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Key Considerations for Choosing the Right RFID Tag for Your Traceability Application

Choosing an RFID tag for your traceability application can be difficult given the huge variation of tags available today. Here are four main factors to keep in mind when selecting a tag, which will greatly contribute to the success of your RFID project.  

 

Choose tag type: I like to start with tags and work backward. Tags come in many shapes and sizes – from paper labels to hang tags, pucks, and even glass capsules and reusable data bolts. First, think about where you want to mount your tag. It is important that it does not interfere with your current product or production process. If you plan to tag a metal product, using a metal-mount style tag will give you the best results.

Assess the required read range: Think about how much range you need between your RFID readers and your tags. Remember that the shorter your range, the more options you will have when selecting a suitable frequency. While all frequencies work for short ranges, long ranges require HF (High Frequency) or even UHF (Ultra High Frequency) products. As a rule of thumb, it is best to keep your reading range as short as possible for the most reliable results.

 

Consider the environment: RFID tags are designed to withstand high temperatures, chemicals, water, and moisture. If your environment involves any of these conditions, you will want a tag that is up to the challenge and will remain functional.

 

Choose the data storage option: RFID tags can be read only or read/write, so think about what kind of data you want to store on your tags. Do you want your tag to be a simple license plate tied back to a centralized database, or do you want to store process/status data directly on the tag? RFID gives you a choice and now is the time to think about what and how much data you want to maximize the benefit of RFID for your process.

 

So now that you have thought about tag type, read range, environment, and data, you already have a promising idea of which tags will work in your application. The final step is to get price quotes and get started with your project. This is a wonderful time to ask the RFID experts for more recommendations and ask about on-site testing to make sure your tags are a great fit for your application. It is also an excellent time to collect recommendations for which reader will pair best with your tag and application.

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Who Moved My Data? Outsourcing Condition Monitoring

This is the first in a three-part blog series on condition monitoring.

 

Critical assets are the lifeblood of the manufacturing plant. They are the devices, machines, and systems that when broken down or not performing to expected standards, can cause downtimes and production or quality losses resulting in rejects. If not maintained at the optimal levels of performance, these assets can damage the overall reputation of the brand. Some examples include evaporate fans, presses, motors, conveyor lines, mixers, grinders, and pumps.

Most manufacturing plants maintain critical assets on a periodic schedule, also known as preventative maintenance. However, in recent years, condition-based maintenance strategies, made possible with advancements in sensor and communications technologies, further improve the uptime, lower the overall cost of maintenance, and enhance the life of critical assets. Condition-based maintenance relies on continuous monitoring of key parameters of these assets.

Once the plant decides to adopt predictive maintenance (PdM) strategies for maintaining the assets, they face an important decision: to implement the condition monitoring strategy in-house or to outsource it to a third party – new term – continuous condition monitoring as a service (CCMAAS).

The bipartisan view expressed in this three-part blog series explores these options to help plant managers make the best, most appropriate decision for their plants. Just a hint: the decision for the most part is based on who controls the data regarding your plant’s critical assets.

In this part, we will delve a little deeper into the advantages and disadvantages of the CCMAAS option.

The advancements in cloud-based data management enable businesses to offer remote monitoring of the data related to the assets. In a nutshell, the service providers will audit the plant’s needs and deploy sensors and devices in the plant. Then, using IoT gateways, they transfer the critical parameters about the assets, such as vibration, temperature, humidity, and other related parameters to the cloud-based storage. The service provider’s proprietary algorithms and expertise would synthesize the data and send the plant’s maintenance personnel alerts about maintenance.

Advantages of outsourcing condition monitoring:

    1. Expertise and support: By outsourcing data management to a specialized provider, the plant has access to a team of experts who possess in-depth knowledge of condition monitoring and data analytics. These professionals can provide valuable insights, guidance, and technical support.
    2. Scalability and flexibility: Outsourced solutions offer greater scalability, allowing businesses to easily accommodate changing monitoring requirements and fluctuating data volumes.
    3. Cost reduction: Outsourcing eliminates the need for upfront investments in hardware and infrastructure, significantly reducing capital expenses. Instead, companies pay for services based on usage, making it a more predictable and manageable operational expense.

Disadvantages of outsourcing condition monitoring:

    1. Data security concerns: Entrusting critical data to a third-party provider raises concerns about data security and confidentiality. Plants must thoroughly assess the provider’s security protocols, data handling practices, and compliance with industry regulations to mitigate these risks.
    2. Dependency on service providers: Outsourcing data management means relying on external entities. If the service provider has technical difficulties, interruptions in service, or business-related issues, it may impact the organization’s operations and decision-making.
    3. Potential data access and control limitations: Plants may face limitations in accessing and controlling their data in real time. Reliance on a service-level agreement with the provider for data access, retrieval, or system upgrades can introduce delays or restrict autonomy.

Just like critical assets are the lifeblood of the manufacturing plants, in the near future data that is being generated every second in the plant will also be equally important. Outsourcing does allow manufacturing plants to adapt quickly to the new normal in the industry.  I would not completely discount outsourcing based on the control of data. The option does have its place. You will just have to wait for my concluding blog on this topic.

In the meantime, your feedback is always welcome.

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Exploring the Versatility of Digital Rotary Encoders

Digital rotary encoders provide precise position feedback and motion control for a range of applications, from simple motor speed control to complex robotics and CNC machines. Here I explore some key applications of digital rotary encoders and how manufacturers benefit from their use.

Incremental and absolute encoders

Digital rotary encoders convert rotary motion into digital signals. They typically consist of a rotating disk or shaft with an optical or magnetic sensor that detects the position of the disk or shaft and generates an electrical signal. The signal can be read by a digital controller, such as a microcontroller or PLC, to provide position feedback and control of motors and other mechanical systems.

There are two main types of digital rotary encoders: incremental and absolute. Incremental encoders generate a series of pulses that indicate the relative position of the encoder shaft or disk. Absolute encoders provide a unique digital code that represents the absolute position of the encoder shaft or disk.

Both types of encoders have their specific applications and choosing the right type of encoder depends on the requirements of the specific application.

Applications

Digital rotary encoders have applications in various industries, from automotive to aerospace, and from robotics to manufacturing. Following are some of their key applications in manufacturing:

Motion control

In motion control systems, encoders provide precise position feedback for accurate control of motors, such as servo motors, to achieve the desired speed and direction of movement. In a CNC machine, for example, encoders provide feedback to the controller, which adjusts the motor speed and position to cut precise shapes and patterns in the material.

Robotics

In robotics, Digital rotary encoders provide position feedback and control of the robotic arms and joints. Encoders provide accurate feedback on the position and orientation of the robotic arm, which enables precise movement and manipulation of objects. Robot grippers also use encoders to detect the force applied to the object and adjust the grip accordingly.

Industrial automation

Digital rotary encoders play a critical role in industrial automation by providing precise position feedback and control of various mechanical systems. For example, in a conveyor belt system, encoders provide feedback on the speed and position of the belt, which allows for accurate control of the product flow and sorting.

Machine tooling

Digital rotary encoders are used in machine tooling, such as lathes and milling machines, to provide precise position feedback and control of the cutting tool. Encoders enable the cutting tool to move accurately and precisely along the material, resulting in high-quality parts and components.

Benefits of using encoders in manufacturing

Using digital rotary encoders in manufacturing offers several benefits, including:

Improved quality. Encoders provide precise position feedback, which results in improved accuracy and quality of the manufactured parts and components. With encoders, manufacturers can achieve high-quality cuts, precise measurements, and accurate movement of mechanical systems.

Increased efficiency. Digital rotary encoders improve the efficiency of manufacturing processes by providing real-time position feedback and control of mechanical systems. This enables manufacturers to optimize the speed and movement of the systems, resulting in faster production cycles and reduced downtime.

Reduced maintenance costs. Digital rotary encoders are reliable and require minimal maintenance. Unlike traditional mechanical sensors, encoders have no moving parts, which reduces wear and tear and extends their lifespan. This results in reduced maintenance costs and downtime, which increases the overall productivity of the manufacturing process.

Overall, digital rotary encoders are versatile devices for measuring and monitoring rotational movements in numerous applications where precise position or speed control is required.

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Using MQTT Protocol for Smarter Automation

In my previous blog post, “Edge Gateways to Support Real-Time Condition Monitoring Data,” I talked about the importance of using an edge gateway to gather the IoT data from sensors in parallel with a PLC. This was because of the large data load and the need to avoid interfering with the existing machine communications. In this post, I want to delve deeper into the topic and explain the process of implementing an edge gateway.

Using the existing Ethernet infrastructure

One way to collect IoT data with an edge gateway is by using the existing Ethernet infrastructure. With most devices already communicating on an industrial Ethernet protocol, an edge gateway can gather the data on the same physical Ethernet port but at a separate software-defined number associated to a network protocol communication.

Message Queue Telemetry Transport (MQTT)

One of the most commonly used IoT protocols is Message Queue Telemetry Transport (MQTT). It is an ISO standard and has a dedicated software Ethernet port of 1883 and 8883 for secure encrypted communications. One reason for its popularity is that it is designed to be lightweight and efficient. Lightweight means that the protocol requires a minimum coding and it uses low-bandwidth connections.

Brokers and clients

The MQTT protocol defines two entities: a broker and client. The edge gateway typically serves as a message broker that receives client messages and routes them to the appropriate destination clients. A client is any device that runs an MQTT library and connects to an MQTT broker.

MQTT works on a publisher and subscriber model. Smart IoT devices are set up to be publishers, where they publish different condition data as topics to an edge gateway. Other clients, such as PC and data centers, can be set up as subscribers. The edge gateway, serving as a broker receives all the published data and forwards it only to the subscribers interested in that topic.

One client can publish many different topics as well as be a subscriber to other topics. There can also be many clients subscribing to the same topic, making the architecture flexible and scalable.

The edge gateway serving as the broker makes it possible for devices to communicate with each other if the device supports the MQTT protocol. MQTT can connect a wide range of devices, from sensors to actuators on machines to mobile devices and cloud servers. While MQTT isn’t the only way to gather data, it offers a simple and reliable way for customers to start gathering that data with their existing Ethernet infrastructures.

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Understanding IP Ratings

Ingress Protection (IP) ratings, developed by the International Electrotechnical Commission (IEC), are a standardized measure for manufacturers to specify and understand the level of protection that an enclosure offers against the intrusion of solid objects and liquids. It helps customers understand the suitability of a product for its intended use.

There are various levels of protection provided by IP ratings, and in this post, we’ll be discussing the differences between them.

Protection against solids

The first digit in an IP rating refers to the level of protection against solids – ranging from 0 to 6, with 0 being no protection and 6 providing protection against dust and other small particles. For example, a product with an IP rating of 4x provides protection against solid objects larger than 1mm in diameter.

Protection against liquids

The second digit in an IP rating refers to the level of protection against liquids – ranging from 0 to 9, with 0 being no protection and 9 providing protection against high temperatures, high pressure, water, and steam. A product with an IP rating of 7, for example, provides protection against immersion in water up to 1 meter for up to 30 minutes.

It is essential to note that higher IP ratings do not necessarily mean better protection. For instance, a product with an IP rating of 68 provides protection against dust and continuous immersion in water, making it suitable for underwater applications. However, it might not be suitable for areas with high humidity levels because it may not protect against condensation. Two common IP ratings are IP20, typical of control cabinet devices, and IP67, which is common in field devices.

Understanding the difference in IP ratings is essential for selecting the right product for its intended application. But it’s also important to follow appropriate guidelines to maintain a given device’s rating. This may include following specific mounting instructions, selecting the right connectors/cables, adhering to torque ratings, and more. One common example where we might see IP rating being negated would be a failure to use port plugs on unused ports on IO-Link master blocks.

In conclusion, the IP rating system is an important standard used to specify the level of protection against solids and liquids of a device. The first digit refers to the level of protection against solid objects, while the second digit refers to the level of protection against liquids. It is important to note that higher IP ratings do not necessarily mean better protection and understanding the difference between the ratings is crucial for selecting the right product for its intended application.

For a full description of the IEC IP ratings, including their testing conditions, please refer to IEC 60529.

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The Benefits of Mobile Handheld and Stationary Code Readers

Ensuring reliable traceability of products and assembly is critical in industries such as automotive, pharmaceuticals, and electronics. Code readers are essential in achieving this, with stationary and mobile handheld readers being the two most popular options. In what situations is it more appropriate to use one type over the other?

Stationary optical ID sensors

Stationary optical ID sensors offer simple and reliable code reading, making them an excellent option for ensuring traceability. They can read various codes, including barcodes, 2D codes, and DMC codes, and are permanently installed in the plant. Additionally, with their standardized automation and IT interfaces, the information readout can be passed on to the PLC or IT systems. Some variants also come with an IO-Link interface for extremely simple integration. The modern solution offers additional condition monitoring information, such as vibration, temperature, code quality, and operating time, making them a unique multi-talent within optical identification.

Portable code readers

Portable code readers provide maximum freedom of movement and can quickly and reliably read common 1D, 2D, and stacked barcodes on documents and directly on items. Various applications use them for controlling supply processes, production control, component tracking, quality control, and inventory. The wireless variants of handheld code readers with Bluetooth technology allow users to move around freely within a range of up to 100 meters around the base station. They also have a reliable read confirmation system via acoustic signal, LEDs, and a light spot projected onto the read code. Furthermore, the ergonomic design and highly visible laser marking frames ensure fatigue-free work.

Both stationary and mobile handheld barcode readers play an essential role in ensuring reliable traceability of products and assembly in various industries. Choosing the right type of barcode reader for your application is crucial to ensure optimal performance and efficiency. While stationary code readers are ideal for constant scanning in production lines, mobile handheld readers offer flexibility and reliability for various applications. Regardless of your choice, both devices offer simple operation and standardized automation and IT interfaces, making them essential tools for businesses that rely on efficient code reading.

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Improving Overall Equipment Effectiveness

Overall equipment effectiveness (OEE) is a critical metric for measuring the efficiency of manufacturing operations. It considers three factors – availability, performance, and quality – to determine the effective use of equipment.

Where do we focus to win the biggest improvements?

To improve OEE, it’s important to focus on these five key areas:

    1. Equipment maintenance: Ensuring equipment is well-maintained is critical to achieving high OEE. Regular inspections, preventive maintenance or, even better, “predictive maintenance,” and prompt repairs can help minimize downtime from unexpected breakdowns. Condition monitoring sensors and the data they generate can predict where failures may to occur so action can be taken to avoid such downtimes.
    2. Production planning: Effective production planning can help optimize production schedules, minimize set-up time, and reduce changeover time, as well as help increase equipment utilization and reduce downtime. Software solutions are available that provide operators with guidance and optimize changeovers between different set-ups or formats.
    3. Process optimization: Analyzing and optimizing production processes can help identify bottlenecks, reduce waste, and improve overall efficiency. This can involve implementing process improvements, such as reducing cycle times or optimizing material flow.
    4. Workforce training: A well-trained workforce can help minimize errors, reduce downtime, and improve overall quality. Providing employees with the necessary skills and training can also help increase productivity and equipment utilization. Operator guidance, including digital work instruction, which is available in a digital format, is increasingly familiar to the newer members of the workforce.
    5. Data analysis: Collecting and analyzing OEE and downtime data, and other key metrics can help identify areas for improvement and guide decision-making on where to focus. Implementing real-time monitoring and analysis can help detect issues early, well before a failure, and thus, minimize the impact on production.

By focusing on and ranking the areas outlined above, manufacturers can improve overall equipment effectiveness and achieve greater efficiency, productivity, and, most importantly, profitability.

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Waterways: the Many Routes of Water Detection

 

Water is everywhere, in most things living and not, and the amount of this precious resource is always important. The simplest form of monitoring water is if it is there or not. In your body, you feel the effects of dehydration, in your car the motor overheats, and on your lawn, you see the dryness of the grass. What about your specialty machine or your assembly process? Water and other liquids are inherently clear so how do you see them, especially small amounts of it possibly stored in a tank or moving fast? Well, there are several correct answers to that question. Let’s dive into this slippery topic together, pun intended.

While mechanical float and flow switches have been around the longest, capacitive, photoelectric, and ultrasonic sensors are the most modern forms of electronic water detection. These three sensing technologies all have their strong points. Let’s cover a few comparisons that might help you find your path to the best solution for your application.

Capacitive sensors

Capacitive sensors are designed to detect nonferrous materials, but really anything that can break the capacitive field the sensor creates, including water, can do this. This technology allows for adjustment to the threshold of what it takes to break this field. These sensors are a great solution for through tank level detection and direct-contact sensing.

Ultrasonic sensors

Want to view your level from above? Ultrasonic sensors give you that view. They use sound to bounce off the media and return to the sensor, calculating the time it takes to measure distance. Their strong point is that they can overcome foam and can bounce off the water where light struggles when there is a large distance from the target to the receiver. Using the liquid from above, ultrasonics can monitor large tanks without contact.

Photoelectric sensors

Use photoelectric sensors when you’re looking at a solution for small scale. Now, this might require a site tube if you are monitoring the level on a large tank, however, if you want to detect small amounts of water or even bubbles within that water, photoelectric sensors are ideal. Using optical head remote photoelectric sensors tied to an amplifier, the detail and speed are unmatched. Photoelectric sensors are also great at detecting liquid levels on transparent bottles. In these applications with short distances, you need speed. Photoelectric sensors are as fast as light.

So, have you made up your mind yet? No matter which technology you choose, you will have a sensor that gives you accurate detail and digital outputs and is easy on the budget. Capacitive, ultrasonic, and photoelectric sensors provide all this and they grow with your application with adjustability.

Liquids are everywhere and not going away in manufacturing. They will continue to be an important resource for manufacturing.  Cherish them and ensure you account for every drop.

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Using Vision Sensors to Conquer 1D and 2D Barcode Reading Applications

As many industries trend towards the adoption and use of two-dimensional barcodes and readers, the growth in popularity, acceptance of use, and positive track record of these 2D code readers offer a better way to track data. Vision-sensing code readers have many benefits, such as higher read rate performance, multi-directional code detection, simultaneous multiple codes reads, and more information storage.

While traditional red line laser scanners or cameras with decoding and positioning software are commonly used to read barcodes, there are three main types of barcodes: 1D, 2D, and QR codes. Each type has different attributes and ways of reading.

1D barcodes are the traditional ladder line barcodes typically seen in grocery stores and on merchandise and packaging. On the other hand, 2D Data Matrix codes are smaller than 1D barcodes but can hold quite a bit more information with built-in redundancy in case of scratches or defacement. QR codes, which were initially developed for the automotive industry, can hold even more information than Data Matrix codes, were initially developed for the automotive industry to track parts during vehicle manufacturing and are now widely used in business and advertising.

There are various types of vision sensors for reading different types of barcodes. QR codes are often used in business and advertising, while micro QR codes are typically seen in industrial applications such as camshafts, crankshafts, pistons, and circuit boards. Deciphering micro QR codes typically require an industrial sensor.

The need to easily track products and collect information about their whereabouts has been a long-standing problem in manufacturing and industrial automation. While one-dimensional barcodes have been the traditional solution, advances in one-dimensional code reading continue to improve. New hardware, code readers, and symbology, however, have made an emergence, and new image-based scanners are becoming a popular alternative for data capture solutions.

In summary, vision sensors are becoming increasingly important in 1D and 2D barcode reading applications due to their higher read rate performance, multi-directional code detection, simultaneous multiple codes read, and more information storage. As the need for tracking products and collecting information about their whereabouts continues to grow, industries will benefit from the use of vision sensors to improve efficiency and accuracy.