The PanelView 550 Standard Terminal HMIs have been in service for many years. Introduced by Allen Bradley to facilitate factory automation and provide real-time actionable data to users and technicians, the 550 Standard was a workhorse. The units were sturdy and reliable and were scalable across a wide range of applications. As automation capabilities have improved through more flexible communication, onboard capabilities provided by machine OEMs and further connectivity on broader networks, Allen Bradley introduced HMIs such as the PanelView 7Plus to provide a more flexible HMI platform to monitor and control devices for even more applications. Comparing the legacy PanelView 550 and the PanelView Plus 7 To fully understand the improvements in the PanelView Plus 7 over the PanelView 550 Standard, here is a direct comparison of the key features and capabilities of both. Screens The importance of HMIs in modern factories is undeniable. And screens and alarms on HMIs help monitor and...
The use of motors in modern society is staggering. It is estimated that motor systems alone account for as much as 47% of the world’s electricity usage. Further, within manufacturing environments, industrial motor systems account for 70% of all electricity used. Intersecting this reality is the fact that as technology in the form of software, AI, cloud-based systems and other advances continues to grow, opportunities exist to improve the performance and efficiency of industrial motor systems through monitoring, automation and more precise management of the entire system. Today, the norm is to link the control of these motors into entire ecosystems to run production lines on scale with better performance for the system overall. Two Approaches to Motor Speed Control To make these complex systems work and to leverage the benefits of an integrated control system, it is important for users to be able to control the most integral cog in the equipment itself – the motor. Performing the...
The PowerFlex family of variable frequency drives gives system builders many options to fit both architecture and budget needs. The PowerFlex 525 is part of Allen Bradley’s compact class of AC drives. These drives are modular and are used for stand-alone control applications or for simple control systems. Of the entrants in the 500 series of compact drives, the 525 offers embedded EtherNet/IP and a modular design that helps in tight spaces and easier installs. The 525 also carries standard safety features and can be programmed via USB. Because it is rated to run in temperatures as high as 158 degrees, the PowerFlex 525 can handle harsh environments. The 525 also has the Safe Torque-Off feature for added safety. Setting the IP Address Parameters for the 525 There are two ways to set the IP address in the 525. The first is through using the keypad on the unit itself. The second is using the USB connection and programming from a PC or laptop. Setting the IP Address with the Keypad Step...
Automation and control systems run the gamut from both simple to complex as well as small to large. Allen Bradley’s PanelView Plus 7 was introduced to better visualization for larger and more complex applications. In addition to best-in-class functionality, the PanelView Plus 7 offers a larger screen and much more processing power. In today’s complex manufacturing environments, visualization is critical to manage production or process flow. To do this, companies rely on multiple terminals as well as many PCs for both remote monitoring as well as programming. The PanelView Plus 7’s embedded Ethernet capability and two Ethernet ports allow it to function in a number of complex control solutions such as device level ring topology. The Ethernet connectivity is key to the PanelView Plus 7’s success in allowing managers and technicians direct as well as remote access to configure devices, troubleshoot process issues and review and address alarms. Because of its importance to the PanelView...
The Kinetix 5500 and 5700 series servo drives offer innovative responses to automation and motion control needs for any system. Combined with the right Kinetix VP servo motors, these systems optimize space and are easier and simpler to use. Because they integrate motion control on EtherNet/IP, a dedicated motion network is not required. This allows for as much as a 60% reduction in cabling and eliminates the requirement for gateways to send and receive data from far away networks. The 5500 comes in 6 sizes while the 5700 series comes in 18 sizes. The 5500 and 5700 work with Kinetix VP servo motors for optimal performance. Kinetix VP servo motors are designed for specific applications such as food grade, continuous duty, low inertia and others. This gives users a motion control system customized for their specific applications. Because Kinetix servo motors have unique winding technology and a DSL encoder onboard, they can connect to smart cable technology to allow communication to the...
PowerFlex low voltage AC drives can be used in a wide variety of control solutions. The PowerFlex family of controllers ranges from low end applications for more simple control needs to more advanced and feature rich models that increase capabilities such as precise positioning and advanced torque control. The PowerFlex family is also easy to program and configure and offers the familiarity of a common user experience regardless of the model selected. This is true for both compact PowerFlex drives used in simple applications at the machine level or in stand alone configuration as well as for architecture sized models with more advanced features and precision built for integration into a factory level or production line control system. The result of this level of flexibility and common software utilization means that the PowerFlex family offers many advantages such as: Low Cost – The range of functionality is so broad along the PowerFlex family that you can choose the right package of...
Graphic terminals are an essential part of most modern operating systems. They provide solutions for human machine interface issues where access at the point of need by an operator, manager or technician is critical. By providing access where needed, users can achieve visualization of the process they seek to manage and allows them to make changes quickly and accurately. Today’s HMIs are also built for shock, vibration and other harsh conditions found in a manufacturing environment. And they are built to work with modern communication protocols such as DeviceNet, ControlNet, EtherNet/IP, and others. One superior family of solutions for automation and interface applications is the PanelView Family by Allen Bradley. The PanelView family offers the above solutions and has all the hardware, software, and communication needs built in. But which PanelView is right for your application? And how do you choose the right model, or mix of models, for your automation system. Here are some...
In recent years, machine learning has found applications in new and often unexpected areas. With the novel coronavirus outbreak in 2019 and 2020, it makes sense that many have tried to apply machine learning and artificial intelligence to various problems relating to the disease. From modeling the spread of the disease to searching for possible drugs and vaccines, machine learning has been integral to understanding many of the problems caused by the COVID-19 pandemic. Case Study – Disease Dynamics A simple internet search will lead you to hundreds of dashboards showing the current number of coronavirus cases around the world. This stems from how easy it is to access data relating to the virus, especially from reputable sources like Kaggle or Johns Hopkins . This data, along with sophisticated models for disease dynamics has, for example, enabled predictive modeling for the number of people who actually have the virus and the risk of hosting an event in any county in the US . Some...
A high-speed counter (HSC) is a functional capability within particular PLCs. HSCs count the frequency of the pulse of processes from systems with elements such as high-speed encoders. In these cases, special input modules ensure the count’s accuracy and deliver the output to the system element within the latency criteria that optimizes machine or system uptime to meet throughput requirements. Normal counters are adequate unless the pulses you are counting will arrive faster than 2 times the scan time. HSC Overview and Application An HSC is a select type of counter. Counters used in systems with lower pulse frequencies (CTU/Ds) can be implemented as a software-defined PLC element. Thus, it only exists virtually. The HSC requires a hardware input module that can operate reliably in the harsh environmental conditions experienced on a factory floor. The engineering design is a simple input/output device that uses ladder logic to develop the output signal from the inputs provided. After...
The position of a shaft within a machine can affect several concerns including safety, quality, volume and other variables. To monitor and control information that can be obtained from the shaft position and rotation, encoders were devised to measure and control the data and motion of the machine along the shaft. There are two types of rotary encoders used today – incremental and absolute. The most common, the incremental encoder, provides position information in real-time. These encoders can measure up to 10,000 counts per revolution and transmit position changes quickly. As a result, they are used in applications that require highly accurate position and velocity measurements. Incremental encoders are available in a variety of technologies depending on applications. These may include mechanical, optical or magnetic sensors which help determine precise positions. They may act as a potentiometer, volume control, and other applications where fine tuning is required. Absolute Encoder...
The GE Fanuc Series 90-30 has long been a workhorse PLC for GE automation control systems. Introduced in 1991, the 90-30 series has been a popular choice for industrial control professionals because of its versatility and modularity. By contrast, the RX3i CPU Programmable Automation Controller by GE Automation represents the move toward a more comprehensive view of automation and one that both builds on the foundation laid by the 90-30 series while offering even more advanced features and versatility. GE 90-30 Series General Specifications and Features That the 90-30 series lasted for the better part of 30 years is a testament to its popularity. By offering a platform that addressed space concerns as well as cost effectiveness, the 90-30 has been known for ease of programming and their ability to be operated through a variety of inputs. The versatility of the 90-30 series is due to its large variety of CPUs, and each of the 11 available CPUs can accept multiple expansion modules for...
With the growing complexity and connected nature of today’s manufacturing and warehousing environments, control systems are being asked to do more and more to improve efficiency and performance. When adding or upgrading a control system, the proper selection of the right variable frequency drive (VFD) for your motor is crucial. While there are many options for VFDs from a variety of manufacturers, there are many things to consider when choosing a new VFD. These include motor considerations, VFD selection and how the VFD can or should integrate with PLCs. What Do You Need from the Motor? Before diving into the VFD itself, it is helpful to understand as much information as possible from the motor itself. Most of the critical information is included on the nameplate and should be easily accessible. This information will inform the buyer and provide a foundation for selecting the proper VFD by helping narrow down options for the optimum sized unit. Horsepower – Even though it is not the...
The Allen-Bradley Logix family of controllers is considered the most popular programmable logic controller family in the US. It consists of numerous variants but for this comparison we will look at the ControlLogix, CompactLogix and MicroLogix PLCs. By comparison, Siemens is much more common in Europe where their extensive line of PLCs are used in automation control systems throughout industries. The Siemens PLC equivalents for Allen-Bradley’s Logix family members above are part of the Siemens SIMATIC controller family and consist of the S7-200, S7-300, and S7-400 as direct comparisons. General Differences Before diving into unit by unit comparisons, we can first discuss some general differences between the Allen-Bradley and Siemens PLC lines: Performance – Both Allen Bradley and Siemens PLC groups have similar speeds and reliability. Their outputs are also close in number as well. The main differences in performance comes in their ease of use and how they integrate into control...
Like the other entrants in the MicroLogix series, the MicroLogix 1500 is small and can be expanded to fit a wide range of control and communication requirements. The 1500 is also expandable to 512 I/O points and is the most powerful in the MicroLogix family in terms of capabilities. As an addition to the MicroLogix 1100 and 1200 series family members, The MicroLogix 1500 has three base options with a removable processor and an updateable flash OS. With its numerous embedded as well as expandable I/O, the 1500 is a workhorse within the MicroLogix family. Main differences between the 1500 and other MicroLogix family members include: Central Processing Unit – Perhaps the biggest distinction between the MicroLogix 1500 and the other members of the MicroLogix Family is that the 1500 is a two-part system. One component consists of the controller, of which there are three base models, the 1764-24BWA, the 1764-24AWA and the 1764-28BXB. The second component is the central processing unit...
In today’s connected factory, visualization and interaction through human machine interfaces (HMI) are critical components of any control system. The PanelView family of HMI devices from Allen-Bradley is ideal for small, medium and large HMI systems. By leveraging the power of these devices, HMIs become scalable, adaptable and perfect for managing critical data and machine level inputs. Before you can determine whether the PanelView 700 or PanelView 1000 is best suited for your needs, one must understand that there are several families within the PanelView ecosystem. Each of these family groups have a 700 and 100 series, but there are differences in the two programming platforms that should be considered. An older offering from the Allen-Bradley line, the PanelView 6 consists of the PanelView Plus 6 and the PanelView Plus 6 Compact. The PanelView Plus 6 platform is used for applications with a larger footprint that connect with many controllers. This platform supports older...
