the site-wide stationary system with tens of thousands of
signals. The iba system can be stepwise upgraded to the growing tasks. ƒƒ Save energy and raw materials ƒƒ ...and many more!

Acquire Record Analyze Derive

The basis of all process data analysis is the time
synchronous acquisition of relevant data from
various sources within an automated environ-
ment. Different signal sources can be combined.
Due to the isochronous measurement, causal
relations can be detected and understood in com-
plex and distributed systems.
Like a flight recorder, the iba system records and
stores various measurement data available for
the long term. The data is recorded continuously
(24/7) or triggered by certain defined events. Any
signal can be visualized real time by the user.
Depending on the objective, data can be analyzed
in real time as well as historically.
ibaAnalyzer
By deriving Key Performance Indicators (KPI), the
user gains valuable information about the pro-
cess. This way, clean measurement data becomes
a tangible competitive advantage.

Interactive analysis
The common method for all unforesee-
able incidents allows for comprehensive
MES
troubleshooting.

Video/HMI
ibaPDA Report Reports
A compact, automatically-generated
ibaBM
Ethernet overview of the results allows the user
.dat to draw fast and meaningful conclu-
Bus
ibaNet sions.

HD Alarm
ibaAnalyzer In case of deviations from the usual
PLC process behavior, the user can be
Request
informed automatically.

ibaLink
ibaPADU
ibaFOB Data extraction to the database
Store compressed information for
analog / remote cross-referencing of process and
digital quality parameters in databases and
access high-resolution measurement
data with just a mouse-click for root
cause analysis.
Connectivity Performance Analyze from anywhere
A main characteristic of the iba system is the The iba system acquires all relevant data: wheth- The generated .dat file can be easily shared LongTerm Long-term trends
distinct connectivity to automation systems and er fast analog values directly from sensors, data and processed with ibaAnalyzer free of charge. Long-term analyses show trends of
bus technologies. Hence, an iba acquisition sys- exchanged over field buses, or variables from Hence, quality data analysis, troubleshooting site and machine parameters that as-
tem can be connected to almost every common automation systems, everything is synchronized. and many other studies can be done remotely sist with predictive maintenance and
automation system. You determine what is relevant! and beyond corporate boundaries. process improvement.

44 55
We get along with almost anybody Areas of application

Connectivity
Common measurement systems acquire sensor signals by means of analog/digital converters. In the era
of digital control systems, most measurement values are now present in the controllers. This is why iba
offers various possibilities for accessing the internal values of open-loop and closed-loop control sys-
tems directly.
Troubleshooting
Failures in automated systems lead to production interruptions and products of inferior quality. Thus,
it is extremely important to find these failures. In these cases, the maintenance personnel need to
have access to the measurement data which was recorded during the disturbance. This data can be
analyzed to find the cause and eliminate the failures in the system.

Maintenance and commissioning

Automation systems Field and drive buses / transfer protocols
ƒƒ ABB ƒƒ Mitsubishi ƒƒ ABB TCP/IP VIP ƒƒ OPC
ƒƒ Bachmann ƒƒ Rockwell ƒƒ EGD (Ethernet Global Data) ƒƒ Modbus TCP
ƒƒ Codesys ƒƒ Schneider ƒƒ Ethernet/IP ƒƒ Generic TCP/IP
ƒƒ Converteam ƒƒ Siemens ƒƒ S7-TCP/UDP ƒƒ Generic UDP
ƒƒ Danieli ƒƒ SMS-Siemag ƒƒ Profibus ƒƒ SIMATIC TDC TCP/IP
ƒƒ Elau ƒƒ TMEIC ƒƒ Profinet ƒƒ Sisteam TCP/IP
ƒƒ GE ƒƒ VAI ƒƒ DDCS ƒƒ System 21 TCP/IP Connectivity
ƒƒ Hitachi ƒƒ VIPA ƒƒ EtherCAT ƒƒ ...and more! Localize errors and eliminate failures
ƒƒ Ingelectric ƒƒ and more!

Your connection to almost every system
A main characteristic of the iba system is the
broad connectivity to automation systems and field
bus technologies. Via manufacturer-specific special
modules, field bus connections, or Ethernet proto-
cols, an iba measurement system can be connected
to almost every automation system - independent of
manufacturer and device generation.
Often, multiple methods of acquisition are available.
Depending on the demands on speed and determin-
ism, time-critical data can be transmitted via the
fiber optic based ibaNet.
Requesting measured data
during running operation
For many systems, our Request technology is
available. This technology allows users to optionally
request internal variables of the controller. Thus, you
can assemble measurement values without having
to stop the controller and adapt these to the respec-
tive requirement.
The measurement values are addressed with their
symbolic name. The rest is done by a software agent
in the controller which has to be integrated once.
Record data continuously
For localizing failures, the plant behavior needs to be
recorded continuously so that it is made transparent.
ibaPDA provides a global view on the plant and also
allows for analyzing interactions between individ-
ual system components. An acquisition system in
the plant provides the data immediately in case of a
failure.
With ibaPDA-PLC-Xplorer, you have a powerful tool
at your disposal which records signals from control-
lers in a flexible and mobile way.
Convenient data analysis with video images
Variables which cannot be acquired with the existing
sensor technology are recorded with the camera
system ibaCapture-CAM in sync to the measured
signals - a valuable help for analysis.
ibaAnalyzer offers various functions for analyzing a
failure using the recorded measurement data. Signal
paths, signal intervals, and delays are measured and
outliers are detected.

Selected case studies for troubleshooting

Field buses Thus, there is no additional load on the control-
Finding and eliminating
ler and no changes in the configuration have to be Offshore use of
Usually, iba bus monitors compose of two modes
made. Moreover, an iba bus monitor offers various malfunctions in a hot rolling mill ibaPDA-S7-Analyzer
of operation: Active mode, in that the bus monitor
receives values sent directly from the control, and diagnostic information about the status of the field
bus, so that potential bus failures can be detected Optimizing the hydraulic actuator on a Plant monitoring
Sniffer mode, where the values communicated on
rapidly. ship propulsion system in paper production
the bus are “listened to” and acquired as signals.

»Our product is focused on the user experience. The

collection and visualization of data has never been easier. «
Scott Bouchillon
Managing Partner
6 7

For detailed information and further case studies, please see www.iba-america.com
Areas of application Areas of application

Process analysis Quality documentation

Process analysis is the prerequisite for process optimization and is always required when new prod- For documenting an automated production line, quality data and characteristic values need to be cal-
ucts are launched, the process is modified, or improvements in quality are to be achieved. Process culated and stored reliably in a quality management system. With the iba system, customer-specific
analysis is most successful when it is based on unaltered long-term-data and statistics. reports can be generated for product documentation, transforming measurement data into quality
data, and saving data in a database.

Process technology and quality management Production and quality management

KPI

QM
Report

DB

Enhance productivity, reduce plant downtimes, improve product quality

Efficient long-term data acquisition
In product analysis, the long-time behavior of a pro-
cess is being regarded under different aspects and
for various product groups. For this purpose, it is
necessary to store the high resolution measurement
values along with the characteristic values or events
necessary for the process analysis over a long term.
The product- or time-related files generated with
ibaPDA, or the data and events saved in ibaHD-Serv-
er, can then be used for analysis. The videos record-
ed with ibaCapture-CAM, along with any triggered
images, help to understand and analyze the process
behavior.
Flexible and reproducible analyses
With ibaAnalyzer and ibaDatManager, you have
powerful analysis and visualization tools at your
disposal for answering technological questions and
doing long-term analysis.
Created templates can be saved, making it simple to
analyze data of different periods and product class-
es.
Automatically calculating characteristic values
With ibaPDA, measurement data are stored per
product in data files. Based on this, with ibaAnalyzer
and ibaDatCoordinator, characteristic values and
quality data can be automatically calculated from the
high-resolution measurement data.
ibaAnalyzer-DB allows for further aggregating the
measured data and stores them, along with the cal-
culated characteristic values, in a database.
Generate quality documentation automatically
After a product has been finished, the customer
specific report is being filled automatically with the
current measurement and quality data. On the basis
of defined layout templates, it is filed as PDF or
HTML document, or sent automatically as e-mail.
For long-term analysis and cross-product documen-
tation, ibaAnalyzer has access to the data in differ-
ent databases.
Hence, a powerful, flexible and always-transparent
reporting system can be implemented very easily.

Selected case studies for process analysis Selected case studies for quality documentation
Process analysis in tube Monitoring and commissioning
manufacturing plants in coal mines Length-related measurement data System monitoring in a
acquisition in strip processing plants medium-wide strip mill
Reduced waste in Optimizing the exhaust air
packaging production cleaning in an absorber plant

»A customer has stated, ‘We never commission without it.’ » The fact that a majority of our business comes from
That relays the value better than I ever could.« repeat customers is a testament to our products. «
Simon Cole Carol Denovcheck
Sr. Applications Engineer Accounting Manager

8 9

For detailed information and further references, please see www.iba-america.com

Areas of application Areas of application

Condition Monitoring Transient fault recorders

Condition Monitoring Systems (CMS) use vibration measurement in combination with intelligent
analysis procedures for detecting wear and tear on mechanical components at an early stage. They
are the basis for the transition from a preventive- to a predictive-based maintenance schedule. Thus,
mechanical components are optimally used over their real service life and the costs for unexpected
downtimes and spare parts are reduced.
Transient fault recorders are used for monitoring plants continuously for well known signal distur-
bances. The data are only recorded in case of a failure. For this purpose, possible failure conditions
are defined as different triggers and the data are only recorded in a pre-defined period preceding and
following the failure.

Maintenance and machine analysis Plant operation and plant maintenance

LongTerm

.dat

Trigger

ibaCMU-S

Enhance reliability
Vibration signatures of machineries can vary greatly
in a complex production plant due to changing loads
and materials. Without taking into account the pro-
cess, static thresholds can yield false alarms. Blindly
increasing these thresholds destroys the benefit of
having an early fault detection system. ibaInSpectra,
our condition monitoring solution, takes advantage
of the power of ibaPDA where thresholds can be
adapted based on a variety of process factors.
Condition Monitoring and process analysis
The scalable ibaInSpectra product range uses the
distinct connectivity of ibaPDA. Thus, it provides to
the CMS all essential process parameters easily,
cost-effectively, and at sufficient sampling rates
without any intervention in the existing control sys-
tem. All relevant operating parameters are stored
along with the vibration information. The process-in-
duced variations in the damage indicators can be
eliminated by the correlation with the process data.
Only when all material, process, and quality data
are available simultaneously, a well-founded cause
analysis can be done.
Acquiring dynamic processes rapidly
With the iba system, fast transient signal transitions
can be acquired and recorded with the appropriate
acquisition hardware in the range from 1 kHz to 100
kHz. ibaPDA initially stores the data in an internal
buffer and, in the application, can record it only when
triggered by a failure. In this process, the time pre-
ceding and following the failure situation is stored
in a measurement file for a subsequent analysis. A
trigger pool allows ibaPDA to manage conveniently
hundreds of individual triggers.
Integration into the control system
In case of a failure, a notification is sent to a super-
visory control system via the standardized IEC61850
transfer protocol for protection and control technol-
ogy. In a complex system, several thousand sig-
nals have to be measured synchronously at a high
acquisition rate. Several ibaPDA systems are cou-
pled and synced using FO-cables. The data recorded
with a Transient fault recorder is then analyzed with
ibaAnalyzer. Thus, the cause of the failure situation
can be determined and counter-measures can be
taken if needed.

Selected case studies for Condition Monitoring Selected case studies for transient fault recorders

Optimizing wind energy plants Tracking critical vibrations

in rolling mills
Fault recordings in HVDC systems

»Get high-precision transient data along with the slower process data at »Our customers consistently experience better efficiency
a fraction of the cost. » and reduced downtime when they use the iba system. «
Manko Ho Jorge Giraldo
Sr. Systems Engineer Sales and Support Engineer
10 11
For detailed information and further case studies, please see www.iba-america.com
Areas of application Areas of application

Automation of test benches Retrofit

Test benches play a decisive role in the development, quality assurance and certification of products. With the many iba interface modules, various hardware components can be mixed independent of the
The requirements are accordingly diverse. In addition to the fast analysis and documentation of the manufacturer and the generation. Thus, it is not critical if old and new devices exist within a plant - we
measurements, it is also important that the test runs can be easily operated, controlled and moni- ensure communication with them all.
tored.

Development and test technology System technology and automation

Control 1
Report
OLD

.dat

Control 2
Controls NEW

All functions in one single system
The iba system integrates the functions necessary
for test bench automation - measurement, opera-
tion, display, documentation - in one system. iba-
Logic acquires the signals of the whole test bench
setup and automates the test procedure. Test proce-
dures can be defined easily, and adapted online, with
the graphic programming interface according to IEC
61131-3. ibaQPanel is used for operating purposes
and the display of the measurement values. With
visually appealing elements, the user can switch
between different views or control test cycles with
different layout profiles.
Selected case studies for test bench automation
Customized analysis and reports
Finally, ibaAnalyzer analyzes the results according
to analysis templates that have been defined at set-
up. Following a test, results are documented auto-
matically in an individually-designed report based
on a layout template. Numeric values, graphical
representations and calculated test results can be
integrated in the test report.
With the iba system, measurement and analysis
procedures can be created and analyzed easily and
efficiently.
Barrier-free modernization
When operating a plant, sooner or later the question
of modernizing individual hardware components and
devices arises. There are a lot of reasons for that:
Enhancing productivity and product quality, instal-
lation of new standards, new legal requirements,
missing spare parts.
With the comprehensive connectivity of the iba sys-
tem, it is possible to integrate new components and
devices in an existing automation environment -
independent of the manufacturer or the device
generation. The communication of individual devices
runs also without iba application directly via ibaNet.
In this process, iba assumes the role of a translator.
Selected case studies for Retrofit
Fast signal processing
In case signals have to be linked or processed rapid-
ly, this can be done easily and flexibly with ibaLogic.
Control tasks can be realized by means of a graphic
programming language according to IEC61131-3,
which is easy to learn. Complex functions can be
encapsulated in a function block or DLL. Programs
can be modified online without having to stop the
production plant. Moreover, signals can be visualized
online and the system behavior recorded in mea-
surement files with ibaLogic.

Modernizing automation Optimizing a roll stand

Measurement value acquisition on a systems gradually online
Load tests for railway sleepers
test bench for diesel drives
Automation of a tandem roll stand Integrating a new thickness measuring
in a section rolling mill system in an existing plant

» By improving your technology, you improve your edge.« »Our focus on constantly improving our software
gives us an edge few can compete with. «
Eric Snyder Kim Snyder
Manager - Standard Products Sr. Software Engineer
12 13

For detailed information and further case studies, please see www.iba-america.com
 Fast, robust, reliable

Hardware
Complex technological systems need high-precision hardware for acquiring measurement values.
Electrically-isolated channels with synchronous sampling and interference-free transmission of de-
centralized devices are properties that make the iba hardware unique.
iba hardware is "Made in Germany" and designed for longevity in a rough industrial environment. The
only exception are our industrial computers which are sourced in the USA. For iba, longevity does not
only mean a five year guarantee, but also the certainty that 20-year-old hardware of the first gener-
ation can be connected to the state-of-the-art computer technology of today. This is ensured by our
ibaNET fiber optic (FO) technology in conjunction with our multi-protocol PC-interfaces.

IO Devices Stand-alone IO systems

Compact modules Modular system Terminal blocks Basic Modules Specialty Modules

ibaPADU ibaPADU-S ibaNet750 ibaPADU-C ibaDAQ-S ibaCMU-S ibaPQU-S

ƒƒ Adjustable level and input
characteristic
ƒƒ Full electrical isolation per
channel
ƒƒ fS = 1 kHz …100 kHz
ƒƒ High quality measurement and
output modules for various
tasks
ƒƒ Customer-specific pre-
processing
ƒƒ fS = 1 kHz … 40 kHz
ƒƒ Wide selection of terminals ƒƒ 8-channel data logger ƒƒ Stand-alone data ƒƒ Modular Condition ƒƒ Modular Power Quality
(WAGO 750) acquisition system Monitoring unit Analyzer
ƒƒ Power grid independent
ƒƒ No electrical isolation ƒƒ Full ibaPDA functionality ƒƒ Configurable calculation ƒƒ Characteristic value
of characteristic values calculation according to
ƒƒ fS < 500 Hz IEC61000-4-X

Industrial computers
ƒƒ Enterprise hard disk technology for robust operation
ƒƒ Practical 19‘‘ form factors for rack installation (kit required)
System interfaces Field and drive buses Fiber Optic (FO)
ƒƒ Industrial motherboard and processor
infrastructure
ƒƒ Pre-configured with iba hardware and software

Time synchronization PC connections Special components

ibaLink
ƒƒ Bidirectional connection to
control systems
ƒƒ VME based systems
ƒƒ SIMATIC S5, SIMATIC MMC,
SIMADYN-D
ƒƒ OEM version for integrating
the ibaNet FO technology in
proprietary systems
1414
ibaBM
ƒƒ Listening mode (Sniffer) ƒƒ Combining and dividing
ibaNET FO protocols of
ƒƒ Receives data actively (Slave)
different speed classes
ƒƒ Bus diagnostics (3 Mbit-32 Mbit).
ƒƒ Profibus, CAN-Bus, EtherCAT, ƒƒ Optical signal multiplication
Silink, ABB-DDCS for multiple use of
transducers
ibaClock ibaFOB ibaFOB-TDCexp/-SDexp
ƒƒ GPS receiver ƒƒ Coupling ibaNet FO to ƒƒ Direct FO connection
measurement computer between measurement
ƒƒ µs-precise computer and Simadyn-D
synchronization of all ƒƒ PCI, PCIe or Expresscard or Simatic TDC GDM
iba systems
ƒƒ Fast transfer of
measurement data
1515
 Scalable, effecient, practical
Software
Acquiring, recording, analyzing and processing of data along with controlling and simulating fast and
dynamic processes - these are the areas of application of iba software. All iba solutions can be extended
modularly by individual add-ons. They can be adapted individually to the requirements of each user - in
functionality as well as in size.
ibaPDA
Modern classic in data acquisition
As the central component of the iba system, ibaPDA has proven for years to be
one of the most versatile measurement value acquisition systems for mainte-
nance and production.
Client/server architecture, flexible recording, and simple configuration are
only a few of the convincing features.
ibaAnalyzer
Analyzing and evaluating without additional costs
ibaAnalyzer is characterized by broad functionalities for analyzing and evalu-
ating. The application offers intuitive operation along with a complex scope of
functions. The license for editing measurement files which have been gener-
ated with the iba system is free.
Stay flexible and effective - without additional costs.
ibaHD-Server
Historical data available immediately
For continuous or long-running projects, find past events rapidly using the
high-resolution Historical Data (HD) server. Zoom functionality allows you to
quickly and easily travel from the annual, monthly or weekly overview down to
the millisecond range.
ibaCapture
Combining measurement data and video images
The video recording system ibaCapture, in conjunction with ibaPDA, records
video images and measurement data synchronously. Data can either be re-
corded continuously or triggered by events. Important events can be captured
automatically as a snapshot. The simultaneous display of recorded measure-
ment data and visual information with ibaAnalyzer offers a whole new quality
of process analysis.
16
ibaDatCoordinator
Automatic post-processing of measurement files
ibaDatCoordinator is a powerful tool for processing and managing data files
automatically. Typical fields of application are automatic extraction of character-
istic values to databases, as well as creation of reports. In synergy with ibaAna-
lyzer, various processing procedures can be fully automated and employees can
be relieved of routine tasks.
ibaQPanel
Display quality data - live and in color
The user-friendly interface of ibaQPanel allows you to display live process data,
quality data, events, conditions, and video images. It combines the functionality
of an interactive measurement value display with HMI elements. All of these
features are seamlessly integrated in ibaPDA.
ibaPDA-PLC-Xplorer
Measuring from the beginning
ibaPDA-PLC-Xplorer offers the full ibaPDA functionality with access to different
PLCs (e.g. Siemens S7 and Codesys-based PLCs). Without additional hardware,
this is an inexpensive way of measuring, displaying and recording signals. You
can detect and eliminate error sources with ibaAnalyzer.
An ideal solution for mobile use.
ibaInSpectra Condition Monitoring
Vibration analysis and condition monitoring
ibaInSpectra constantly monitors mechanical components for vibration and
detects possible error sources early on. With acquisition rates of up to 100
kHz, you can adapt the system easily to the individual requirements. Since the
ibaInSpectra Condition Monitoring Library is fully integrated in ibaPDA, you
can identify - along with the vibration analysis - possible correlations between
vibration effects and process behavior in real time.
ibaDatManager
Fast overview of all iba data
ibaDatManager allows for rapidly finding process-related data using the prop-
erties of measured signals and the characteristic values extracted from them..
An important advantage of this application is the possibility to evaluate quality
parameters statistically, at a glance. Thus, deviations from the normal behavior
can be discovered rapidly and analyzed in detail.
ibaLogic
Signal processing and automation
In measurement and control technology with fast and dynamic processes,
ibaLogic is used for signal processing, controlling, simulating, and a commu-
nicating. Due to its ease of use, seamless integration with other iba products,
and the outstanding price-performance ratio, ibaLogic is highly versatile.
17
iba America, LLC
370 Winkler Drive
Suite C
Alpharetta, GA 30004

Phone: +1 (770) 886-2318

www.iba-america.com
sales@iba-america.com

iba America is a subsidiary of iba AG. iba AG is represented worldwide with subsidiaries and sales partners.