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Control Meets IIoT, Providing Insights into a New World

In manufacturing and automation control, the programmable logic controller (PLC) is an essential tool. And since the PLC is integrated into the machine already, it’s understandable that you might see the PLC as all that you need to do anything in automation on the manufacturing floor.

Condition monitoring in machine automation

For example, process or condition monitoring is emerging as an important automation feature that can help ensure that machines are running smoothly. This can be done by monitoring motor or mechanical vibration, temperature or pressure. You can also add functionality for a machine or line configuration or setup by adding sensors to verify fixture locations for machine configuration at changeovers.

One way to do this is to wire these sensors to the PLC and modify its code and use it as an all-in-one device. After all, it’s on the machine already. But there’s a definite downside to using a PLC this way. Its processing power is limited, and there are limits to the number of additional processes and functions it can run. Why risk possible complications that could impact the reliability of your control systems? There are alternatives.

External monitoring and support processes

Consider using more flexible platforms, such as an edge gateway, Linux, and IO-Link. These external sources open a whole new world of alternatives that provide better reliability and more options for today and the future. It also makes it easier to access and integrate condition monitoring and configuration data into enterprise IT/OT (information technology/operational technology) systems, which PLCs are not well suited to interface with, if they can be integrated at all.

Here are some practical examples of this type of augmented or add-on/retrofit functionality:

      • Motor or pump vibration condition monitoring
      • Support-process related pressure, vibration and temperature monitoring
      • Monitoring of product or process flow
      • Portable battery based/cloud condition monitoring
      • Mold and Die cloud-based cycle/usage monitoring
      • Product changeover, operator guidance system
      • Automatic inventory monitoring warehouse system

Using external systems for these additional functions means you can readily take advantage of the ever-widening availability of more powerful computing systems and the simple connectivity and networking of smart sensors and transducers. Augmenting and improving your control systems with external monitoring and support processes is one of the notable benefits of employing Industrial Internet of Things (IIoT) and Industry 4.0 tools.

The ease of with which you can integrate these systems into IT/OT systems, even including cloud-based access, can dramatically change what is now available for process information-gathering and monitoring and augment processes without touching or effecting the rudimentary control system of new or existing machines or lines. In many cases, external systems can even be added at lower price points than PLC modification, which means they can be more easily justified for their ROI and functionality.

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How Hot is Hot? – The Basics of Infrared Temperature Sensors

Detecting hot objects in industrial applications can be quite challenging. There are a number of technologies available for these applications depending on the temperatures involved and the accuracy required. In this blog we are going to focus on infrared temperature sensors.

Every object with a temperature above absolute zero (-273.15°C or -459.8°F) emits infrared light in proportion to its temperature. The amount and type of radiation enables the temperature of the object to be determined.

In an infrared temperature sensor a lens focuses the thermal radiation emitted by the object on to an infrared detector. The rays are restricted in the IR temperature sensor by a diaphragm, to create a precise measuring spot on the object. Any false radiation is blocked at the lens by a spectral filter. The infrared detector converts radiation into an electrical signal. This is also proportional to the temperature of the target object and is used for signal processing in a digital processor. This electrical signal is the basis for all functions of the temperature sensor.

There are a number of factors that need to be taken into account when selecting an infrared temperature sensor.

  • What is the temperature range of the application?
    • The temperature range can vary. Balluff’s BTS infrared sensor, for example, has a range of 250°C to 1,250°C or for those Fahrenheit fans 482°F to 2,282° This temperature range covers a majority of heat treating, steel processing, and other industrial applications.
  • What is the size of the object or target?
    • The target must completely fill the light spot or viewing area of the sensor completely to ensure an accurate reading. The resolution of the optics is a relationship to the distance and the diameter of the spot.

  • Is the target moving?
    • One of the major advantages of an infrared temperature sensor is its ability to detect high temperatures of moving objects with fast response times without contact and from safe distances.
  • What type of output is required?
    • Infrared temperature sensors can have both an analog output of 4-20mA to correspond to the temperature and is robust enough to survive industrial applications and longer run lengths. In addition, some sensors also have a programmable digital output for alarms or go no go signals.
    • Smart infrared temperature sensors also have the ability to communicate on networks such as IO-Link. This network enables full parameterization while providing diagnostics and other valuable process information.

Infrared temperature sensors allow you to monitor temperature ranges without contact and with no feedback effect, detect hot objects, and measure temperatures. A variety of setting options and special processing functions enable use in a wide range of applications. The IO-Link interface allows parameterizing of the sensor remotely, e.g. by the host controller.

For more information visit www.balluff.com