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Top 5 Insights from 2019

With a new year comes new innovation and insights. Before we jump into new topics for 2020, let’s not forget some of the hottest topics from last year. Below are the five most popular blogs from our site in 2019.

1. How to Select the Best Lighting Techniques for Your Machine Vision Application

How to select the best vision_LI.jpg The key to deploying a robust machine vision application in a factory automation setting is ensuring that you create the necessary environment for a stable image. The three areas you must focus on to ensure image stability are: lighting, lensing and material handling. For this blog, I will focus on the seven main lighting techniques that are used in machine vision applications.

2. M12 Connector Coding

blog 7.10_LI.jpg New automation products hit the market every day and each device requires the correct cable to operate. Even in standard cables sizes, there are a variety of connector types that correspond with different applications.

3. When to use optical filtering in a machine vision application

blog 7.3_LI.jpg Industrial image processing is essentially a requirement in modern manufacturing. Vision solutions can deliver visual quality control, identification and positioning. While vision systems have gotten easier to install and use, there isn’t a one-size-fits-all solution. Knowing how and when you should use optical filtering in a machine vision application is a vital part of making sure your system delivers everything you need.

4. The Difference Between Intrinsically Safe and Explosion Proof

5.14_LI The difference between a product being ‘explosion proof’ and ‘intrinsically safe’ can be confusing but it is vital to select the proper one for your application. Both approvals are meant to prevent a potential electrical equipment malfunction from initiating an explosion or ignition through gases that may be present in the surrounding area. This is accomplished in both cases by keeping the potential energy level below what is necessary to start ignition process in an open atmosphere.

5. Smart choices deliver leaner processes in Packaging, Food and Beverage industry

Smart choices deliver leaner processes in PFB_LI.jpg In all industries, there is a need for more flexible and individualized production as well as increased transparency and documentable processes. Overall equipment efficiency, zero downtime and the demand for shorter production runs have created the need for smart machines and ultimately the smart factory. Now more than ever, this is important in the Packaging, Food and Beverage (PFB) industry to ensure that the products and processes are clean, safe and efficient.

We appreciate your dedication to Automation Insights in 2019 and look forward to growth and innovation in 2020!

M12 Connector Coding

New automation products hit the market every day and each device requires the correct cable to operate. Even in standard cables sizes, there are a variety of connector types that correspond with different applications.

When choosing a cable, it is essential to choose the correct size, length, number of connectors, pinout, and codes for your application. This post will review cable codes, which signify different capabilities and uses for a cable. Cables that are coded differently will have different specifications and electrical features, corresponding to their intended uses. To distinguish between the different styles of cable, each connector has a different keyway, as shown in Figure 1. This is to prevent a cable from being used in an incorrect application.

Cable Codes-01

There are a wide variety of cable codings used for different purposes. Below are the five most common M12 cable codes and their uses. They are as follows:

A-coded connectors are the most common style of connector. These are used for sensors, actuators, motors, and most other standard devices. A-coded connectors can vary in its number of pins, anywhere between two pins and 12 pins.
B-coded connectors are mostly used in network cables for fieldbus connections. Most notably, this includes systems that operate with Profibus. B-coded connectors typically have between three and five pins.
C-coded connectors are less common than the others. These connectors are primarily used with AC sensors and actuators. They also have a dual keyway for added security, ensuring that this connector will not be accidentally used in the place of another cable. C-coded connectors have between three and six pins.
D-coded connectors are typically used in network cables for Ethernet and ProfiNet systems. D-coded connectors transfer data up to 100 Mb. These connectors typically provide three to five pins.
X-coded connectors are a more recent advancement of the cables. They are growing in popularity due to their ability to transfer large amounts of data at high speeds. X-coded cables transfer data up to 1 Gb. These are ideal for high-speed data transfer in industrial applications. While the other coded cables typically vary in number of connectors, X-coded cables will always have eight pins.

What Exactly is Safety Over IO-Link?

Users of IO-Link have long been in search of a solution for implementing the demands for functional safety using IO-Link. As a first step, the only possibility was to turn the actuators off using a separate power supply (Port class “B”, Pins 2, 5), which powers down the entire module. Today there is a better answer: Safety hub with IO-Link!

Automation Pyramid.png

This integrated safety concept is the logical continuation of the IO-Link philosophy. It is the only globally available technology to build on the proven IO-Link standards and profisafe. This means it uses the essential IO-Link benefits such as simple data transport and information exchange, high flexibility and universal applicability for safety signals as well. Safety over IO-Link combines automation and safety and represents efficient safety concepts in one system. Best of all, the functionality of the overall system remains unchanged. Safety is provided nearly as an add-on.

In the center of this safety concept is the new safety hub, which is connected to an available port on an IO-Link master. The safety components are connected to it using M12 standard cable. The safety profisafe signals are then tunneled to the controller through an IO-Link master. This has the advantage of allowing existing infrastructure to still be used without any changes. Parameters are configured centrally through the user interface of the controller.

Safety Hub

The safety hub has four 2-channel safe inputs for collecting safety signals, two safe outputs for turning off safety actuators, and two multi-channel ports for connecting things like safety interlocks which require both input and output signals to be processed simultaneously. The system is TÜV- and PNO-certified and can be used up to PLe/SIL 3. Safety components from all manufacturers can be connected to the safe I/O module.

Like IO-Link in general, Safety over IO-Link is characterized by simple system construction, time-and cost-saving wiring using M12 connectors, reduction in control cabinet volume and leaner system concepts. Virtually any network topology can be simply scaled with Safety over IO-Link, whereby the relative share of automation and safety can be varied as desired. Safety over IO-Link also means unlimited flexibility. Thanks to varying port configuration and simple configuration systems, it can be changed even at the last minute. All of this helps reduce costs. Additional savings come from the simple duplication of (PLC-) projects, prewiring of machine segments and short downtimes made possible by ease of component replacement.

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To learn more about Safety over IO-Link, visit www.balluff.com.

One M12 Port = Endless Possibilities

Paradigm shifts in automation are always occurring. The need for cost savings and higher diagnostics caused the shift from IP20 I/O to IP67 I/O. Now, we are in the midst of a shift to reduce or eliminate enclosures in industrial applications by removing control and power from the cabinet. With the reduction of IP20 I/O and enclosures, adding more I/O (discrete and analog) or specialty devices (RF identification, measurement devices, etc…) is now more difficult. In the past it was relatively easy, but expensive, to add another “slice” of I/O to an existing IP20 solution.

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