As time goes on, the drives that were originally new and modern soon become outdated and obsolete. New safety standards are being rolled out, different communication protocols have proven to be much more effective, and better software and hardware technology are ushering in a new era of smart factories. The question then becomes whether it is worth upgrading to a new, modern system, trying to retrofit modern equipment, or sticking with the old and keeping it running for as long as possible. Such could be the case for the 1336 Plus II. Today, we would like to provide some thought-provoking insight into a tough question that may need to be answered sooner rather than later: Should you keep or replace your 1336 Plus II system? When a factory decides to keep its 1336 Plus II drives, it’s usually not because it doesn’t know what a modern drive can offer but because its current system works in a way that’s tough (or expensive) to replace. However, there is usually a bit more to it than...
The argument between DC and AC drives is still being debated in motor control and industrial automation. Although AC drives are now the norm in many applications because of their cost-effectiveness, efficiency, and reduced maintenance requirements, DC drives—especially Rockwell Automation’s PowerFlex DC drives—still perform better in some situations. This article examines those particular use cases, emphasizing PowerFlex DC drives’ special benefits and why they are essential to several industrial settings. Shop for PowerFlex DC Drives and Parts Here It’s critical to understand the basic distinctions between AC and DC drives before delving into the application cases: By altering the frequency and voltage applied to the motor, AC drives regulate the speed of an AC motor. By modifying the armature voltage and, occasionally, the field current, DC drives regulate the speed of a DC motor. DC drives provide greater torque control, easier speed regulation, and better performance at low...
Selecting the optimal drive for your application is an all-important task that impacts your motion control system’s overall cost of ownership, performance, and efficiency. Allen-Bradley’s Kinetix, PowerFlex, and Ultra drives are cutting-edge motion control solutions designed for specific applications. Each drive series offers distinct levels of control, precision, and cost-effectiveness. As such, understanding the differences between the three Allen-Bradley drive families is critical when determining which drive series is the best match for your application needs. Kinetix Servo Drives: These drives provide precise position, torque, and speed control using closed-loop technology. They feature advanced features that offer complex motion control capabilities, high performance, rapid deceleration and acceleration, and high precision. Such features include adaptive auto-tuning, CIP Motion instructions for multi-axis cams and gearing, virtual torque sensing, and notch filtering (to reduce...
Allen-Bradley Drives play a critical role in modern automation by improving efficiency, controlling motor performance, and reducing energy costs. However, like all advanced equipment, they are susceptible to faults if not properly maintained or configured. Common issues range from overvoltage and ground faults to communication errors and thermal derating. Each of these faults can disrupt production, damage equipment, or compromise safety if left unchecked. Fortunately, with the right preventive measures and strict adherence to manufacturer guidelines, most problems can be minimized or avoided entirely. Allen-Bradley drives, widely trusted across industries, provide built-in protections and diagnostic tools, but their effectiveness depends heavily on proper installation, monitoring, and maintenance practices. Let’s take a look at some of the most common issues and how to prevent them from showing up. Shop for Allen-Bradley Drives Here Overvoltage faults typically occur when the DC bus...
Allen-Bradley, a prominent brand under Rockwell Automation, stands as a global leader in industrial automation and control technologies. Among its vast suite of offerings, variable frequency drives (VFDs) are a cornerstone product, enabling precise and efficient motor control across a multitude of industries. These drives are systematically organized into several families designed to support diverse operational requirements. Whether a facility demands basic motor control or a high-performance solution for complex applications, Allen-Bradley provides a robust selection that caters to low, medium, and high voltage needs. This article explores the full spectrum of Allen-Bradley drive systems, categorizing them by power range and application to help engineers, integrators, and plant managers choose the most suitable drive for their specific demands. Allen-Bradley drives are strategically grouped into three principal voltage categories to support a wide range of industrial automation...
Choosing the correct motor control drive in industrial automation is crucial as it affects system performance and operational safety. From simple motor control tasks to sophisticated high-performance systems, the Rockwell Automation PowerFlex family of AC drives is made to meet a wide range of application demands. The increasing characteristics of PowerFlex drives are examined in this article, which also advises customers on when to upgrade from entry-level versions like the 523 to more expensive models like the 755. Industries can guarantee smooth scaling, preserve system safety, and optimize operational efficiency by comprehending the distinct capabilities of each model. This technical knowledge will assist you in pinpointing the precise moment at which upgrading to a more sophisticated PowerFlex drive is necessary for your application. Let’s look into different series one by one. The PowerFlex 523 is the entry-level model of the PowerFlex 520 series, designed for users requiring...
The industrial complex of our world is always evolving, from steamboats and turbines to assembly lines at Ford. We are now at an age where the industry is shifting to a more connected and digital format. Whether AI is being implemented in our systems, the Internet of Things, where everything is controlled via Ethernet or Wi-fi, or having a system where drives can reliably predict the life cycle of the components it controls. Modicon understood this technological shift when they were developing the first PLC. Decades later, they still hold strong under Schneider Electric, boasting a range from HVAC controllers to safety and networking. Let’s take a look at how they’re contributing to the Industry 4.0 movement! Buy Modicon PLCs Here While we did set the stage of a digitized world filled with online computing and AI, the truth of the matter is that without a robust hardware foundation, this new age of technology simply cannot progress. The new silicon quietly running at the edge that...
The Rockwell Automation Kinetix 3 servo drive is a small, affordable motion control solution for small-scale automation. Nonetheless, its applications and weaknesses are determined largely by the motor system with which it is integrated. Hence, one must acquaint themselves with its scope of operation before installing it. Shop for Kinetix 3 Drives Here Various modules with varying power outputs and input voltages are available for Kinetix 3. The 2071-A15 (50W, 0.85 A peak) has the lowest power capacity of all the modules. Mid-range models like 2071-AP8 (800 W) and 2071-A10 (1.0 kW) are also available, and select models support single—or three-phase 240V AC inputs. In order to take advantage of the Kinetix 3’s capability, some key accessories are necessary. Configuration and control cables like the 2090-CGMPC05-23AAxx are needed for PC programming and diagnostics, while the 2090-CGMC005-48AAxx allows Modbus-RTU communication with MicroLogix PLCs. Drive-mounted breakout boards improve...
Ensuring machine safety in modern industrial automation is crucial for safeguarding people, machinery, and process integrity, and it is required by law. Integrated safety systems have become much more necessary as industrial machinery grows in strength, complexity, and connectivity. Conventional safety measures, including completely cutting off the electricity, are insufficient and ineffective nowadays. Intelligent safety features like Safe Torque Off (STO) provide a more sophisticated strategy. STO ensures that motor torque may be safely and consistently turned down without cutting the drive’s power. This paper explores how STO is integrated into Rockwell Automation’s PowerFlex 753 AC drive, highlighting its operational, safety, and regulatory advantages in a range of industrial contexts. This article is meant to be a reference; always consult with an engineer for proper safety equipment installation. Buy a Safe Torque Off Option Module Here A useful safety feature called Safe Torque...
When a drive in a system goes down, the clock starts to tick. Every minute of downtime is a minute lost in productivity, money lost, frustrated operators, and production schedules sliding off track. Allen-Bradley understood this issue well and designed its PowerFlex 750 series drives with an interchangeable parts approach. The idea was that instead of scrambling for model-specific replacements, you could swap in components across the 753, 755, and even 755T drives. This isn’t just convenient, but a deliberate choice that turns a maintenance headache into a quick fix. By incorporating so many interchangeable parts into the 750 platform, Allen-Bradley has made it possible to keep more spares on hand, reduce stocking costs, and get machines running faster than it would take to fill out a downtime report. It’s not just a couple of token parts either. The interchangeable parts list for the PowerFlex 750 series is extensive, covering everything from control and power modules to cooling...
When spec’ing out a new automation system with a PowerFlex 755 drive, you will notice a few variations. You have the standard 755 with FORCE technology, or the 755TS with TotalFORCE tech. While it initially sounds very similar, the TotalFORCE tech provides a generational leap in performance, all while utilizing the same hardware that we all know and love. But that brings us to the main question: Do you need TotalFORCE? Buy Allen-Bradley PowerFlex 755 Drives Here Let’s take a moment to go over the offerings we have before answering that question. The PowerFlex 755 has been the go-to VFD for countless installations over the past decade, and for a good reason, too. It’s powerful, reliable, and very modular, making it stick out as one of the most flexible options that AB has to offer. Whether you’re automating a conveyor line, fine-tuning a pump motor, or even lifting a crane, chances are that the 755 has done it. The 755 line covers a wide power spectrum. You’ll find versions for:...
For any power system to run smoothly and efficiently, the voltage and current wave forms should ideally be perfect sinusoids. However, in practical applications, power quality problems like voltage dips, transients, fluctuations, and harmonic distortion occur commonly. The imperfections in the waveforms are represented as the presence of harmonics. Harmonics are the distortions caused by non-linear loads consuming currents that are non-sinusoidal. These distortions significantly reduce the power system efficiency and lead to equipment failures and operational disruptions. Harmonics are sinusoidal waveforms with a frequency that is an integer multiple of the base power system frequency (50 or 60 Hz for most practical applications). These harmonic frequencies overlap onto the base waveform and introduce distortion. This distortion is measured as Total Harmonic Distortion (THD). If not dealt with appropriately, harmonics result in overheating, premature equipment degradation, and...
Maintaining a secure and efficient network in modern manufacturing plants is critical for operational continuity and cybersecurity. As industrial systems become more connected, the need for robust network segmentation grows—allowing manufacturers to isolate critical assets, control data flow, and minimize the risk of cyberattacks. The Stratix 5900 services router plays a pivotal role in this process, offering advanced features that support precise segmentation and secure communication across industrial environments. From VLANs and firewalls to VPN and access control, this router is purpose-built for industrial automation. In this article, we explore how Stratix 5900 enables effective network segmentation in manufacturing facilities. Network segmentation involves dividing a computer or industrial network into multiple smaller, isolated zones. In manufacturing plants, this helps isolate critical systems such as PLCs, HMIs, and SCADA from general business traffic. The Stratix 5900...
Finding the right AC Drive size is crucial to your motor-driven application’s health, energy efficiency, and longevity. Whether you are running complicated machinery like a conveyor system, a pump, or a fan, an improper drive can lead to inefficiencies, overheating, or equipment failure. In this article, we will first discuss the motor’s requirements and then the AC drive itself to choose which AC drive would be the best for our use. This article aims to clear the key factors and procedures required to choose the best drive for your needs, guaranteeing a balance between dependability and affordability in commercial and industrial automation systems. Compiling comprehensive information on the motor the AC drive will be controlling is crucial before choosing one. The majority of the essential characteristics are included on the motor nameplate, which is a good place to start when reducing the number of drive options available. Shop Allen-Bradley PowerFlex 755 Series Drives Here Although...
Smart motor controllers (SMCs) are advanced, microprocessor-based soft starters designed to manage and protect AC motors in a variety of industrial applications. They offer a wide array of advanced functionalities beyond solely starting and stopping motors efficiently. These functionalities include comprehensive monitoring, precise speed control, integrated diagnostics, communication and networking capabilities, and advanced motor protection. Prominent smart motor controller brands include Allen-Bradley (from Rockwell Automation), Mitsubishi Electric, Siemens, ABB, Honeywell, Schneider Electric, and Eaton. SMC controllers use diverse operating modes to precisely control motor starting & stopping characteristics, speed, and torque. Common modes of operation include Current Limit Start, Soft Start, Soft Stop, Full Voltage Start, and Selectable Kickstart, alongside specialized control options such as Dual Ramp Start, Preset Slow Speed, Accu-Stop, Smart Motor Braking, Pump Control, and...
