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The Allen-Bradley PowerFlex® is a family of Compact-class AC drives developed by Rockwell Automation, to deliver cost-effective solutions for simple system integration or standalone machine-level control applications. In general, PowerFlex drives provide extreme application flexibility, linear scalability, and excellent performance while simplifying the management of workload infrastructure. PowerFlex 40 and 40P drives are the most compacts and cost-effective members of the Allen-Bradley PowerFlex® series of AC drives. They are a general-purpose class of AC drives, which provide a compact package to optimize application versatility and panel space. They are designed for ease of use, providing users with powerful and dynamic motor speed control in a compact, space-saving design. This article seeks to provide an in-depth comparison of the features and control capabilities of PowerFlex 40 and PowerFlex 40P AC drives. Allen Bradley PowerFlex 40 Allen-Bradley PowerFlex® 40 drives are an...
Allen-Bradley PanelViews are graphical operator interfaces, similar to Human-Machine Interfaces (HMIs). They are a combination of hardware and software through which users interact with a controller. These PanelView terminals are popular in a variety of industrial applications that require monitoring, control, and graphical display of operational data. Their color graphics displays allow operators to quickly understand the status of the controller and the system or machine being controlled, to make better control decisions. However, with so many different PanelView terminals available from Rockwell Automation, selecting the right one for your application can be confusing especially if you’re not familiar with their features. This article seeks to provide a detailed comparison of PanelView 800 and PanelView plus 7, to hopefully assist you to make a more informed choice between the two. PanelView 800 PanelView 800 terminals are color graphic Human-Machine Interface (HMI) devices under...
PLCs and CNCs are two major categories of digital controllers employed in different industrial control applications. On a surface level, it’s easy to group them together since they are both run by programs, digital processors, and they both interface with input and output devices. For example, if you ask a systems programmer whether a CNC controller can be used in place of a PLC system, the answer could be a frustrating variation of “Yes or No.” It’s therefore important to identify the differences between the two control systems, as discussed in this article. In electrical terms, PLC stands for Programmable Logic Controller. It is a compact, special-purpose computer designed to perform logic operations to control different electro-mechanical systems. Initially, PLCs were developed to perform the functionalities of hard-wired relays in the automotive industry. Today, Programmable Logic Controllers (PLCs) are widely used to automate manufacturing processes, assembly lines, and different...
Both Eaton S801+ and Eaton S811+ industrial soft starters, products of Eaton’s electrical business are very compact and smart electronic devices to smoothly start three-phase induction motors. Both share many common features and are distinct slightly from each other. This article focuses on some of their major characteristics which could be related to their power or control actions, hardware features, and/or environmental specifications with reference to applications, and outlines all similarities as well as differences. Both soft starters S801+ and S811 are very compact so they could be retrofitted in existing wye-delta starters, NEMA (National Electrical Manufacturers Association) and IEC (International Electrotechnical Commission) starters, or other soft starters. As this feature of S801+ and S811+ starters makes replacement of the whole system or structure avoidable, so huge expenses are emitted. This feature makes these soft starters more usable and demanding. Eaton Corporation...
A Soft Starter is a device that provides an alternative startup method to a typical AC motor with fewer power requirements at start-up. It reduces the amount of drawn inrush current and limits the motor starting torque; this helps reduce potentially damaging mechanical and electrical shocks on the motor system. When a soft starter is added to a motor’s circuit, it continuously regulates the motor’s supply voltage during the start-up phase. This means that the motor will gradually adjust to the machine’s load behavior. So, the soft starter provides the motor with a smooth acceleration up to full speed. This improves the operating behavior and lengthens the service life of your motor; it also smooths workflows. As the name suggests, soft starters are mainly used in the start-up phase of electric motors or other mechanical operating equipment. But they can also be used to stop, accelerate, reverse and protect such equipment. Moreover, they are used to reduce motor heating in case of...
No matter what industry you work in, you’ve almost certainly dealt with electrical components made by companies under the Eaton Corporation’s umbrella. Generations of industrial power and controls professionals have turned to Eaton for solutions, and as the Eaton family of companies continues to grow, we find ourselves handling products that our predecessors trusted all the same, just under different brand names. One of these evolving product families is found in Eaton’s SVX and HVX Adjustable Frequency Drives, previously sold under the Cutler-Hammer banner. In this article, we’ll update you on the current state of these still-relevant SVX and HVX drive models, as well as offer a comparison between their features. While most control hardware buyers know Eaton Corporation for its wiring, power distribution, and panel hardware products, the company has an extensive array of higher-level control and automation devices positioned to compete against industry giants Rockwell Automation and...
Recent advancements in industrial automation have led to the development of more powerful and more flexible control systems, which are easier to program, configure and communicate with. Modern industrial controllers are characterized by higher processing power and better interconnectivity in comparison to traditional controllers. Today, many industrial control applications utilize Human Machine Interfaces (HMIs) and Industrial Personal Computers (IPCs) to acquire raw data, process, visualize or store the processed data. You’ll often find both HMI and IPC on the factory floor, and it is almost impossible to distinguish them at first glance; as they resemble each other in physical appearance. Even many plant operators usually call an IPC an HMI, which adds to potential confusion. However, there are technical and functional differences between an IPC and an HMI that go beyond their outward physical design. These differences include processing and connectivity capabilities, feature set...
Allen-Bradley’s Kinetix family of motion control components offers arguably the most versatile and reliable automated motion product line on the market today. Within the Kinetix family, we find solutions for every motion-kit component type downstream of the controller – encoders, servo drives, cabling, motors, and more. Kinetix servo drives are of particular interest given the vast range of performance and application options available. To begin exploring Allen-Bradley’s servo drive options, we’ll start with this article on the Kinetix 300 / 350 servo drive series, its performance and technical details, and a comparison of models. Motion Control Automation describes the concepts, hardware, and software that perform spatial or location-based tasks in manufacturing machinery. Robotic motion is found virtually everywhere these days – from an average automatic standing office desk, to the massive boom jib on the International Space Station. In industrial manufacturing, machine engineers...
Industries globally understand the importance of electric drives in ensuring efficient control of motor outputs. And with the constant developments and innovations springing up in the industrial automation field, the need for alternating current (AC) and direct current (DC) drives have continued to grow in leaps. Both AC and DC drives are indispensable to the regulation of control signals. However, there are notable differences between the two drives. This article focuses on these differences in terms of benefits, composition, operation, capability, cost, and usability. The AC Drive and its Benefits The AC drive is used to control motor speed through the conversion of direct current (DC) to alternating current (AC). This drive involves such components as an inverter unit, DC circuit, rectifier unit, etc. It has helped increase productivity and innovation in the electronics industry. AC drives operate only with motors whose speeds are controlled by switching frequency from the...
Servo drives are an integral part of a servo system. Working in tandem with a motor, controller, and a feedback device, servo drives receive instructions from the controller for the prescribed motion for the motor. It then sends the right amount of electrical current to enable the motor to perform the motion required. There are several types of servo drives including those that control torque as well as velocity and positioning. But torque is the most used variable in many servo systems. Because they deliver the precise required voltage and current to motors, servo drives are also called amplifiers. All variables encountered by service systems – torque, position, velocity – are part of a complex motion control system that impacts safety, efficiency, and equipment condition. So, having the right servo system components are critical. Without the right components, servo systems could overheat and shorten the lifespan of the motor. There are many OEM producers of servo drives across the...
In any automation system design: cost, functionality, space, and interoperability are always on the mind of the engineer designing the system. This is true of small control builds and complex, factory-wide control environments with numerous machines connected to the system. For many decades, PLCs have been the workhorse of such automation and control systems, providing an effective and reliable way for engineers to get the job done. But within the last decade, microcontrollers have come to the forefront of numerous applications leading many to wonder if they can be considered a more cost-effective and smaller substitute for PLCs. As the “maker” culture arose with small automation applications such as desktop 3D printers, an entire ecosystem of accessories grew with them until many have reached a comparable feature set and list of capabilities of PLCs. Why then can’t they be used in place of traditional PLCs? The answer lies in a few important distinctions between the two. Benefits of...
As smart factories, facilities and cities continue to grow, so does the need for improved visualization and functionality in Human Machine Interfaces (HMI). By bringing that visualization down to the operator and technician level at the machine level, machine state, error messaging, real-time running conditions, and other information can be graphically displayed to assist in decision-making and remediation of problems. Introduced in 2015, Allen Bradley’s PanelView Plus 7 Performance offers a broader range of features than its predecessor, the PanelView Plus 7 Standard. For system designers looking to use the PanelView 7 family in their control design, here is a comparison of the most common features of each: There is quite a difference in screens and alarms allowed in a system between the Standard and the Performance. The PanelView Plus 7 Standard allows up to 100 graphics screens within a control system. The Standard is also limited to 500 alarms. By contrast, the PanelView Plus 7...
The Allen Bradley VersaView line is distinctly different from the PanelView and Component HMI class. The VersaView line combines monitors, industrial PCs, and thin clients that work on an open architecture platform. The VersaView line also has fewer connectors and is fanless, reducing commissioning time and setup costs. By combining these industrial computers and monitors with software applications and thin client software, the entire visualization experience is enhanced. The use of thin clients provides a cost-effective solution for both standalone and complex visualization systems throughout an operation. By connecting via server to access stored applications, local hard drives are not needed. This centralized approach also helps users better ensure security than distributed hard drives that may be more susceptible to breach. The VersaView Family The VersaView line is designed for system flexibility and centralized server access to power the visualization applications. This is...
Variable Frequency Drives (VFD) and Soft Starters are electronic devices that are popularly used in a wide variety of industrial processes which require the utilization of AC motors. These devices share a common, specific purpose to which they are applied, particularly in the field of motor protection and lowering of energy consumption. But what is the difference between a VFD and a Soft Starter? Before we differentiate the difference between each of the devices, let us understand first the common industry terms used to refer to these devices. A Soft Starter is commonly termed as Soft Starter, Motor Starter, or simply starter. A VFD is popularly termed as Variable Speed Drive (VSD), Adjustable Frequency AC Drive, Adjustable Speed Drive, or simply an Inverter. Soft Starters are generally used to protect the AC motor from the stress produced by a large amount of electrical inrush when the motor is started or stopped. During start-up, high amount of inrush current is absorbed directly by...
Continuing our article series on Programmable Logic Controller selection, we’ll look next at Rockwell Automation’s line of Allen-Bradley Micro800 PLCs. These controllers are particularly well positioned to tackle basic single-machine control, offering a versatile range of form factor, expansion, and connectivity options. Despite their modest cost and size, the Micro800 series is packed with advanced features that you’d normally expect only of much larger platforms. The Micro800 (and sister MicroLogix) series sits at the micro-scale end of Allen-Bradley’s PLC offerings, just under small-scale options such as the CompactLogix series, and farther yet under large-scale solutions including the flagship ControlLogix series. These series groupings do not translate into differences in quality or reliability – these names only refer to the scale of the applications each family is designed to serve. Where a ControlLogix PLC may control an entire plant, a Micro PLC is a much better fit to...