Author: Ken Cheng

When it comes to the debate on what what is the most crucial device in industrial automation; there exists and spectrum of varying opinions. Some argue that the VFD’s (Variable Frequency Drives) play the most crucial role. Others would believe that it is the motors themselves seeing as without their power and movement nothing can get done.  Ultimately all components in industrial automaton are crucial. However unless an operator can give commands for a function, the entire process doesn’t happen.  In order to achieve this, the operator has to be able to give commands to a symphony of devices. He conducts orchestra of machinery on when and how to play.  This where the industrial control panel comes into play.

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Have you ever used a dimmer on a lamp or room light and wondered how you were able to adjust the brightness of light so easily? How about a running fan in your room on a hot day? Ever wondered what it was that allowed you to change how fast the fan went? Maybe you work at an assembly plant, and see the machines moving and performing tasks with precise speed and timing. Has it ever crossed your mind as to how these giant machinations can do such complicated things and not breakdown or catastrophically collide into one another? That is the wonder known as the Variable Frequency Drive or VFD.

So WTF is a VFD?

Variable Frequency Drives (VFDs), alternatively referred to as Variable Speed Drives (VSDs) or Adjustable Frequency Drives (AFDs), constitute a fundamental aspect of industrial automation. These electronic devices are meticulously engineered to govern the speed and torque of electric motors. They achieve tha by manipulating the frequency and voltage supplied to them. By exerting control over these parameters, VFDs grant the ability to finely regulate motor speeds. This results in optimized operational efficiency and performance across a wide array of industrial applications.

In the realm of industrial automation, VFDs offer a multifaceted range of advantages. Among their most prominent benefits is the potential for substantial energy conservation. By permitting motors to operate at lower speeds when maximum power output isn’t essential, VFDs contribute to marked reductions in power consumption, thereby fostering an environment of heightened energy efficiency. Moreover, these drives contribute significantly to the realm of process control and productivity enhancement. Through the implementation of gradual acceleration and deceleration of motors, VFDs curtail mechanical stress and wear on machinery, leading to prolonged equipment lifespan and diminished maintenance expenditures. Their capacity for intricate adjustments further facilitates seamless synchronization with other processes and components, ultimately culminating in elevated product quality and consistency within the sphere of manufacturing and production.

A Brief History in VFD’s

The history of Variable Frequency Drives (VFDs) traces back to the mid-20th century. During this time advancements in power electronics and control systems set the stage for their development. The initial concept of controlling motor speeds by varying the frequency of the power supply emerged in the 1960s. However, the state of electronics at the time limited the technology. The 1970s saw the advent of solid-state devices like thyristors and later insulated gate bipolar transistors (IGBTs). These components enabled more efficient and precise control over motor speeds by allowing the modulation of voltage and frequency.

By the 1980s, the electronics industry had made significant strides, making VFDs more practical and cost-effective. Advances in microprocessors and digital control algorithms led to the emergence of more sophisticated and versatile VFD systems. These drives gained traction in various industries where precise speed control and energy efficiency were crucial. Some examples include HVAC systems, pumps, and conveyors. The turn of the millennium saw further improvements in power electronics, enabling higher switching frequencies and greater efficiency. Additionally, advancements in communication protocols and networking facilitated seamless integration of VFDs into larger industrial automation systems.

How Are VFD’s Used

Variable Frequency Drives (VFDs) operate based on the principles of pulse width modulation (PWM) and voltage-frequency control. These drives consist of three main components: a rectifier, a DC bus, and an inverter. The process begins with the rectifier, which converts the incoming AC power supply into DC voltage. This DC voltage is then stored in the DC bus, creating a stable power source. The inverter stage is where the magic happens. The VFD generates variable frequency AC output by rapidly switching the DC voltage from the bus into a series of pulses through the inverter’s transistors. The width of these pulses determines the effective voltage and frequency delivered to the motor, effectively controlling its speed and torque.

To elaborate on the concept of pulse width modulation (PWM), imagine turning a light switch on and off very rapidly. When the switch is on, the light receives full power, and when it’s off, the light receives no power. By adjusting the duration of the on and off states, you can regulate the average power delivered to the light, thus controlling its brightness. Similarly, VFDs use PWM to regulate motor speed. The width of the output pulses corresponds to the voltage and frequency applied to the motor. By adjusting this pulse width, VFDs can provide a wide range of speeds, allowing precise control over the motor’s performance.

Voltage-frequency control is another fundamental aspect of VFD operation. The relationship between voltage and frequency needs to be maintained within certain limits to prevent overloading the motor. As the frequency changes, the VFD adjusts the voltage to maintain an appropriate ratio. For example, as the frequency is reduced to slow down the motor, the VFD decreases the voltage proportionally to ensure the motor’s torque remains consistent. Conversely, at higher frequencies, the VFD increases the voltage to sustain the motor’s torque output. This coordinated adjustment of voltage and frequency ensures the motor operates within its safe and efficient operational range, enabling seamless control over its speed and performance in various industrial applications.

What Uses a VFD?

Implementing VFDs in industrial settings involves careful planning and integration to harness their benefits effectively. First, a thorough assessment of the application’s requirements and the specific motor system is necessary. This includes considering factors like load characteristics, torque demands, and desired speed ranges. Once the appropriate VFD is selected, the installation process involves connecting the drive to the motor and the power source. It’s essential to ensure proper grounding, wiring, and following manufacturer guidelines for correct setup.

After physical installation, configuring the VFD settings becomes crucial. This involves programming parameters such as motor nameplate data, acceleration and deceleration rates, maximum and minimum speed limits, and control modes (e.g., open-loop or closed-loop control). Advanced VFDs might also offer features like communication interfaces (such as Modbus or Ethernet) to integrate with larger automation systems for centralized control and monitoring. Careful tuning of these parameters ensures that the VFD operates optimally, delivering the desired motor performance while minimizing energy consumption and wear on equipment.

Implementing VFDs also requires considerations for safety and maintenance. Properly trained personnel should handle VFD installation and configuration to prevent accidents. Regular maintenance and periodic inspections are necessary to ensure the drives and associated components are functioning correctly. Monitoring for anomalies, such as overheating or unusual noises, can help detect potential issues early and prevent costly downtime. As technology evolves, the implementation of VFDs might also involve exploring predictive maintenance strategies that leverage data analytics and sensors to anticipate maintenance needs and enhance system reliability.

Conclusion

VFDs stand as a testament to synergy between technological innovation and industrial efficiency. VFDs have transformed the way we control and optimize electric motor-driven systems. Not only do VFDs empower industries to achieve unparalleled precision and performance through dyanmic controls. They also contribute significantly to energy conservation, equipment longevity, and process refinement. As industries continue to evolve and prioritize sustainability, VFDs will undoubtedly remain at the forefront of this evolution. VFDs continue to drive innovation, enhance productivity, and leading to a more efficient and environmentally conscious industrial landscape.

On the surface, The Internet of Things (IoT) may sound like tech jargon for something really complicated and sophisticated. In a way that is true when you get into the technical aspects of “how”. The formal definition of the IoT is: the interconnection via the internet of computing devices embedded in everyday objects, enabling them to send and receive data. Fundamentally however, IoT is just a really fancy way of saying all our home devices and technology are capable of connecting and talking to one another.

What makes up the Internet of Things

The Internet of Things is often characterized by different features. While all these features may not be in every device, generally all devices have more than one of these.

Devices and Sensors

Device and sensors describe physical objects equipped with communication interfaces that collect (sensors) and transmit (actuators) data. These devices can range from simple household appliances like thermostats and smart lights to more complex industrial machinery and vehicles.

Connectivity

IoT devices rely on various communication technologies to transmit data. These technologies can include Wi-Fi, Bluetooth, cellular networks, Zigbee, LoRa, and more. The choice of connectivity depends on factors like range, power consumption, and data bandwidth.

Data Processing and Analytics

The massive amount of data generated by IoT devices needs to be processed, analyzed, and interpreted to extract meaningful insights. This often involves using cloud computing resources and advanced analytics techniques, such as machine learning, to derive valuable information from the collected data.

Cloud Computing

IoT devices typically send their data to cloud-based platforms for storage, processing, and analysis. Cloud computing provides the scalability and computational power required to handle the vast quantities of data generated by IoT devices.

Applications and Services

IoT data creates a wide range of applications and services. These can include remote monitoring and control of devices, predictive maintenance of machinery, smart homes and cities, healthcare monitoring, environmental monitoring, and more.

Security and Privacy

When it comes to the collection and transmission of sensitive data, security and privacy are major concerns. In IoT, ensuring the confidentiality, integrity, and authenticity of the data is crucial.

Interoperability

The seamless interaction of various IoT devices and systems is essential for the success of IoT ecosystems. Standards and protocols ensure compatibility and smooth communication between devices from different manufacturers.

The History of Things

The Internet of Things as a concept spans back several decades. However, its development into a widespread and recognizable technology trend began in the late 20th century.

Pre-Internet Origins (1960s – 1980s)

The idea of interconnected devices predates the internet itself. In the 1960s, early computer networks like ARPANET laid the foundation for later

The Term “Internet of Things” (1990s)

Kevin Ashton, a British technology pioneer, coined the term “Internet of Things” in the late 1990s. Ashton was working on radio-frequency identification (RFID) technology, which used small chips to communicate data over short distances. He used the term to describe a system where physical objects connected to the internet, sharing data without human intervention.

Development in the Early 2000’s

 In the early 2000s, developments in sensor technology, wireless communication, and data processing began to pave the way for practical IoT applications. This decade saw the emergence of various projects and initiatives exploring IoT concepts, including smart homes, industrial automation, and RFID-based supply chain management.

The 2010’s to the Present

The proliferation of wireless communication technologies, such as Wi-Fi, Bluetooth, and cellular networks, played a crucial role in enabling widespread IoT adoption. As these technologies became more accessible and cost-effective, IoT devices could communicate over longer distances and with greater efficiency.

It also gained momentum in specific industries, such as manufacturing and agriculture. Here, sensor-equipped machinery and data analytics improved efficiency and productivity. The concept of “Industrial IoT” (IIoT) emerged, highlighting the use of IoT technology in industrial processes and automation.

By seamlessly connecting machinery, sensors, and control systems, IoT has enabled the creation of “smart factories” that operate with heightened responsiveness and optimization. Real-time data from IoT-enabled sensors monitors every facet of production, offering insights into variables such as temperature, pressure, and quality. This data-driven approach empowers manufacturers to implement predictive maintenance strategies, identifying potential equipment failures before they occur and minimizing downtime. This results in a substantial reduction in operational costs, increased productivity, and enhanced product quality, as intelligent automated systems replaced manual processes. These systems can adapt to changing conditions in real time.

Moreover, IoT’s impact extends beyond the confines of individual factories. Supply chains have become more transparent and interconnected, as IoT-enabled tracking devices provide real-time visibility into the movement and status of goods at every stage. This heightened visibility enhances inventory management, reduces delays, and allows for agile responses to market demands. The convergence of IoT with advanced data analytics and artificial intelligence offers the potential for more sophisticated decision-making. Manufacturers can optimize production schedules based on predictive demand trends, allocate resources efficiently, and even customize products in response to specific customer preferences. As the synergy between IoT and industrial automation deepens, it is reshaping traditional manufacturing paradigms and propelling industries into a future defined by intelligent, interconnected, and agile production ecosystems.

Conclusion

The IoT continues to expand its influence across various sectors, including healthcare, transportation, agriculture, and more. As technology advances, the IoT is becoming more integrated with other emerging technologies like artificial intelligence (AI) and edge computing. Edge computing allows data processing to occur closer to the source, while also reducing latency and improving real-time decision-making.

While the IoT has come a long way, challenges remain, including concerns about security, privacy, data governance, and the need for continued standardization. However, as technology continues to evolve, the IoT poises an even more significant role in shaping the way we interact with the digital and physical worlds.

Over the years sensors and actuators play a crucial role in the world of industrial automation. They transformed the manual processes into highly efficient, automated systems. This is the run down of their history and evolution and how they are integral the automation industry.

A Tale of Two Components

What are Sensors?

A sensor is an electrical instrument that monitors and measures physical aspects of an environment and then sends an electrical signal to a control center when it detects pre-determined conditions. On the most basic level, sensors turn physical inputs into electrical signals that are output to the control center. Sensors can be used to monitor the health of equipment and status of a sensitive environment. One example is a sensor that can alert temperature changes to an operator if a unit gets too hot.

What are Actuators?

In contrast, actuators take electrical signals from control modules and turn them into physical outputs. They can perform a wide range of functions, from turning rotors and valves to virtually anything else. You can program them to control almost any physical action. An example of an actuator is a shutoff valve. When it receives a signal from a sensor or control module, it closes the valve. The actuator receives the input of an electrical signal and turns it into a physical action. 

The History of Sensors and Actuators

Both sensors and and actuators have their roots going as far back as the early 20th century. Basic switches and relays served as the first primitive forms of automation. These simple devices were used to detect changes in physical properties, such as temperature, pressure, and position, and to initiate mechanical actions accordingly. While this technology had very limited functionality at the time, they paved the way for the future of automation.

Pneumatic Actuators

In the early stages of automation, pneumatic actuators dominated the landscape due to their simplicity and reliability. Compressed air was used to control mechanical movements, making them ideal for industrial applications. However, the advent of electric actuators brought about a significant shift. Electric actuators, driven by motors, offered finer control, quieter operation, and the ability to integrate with digital control systems.

Sensors at the Turn of the Century

By the mid-20th century, sensors experienced a revolutionary transformation. Devices like thermocouples, strain gauges, and pressure sensors emerged, enabled precise measurements and real-time data acquisition. The integration of these sensors into industrial processes improved process control laying the foundation for more sophisticated automation systems.

Microprocessors Take the Stage

The introduction of microprocessors and microcontrollers in the 1970s and 1980s marked a turning point in sensor and actuator technology. These tiny computational devices allowed for on-board processing, enabling sensors to not only gather data but also interpret and transmit it intelligently. Smart sensors emerged, capable of self-calibration, data filtering, and communication with other devices, making them indispensable for complex automation tasks.

Sensors and Actuators Evolve

Integrating PLC’s

The 1980s brought sensors and actuators closer to the heart of industrial automation with the widespread adoption of PLCs. PLCs acted as the brain of automation systems, receiving input from sensors, processing it, and triggering actions through actuators. This integration simplified automation programming and allowed for more extensive and flexible control over industrial processes.

Internet Networking

The rise of the internet and networking technologies allowed sensors and actuators to communicate on a broader scale. Fieldbus protocols and industrial communication standards, such as Modbus, Profibus, and Ethernet/IP, facilitated seamless data exchange between devices and supervisory systems. This enhanced connectivity allowed for remote monitoring, predictive maintenance, and real-time process optimization.

Conclusion

From the simplicity of basic switches to the intelligence of smart devices, sensors and actuators continue to play a vital role in shaping the world of industrial automation. We can expect sensors and actuators to become even more integrated, intelligent, and indispensable, driving the industry towards unprecedented levels of efficiency and automation.

In the past we’ve covered the rise of automation in the industry. More specifically we’ve talked about the underlying anxieties of job loss and they human element being replaced as AI becomes more advanced. However, there’s never really been much coverage in regards to how this uncharted relationship between human and machine could lead to long term job growth. While the outlook of the human race keeping our jobs and being able to make a livable wage in the world of machines looks pretty grim. We have yet to be in the dystopian sci-fi world of Terminator. On the other hand, the discussion about the potential for job growth is seldom discussed. Too often we bring the machine aspect of automation into focus, but we don’t often talk about the human potential. These are a few ways Human-Machine collaboration becomes advantageous to job growth.

Job Creation in Automation Industries

As industries embrace automation, there is an increased demand for professionals with expertise in robotics, artificial intelligence, data analytics, and system integration. The development, deployment, and maintenance of automation systems require a skilled workforce, leading to job opportunities in these emerging fields.

Prioritizing Higher Value Tasks

Automation allows humans to transition from repetitive, mundane tasks to more complex and value-added responsibilities. As machines handle routine operations, humans can focus on tasks that require creativity, critical thinking, problem-solving, and decision-making abilities. This shift empowers employees to engage in challenging and fulfilling work

Skill Development

The introduction of automation technologies necessitates upskilling and reskilling of the existing workforce. Employees can receive training in areas such as system operation, maintenance, programming, data analysis, and process optimization. This investment in workforce development enhances employee skill sets, making them more valuable in the job market and fostering job growth.

New Job Roles and Specialization

Collaboration between humans and machines often leads to the emergence of new job roles and specializations. These include automation technicians, robot coordinators, data analysts, machine learning specialists, process optimization experts, and human-robot interaction designers. Job growth occurs as organizations create positions to address the evolving needs of their automated systems.

Entrepreneurship and Innovation

The rise of automation provides opportunities for entrepreneurship and innovation. Individuals can develop automation solutions, create startups focused on specialized automation services, or establish consulting firms that help organizations adopt and optimize automation technologies. These entrepreneurial ventures contribute to job creation and economic growth.

Support and Maintenance Roles

As automation systems become more prevalent, the need for support and maintenance personnel also increases. Skilled technicians are required to install, configure, troubleshoot, and repair automation equipment. This includes tasks such as sensor calibration, programming updates, and diagnosing system issues. The growth in automation installations leads to job opportunities in these support and maintenance roles.

Collaborative Robotics

Collaborative robots, or cobots, are designed to work alongside humans, enhancing productivity and safety. These robots require human operators for programming, monitoring, and collaboration. As the adoption of cobots increases, job opportunities arise for individuals skilled in operating and coordinating the interactions between humans and robots.

Job Expansion

The adoption of automation in one industry often leads to job growth in related industries. For example, the increased use of automation in manufacturing can drive job growth in industries such as component manufacturing, robotics engineering, software development, and logistics.

Final Thoughts

While automation can lead to job displacement in certain areas, the overall impact of human-machine collaboration tends to be positive for job growth. By leveraging the strengths of humans and machines, organizations can create new roles, upskill their workforce, and drive innovation, contributing to the growth of the job market in automation-related industries.

Introduction

With the evolution of technology becoming more sophissticated stresses the importance of faster and more efficient communication. In the early days of machinery, the way humans interacted with equipment would be with pullies and levers. While this system made labor easier, it still required a lot of physical involvement and manpower. Also because workers had communicate manually, orders on each level took a while to convey. As manufacturing and industrial processes advanced, there was more progression in the way humans and machines interacted.

In a previous article, we discussed the Second Industrial Revolution which was characterized by the expansion of electricity. The modern concept of automation begins around this time. Hefty ropes, pullies, and levers eventually became surpassed by switches and buttons. No longer did a team of workers pull heavy chains to raise and lower heavy objects. The use of electricity meant that motorized pulleys and wenches could replace these tasks with a push of a button. This development also meant faster response times in between processes, therefore resulting in faster production times.

While this by far made production in factories a lot faster and more efficient. The need to be more streamlined meant factories still needed to up the game on productivity. This is where the HMI enters the story.

A Brief History

In the Beginning

While we are hard pressed to find one today, the earliest HMI can be traced back to the typewriter. Invented in the 1860s, the device provided a tangible connection between human input and machine output. While the typewriter is considered rudimentary by today’s standards. A person able to punch keys and output the information onto paper marked a milestone in machine interfacing. However, the biggest progress for HMI technology comes about during the 20th century.

The 20th Century

The mid-20th century saw the rise of computers. Unlike the typewriter, these powerful machines and their interfaces evolved from punch cards to command-line interfaces. This later would progress to graphical user interfaces (GUIs). By 1965 the Royal Radar Establishment developed the first touch screen. Popularized by Xerox PARC’s Alto computer in the 1970s, the GUI allowed users to interact with computers through visual representations such as icons, windows, and menus. Ths technology saw niche use in industries like air traffic control. However, it wasn’t until the 1980s that it gained widespread recognition. Two prominent examples of devices being the Hewlett-Packard HP-150 and the Atari 520ST. Touchscreens revolutionized the way users interacted with machines, providing a more intuitive and direct method of input. Another significant advancement in HMI was the introduction of voice recognition systems.

HMI in the Digital Age

Recent years have witnessed the rise of virtual and augmented reality as emerging interfaces. Virtual reality (VR) and augmented reality (AR) technologies have gained significant traction. VR immerses users in computer-generated environments, while AR overlays digital information onto the real world. These immersive technologies are opening up new possibilities with training and the way operators interact with equipment.

What is HMI?

In the world of industrial automation, Human-machine interface (HMI) plays a crucial role in completing tasks. It enables effective communication and interaction between humans and machines in manufacturing and industrial settings. HMIs serve as the primary interface through which operators monitor and control industrial processes. These interfaces provide real-time data visualization, alarms, and controls that allow operators to make informed decisions and respond quickly to changing conditions. They typically consist of touchscreens, graphical displays, and input devices such as keyboards or keypads. HMIs are used to manage a wide range of industrial automation systems, including robotic assembly lines, control panels, and supervisory control and data acquisition (SCADA) systems.

The use of HMIs in industrial automation has greatly enhanced productivity, efficiency, and safety in manufacturing environments. HMIs in minimize human error and help with downtime. They allow operators to visualize critical information, receive real-time alerts, and respond promptly to abnormal conditions. HMI’s provide clear and concise displays, making it easier for operators to interpret data and make informed decisions. Furthermore, HMIs implement preventive maintenance strategies by providing insights into equipment performance and condition monitoring. By integrating advanced functionalities like data analytics and predictive maintenance, HMIs contribute to proactive approaches in industrial automation.

Conclusion

As industry continues to evolve we already seeing the integration of VR and voice commands in HMI technology. At this point the questions is not so much about “Can we do it?” but rather how streamlined and cost efficient can they be? Only time can tell.

When discussed in the context of sustainability, the average person might not think of industrial automation as ‘sustainable’. After all, when we think of industrial automation our brains turn to the worst thoughts. We think of dirty machines sucking up enormous amounts of energy while being in factories outputting copious amounts of waste. However, recent decades have shown companies moving towards sustainability. Not just because of environmental issues, but also as a means to cushion the cost of manufacturing.

As the world continues prioritizing sustainable practices, industrial automation has emerged as a potential solution for reducing environmental impact. However, there are concerns about whether industrial automation in general is sustainable.

What is Sustainability?

What do we mean by “sustainability”? According to the United Nations, sustainability is defined as “meeting the needs of the present without compromising the ability of future generations to meet their own needs.” In short, sustainable practices should not harm the environment in ways that can obstruct future generations from thriving.

Common Sustainability Concerns

One major concern is the energy consumption of automated systems. Automated machines require significant amounts of energy to operate, especially during the initial stages of setup and installation. This high energy consumption leads to increased greenhouse gas emissions and contributes to climate change. Additionally, companies design automated systems to operate at full capacity, regardless of the actual product demand. This can result in overproduction, leading to a waste of materials, energy, and resources.

Another concern is automation is the displacement of human workers. Automation usually results in job losses for human workers. This is especially true when performing repetitive and monotonous tasks. This not only affects the livelihoods of these workers but also has social implications. Extreme unemployment and income inequality can lead to social unrest and economic instability.

The Road to Sustainability

The direction of sustainability in industrial automation needs plenty of improvement. However, current trends show a shift by companies toward a sustainable goal. This includes things like reducing waste, improving energy efficiency, and safety conditions for employees.

When talking about efficiency, companies using sensors and software in manufacturing processes can reduce material waste. They achieve this by accurately measuring and cutting materials to exact specifications. This reduces the amount of scrap material wasted and lowers the overall environmental impact of the manufacturing process. Additionally, automated systems can optimize production schedules and reduce downtime, resulting in less energy waste and lower carbon emissions.

When people talk about employees regarding sustainability in industrial automation. They often think of job security as the thing to fear when it comes to automation. However, when discussing sustainability, employee safety often gets left out of the conversation. Keeping healthy and uninjured employees also counts as sustainability. Automation allows machines to complete the most dangerous tasks. This reduces the risk of injury or death to workers. Companies can use automated safety systems to detect potential hazards and shut down machinery if necessary.

Regarding environmental sustainability, having more efficient manufacturing does help stave off environmental impacts. It also has more efficient logistics that can result in better sustainability. Automated vehicles can optimize routes, reduce fuel consumption, and lower emissions by avoiding traffic congestion and reducing idle time. This not only benefits the environment but also saves time and money for businesses. Additionally, automated warehouses can reduce the need for large, energy-intensive storage facilities. This lowers the overall environmental impact of the supply chain.

The Outlook

The general consensus seems to be that industrial automation has the potential to be a sustainable solution. Especially if implemented responsibly and with consideration for the broader social and environmental implications. While there certainly exist concerns that need addressing. The overall evidence suggests that automation may be a key tool when pursuing long-term sustainability.