Motro & Drives - Summer Edition

MOTORS
& DRIVES
SU MME R E D I T I O N
Contents
3 — Stepper motor torque basics
6 — Motion Control: Beckhoff XPlanar — The Flying Motion
7 — XPlanar transports workpiece during plasma surface treatment process
12 — VFDs: six benefits, energy efficiency
17 — The Importance of Isolated Signal Conditioners in Protecting Sensors
and Measurement Equipment
31 — What Is Signal Conditioning?
32 — Recognize service conditions for motors and generators
39 — MOVISUITE Engineering and Software EN
40 — SEW-EURODRIVE’s MOVI-C Modular Automation System
43 — Transform pneumatics systems for energy conservation, efficiency
and safety
52 — Five Signs That it is Time to Replace the Mercury Based Relays and
Switches in Your Industrial Application and What to Look for in a Suitable
Replacement
60 — Direct drive vs. geared rotary servomotor: A quantification of design
advantage
2
Stepper motor torque basics Stepper motor torque
basics
Stepper motors remain popular for industrial motor applications because Motion Control: Beckhoff XPlanar
they are low-cost, rugged, simple, have high torque at startup and low — The Flying Motion
speeds, require little maintenance, and they can operate in an open loop XPlanar transports workpiece
during plasma surface treatment
control system. process
VFDs: six benefits, energy
A stepper motor divides a full rotation into a number of equal steps, important for
many industrial motor and motion control applications. The motor’s position can
be caused to move and hold at one of these steps as long as the motor is carefully
efficiency
The Importance of Isolated

Signal Conditioners in Protecting
Sensors and Measurement
sized to the application in respect to torque and speed. Holding torque is a measure- Equipment
ment of how much rotating force is required to force a stationary stepper motor shaft
What Is Signal Conditioning?
out of position. Holding torque (T) is the product of a motor’s torque constant (KT) and
Recognize service conditions for
the current (i) applied to the stator windings. motors and generators
MOVISUITE Engineering and

T = KTi Software EN
SEW-EURODRIVE’s MOVI-C
In most applications, electronic drivers control stepper motors. They employ pulse Modular Automation System
width modulation (PWM) technology to monitor the stator current and apply the prop- Transform pneumatics systems for
energy conservation, efficiency
er voltage to achieve the desired current and torque. When a motor is stationary, the and safety
driver only needs to use enough voltage to overcome the resistance of the stator coils
Five Signs That it is Time to
(also known as motor phases). This is described by Ohm’s law that calculates voltage as Replace the Mercury Based Relays
the current in amps multiplied by the resistance in ohms. If voltage increases, so does and Switches in Your Industrial
Application and What to Look for
current, but if resistance increases, current reduces. in a Suitable Replacement
Direct drive vs. geared rotary

V = iR servomotor: A quantification of
design advantage
Because most high-performance stepper motors have low phase resistance, the driver
3
Stepper motor torque basics
Stepper motor torque
basics
does not need much power sup-
Motion Control: Beckhoff XPlanar
MOVI-C
® ply voltage to hold the motor in — The Flying Motion
position. For real applications,
XPlanar transports workpiece
The one-software, one-hardware automation platform the motor does not remain forev- during plasma surface treatment
er stationary; it is used to move process
a load. Moving something at a VFDs: six benefits, energy

efficiency
particular speed requires that dy-
namic torque be available at that
speed. Stepper motors do not Sensors and Measurement
Equipment
change instantly from standstill to
a given speed. They must acceler- What Is Signal Conditioning?
ate just as a car gradually increas- Recognize service conditions for

motors and generators
es speed when the driver steps on
the gas pedal. To accelerate the MOVISUITE Engineering and
Software EN
vehicle faster requires more gas.
Stepper motors are similar, follow- Modular Automation System
ing Newton’s famous law F = ma.
MOVI-C is a one-software, one-hardware automation platform Transform pneumatics systems for
that combines fully integrated drive components, control Below is the formula for Newton’s energy conservation, efficiency
and safety
electronics and automation software – all from one source. law expressed in rotational terms,
Whether you are designing simple, single-axis applications or Five Signs That it is Time to
where torque (T) is proportional to
complex motion control or automation systems, MOVI-C provides Replace the Mercury Based Relays
the power, flexibility, and ease of use you need. the rotor and load inertia (J) and and Switches in Your Industrial
angular acceleration (A): Application and What to Look for
in a Suitable Replacement

T = JA servomotor: A quantification of
design advantage
To manage a heavier load or
4
seweurodrive.com
Stepper motor torque
basics
accelerate faster requires more torque. However, the dynamic torque of a stepper motor
decreases as speed increases because when a motor starts moving, it becomes a gen- — The Flying Motion
erator. As the rotor’s magnetic field moves among the stator coils, a voltage appears on
the motor terminals. The driver must apply an extra voltage to the motor to overcome during plasma surface treatment
this voltage, known as back EMF, which is a product of motor speed (w) and voltage con- process
stant (KE). Also, stator coils, like all coils, have inductance that resists the current change. VFDs: six benefits, energy
efficiency
As the stator current changes to keep the rotor turning, more voltage must be used to
overcome inductance (L). The voltage equation for a motor in motion is:
Equipment
V = KEώ + iR + L(di/dt)
A PWM driver will increase the voltage applied to the stepper motor to keep the cur- Recognize service conditions for
rent and torque constant. At some speed, the power supply will not have enough volt-
age, and the motor current will begin to fall. The torque drops with the current. If using MOVISUITE Engineering and
Software EN
a higher voltage power supply, the dynamic torque remains flat to a higher speed.
Modular Automation System
The process of sizing an application involves calculating the required torque and speed
Transform pneumatics systems for
range necessary to move the load. For example, if the application needed 80 oz.-in. of energy conservation, efficiency
and safety
torque up to 10 revolutions/second (rps), this motor could use a 24-V power supply.
Replace the Mercury Based Relays
If we need to go farther and faster, one might accelerate to 80 oz.-in. at 20 rps. The and Switches in Your Industrial
stepper motor would require a 48-V power supply. Application and What to Look for

Eric Rice servomotor: A quantification of
Eric Rice is an application engineer at Applied Motion Products. He has worked in design advantage
the motion control industry for 20 years, specializing in stepper motors, servo motors,
drives, and controls. 5
Motion Control: Beckhoff XPlanar — The Flying Motion
Motion Control: Beckhoff

XPlanar — The Flying
Motion
process

efficiency

Equipment



Software EN

Motion Control: Beckhoff XPlanar — The energy conservation, efficiency
and safety
Flying Motion Five Signs That it is Time to
Beckhoff is revolutionizing drive technology with the eXtended Replace the Mercury Based Relays
and Switches in Your Industrial
planar motor system. Free-floating planar movers move jerk-free Application and What to Look for
and without contact over arbitrarily arranged planar tiles, thus in a Suitable Replacement
enabling the wear-free transport of products – noiselessly and Direct drive vs. geared rotary
servomotor: A quantification of
without mechanical abrasion and the generation of particles. design advantage
6
XPlanar Floating planar system from Beckhoff helps
Plasmatreat simplify transportation of sensitive
workpieces
transports
workpiece during P lasmatreat GmbH, a Steinhagen, Germany-based
manufacturer of plasma systems for high-efficiency
surface treatment and environmentally friendly production
plasma surface
processes, recently unveiled a new plasma treatment unit.
A key innovation with this treatment unit is that it uses
XPlanar, a planar motor system from Beckhoff Automation,
treatment process to transport workpieces with high precision and flexibility.

XPlanar replaces prior systems used to move often sensi-
tive workpieces such as PCBs and eliminates the need to
install complex six-axis robots
and linear motors.
The plasma treatment unit

can surface-treat a variety of
material samples in a two-
stage process, according
to Jochen Stichling, Head
of Design at Plasmatreat.
Jochen Stichling, Head of Design
“During the first stage, the at Plasmatreat: “When it came
substrate is moved under a to custom-programming mover
Uwe Prüßmeier, Senior Product travel routes, there was no
nozzle for cleaning and acti-
Manager Drive Technology, XTS, vation. During the second, a
real alternative to XPlanar.” (©
Plasmatreat, Germany)
XPlanar, Beckhoff Automation
XPlanar transports workpiece during plasma surface treatment process
separate nozzle applies a func- Motion Control: Beckhoff XPlanar

— The Flying Motion
tional coating,” Stichling says.
This, he explains, is where the XPlanar transports
workpiece during plasma
company focused its innova- surface treatment
tion efforts: “We wanted a fast, process
fully programmable, wear-free VFDs: six benefits, energy
system to transport the work- efficiency
pieces. And when it came to The Importance of Isolated

custom-programming of tracks Sensors and Measurement
and travel there was no real Equipment
alternative to XPlanar.” What Is Signal Conditioning?

Planar motor system motors and generators
with floating movers MOVISUITE Engineering and

The XPlanar system consists Software EN
of planar tiles that can be SEW-EURODRIVE’s MOVI-C

XPlanar eliminates the need to move the Modular Automation System
arranged in any pattern, combined with contact- plasma jet; instead, a floating planar mover
less movers that float over them and provide ex- Transform pneumatics systems for
carries the workpiece exactly into position
ceptionally fast, flexible and precise positioning. for precise surface treatment. and safety
(© Plasmatreat, Germany)
The movers operate jerk-free and are capable of Five Signs That it is Time to
traveling at speeds of up to 2 m/s; they can also Replace the Mercury Based Relays
accelerate at 2 g and be positioned with a repeatability of 50 µm – silently, and without Application and What to Look for
wear or abrasion. The system not only supports movement within the x-y space, but it in a Suitable Replacement
also provides additional functions to allow mover positioning with up to six degrees of Direct drive vs. geared rotary
freedom when necessary: design advantage
8
• Raising and lowering by up to 5 Motion Control: Beckhoff XPlanar

mm (unloaded), with weighing ca-
pabilities available as an option XPlanar transports
surface treatment
• Tilting by up to 5° when transport- process
ing and handling liquids VFDs: six benefits, energy
efficiency
• Rotation of 360° over all planar The Importance of Isolated

tiles Sensors and Measurement
Equipment
The XPlanar system in the Plasmatreat What Is Signal Conditioning?
machine consists of six 240 x 240 mm Recognize service conditions for
planar tiles and a single planar mover. motors and generators

XPlanar increases flexibility Software EN
while reducing mechanical SEW-EURODRIVE’s MOVI-C

complexity
A major advantage Plasmatreat gained by implement- Plasmatreat’s new plasma Transform pneumatics systems for
treatment unit is highly compact
ing XPlanar is that the plasma jets used to treat surfaces and safety
as it no longer requires a six-axis
no longer need to be moved and, as a result, can now robot or additional linear axes. (© Five Signs That it is Time to
be installed in fixed mountings. The jets are complex, Plasmatreat, Germany) Replace the Mercury Based Relays
both mechanically and electrically, and the ability to Application and What to Look for
move the workpieces rather than the plasma jets themselves reduces wear to the in a Suitable Replacement
feed lines. Stichling sees additional benefits from the increased flexibility too: “We Direct drive vs. geared rotary
can attach a variety of material samples to the mover for treatment using just simple design advantage
adapters. We can easily add processing stations alongside the plasma jets – markers
9
for good parts, for instance, or Motion Control: Beckhoff XPlanar

| AT11-20USA |

optical sensing heads to con-
: Gain unrivaled duct full part inspections – and XPlanar transports
flexibility and throughput! carry workpieces to them flexibly
as needed. And XPlanar’s rapid
surface treatment
process
Flying 2D product transport with up to 6 degrees of freedom
acceleration also lets us move VFDs: six benefits, energy
material samples at high speeds; efficiency
with thin samples, for instance, The Importance of Isolated

this helps minimize treatment Sensors and Measurement
time with the fixed jet.” Equipment

According to Stichling, XPlanar’s Recognize service conditions for
functional benefits are proving motors and generators
Levitating 6D valuable in a range of applica- MOVISUITE Engineering and

planar movers motion
tions: “Conventional setups use Software EN

Scalable Velocities
kg payload up to 2 m/s
Individual Free system

a six-axis robot or linear motors SEW-EURODRIVE’s MOVI-C
product transport layout Modular Automation System
to move a plasma jet around a
stationary workpiece. From a cost Transform pneumatics systems for
perspective, XPlanar comes in and safety
www.beckhoff.com/xplanar somewhere between linear-axis Five Signs That it is Time to
XPlanar enables new dimensions of freedom in product and material handling: Levitating planar movers
fly over flexibly arranged planar tiles accommodating nearly any track layout and path planning. and robotic systems. With flat Replace the Mercury Based Relays
Individual 2D transport at up to 2 m/s
Processing with up to 6 degrees of freedom
Transport and processing in one system parts that don’t require much Application and What to Look for
Wear-free, hygienic and easy to clean
Free arrangement of planar tiles enabling totally customized machine and process layouts vertical travel on the z-axis, where in a Suitable Replacement
Multi-mover control enables parallel and individual product handling
Fully integrated into the powerful and standardized PC-based Beckhoff control system
(TwinCAT, PLC IEC 61131, Motion, Measurement, Machine Learning, Vision, Communication, HMI) robotic systems are usually ideal, Direct drive vs. geared rotary
For use across all industries: assembly, packaging, food/bev, pharma, laboratory, entertainment, … servomotor: A quantification of
XPlanar offers an excellent alter- design advantage
native to gantry-type systems.
10
XPlanar’s advantages in terms of lack of wear, easy cleaning and clean-room compati- Motion Control: Beckhoff XPlanar
bility also play out here.”
XPlanar transports
For Stichling, XPlanar has the potential to optimize plasma surface treatment in two key surface treatment
areas, going forward: direct integration of in-line testing for full inspections during the process
treatment process, and custom-programmable mover travel routes for end customers. VFDs: six benefits, energy
efficiency
Another advantage for Plasmatreat was that it took less than two months to integrate The Importance of Isolated
the XPlanar system into its machine – not least because Beckhoff was quick to supply Sensors and Measurement
the 3D data and the electrical connection information that enabled the company to Equipment
rapidly incorporate the XPlanar starter kit into its machine design. XPlanar, according What Is Signal Conditioning?
to Jochen Stichling, has proved to be both robust and reliable. And another advan- Recognize service conditions for
tage, he points out, is that the entire plasma treatment cell has now been fully auto- motors and generators
mated using PC-based control, making it a complete system solution from a single MOVISUITE Engineering and
source. Software EN
Further information:
www.plasmatreat.com Transform pneumatics systems for
www.beckhoff.com/xplanar and safety


design advantage
11
VFDs: six benefits, energy efficiency Stepper motor torque basics

Drives: A growing emphasis on boosting energy efficiency and — The Flying Motion
meeting energy requirements are increasing demand for variable XPlanar transports workpiece
frequency drives (VFDs). process
T he global variable frequency drive (VFD) market is slated to experience healthy VFDs: six benefits,
energy efficiency
growth over the coming years. These drives are emerging as an integral part of
several machine markets globally both small- and large-scale. They are used in appli- The Importance of Isolated
cations ranging from small devices to large compressors. VFDs are power conversion Sensors and Measurement
Equipment
devices that are available as ac drives, dc drives, and servo drives.
Board members of the small village of Enosburg Falls, Vt., approved the purchase of a new Recognize service conditions for
VFD for well pump of village’s water department. This step is likely to cut down the annual
electric bill of the department by $2,000. On the other end of the scale, VFDs are an imper- MOVISUITE Engineering and
Software EN
ative part of the technology behind the longest single-flight pipe conveyor of the world.
It is estimated electric motors in industrial applications consume approximately one-
fourth of the world’s electrical energy. When these motors are incorporated with VFDs energy conservation, efficiency
in centrifugal load service, their efficiency increases. With technological advancements and safety
in power electronics technology, VFD cost and size have decreased, while performance Five Signs That it is Time to
has improved. and Switches in Your Industrial
The EU has proposed to revise its goal under the Energy Efficiency Directive from tar-
get of 20% by 2020 to 30% target by 2030. This includes incentives to small and medi- servomotor: A quantification of
um-sized enterprises (SMEs) to monitor efficiency levels in new capacities for energy design advantage
generation and undergo energy audits. This is likely to boost the incorporation of VFDs
in conveyors, electric fans, industrial pumps, and HVAC, among others.
12
VFDs: six benefits, energy efficiency

VFD advantages — The Flying Motion
Globally, VFDs are used across several end-use sectors, including infrastructure, indus-
trial, power generation, and oil and gas. Growing concerns regarding energy efficiency during plasma surface treatment
process
worldwide coupled with rising awareness about benefits of these drives are boosting
their adoption across these sectors. For instance, as per a recent announcement by Si- VFDs: six benefits,
mark Controls Ltd., they received a follow-up order of $849,937 ($1.1 million Canadian) energy efficiency
for integrated VFDs from an existing customer in the Alberta oil sands. In the oil & gas The Importance of Isolated
sector, these drives help in reducing installation and operating costs, optimizing pump Sensors and Measurement
operations, improving pump uptimes, and boosting oil production. Equipment

Six primary benefits of VFDs are: Recognize service conditions for
1. Keeps starting current in control: A VFD has the capability of starting the mo- MOVISUITE Engineering and
Software EN
tor at zero voltage and frequency, which keeps a check on motor winding flexing
and heat generation. This helps in extending the motor life. SEW-EURODRIVE’s MOVI-C

2. Reduces power line disturbances: Any voltage sag caused in the power line energy conservation, efficiency
can adversely affect voltage sensitive devices such as proximity switches, sensors, and safety
and computers. Using VFDs eliminates voltage sag. Five Signs That it is Time to
3. Demands lower power on start: Power required to start an ac motor across Application and What to Look for
the line is substantially greater than with a VFD. When industrial customers start
these motors during peak hours of electrical consumption, they are likely to be Direct drive vs. geared rotary
charged with surge prices. However, with VFD demanding lower starting power, design advantage
the issue can be addressed.
13
4. Helps in controlling operating speed and acceleration: Applications such as Motion Control: Beckhoff XPlanar
bottling lines that include easy-to-tip product significantly benefit from a grad-
ual increase in power. This allows conveyer belts to smoothly rev up rather than during plasma surface treatment
an abrupt jerk to full power. They also allow speed to be remotely adjusted by process
a controller. Control is speed and acceleration is a big bonus to industries in a VFDs: six benefits,
production process. energy efficiency
5. Limits and adjusts torque: The drive is capable of limiting and adjusting the
amount of torque so the ac motor never surpasses this limit. This protects ma- Equipment
chinery from damage and protects the process or product. What Is Signal Conditioning?

6. Saves energy and cost: A VFD regulating a pump motor that usually runs less motors and generators
than full speed can cut down energy consumption over a motor running at con- MOVISUITE Engineering and
stant speed for the same period. In addition, it eliminates the need for mechani- Software EN
cal drive components, which also helps reduce overall costs. SEW-EURODRIVE’s MOVI-C
Competition from substitutes Transform pneumatics systems for

Several VFD substitutes are available on the market. Soft-starter drives are one of the and safety
biggest and are useful in limiting inrush current associated with electric motor startup. Five Signs That it is Time to
They lower the initial voltage and ramp up until desired speed is attained. Soft-starter Replace the Mercury Based Relays
advantages include easy set-up and they’re cheaper compared to VFDs. They’re also Application and What to Look for
designed to extend motor life. in a Suitable Replacement

VFDs do not perform as needed in no flow or near-zero flow conditions and may not design advantage
be well-suited for specialist applications. In these cases, instantaneous high-speed
response is required. These drives are acknowledged for the ability to deliver higher
14
frequency source power during startup, Motion Control: Beckhoff XPlanar

which is beneficial if control is sought after
the desired speed is attained. during plasma surface treatment
process
Demand trends for VFDs VFDs: six benefits,

A report by Grand View Research indicates energy efficiency
the global VFD market size will reach an The Importance of Isolated
estimated $33.10 billion by 2025. Growing
emphasis from government organizations Equipment
to reduce energy consumption to achieve What Is Signal Conditioning?
a net zero energy goal is one of the key Recognize service conditions for
trends contributing to the growth of the motors and generators
Industrial market. Rapid technological advance- MOVISUITE Engineering and
Electronics ments along with proliferation of connect- Software EN
• Process Control ed devices in commercial, household, and SEW-EURODRIVE’s MOVI-C

• Test and Measurement Modular Automation System
• Automotive
industrial sectors are anticipated to bol-
• Battery Testing ster the demand for VFDs. Transform pneumatics systems for
• Avionics/Space energy conservation, efficiency
and safety
High-Performance, Signal Conditioning
SCM5B • SCM7B • SensorLex 8B ®
Also available in DIN Rail Mounts Energy efficiency is needed to not only Five Signs That it is Time to
• Minimize Crosstalk
• Analog Filtering
meet burgeoning power requirements, but Replace the Mercury Based Relays
• Analog Isolation curtail greenhouse emissions. On a global Application and What to Look for
• Input Protection
• Common Mode Rejection scale, energy efficiency can reduce green- in a Suitable Replacement
house emissions by around 40%. Direct drive vs. geared rotary

design advantage
Instrument Class® Signal Conditioning
dataforth.com • 800-444-7644
DSCA / DSCT / DIN Rail Carrier for 5B/7B/8B This increased focus on augmenting en-
ergy efficiency is poised to increase VFD
15
adoption. In 2016, total investments in energy efficiency were valued at $231 billion. Motion Control: Beckhoff XPlanar
In this, investments in appliances, lighting, and HVAC and control amounted to $13.94
billion, $27.42 billion, and $22.86 billion, respectively. With surging energy consump- during plasma surface treatment
tion and its unit rate, operational engineers in several process sectors are trending process
toward VFDs for productivity, optimum operation, and improved energy efficiency of VFDs: six benefits,
machines. This also is projected to stir up the demand for VFDs across applications energy efficiency
such as automotive, HVAC, and elevators. The Importance of Isolated
Asia Pacific is slightly ahead of other regions in revenue generated through sales of Equipment
VFDs thanks to rapidly improving economic conditions in countries such as India and What Is Signal Conditioning?
China. Governments and other organizations in these countries are pouring hefty funds Recognize service conditions for
into energy efficient devices. motors and generators

Latin America also is expected to be a promising region because of stringent regula- Software EN
tions and law enforcement for the use of energy efficient devices. Developed regions SEW-EURODRIVE’s MOVI-C
such as North America and Europe also are likely to witness healthy growth over the
coming years. Transform pneumatics systems for
and safety
Aishwarya Vijay Five Signs That it is Time to
Aishwarya Vijay is a content creation executive at Grand View Research. Replace the Mercury Based Relays

design advantage
16
The Importance Introduction
Connecting a physical sensor to a data acquisition system
of Isolated Signal
is a serious undertaking. A laboratory connection may work
well when connected with short wires in a benign environ-
ment, but when mounted in the real world of electromag-
Conditioners netic signals and repetitive or one-time emissions, several

things should be considered.
in Protecting Isolating power sources and sensor signals is the most

effective method for eliminating undesirable ground loop
Sensors and currents and induced electrical noise.
Measurement The need to measure and control the operation of ma-

chinery or process equipment is as old as the Industrial
Equipment
Revolution. Plant instrumentation has now become the
nerves and brain of the modern manufacturing plant as it
regulates and supervises the operation of the equipment
within the plant. It also provides the means to make plants
economically viable. Instrumentation allows the use of pro-
cesses which would be difficult or impossible to operate
without automation.
When you move a data acquisition system from the con-

trolled environment of the laboratory to validation test-
ing or the manufacturing floor, some problems may arise.
Many factors may combine to invalidate measured sensor
The Importance of Isolated Signal Conditioners in Protecting Sensors
signals, ruin measurement accuracy, or possibly even destroy the equipment physically. Motion Control: Beckhoff XPlanar
Understanding these factors is crucial to any measurement success.
In this article, we will address five recurring roadblocks to successful measurements, in process
the order of most to least common, together with some real-life examples. This discus- VFDs: six benefits, energy
efficiency
sion will provide an understanding of how measurement inputs become corrupted and
the need to isolate them. The Importance
of Isolated Signal
Conditioners in
1. Crosstalk Protecting Sensors and
By far the most common question heard involves a phenomenon where the contents of Measurement Equipment
one data acquisition channel are superimposed on another. This condition, known as What Is Signal Conditioning?
crosstalk, can cause subtle to major measurement errors that may go undetected. In its
most exaggerated form, a nearly exact duplicate of one channel appears on an adja- motors and generators
cent channel to which nothing is connected. MOVISUITE Engineering and
Software EN
The PC-based instrumentation revolution generated the active use of multiplexers. The SEW-EURODRIVE’s MOVI-C
revolution is driven by the promise of low cost per channel, with a target per-channel Modular Automation System
cost of approx. $50. However, along the way, the hallmark of traditional instrumenta- Transform pneumatics systems for
tion has been dropped - the use of an isolation amplifier for each channel. The sys- and safety
tem-under-test is connected directly to the multiplexer’s inputs; however, the multi-
plexer is not an ideal signal processing device. Its inputs have capacitance that stores Replace the Mercury Based Relays
a charge that is directly proportional in magnitude to the sample rate and the imped- Application and What to Look for
ance of the signal source. This inherent characteristic causes crosstalk. in a Suitable Replacement

Consider an application where the multiplexer’s input is connected directly to the
design advantage
output of an isolation amplifier. In this situation, the impedance the multiplexer sees is
18
stable and low, with 10Ω being a typical value. Crosstalk is greatly minimized, or elim- Motion Control: Beckhoff XPlanar
inated altogether, since the impedance of the source is low enough to bleed off the
charge on the multiplexer’s input capacitance before the analog-to-digital converter during plasma surface treatment
(ADC) reports a value. process

efficiency
Even under this nearly ideal impedance situation, a high sample rate can boost cross-
talk by minimizing the capacitive discharge time on the multiplexer’s channels. In ef- The Importance
fect, the capacitance has less time to bleed off its charge before the analog-to-digital of Isolated Signal
Conditioners in
conversion takes place, resulting in crosstalk where none existed before. Protecting Sensors and
Measurement Equipment
As source impedance and sample rate increase, the probability of crosstalk increases What Is Signal Conditioning?
as well. To prevent this from happening, keep these points in mind:
• Minimize the source impedance of the signal source. Use isolation amplifiers to MOVISUITE Engineering and
keep it below 100Ω, although at very high sample rates, even this value may be Software EN
too high. SEW-EURODRIVE’s MOVI-C
• When source impedance cannot be controlled, an isolation amplifier is needed Transform pneumatics systems for
between the signal source and the data acquisition card multiplexer. An instru- and safety
ment with a built-in isolation amplifier is needed on each channel to provide pro-
tection from stray signal paths. Replace the Mercury Based Relays
• These strategies become even more important as the sample rate increases. The in a Suitable Replacement
best and most predictable results are obtained when an instrument is used that Direct drive vs. geared rotary
has a fixed scan interval; this helps control any high-sample-rate bursts.
design advantage
19

2. Common-Mode Voltage — The Flying Motion
Although crosstalk leads the list in number of measurement problems, common-mode
voltage (CMV) leads in its capability to distort data. during plasma surface treatment
process
Using familiar measurement methods, like a battery-powered, hand-held digital volt- VFDs: six benefits, energy
efficiency
meter (DVM), input readings are almost impervious to CMV problems. Many engineers
assume they can extend the success of DVMs to computer-based measurement ap- The Importance
of Isolated Signal
proaches. However, in most cases, the results range from poor to disastrous.
Conditioners in
Protecting Sensors and
The problems encountered are tied to two specifications on the manufacturer’s data Measurement Equipment
sheet: full-scale input range and maximum input voltage (without damage). Full-scale What Is Signal Conditioning?
input range indicates the magnitude of voltage connected across the instrument’s in- Recognize service conditions for
puts (normal-mode voltage or NMV), which can successfully be measured. As its name motors and generators
implies, maximum input voltage indicates how much NMV the instrument will tolerate MOVISUITE Engineering and
before incurring damage. Software EN
The CMV, which appears simultaneously and in phase on each of the instrument’s inputs
with respect to power ground, combines with the NMV to test the limits of the measure-
ment system. Most data acquisition products and safety
for the computer permit measurements when Five Signs That it is Time to
the sum of CMV and NMV is equal to or less Replace the Mercury Based Relays
than the instrument’s full-scale input range. Application and What to Look for
Measurements can be made under these condi- Direct drive vs. geared rotary
tions only if the data acquisition product’s input design advantage
is configured for differential operation as shown
in Figure 1.
20
With this basic rule for differential measurements established, here are the possible Motion Control: Beckhoff XPlanar
measurement results, in the order of best to worst:
• (CMV + NMV) ≤ Full Scale Range: This is a good measurement, subject to the process
common-mode rejection (CMR) specification of the instrument. VFDs: six benefits, energy
efficiency
• Full Scale Range ≤ (CMV + NMV) ≤ Maximum Input Voltage (without damage): The The Importance
measurement could be latched at plus or minus, full scale. There are no usable of Isolated Signal
Conditioners in
measurement results, but no damage either. Protecting Sensors and
• (CMV + NMV) > Maximum Input Voltage (without damage): There is potential for What Is Signal Conditioning?
damage to the data acquisition product and to the attached computer.
For most data acquisition products, it doesn’t take long to reach the destructive stage. MOVISUITE Engineering and
Most will tolerate a maximum input voltage (without damage) of ±30VDC or peak AC. Software EN
In the realm of production measurements, with 120V to 440VAC motor supplies or SEW-EURODRIVE’s MOVI-C
24VDC process current supplies and the high probability of ground loops, this limit can Modular Automation System
be very quickly and irrevocably exceeded. Transform pneumatics systems for

and safety
How can the comparatively expensive data acquisition instrument be used to collect
the same measurements that are made so effortlessly and safely with the hand-held Replace the Mercury Based Relays
DVM? The answer is to choose a product that provides isolation. Application and What to Look for
Isolation is what its name implies. As with a battery-powered DVM, there is no elec- Direct drive vs. geared rotary
trical connection between the common connection associated with the instrument’s
design advantage
front-end input terminals and the power common connection associated with the back-
21
end of the instrument and the computer. Motion Control: Beckhoff XPlanar

As such, the instrument’s front end is free to float at a level defined by the magnitude during plasma surface treatment
of the CMV, without damage and with complete measurement accuracy. Here, the max- process
imum CMV that can be tolerated is not dictated by its maximum input voltage specifi- VFDs: six benefits, energy
efficiency
cation, or even by its full-scale range, but rather by the voltage at which the isolation
barrier breaks down. The Importance
of Isolated Signal
Conditioners in
For example, with most Dataforth isolated Protecting Sensors and
signal conditioning products, isolation bar- Measurement Equipment
rier breakdown occurs above 1500VAC or What Is Signal Conditioning?
2200VDC, which is much higher than the ex-
pected CMV of most production applications. motors and generators

Figure 2 describes a typical application where Software EN
isolation allows a measurement in the presence SEW-EURODRIVE’s MOVI-C
of a high CMV. Modular Automation System

Understand that isolation can be provided in more than one form: input-to-output, and safety
channel-to-channel, and a combination of both. For the vast majority of multi-channel
production applications, both input-to-output and channel-to-channel isolation are Replace the Mercury Based Relays
needed. Such an arrangement allows each channel’s input to float with respect to all Application and What to Look for
other channels. in a Suitable Replacement

A CMV on channel one, for example, will not disrupt measurements on the other chan-
design advantage
nels, even if they are referenced to power supply ground, the same CMV, or an en-
22
tirely different CMV. In contrast, systems designed with just input-to-output isolation Motion Control: Beckhoff XPlanar
essentially tie together the CMVs of all the channels. A CMV on one channel floats all
channels at the same voltage with potentially disastrous results if another channel is during plasma surface treatment
connected to a ground-referenced signal or a different CMV. process

efficiency
There is only one reason to buy a product that offers only input-to-output isolation,
and that reason is cost. For example, it is less expensive to build one isolation barri- The Importance
er into an 8-channel product than one for each channel. The cost savings usually are of Isolated Signal
Conditioners in
reflected in a lower system price. However, in the actual application of such an instru- Protecting Sensors and
ment, the initial cost savings may be offset by expensive repairs later. Measurement Equipment
Before leaving the topic of isolation, one point needs to be established firmly and
clearly: Do not confuse a product that offers differential measurement capability with motors and generators
one that offers isolation. These are two entirely different and unrelated features. MOVISUITE Engineering and
Software EN
Moreover, some engineers are still under the impression that a product with differential SEW-EURODRIVE’s MOVI-C
measurement capability allows them to apply the instrument in high CMV conditions. As dis- Modular Automation System
cussed previously, differential but non-isolated inputs tolerate only moderate CMVs (without Transform pneumatics systems for
damage) and even lower CMVs are required for more trustworthy measurement results. and safety

3. DC Common-Mode Rejection (CMR) Replace the Mercury Based Relays
Whenever a measurement is made in the presence of a CMV, accuracy will be adverse- Application and What to Look for
ly affected. The question that remains is the magnitude of the inaccuracy. This can be in a Suitable Replacement
determined by looking up the specification for CMR in the product’s data sheet. Any Direct drive vs. geared rotary
instrument that provides a differential input, isolated or not, offers the capability to
design advantage
reject a CMV to a degree determined by its CMR. CMR is most commonly defined as
23
a logarithmic ratio of input-to- output CMV (in decibels). The common-mode rejection Motion Control: Beckhoff XPlanar
ratio (CMRR) for most general-purpose, analog-to-digital products for the PC is around
80dB. How does this figure apply to the measurement? Here’s a simple example that during plasma surface treatment
includes the math. process

efficiency
Example 1
Assume that you want to measure a 3VDC normal-mode signal in the presence of a The Importance
+6VDC CMV and assume that the normal-mode signal gain is 1. of Isolated Signal
Conditioners in
• 80dB = 20 log (VCMV in / VCMV out) Measurement Equipment
• 80dB = 20 log (6VDC / VCMV out)
• 4 = log (6VDC / VCMV out) MOVISUITE Engineering and
Software EN
• 10,000 = 6VDC / VCMV out SEW-EURODRIVE’s MOVI-C
• VCMV out = 0.6mV Transform pneumatics systems for

and safety
Measurement Accuracy = 3VDC +0.6mV, or +0.02% Five Signs That it is Time to
The measurement accuracy determined in the example above would be considered Application and What to Look for
reasonable for most applications. The starting CMV was twice the magnitude of the in a Suitable Replacement
starting signal. The differential amplifier, with its 80dB CMRR specification, reduced Direct drive vs. geared rotary
the CMV’s effect on the amplifier’s output to fractions of a millivolt, with a negligible
design advantage
impact on accuracy. It may appear from this example that 80dB rejection is suitable for
most applications. 24

Example 2 — The Flying Motion
The following example tests that hypothesis, using the real-world application shown in
Figure 2. during plasma surface treatment
process
• 80dB = 10,000 = +200VDC / VCMV out VFDs: six benefits, energy

efficiency
• VCMV out = +20mV The Importance

TABLE 1: CMRR versus CMV Reduction of Isolated Signal
Conditioners in
Measurement Accuracy = CMRR (dB) Antilog Equivalent (10db/20) Protecting Sensors and
50mV +20mV, or +40% 20 10 Measurement Equipment
30 32
40 100
The instrument that works well when 50 316 Recognize service conditions for
the spread between the CMV and 60 1,000 motors and generators
NMV potentials is narrow (only 2:1 70 3,162 MOVISUITE Engineering and

80 10,000 Software EN
in the first example) fails when the
90 31,623
spread increases exponentially. This is 100 100,000
a common situation in many produc- 110 316,228
120 1,000,000 Transform pneumatics systems for
tion measurements, like the 4,000:1
130 3,162,280
spread of the typical current shunt and safety
140 10,000,000
measurement in Figure 2. 150 31,622,800 Five Signs That it is Time to
160 100,000,000
Since you cannot lower the CMV in General Equation: Voltage Error = CMV / CMRR Application and What to Look for
these situations, the only solution is Example: Assume that CMV = 100V, CMRR = 90dB in a Suitable Replacement
Voltage Error = 100 / 31,623 = 3.2mV
to apply an instrument with better Direct drive vs. geared rotary
CMR. design advantage
Compare the calculated 3.2mV error with your sig-
nal of interest to determine overall accuracy.
25

Example 3 — The Flying Motion
Here’s how the math stacks up for the same application using 120dB CMRR:
process
• 120dB = 20 log (VCMV in / VCMV out)
efficiency
• 120dB = 20 log (200VDC / VCMV out)
The Importance
of Isolated Signal
• 6 = log (+200VDC / VCMV out)
Conditioners in
• 1,000,000 = (+200VDC / VCMV out) Measurement Equipment
• VCMV out = +0.2mV Recognize service conditions for
Measurement Accuracy = 50mV +0.2mV, or +0.4% MOVISUITE Engineering and

Software EN
As the examples show, knowing how a CMV will affect measurement accuracy is at SEW-EURODRIVE’s MOVI-C
least as important as knowing that it exists. To help evaluate an instrument you may
already have or might purchase, Table 1 provides a guide to the error caused by a CMV
as a function of your instrument’s CMRR. and safety

To use it, determine the CMV of the application and look up the instrument’s CMRR Replace the Mercury Based Relays
specification on its data sheet. Application and What to Look for
Table 1 provides a range of CMRRs in decibels and their equivalent antilog ratios, mak- Direct drive vs. geared rotary
ing it unnecessary to work with logarithmic math. design advantage
26
Plug the appropriate CMV and antilog ratio into the equation shown. The result is the Motion Control: Beckhoff XPlanar
expected measurement error in volts. To determine the instrument’s suitability for the
application, compare the resulting figure with the NMV you need to measure. during plasma surface treatment
process
4. AC Common-Mode Rejection (CMR) VFDs: six benefits, energy

efficiency
AC CMVs are as prevalent as DC CMVs, and even more so when you include unpre-
dictable noise sources such as motor brushes, and inductive conducted and radiated The Importance
electromagnetic fields (EMFs). Therefore, the assumption of pure DC CMVs may not be of Isolated Signal
Conditioners in
supported in actual practice. It’s worthwhile to explore how AC CMVs may adversely Protecting Sensors and
affect an amplifier’s CMRR and measurement accuracy. Measurement Equipment
An isolation amplifier’s capability to reject CMVs is tied directly to how well its two
inputs are balanced. Falling back to an ideal example, if 1VDC is connected to one of motors and generators
the inputs and 1VDC is connected to the other, the expected output from the amplifier MOVISUITE Engineering and
is 0V. However, because no real-life situation is ever ideal, small tolerance variations Software EN
within the amplifier, and even in the system-under-test, will force the amplifier to be SEW-EURODRIVE’s MOVI-C
slightly out of balance, yielding inaccuracies. When an AC CMV is applied, a whole Modular Automation System
new set of inaccuracies is introduced. The culprit heralds back to the beginning of this Transform pneumatics systems for
paper – capacitance. and safety

Under pure DC CMV conditions, any capacitance in the signal source, signal cable, and Replace the Mercury Based Relays
connectors, as well as within the amplifier itself, is inconsequential. As AC components Application and What to Look for
are introduced, these capacitances form complex and unpredictable impedance, which in a Suitable Replacement
can force the amplifier out of balance. This unbalanced condition can and will change Direct drive vs. geared rotary
as a function of frequency.
design advantage
27
To account for this, most manufacturers specify CMRR at other than ideal DC condi- Motion Control: Beckhoff XPlanar
tions. Typically, specifications are given at 50 or 60Hz with a 1,000Ω imbalance between
the amplifier’s inputs. This is done to provide a worst-case estimate for CMRR under during plasma surface treatment
the most likely source of AC interference - the frequency of the AC power line. Beyond process
this, a manufacturer cannot predict what particular frequencies different applications VFDs: six benefits, energy
efficiency
may experience.
The Importance
For example, it is possible to find that an instrument specified at 100dB CMR yields of Isolated Signal
Conditioners in
much lower rejection in the presence of higher frequency noise. However, the product Protecting Sensors and
still operates within specification, as defined by the manufacturer. Measurement Equipment
It is difficult to determine the suitability of an instrument in the presence of noise (fre-
quency) that goes beyond that of the power line; there is no easy answer to this ques- motors and generators
tion. However, keep in mind that a product that successfully addresses such an applica- MOVISUITE Engineering and
tion does not do so by chance. Wide-spectrum AC rejection must be incorporated into Software EN
the initial product design. SEW-EURODRIVE’s MOVI-C
5. Measurement Range and Input Protection Transform pneumatics systems for

Up to this point, some of the more esoteric, yet highly relevant, issues have been ex- and safety
amined that must be considered when an instrument is applied to demanding produc-
tion applications. Other more obvious issues involve the instrument’s measurement Replace the Mercury Based Relays
range and input protection. Application and What to Look for
Most production applications will test an instrument’s capability on both ends of the Direct drive vs. geared rotary
measurement spectrum: from high voltages in the range of several hundred volts to
design advantage
low shunt voltages in the range of tens of millivolts. The system design chosen for
28
these applications should be able to function easily over a variety of measurement Motion Control: Beckhoff XPlanar
ranges; it should do so on a channel-by-channel basis, since it is very common to mea-
sure voltage and current simultaneously. during plasma surface treatment
process
Nevertheless, the very nature of these highly variable and wide-ranging dynamic mea- VFDs: six benefits, energy
efficiency
surements carries an implied need for input protection. It’s common for someone to
attempt to measure a high voltage on an instrument set to a millivolt range. Typical The Importance
input protection allows any input signal within an instrument’s maximum range (without of Isolated Signal
Conditioners in
damage to the instrument) to be connected indefinitely, regardless of the measure- Protecting Sensors and
ment range selected. More practical input protection allows input signals many times Measurement Equipment
that of the maximum input range to be connected without damaging the instrument. What Is Signal Conditioning?

Finally, if the instrument’s maximum range is exceeded and there is inadequate input motors and generators
protection, there can be consequences such as damage to the instrument, the cost MOVISUITE Engineering and
and inconvenience of downtime and repairs, etc. Although many types of input pro- Software EN
tection abound, none can absolutely or completely protect an instrument. Fortunately, SEW-EURODRIVE’s MOVI-C
damage can be minimized using products designed to tolerate high-voltage differen- Modular Automation System
tial transients (for example, those defined by ANSI/IEEE C37.90.1) as well as high com- Transform pneumatics systems for
mon-mode voltages. and safety

Conclusions Replace the Mercury Based Relays
Isolated signal conditioning products protect and preserve valuable measurements Application and What to Look for
and control signals, as well as equipment, from the dangerous and degrading effects in a Suitable Replacement
of noise, transient power surges, internal ground loops, and other hazards present in Direct drive vs. geared rotary
industrial environments.
design advantage
29
For more information, email sales@dataforth.com or visit www.dataforth.com. Motion Control: Beckhoff XPlanar

Acknowledgement during plasma surface treatment
Dataforth acknowledges and credits Roger Lockhart, DATAQ Instruments, Inc., for process
technical contributions to this article. VFDs: six benefits, energy

efficiency
References The Importance

1. Dataforth Corp. http://www.dataforth.com of Isolated Signal
Conditioners in
2. Application Note AN108 http://www.dataforth.com/catalog/pdf/an108.pdf Protecting Sensors and
Georg Haubner, MSEE, MBA What Is Signal Conditioning?
Georg Haubner, MSEE, MBA, is the Vice President of Sales & Marketing at Dataforth
Corp., a worldwide leader and innovator of signal conditioning, data acquisition, and motors and generators
data communication products. MOVISUITE Engineering and
Software EN

and safety


design advantage
30


process

efficiency

Equipment
What Is Signal

Conditioning?

Software EN

What Is Signal Conditioning? energy conservation, efficiency
and safety
The ability to effectively measure and control industrial Five Signs That it is Time to
processes is essential for reliable automation, data acquisition, Replace the Mercury Based Relays
and quality assurance in today’s industrial environment. Signal Application and What to Look for
conditioners are the vital link between analog input signals
from sensors, and your process control equipment. Direct drive vs. geared rotary
design advantage
31
Recognize service conditions for Stepper motor torque basics
motors and generators Motion Control: Beckhoff XPlanar


It is important to understand the differences between the usual service during plasma surface treatment
process
conditions most motor designs assume and unusual service conditions that
lead to unreliable operation and costly shutdowns efficiency
W
hen selecting a motor for a new application or solving a problem with an exist- Signal Conditioners in Protecting
ing one, it’s important to verify the motor will operate normally in the conditions Sensors and Measurement
Equipment
the application presents. Although these situations may not occur often, it’s helpful to
understand the differences between the usual service conditions most motor designs
assume and the unusual service conditions that can lead to unreliable operation and Recognize service
costly shutdowns. conditions for motors
and generators
Good starting points for this discussion are the definitions of usual and unusual service MOVISUITE Engineering and
Software EN
conditions in the National Electrical Manufacturers Association (NEMA) Standard MG
1: Motors and Generators (MG 1). The International Electrotechnical Commission (IEC) Modular Automation System
Standard 60034-1: Rotating Electrical Machines, Part 1: Ratings and Performance, also
addresses application conditions (see Clause 6) but to a lesser extent, so the focus energy conservation, efficiency
and safety
here is on MG 1.
Usual conditions and Switches in Your Industrial
MG 1, 1.6 defines usual service conditions for a wide variety of motors and generators. Application and What to Look for
These include general-purpose alternating-current motors, general-purpose direct-cur-
rent small motors, general-purpose generators, industrial direct-current medium mo- servomotor: A quantification of
tors and industrial direct-current generators. design advantage
32
Recognize service conditions for motors and generators
According to MG 1, gener- Motion Control: Beckhoff XPlanar

al-purpose ac motor designs
have “standard ratings with during plasma surface treatment
standard operating char- process
acteristics and mechanical VFDs: six benefits, energy

efficiency
construction for use under
usual service conditions The Importance of Isolated
without restriction to a par- Sensors and Measurement
Equipment
ticular application or type of
application.” Its definitions What Is Signal Conditioning?
of the four other motor cate- Recognize service

gories share this characteris- conditions for motors
tics: mechanical construction and generators
suitable for use under usual service conditions. Since the Figure 1. A motor in an application MOVISUITE Engineering and
that could be classified as “usual.” Software EN
manufacturer designs the mechanical construction for a
Courtesy: EASA
specific type of motor (e.g., a general-purpose ac motor), SEW-EURODRIVE’s MOVI-C
the variables that could affect successful operation are the usual service conditions.
According to MG 1, 14.2, the usual environmental/service conditions include (see Figure 1): and safety

• Exposure to ambient temperature in the range of -15°C to 40°C, or 5°C to 40°C
for water-cooled machines (to prevent water from freezing). For machines rated Application and What to Look for
less than 3/4 hp and all machines (except water-cooled) that have a commutator or
sleeve bearings, the minimum ambient temperature is 0°C. Direct drive vs. geared rotary
design advantage
• Exposure to an altitude of 3,300 feet (1,000 meters) or less
33
• Installation on a rigid mounting surface Motion Control: Beckhoff XPlanar


• Installation in areas or supplementary enclosures that do not seriously interfere during plasma surface treatment
with the ventilation of the machine. process

efficiency
Each of these items deserves fuller explanation.
Ambient temperature. Motor nameplates frequently indicate the maximum ambient rating Sensors and Measurement
Equipment
of 40°C but rarely state the lower ambient temperature limit. Nevertheless, operation below
the minimum or above the maximum ambient temperature normally is not permissible. What Is Signal Conditioning?
Recognize service
A best practice is to check with the motor manufacturer regarding operation outside of conditions for motors
the usual ambient temperature range. At low temperatures, bearings and lubrication and generators
may be the primary concerns. At high temperatures, the winding, as well as bearings MOVISUITE Engineering and
Software EN
and lubrication, may be the main issues.
Caution. The ambient rating on nameplates applies to what we often term “room tem-
perature.” The temperature rise, or maximum winding temperature, rarely appears on energy conservation, efficiency
motor nameplates and is beyond the scope of this article. and safety

Altitude. Operation above 3,300 feet (1,000 meters) is not normally permissible with-
out derating the motor power rating. Temperature rise may provide guidance for op- Application and What to Look for
eration at such altitudes without derating the motor’s power rating, but as mentioned
earlier, that is beyond the scope of this article. Direct drive vs. geared rotary
design advantage
Rigid mounting. Most motors mount on a rigid base, so this is seldom a concern. Con-
34
sult the motor manufacturer about other mounting arrangements (e.g., a cantilevered Motion Control: Beckhoff XPlanar
base supported by belt tension).
Ventilation. An uncompromised ventilation system is the normal condition for a motor. process
An example that violates this rule would be to place a compressor motor, air compres- VFDs: six benefits, energy
efficiency
sor and controls inside an enclosure such as a cabinet.
Unusual conditions Sensors and Measurement
Equipment
MG 1, 14.3 provides a list of unusual service conditions and recommends consulting
the manufacturer if any of them may affect motor construction or operation (see Figure What Is Signal Conditioning?
2), including exposure to: Recognize service

conditions for motors
• Combustible, explosive, abrasive or conducting dusts and generators
Software EN
• Accumulated dirt and debris that may interfere with normal ventilation
• Chemical fumes; flammable or explosive gases
• Steam, salt-laden air, oil vapor and safety

• Damp locations, radiant heat, vermin infestation, atmospheres conducive to the
growth of fungus Application and What to Look for
• Abnormal shock, vibration or mechanical loading from external sources. Direct drive vs. geared rotary
design advantage
The list of unusual exposure conditions in MG 1, 14.3 is not intended to be exhaustive
35
or complete, because Motion Control: Beckhoff XPlanar

that would be too volu-
minous for practical use. during plasma surface treatment
To better appreciate what process
constitutes unusual ser- VFDs: six benefits, energy

efficiency
vice conditions, consider
their opposites. From that The Importance of Isolated
perspective, exposure Sensors and Measurement
Equipment
should be to clean, dry
(but not too dry) air with What Is Signal Conditioning?
no mechanical or phys- Recognize service

ical disturbances, e.g., conditions for motors
conditions that would be and generators
Figure 2. Motors exposed to
expected for factory testing new motors. unusual an condition of chemical
Software EN
(possibly explosive) fumes.
As with exposure conditions, the list of unusual operating Courtesy: EASA SEW-EURODRIVE’s MOVI-C
conditions in MG 1, 14.3 is not intended to be exhaustive
or complete. Among the items it covers are: energy conservation, efficiency
and safety
• Electrical supply voltage and frequency Five Signs That it is Time to

• Excessive departure from rated voltage or frequency, or both
• The ac supply voltage more than 1% unbalanced Application and What to Look for
• Operation at above rated speed (see Table 1) Direct drive vs. geared rotary
design advantage
• Operation in a poorly ventilated room or a pit
36
• Operation in an inclined position Motion Control: Beckhoff XPlanar


• Excessive mechanical forces during plasma surface treatment
• Repetitive abnormal overloads process
• Torsional impact VFDs: six benefits, energy

efficiency
• Frequent starting or reversing
• Electric braking. The Importance of Isolated
Equipment
As with the list of usual conditions, each of these unusual conditions merits more discus-
sion. What Is Signal Conditioning?
Recognize service
Electrical supply voltage and frequency. Unusual service conditions exist if voltages conditions for motors
exceed ±10% of motor rated voltage, frequency exceeds ±5% of rated (+3%/-5% per and generators
IEC 60034-1, 7.3), or both. Voltage unbalance greater than 1% among phases also is an MOVISUITE Engineering and
Software EN
unusual service condition.
Operation at above rated speed. This could be a concern for a motor powered by a
variable frequency drive (VFD). Table 1 provides overspeed limits for induction motors. energy conservation, efficiency
and safety
Poor ventilation and pit operation. Poor ventilation resembles unusual exposure Five Signs That it is Time to
conditions already mentioned. Likewise, operation in a pit may lead to problems with
dampness or possibly submergence. Application and What to Look for
Operation in an inclined position. Small and medium horizontal motors typically can Direct drive vs. geared rotary
operate in an inclined or even a vertical position, but those orientations are classified design advantage
as unusual service conditions. Changing the motor’s orientation could affect its lubri-
37
cant pathways, preventing grease from Motion Control: Beckhoff XPlanar

reaching the bearings. On oil-lubricat-
ed motors, it could cause leaks. during plasma surface treatment
process
Excessive mechanical forces. Exces- VFDs: six benefits, energy

efficiency
sive mechanical forces, such as over-
load and torsional impact, are obvious- The Importance of Isolated
ly unusual service conditions because Sensors and Measurement
Equipment
they can lead to premature shaft fail-
ure. Frequent starting or reversing also What Is Signal Conditioning?
Table 1: Overspeed limits for
can result in excess mechanical load, as well as stator induction motors. Courtesy: EASA Recognize service
and rotor overheating due to the high ratio of starting conditions for motors
to full-load current (typically from 5:1 to 8:1). and generators
Software EN
Similarly, electric braking can cause above-rated current during braking, and rapid
heating if the braking power is still applied after the motor is at rest. SEW-EURODRIVE’s MOVI-C

Final thoughts energy conservation, efficiency
Knowing the differences between usual and unusual motor service conditions may not and safety
be something you’ll use often. But this information will be invaluable when it’s time to Five Signs That it is Time to
choose a motor for a new application or to troubleshoot a problem or failure.
Thomas H. Bishop, P.E.
Thomas Bishop is a senior technical support specialist at EASA Inc., St. Louis. EASA, Direct drive vs. geared rotary
a CFE Media content partner, is an international trade association of more than 1,800 design advantage
firms in about 70 countries that sell and service electromechanical apparatus.
38
MOVISUITE Engineering and Software EN


process

efficiency

Equipment

MOVISUITE Engineering
and Software EN

MOVISUITE® Engineering Software EN and safety

This engineering software for automation projects saves Replace the Mercury Based Relays
time and money, and gets you where you want to be and Switches in Your Industrial
intuitively and with ease. One software suite that can be in a Suitable Replacement
used for planning, startup, operation and diagnostics. Direct drive vs. geared rotary
design advantage
39
SEW- Can you please describe one innovative mo-
tor or drive that a machine builder would
EURODRIVE’s
find valuable, as well as the technology that
makes it work?
MOVI-C Modular SEW-EURODRIVES’s MOVI-C® modular automation sys-

tem is a flexible one-software, one-hardware automation
Automation platform that combines fully integrated drive components,

control electronics and automation software – all from one
System
source. The key to the MOVI-C platform is that each of
those components is designed to work together perfectly.
The MOVI-C platform utilizes our newest technologies –

from high efficiency asynchronous gearmotors to ultra-ef-
ficient permanent magnet servomotors. Machine builders
will appreciate the seamless integration and the availability
of proven and value-adding software kits tailored to the
customer’s application.
What specific applications or problems was

MOVI-C designed for?
Today’s engineers can quickly get overwhelmed with au-

tomation complexity. The MOVI-C platform has been de-
signed to simplify motion control and automation challeng-
es from basic to advanced needs and requirements– using
SEW-EURODRIVE’s MOVI-C Modular Automation System
controls and components designed Motion Control: Beckhoff XPlanar

to work perfectly together.
The new MOVI-C product family is process
designed to solve a wide range of VFDs: six benefits, energy

efficiency
motion control challenges ranging
from standard shaft spinning ap- The Importance of Isolated
plications like simple conveyors all Sensors and Measurement
Equipment
the way to complex multi-axis kine-
matics and robotics - for beginner What Is Signal Conditioning?
or advanced level engineers. Our Recognize service conditions for

approach: more parametrization, less programming. With this modular automation
platform, we cover decentralized control architectures as well as centralized approach- MOVISUITE Engineering and
Software EN
es, all the way to highly complex multi-axis systems. From the controller and inverter all
the way to the gearbox: automation made simple. SEW-EURODRIVE’s
MOVI-C Modular
Automation System
What makes the design of the MOVI-C automation platform
unique? energy conservation, efficiency
and safety
Typically, engineers order control electronics from one source, software from anoth- Five Signs That it is Time to
er, and drive components from yet another. Getting these building blocks all to work and Switches in Your Industrial
together is another story. The MOVI-C platform offers a complete automation solution Application and What to Look for
– without all the headaches of mismatched components and complexity.
As an added benefit, our MOVIKIT® pre-built software modules are available for many design advantage
common motion control applications from simple to complex, even robot control. This
41
SEW-EURODRIVE’s MOVI-C Modular Automation System
makes it easy for engineers of all skill Motion Control: Beckhoff XPlanar
levels to do their own automation.
process
What should users know about
the MOVI-C platform, whether VFDs: six benefits, energy
efficiency
it’s a rookie who’s unfamiliar
with it or a veteran in need of a Signal Conditioners in Protecting
refresher? Equipment

The MOVI-C platform is easy to deploy
and intuitive to start up. Plus, with standardized MOVIKIT pre-built application mod- motors and generators
ules, there is very little programming required, even for advanced automation tasks.
MOVI-C also integrates with all major PLC manufacturers. Software EN
SEW-EURODRIVE’s
Combining MOVI-C’s ease of use and MOVIKIT’s flexible pre-built modules is the most MOVI-C Modular
intuitive way to integrate state of the art drive technology into your machine. Custom- Automation System
ized solutions also include open loop, closed loop, functional safety, and decentralized Transform pneumatics systems for
applications. Communication compatibility includes Ethernet IP, PROFINET®, PROF-
and safety
INETSave®, EtherCat®, FSoE, and other standards.

design advantage
42
Transform pneumatics systems Stepper motor torque basics
for energy conservation, Motion Control: Beckhoff XPlanar

efficiency and safety XPlanar transports workpiece

process
Machine automation evolution proves the only limitation is the imagination VFDs: six benefits, energy
efficiency
I
n the past, the idea of, “air is for breathing, water is for drinking, oil is for your au- Signal Conditioners in Protecting
tomobile” was one shared by many designers when specifying components, de- Sensors and Measurement
Equipment
signing systems and building machinery. The result was big, inefficient machines that
consumed great amounts of commodities.
As manufacturing evolves to accommodate more demanding, safer and more precise
processes, including for compressed air use and energy-conscious automation, the
Software EN
pneumatics industry is aligning itself as a critical strategic partner.
Manufacturers of pneumatic systems are highly motivated to stay ahead of the lat-
Transform pneumatics
est trends. The emergent technologies enhancing factory expressly address size and systems for energy
footprint, energy consumption and connectivity as well as monitoring of plant auto- conservation, efficiency
mation as it relates to maintenance planning and operational efficiency. and safety
In earlier manufacturing plants, factory installations were dominated by a mass of and Switches in Your Industrial
valves, actuators and other big, bulky and inefficient pneumatic system components. Application and What to Look for

Air preparation was exceptionally oversized, and valving was placed on sub-bases
the size of bricks and weighing more. Pneumatic actuators used up large amounts design advantage
of machine real estate (although they did have a calming hiss to them, ensuring that
43
Transform pneumatics systems for energy conservation, efficiency
compressed air was Motion Control: Beckhoff XPlanar

present and ready
for work). While the during plasma surface treatment
traditional designs of process
the past were useful VFDs: six benefits, energy

efficiency
and effective, the
days of using the air The Importance of Isolated
control valve as a Sensors and Measurement
Equipment
step stool to reach
higher on the ma- What Is Signal Conditioning?
chine are gone. Recognize service conditions for

What’s replaced MOVISUITE Engineering and

Software EN
them are a sleeker, Figure 1: Today’s air cylinders encompass further
more energy efficient and aesthetically development of proven ISO cylinder designs. They
address needed solutions addressing tasks and
pleasing means to deliver air to automated
applications encountered in nearly all industries.
processes.
Courtesy: Emerson/Aventics
systems for energy
conservation, efficiency
Efficiency-focused demand vis-à-vis automated machinery has impacted valves, re- and safety
sulting in less weight, smaller size and power savings. Air preparation encompasses Five Signs That it is Time to
full-featured assemblies that ensure efficiency, copious functionality and safety. Ac- Replace the Mercury Based Relays
tuators are lightweight, incorporate position feedback and a wider range of applica- Application and What to Look for
tions. Component lubrication has all but been eliminated. in a Suitable Replacement

These innovations allow designers to focus on compact machine footprints and con- design advantage
nectivity while retaining a focus on plant savings. Durability results in assemblies
44
capable of attaining millions of valve cycles and actuations, while being paired with Motion Control: Beckhoff XPlanar
monitoring technologies that support streamlined preventive maintenance programs
in many facilities. during plasma surface treatment
process
Improving efficiency VFDs: six benefits, energy

efficiency
To start improving overall pneumatics efficiency, the first place to start is always the
compressor room — the place where the larger horsepower motors and biggest en- Signal Conditioners in Protecting
ergy users reside. Decrease the load on the compressor room and the plant will see Sensors and Measurement
Equipment
bottom-line benefits.
Compressor manufacturers “feel” the demand for greater efficiencies, less noise and Recognize service conditions for
more environmentally friendly environments, as well as integration of pneumatic sys-
tems into the plant’s primary monitoring and control systems. MOVISUITE Engineering and
Software EN
They’ve delivered solutions smaller footprints that are less noisy in operations, as Modular Automation System
well as more effective enclosures that make use of variable frequency drives, oil-free
options and innovative control schemes that tie into the factory monitoring platform
systems for energy
(see Figure 1). These designs allow a compressor to be controlled, i.e., accelerated, conservation, efficiency
decelerated or even idled and turned off according to plant demand. These moni- and safety
toring and control options mean pneumatics can be managed from anywhere in the Five Signs That it is Time to
plant as well as, in some cases, from offsite. Replace the Mercury Based Relays
Where once compressed air was considered to be just a commodity, it is now a bal-
ance-sheet line item controlled and monitored via emergent technologies that deliv- Direct drive vs. geared rotary
er real operational improvements. design advantage
45
Gaining control of pneumatics use can be seen as an initial step in an overall plant Motion Control: Beckhoff XPlanar
efficiency program by reducing compressed air usage.
On the production floor, machine users have options at their fingertips when it process
comes to solution selection. Correct sizing has been a perennial topic of discussion VFDs: six benefits, energy
efficiency
over the years. Conducting a Google search on the term, “pneumatic system de-
sign,” elicits more than 84 million results. Included in the results are many pneumatic The Importance of Isolated
solution providers offering software applications that support maximum efficiency Sensors and Measurement
Equipment
when sizing machine components, eliminating whatever value was once found in the
rule-of-thumb: “pipe size, right size.” What Is Signal Conditioning?

These software application tools eliminate the need to upsize components, eliminat-
ing the need to bake in the extra capacity that was the norm and ensuring that ma- MOVISUITE Engineering and
Software EN
chines will operate as designed without wasting utility resources.
Component efficiency
While the compressor room with the high horsepower motors is the first place to
systems for energy
look, there are other targets primed to be made more efficient. Valve technology has conservation, efficiency
addressed the same need for energy conservation as has impacted other pneumatic and safety
components and done so in a comprehensive manner. Five Signs That it is Time to
Valves that once required more than 6 watts of power are now using 0.8 watts, and Application and What to Look for
soon-to-be introduced designs will improve this further. Manifolding multiple valves
the standard, which saves machine space, exploits less power and adds opportunities Direct drive vs. geared rotary
for fieldbus technology inclusion. This in turn will reduce the amount of wiring need- design advantage
ed while bringing components into the realm of real-time data and information.
46
Besides the sizing tools available for setting design parameters and supporting solu- Motion Control: Beckhoff XPlanar
tion choice, pneumatic system technology supports efforts to ensure that exhausting
compressed air can be a potentially costly eventuality. during plasma surface treatment
process
Manufacturers are scrutinizing and seeking better understanding of parameters that VFDs: six benefits, energy
efficiency
include force, pressure, flow and speed to discover innovative ways to decrease
compressed air usage. Technologies involved include for actuator position sensing, The Importance of Isolated
wireless communications, proportional pressure and flow regulation and emergent Sensors and Measurement
Equipment
technologies like smart pneumatics with Industrial Internet of Things (IIoT) pathways.
These intelligent pneumatic systems build bridges to the IIoT, ensure system visibili- Recognize service conditions for
ty and lower operating costs — supported by central analysis and control electronics
equipped with the ability to alert the factory of potential abnormalities or breakdowns. MOVISUITE Engineering and
Software EN
More than just compressed air Modular Automation System
In addition to solution enhancements, machine control design has changed in other
ways, including how projects are managed. Machine design and control projects of
systems for energy
the past have had two sides of the equation: a mechanical side encompassing the conservation, efficiency
pneumatics, and an electrical side focused on signaling valves and machine opera- and safety
tion. The two sides would review their schematics, overlay their plans and decide on Five Signs That it is Time to
a place to hand off the control signals. Replace the Mercury Based Relays
While technology continues to improve efficiency, demands for best practices in sup-
port of project management brings a new profile for the “controls” project leader. Direct drive vs. geared rotary
The new controls project lead creates the conduit for controlling machine movement, design advantage
encompassing electronics, airflow, feedback, positioning and machine health mon-
47
itoring. This responsibility is continuously evolving with user demands for efficient Motion Control: Beckhoff XPlanar
technology placing pressure on providers to stay up to date when it comes to inno-
vation trends. during plasma surface treatment
process
Embracing continuous technology enhancements in factory automation will reduce VFDs: six benefits, energy
efficiency
manufacturing costs and raise visibility of predictive maintenance schemes capable
of keep the plant operations efficient and continuous. The Importance of Isolated
Equipment
Pneumatic system design enhancement on the electrical side include the incorpora-
tion of fieldbus communications, IIoT and machine health monitoring as fundamental What Is Signal Conditioning?
improvements from the air and power circuits of the past. Recognize service conditions for
Fieldbus allows component communication related to the machine and across the MOVISUITE Engineering and
Software EN
plant to be streamlined via a single cable, while enabling real-time insight into the
operation of each component via the plant network or IIoT hub.
Controls leaders can review plant operations from any location — even other factory
systems for energy
locations around the world. Maintenance data supports strategic plant management conservation, efficiency
insight and support in making necessary changes or weighing requests for machin- and safety
ery improvements or replacements. Plant operations are being monitored and pro- Five Signs That it is Time to
grammed to communicate with smartphones and other intelligent devices, address- Replace the Mercury Based Relays
ing much more than just the compressed air conservation challenge. Application and What to Look for
Machine safety and energy conservation Direct drive vs. geared rotary
In addition to the pathways to IIoT, smart pneumatics and other trending technolo- design advantage
gies, safety will always be considered the priority in plant machinery product devel-
48
opment. In many Motion Control: Beckhoff XPlanar

cases, technology
is focused on safe- during plasma surface treatment
ty concerns, in- process
cluding for zoned VFDs: six benefits, energy

efficiency
safety valve prod-
ucts as well as for The Importance of Isolated
Figure 2: The latest generation of rodless cylinders Signal Conditioners in Protecting
spool sensing technology. With the ability Sensors and Measurement
features robust, virtually leak-free designs with high
Equipment
to sense the position of control valves and speed capability. Courtesy: Emerson/Aventics
confirm their position with redundant moni- What Is Signal Conditioning?
toring, the potential for injuries is significantly reduced. The ability to integrate these Recognize service conditions for
smart components into machine build strategies is ever improving and is being intro-
duced into the safety systems in the form of stand-alone circuits, isolated from the MOVISUITE Engineering and
Software EN
operation of the machine.
As product enhancements continue to evolve, system designers can count on pneu-
matic actuation that is lightweight, efficient, accurate and on the cutting edge. Actu-
systems for energy
ation also is a focus for safety, giving a variety of configurations such as linear, rotary conservation, efficiency
and rodless to achieve compact design, as well as machine design capsulations, and safety
protecting the automation-driven motions from the machine operator (see Figure 2). Five Signs That it is Time to
One popular function related to enhanced safety is actuator position sensing across Replace the Mercury Based Relays
its entire working length. This provides an additional monitor and proactive call to Application and What to Look for
action, removing many potential hazards when combined into a safety sensing circuit. in a Suitable Replacement

Working in tandem with goals for energy conservation and overall efficiency, ma- design advantage
chine safety is greatly improved with modern pneumatic components and controls.
49
Standards developed by governing bodies require machine safety functions such as Motion Control: Beckhoff XPlanar
parameter guarding with operation-stopping safety interlocks, vision systems and the
means to release stored energy. Additional standards for safe workspace actions are during plasma surface treatment
being implemented, all to keep our friends, family and co-workers safe. process

efficiency
Machine automation experts keep safety the highest priority with products, solutions
and technologies that integrate pneumatics with other factory automation products. The Importance of Isolated
Their goal is to make the machines of today safer to use while making the machines Sensors and Measurement
Equipment
of tomorrow even safer.
Looking ahead Recognize service conditions for

Factory automation technology is being designed, released to the market and in-
corporated into new projects in response to demands for greater efficiency that is MOVISUITE Engineering and
Software EN
strong and growing. Pneumatic systems designers and providers are rising to meet
that demand with creative and innovative approaches for new and challenging appli- Modular Automation System
cations. One can argue that earlier pneumatic systems were oversized air consumers,
but technology has changed the landscape of the entire factory. Pneumatic system
systems for energy
manufacturers consider the plant in all its aspects as they address design and appli- conservation, efficiency
cation projects, with an express understanding that compressed air is no longer the and safety
commodity it was once considered to be. Five Signs That it is Time to
The factory of today runs more efficiently than it did in the past and in full awareness Application and What to Look for
of the demand for more efficient processes. The factory of tomorrow will undergo an
even more fundamental technology paradigm shift. Pneumatic system manufacturers Direct drive vs. geared rotary
are stepping outside the boundaries of technologies with which they’ve been most design advantage
familiar to incorporate smartphone apps, wireless communication, real-time aware-
50
ness of machine issues and production output, and most importantly, operator safety Motion Control: Beckhoff XPlanar
and accident prevention. As these innovations continue to improve efficiency and
introduce innovation, the factory of tomorrow will have options only limited to one’s during plasma surface treatment
imagination. process

efficiency
Bob Bradley and Robby Haun
Bob Bradley is a certified fluid power specialist with Motion Industries and lives in The Importance of Isolated
Loves Park, Ill. He has worked in the fluid power industry since 1988, and with Mo- Sensors and Measurement
Equipment
tion Industries for 17 years. He currently supports sales in Northern Illinois for many
Motion Industries locations. Robert (Robby) Haun is national sales manager for What Is Signal Conditioning?
mechanical products for Emerson where he has worked since 2012. He lives in Knox- Recognize service conditions for
ville, Tenn., and has a Bachelor of Science degree from Ashford University as well as
an MBA from South College. He began his career in machine automation in 2000 and MOVISUITE Engineering and
Software EN
has since moved into a heavier fluid power focus, designing and selling pneumat-
ics and hydraulic systems and managing electrical control and automation business
units.
systems for energy
conservation, efficiency
and safety

design advantage
51
Five Signs That it
is Time to Replace
the Mercury
Based Relays
and Switches in
Your Industrial Summary
Application and Mercury relays have been used in industrial applications

for decades, most commonly for power switching. For
example, in applications that use process heating, mer-
What to Look cury relays are traditionally used to power on and off of
electric heaters efficiently. But these kinds of relays are
for in a Suitable being replaced for several reasons. The latest generation
of mercury relay/mercury switch alternatives is safer and
Replacement
more accurate and just as durable.
The Background: Mercury in Industry

U.S. patents for a mercury-based relay can be found as
far back as 1937, and they have been used in industry for
Five Signs That it is Time to Replace the Mercury Based Relays
decades. They were first developed for applications Motion Control: Beckhoff XPlanar
where contact erosion could present a challenge for
more conventional relay contacts, or where constant during plasma surface treatment
cycling was needed (such as heating operations). process

efficiency
Mercury relays have been known to overheat, how-
ever, and there have been known cases of relays The Importance of Isolated
exploding and sending vaporized mercury into the Sensors and Measurement
Equipment
workspace. This can potentially create a serious environmental and safety issue, not
to mention the need for costly clean-up. But even with that risk, and with the EPA What Is Signal Conditioning?
and the European Union placing bans on the use of mercury, some manufacturers are Recognize service conditions for
still using mercury relays or similar outdated switching devices. Why?
Software EN
Some industrial engineers claim to prefer mercury relays because they believe them
to be durable and capable of handling difficult and dirty environments. While this
might be the case for some applications, financial pressure and limited design re-
sources are more likely the issue: When a relay goes bad, it just seems simpler to energy conservation, efficiency
order a replacement relay of the older design, rather than think through the introduc- and safety
tion of a more modern alternative. Five Signs That it is

Time to Replace the
Mercury Based Relays
The truth is that older mercury relays are more costly in the long run, both in terms and Switches in Your
of time and money, especially when it comes to applications like diffusion bonding Industrial Application
and superplastic forming. Replacing mercury switches and relays should be high on and What to Look for in a
Suitable Replacement
an engineer’s list, especially when the following circumstances — “red flags,” if you
will—present themselves. servomotor: A quantification of
53
design advantage
• You find that your application is going through more heaters than usual. Motion Control: Beckhoff XPlanar

• You have had multiple switches fail, or even “blow.” during plasma surface treatment
process
• Local laws or company policies are “going green.” VFDs: six benefits, energy
efficiency
• Your production line is switching from riveting to robotic welding, diffusion The Importance of Isolated
bonding. Sensors and Measurement
Equipment
• Your HS&E engineer says mercury has to go. What Is Signal Conditioning?

You Find That Your Application is Going Through More
Heaters Than Usual Software EN
Both excessive thermal cycling and temperature swings can accelerate heater failure.
This is especially true when it leads to high-frequency expansion and contraction of Modular Automation System
the heater (approximately 30 to 60 seconds on and off). Mercury switches are limited Transform pneumatics systems for
in their ability to control such thermal excursions, meaning that heaters can have a energy conservation, efficiency
and safety
shorter lifespan and fail more often.
Five Signs That it is
Time to Replace the
Another issue is moisture. Over time, the moisture in a humid environment (like that Mercury Based Relays
found on many factory floors) will seep into a heater and be absorbed by the insulat- and Switches in Your
ing material (usually magnesium oxide (MgO)). When voltage is then applied to the Industrial Application
and What to Look for in a
heater, it can lead to a blown fuse or voltage arc, destroying the heater. For this rea- Suitable Replacement
son, many applications use a “bakeout” phase when starting a heater. This requires a
more modern controller, however, and so heater failure due to moisture is bound to servomotor: A quantification of
54
be more common in some applications still using mercury switches. design advantage

You’ve had Multiple Switches Fail, or Even “Blow” — The Flying Motion
Though mercury switches are known for their durability, they can still fail. When they
do, the result can be messy. A switch that has overheated can crack or burst, poten- during plasma surface treatment
process
tially releasing mercury into the workspace.
efficiency
Less dramatically, there is also evidence that mercury switches can experience a
“bridging failure,” where an accumulation of debris particles (NiHg4) in the mercu- Signal Conditioners in Protecting
ry can form a kind of bridge between the contacts, causing the switch to fail.2 This Sensors and Measurement
Equipment
tends to happen to switches at higher temperatures, and can cause the switches to
stick in an “on” position.
Local Laws or Company Policies
are “Going Green” Software EN
If you are lucky, your facility has not had a SEW-EURODRIVE’s MOVI-C
problem with heater failure or switch failure. Modular Automation System
But it is still worth being proactive about Transform pneumatics systems for
switch replacement, given the increasing pres- energy conservation, efficiency
and safety
sure on manufacturers over the past decade to
“go green.” That pressure is coming not only
Time to Replace the
from governments, but also increasingly from policy decisions made by company Mercury Based Relays
leadership. While much press has focused on CO² emissions, the use (or rather, the and Switches in Your
Industrial Application
discontinuation) of mercury is also a significant part of these environmental initia-
tives. Suitable Replacement
In the U.S.: The U.S. EPA, as well as several state EPAs, have banned mercury in a servomotor: A quantification of
55
design advantage
number of applications.
While many of these restrictions speak to specific non-industrial uses—such as mer- Motion Control: Beckhoff XPlanar
cury switches in automobiles and thermostats—it is not too far of a stretch to imag-
ine that states will be restricting the use of mercury relays and mercury switches in all during plasma surface treatment
but a few manufacturing applications. process

efficiency
Here is the EPA’s stance on the issue, from its Guide to Mercury Reduction in Industri-
al and Commercial Settings: The Importance of Isolated
Equipment
Mercury is a pollutant of concern due to its toxic and bioaccumulative properties. What Is Signal Conditioning?
Large industrial complexes often use devices such as gauges, relays, switches, ma- Recognize service conditions for
nometers and thermometers that contain mercury...These devices can leak or break,
and when they do, the resulting uncontrolled mercury spills may pose dangers to MOVISUITE Engineering and
Software EN
human health and the environment and impact the facility’s ability to meet discharge
permit limits. In addition, properly cleaning up a mercury spill in order to meet cur-
rent safety standards is extremely expensive.
and safety
In Europe: Europe has been even more aggressive in its stance toward the use of Five Signs That it is
mercury and other substances in manufacturing, specifically via European Union’s Time to Replace the
Directive 2002/95/EC, the Restriction of the Use of Certain Hazardous Substances in and Switches in Your
Electrical and Electronic Equipment (RoHS). RoHS prohibits the use of six substances Industrial Application
in electrical and electronic equipment in the EU: Lead (Pb), mercury (Hg), cadmium and What to Look for in a
(Cd), hexavalent chromium (Cr 6+), polybrominated biphenyl (PBB) and polybromi-
nated diphenyl ether (PBDE). Switches would thus be covered by RoHS. servomotor: A quantification of
56
design advantage

Your Production Line is Switching From Riveting to Robot- — The Flying Motion
ic Welding, Diffusion Bonding XPlanar transports workpiece
In many industrial processes, riveting is being replaced with robotic welding, and for during plasma surface treatment
process
good reason: Robotic welding is less labor intensive, uses less material and creates
less waste. That said, it also has stricter specifications and requirements. Precise
efficiency
measurements and temperature control are needed.
Diffusion bonding is a solid-state welding technique, widely used to fuse sheets of Sensors and Measurement
Equipment
dissimilar metals together. To do this, the metals need to be brought to a tempera-
ture that is approximately 50%-70% of the absolute melting temperature of the met-
als involved. Again, temperature control is important to get a proper weld, and the Recognize service conditions for
heater cannot experience too much swing during the process. Mercury switches are a
poor fit in this application. Software EN
Your HS&E Engineer Says Mercury Has to Go Modular Automation System
Even with all of the above, it is quite possible that the push to replace mercury relays Transform pneumatics systems for
comes more from inside your organization. If an internal HS&E engineer expresses energy conservation, efficiency
and safety
concerns over mercury relays, or asks to consider other alternatives, it might be time
to prioritize their replacement.
Time to Replace the
While there have historically been some applications where mercury relays make and Switches in Your
more sense, modern replacements have caught up in terms of lifespan, reliability and
tolerance of dirty and difficult environments. Thus, replacing older mercury relays (or Suitable Replacement
even older solid-state alternatives) might be the most financially feasible option in Direct drive vs. geared rotary
the long run, as well as the safest option. servomotor: A quantification of
57
design advantage

Things to Look for in a Mercury — The Flying Motion
Switch Replacement XPlanar transports workpiece
There are naturally some qualities that any switch during plasma surface treatment
process
must have in an industrial application—things like
durability, accuracy and safety. The real question
efficiency
when looking for a mercury switch replacement is
how a given switch will perform with regard to these Signal Conditioners in Protecting
qualities under usual operation conditions. It is Sensors and Measurement
Equipment
worth asking about:
• Durability - How many cycles of switches can be performed before the part Recognize service conditions for
needs to be replaced (“switching life”)? What is its contact life? What is its heat
tolerance like? What is its mechanical/vibrational tolerance like? Software EN
• Accuracy - How accurate does the switch need to be, and under what load and Modular Automation System
temperatures? What thermal excursion can be tolerated? Will you need RC sup- Transform pneumatics systems for
pression, or will your output device tolerate output leakage? energy conservation, efficiency
and safety
• Safety - Is the switch touch safe? Even if it becomes cracked or bursts? Does Five Signs That it is
Time to Replace the
it have a tendency to heat up? Can it work with heaters that have higher watt Mercury Based Relays
densities? and Switches in Your
Some other features to consider include: Suitable Replacement
• Zero-cross switching servomotor: A quantification of
58
design advantage
• Heat dissipation/need for heat sinks Motion Control: Beckhoff XPlanar


• Three-phase operation (no need to wire during plasma surface treatment
multiple command signals) process

efficiency
• Touch-safe terminations
Have further questions? Sensors and Measurement
Equipment
For decades, Watlow has been manufacturing
and selling both mercury-based and non-mer- What Is Signal Conditioning?
cury relays and switches to control industrial Recognize service conditions for
process heaters. Our engineers and sales
staff are happy to discuss the pros and cons MOVISUITE Engineering and
Software EN
of different switches and help your organiza-
tion plan out its shift to non-mercury-based Modular Automation System
options. We can match a switch to your product’s or application’s unique specifica-
tions. Contact us at www.watlow.com. energy conservation, efficiency
and safety

Time to Replace the
and Switches in Your
59
design advantage
Direct drive vs. geared rotary Stepper motor torque basics
servomotor: A quantification of Motion Control: Beckhoff XPlanar

design advantage XPlanar transports workpiece

process
A geared servomotor can be useful for rotary motion technology, but there VFDs: six benefits, energy
efficiency
are challenges and limitations users need to be aware of.
F or decades, geared servomotors have been one of the most common tools in
the industrial automation toolbox. Geared sevromotors offer positioning, veloc-
ity matching, electronic camming, winding, tensioning, tightening applications and
Equipment
efficiently match the power of a servomotor to the load. This raises the question: is a Recognize service conditions for
geared servomotor the best option for rotary motion technology, or is there a better
solution? MOVISUITE Engineering and
Software EN
In a perfect world, a rotary servo system would have torque and speed ratings that Modular Automation System
match the application so the motor is neither over-sized nor under-sized. The com-
bination of motor, transmission elements, and load should have infinite torsional energy conservation, efficiency
stiffness and zero backlash. Unfortunately, real world rotary servo systems fall short of and safety
this ideal to varying degrees. Five Signs That it is Time to

In a typical servo system, backlash is defined as the loss of motion between the mo- Application and What to Look for
tor and the load caused by the mechanical tolerances of the transmission elements;
this includes any motion loss throughout gearboxes, belts, chains, and couplings. Direct drive vs. geared
rotary servomotor: A
When a machine is initially powered on, the load will float somewhere in the middle
quantification of design
of the mechanical tolerances (Figure 1A). advantage
60
Direct drive vs. geared rotary servomotor: A quantification of design
Before the load itself may be moved by the Motion Control: Beckhoff XPlanar
motor, the motor must rotate to take up all
slack existing in the transmission elements during plasma surface treatment
(Figure 1B). When the motor begins to decel- process
erate at the end of a move, the load position VFDs: six benefits, energy
efficiency
may actually overtake the motor position as
momentum carries the load beyond the mo- The Importance of Isolated
tor position. Sensors and Measurement
Equipment
The motor must again take up the slack in the What Is Signal Conditioning?
opposite direction before applying torque to Recognize service conditions for

the load to decelerate it (Figure 1C). This loss
of motion is called backlash, and is typically MOVISUITE Engineering and
Software EN
measured in arc-minutes, equal to 1/60th of
a degree. Gearboxes designed for use with
servos in industrial applications often have
backlash specifications ranging from 3 to 9 energy conservation, efficiency
arc-minutes. and safety

Torsional stiffness is the resistance to twisting and Switches in Your Industrial
of the motor shaft, transmission elements, Application and What to Look for
Figure 1: In a typical servo system, in a Suitable Replacement
and the load in response to the application of torque.
backlash, rotation and slack are all
An infinitely stiff system would transmit torque to the elements that are part of the drive
Direct drive vs. geared
load with no angular deflection about the axis of rota- process. Courtesy: Yaskawa America
tion; however, even a solid steel shaft will twist slightly advantage
under heavy load. The magnitude of deflection varies with the torque applied, the
61
material of the transmission elements, and their shape; intuitively, long, thin parts will Motion Control: Beckhoff XPlanar
twist more than short, fat ones. This resistance to twisting is what makes coil springs
work, as compressing the spring twists each turn of the wire slightly; fatter wire during plasma surface treatment
makes a stiffer spring. Anything less than infinite torsional stiffness causes the system process
to act as a spring, meaning potential energy will be stored in the system as the load VFDs: six benefits, energy
efficiency
resists rotation.
When combined together, finite torsional stiffness and backlash can significantly degrade Sensors and Measurement
Equipment
the performance of a servo system. Backlash can introduce uncertainty, as the motor en-
coder indicates the position of the motor’s shaft, not where the backlash has allowed the What Is Signal Conditioning?
load to settle. Backlash also introduces tuning issues as the load couples and uncouples Recognize service conditions for
from the motor briefly when the load and motor reverse relative direction.
Software EN
In addition to backlash, finite torsional stiffness stores energy by converting some of
the kinetic energy of the motor and load into potential energy, releasing it later. This
delayed energy release causes load oscillation, induces resonance, reduces maxi-
mum usable tuning gains and negatively impacts the responsiveness and settling energy conservation, efficiency
time of the servo system. In all cases, reducing backlash and increasing the stiffness and safety
of a system will increase servo performance and simplify tuning. Five Signs That it is Time to
Rotary axis servomotor configurations Application and What to Look for
The most common rotary axis configuration is a rotary servomotor with a built-in en-
coder for position feedback and a gearbox to match the available torque and speed Direct drive vs. geared
of the motor to the required torque and speed of the load. The gearbox is a constant quantification of design
power device that is the mechanical analog of a transformer for load matching. advantage
62
An improved hardware configuration uses Motion Control: Beckhoff XPlanar

a direct drive rotary servomotor, which
eliminates the transmission elements by during plasma surface treatment
directly coupling the load to the motor. process
Whereas the gearmotor configuration VFDs: six benefits, energy

efficiency
uses a coupling to a relatively small diam-
eter shaft, the direct drive system bolts The Importance of Isolated
the load directly to a much larger rotor Sensors and Measurement
Equipment
flange. This configuration eliminates
backlash and greatly increases torsional What Is Signal Conditioning?
stiffness. The higher pole count and high Recognize service conditions for
torque windings of direct drive motors
Figure 2: The performance of MOVISUITE Engineering and
match the torque and speed characteristics of a gear-
a gearmotor and direct drive Software EN
motor with a ratio of 10:1 or higher. servomotor are tested by mounting
each to a common load that simulates SEW-EURODRIVE’s MOVI-C
a high inertia rotary indexing table.
The least common and most complicated configura-
Courtesy: Yaskawa America Transform pneumatics systems for
tion is a fully closed-loop system, whereby a regular energy conservation, efficiency
rotary servomotor and gearbox or other transmission and safety
elements is combined with a second encoder used to measure the position of the Five Signs That it is Time to
load, masking, but not eliminating the effects of backlash. This adds significant cost and Switches in Your Industrial
and complexity of a second encoder, additional machining and mounting hardware, Application and What to Look for
additional cabling, and added maintenance.
Of these three system designs, the direct drive rotary servomotor offers the best
performance and lowest system complexity, but at a higher cost than the gearmotor advantage
solution. Attempting to quantify the performance advantage through manufacturer
63
manuals and catalogs is impossible though, as the motors seem remarkably similar in Motion Control: Beckhoff XPlanar
terms of specification.
The performance of a gearmotor and direct drive servomotor (Figure 2) are tested by process
mounting each to a common load that simulates a high inertia rotary indexing ta- VFDs: six benefits, energy
efficiency
ble. Using a 30-bit ring encoder on the load, the motion of the load is recorded, and
compared to each motor. Performance metrics including positioning accuracy, back- The Importance of Isolated
lash, settling time and total motion cycle time are evaluated and weighed against the Sensors and Measurement
Equipment
cost and complexity of each system.
Bryan Knight and Dakota Miller Recognize service conditions for

Bryan Knight is product marketing manager, Yaskawa America; Dakota Miller is au-
tomation product specialist, Yaskawa America. MOVISUITE Engineering and
Software EN

and safety


advantage
64
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MOTORS

VFDs: six benefits, energy

The Importance of Isolated

MOVISUITE Engineering and

Direct drive vs. geared rotary

a load. Moving something at a VFDs: six benefits, energy

ate just as a car gradually increas- Recognize service conditions for

Direct drive vs. geared rotary

Direct drive vs. geared rotary

Motion Control: Beckhoff

VFDs: six benefits, energy

The Importance of Isolated

Recognize service conditions for

MOVISUITE Engineering and

Transform pneumatics systems for

treatment process to transport workpieces with high precision and flexibility.

The plasma treatment unit

separate nozzle applies a func- Motion Control: Beckhoff XPlanar

pieces. And when it came to The Importance of Isolated

Recognize service conditions for

with floating movers MOVISUITE Engineering and

of planar tiles that can be SEW-EURODRIVE’s MOVI-C

• Raising and lowering by up to 5 Motion Control: Beckhoff XPlanar

• Rotation of 360° over all planar The Importance of Isolated

MOVISUITE Engineering and

while reducing mechanical SEW-EURODRIVE’s MOVI-C

for good parts, for instance, or Motion Control: Beckhoff XPlanar

— The Flying Motion

with thin samples, for instance, The Importance of Isolated

What Is Signal Conditioning?

Levitating 6D valuable in a range of applica- MOVISUITE Engineering and

tions: “Conventional setups use Software EN

Individual Free system

Five Signs That it is Time to

Direct drive vs. geared rotary

Motion Control: Beckhoff XPlanar

Motion Control: Beckhoff XPlanar

What Is Signal Conditioning?

Transform pneumatics systems for

Recognize service conditions for

Competition from substitutes Transform pneumatics systems for

Direct drive vs. geared rotary

frequency source power during startup, Motion Control: Beckhoff XPlanar

Demand trends for VFDs VFDs: six benefits,

• Process Control ed devices in commercial, household, and SEW-EURODRIVE’s MOVI-C

house emissions by around 40%. Direct drive vs. geared rotary

MOVISUITE Engineering and

Direct drive vs. geared rotary

Conditioners netic signals and repetitive or one-time emissions, several

in Protecting Isolating power sources and sensor signals is the most

Sensors and currents and induced electrical noise.

Measurement The need to measure and control the operation of ma-

When you move a data acquisition system from the con-

Direct drive vs. geared rotary

VFDs: six benefits, energy

Motion Control: Beckhoff XPlanar

be very quickly and irrevocably exceeded. Transform pneumatics systems for

XPlanar transports workpiece

MOVISUITE Engineering and

Transform pneumatics systems for

Direct drive vs. geared rotary

VFDs: six benefits, energy

Five Signs That it is Time to