In a robot system you may need to jog the robot if:

• The robot is in an unexpected position.
• The robot position needs to be moved for maintenance and/or PM.
  programming to teach points and test motion.
• The controller keyswitch needs to be in either T1 or T2 instead of AUTO.
• If the controller key is turned to teach mode after the DEADMAN switch is held in then the robot will have a fault. When jogging the robot all safety systems must be green, and all faults must be clear.

1. Start with the COORD KEY pressing to toggle through the coordinate system you would like to use. The display for the COORDINATE SYSTEM is found in the Upper Right corner of the teach pendant.

The options for this include:

• Joint – select this coordinate system to jog each joint individually or at the same time.
• S/World – moves the robot TCP in the x, y, or z directions and rotates about x (w), y (p), or z (r).
• S/Tool – moves the robot TCP in the x, y, or z direction and rotates x(w), y(p), and z(r) in the selected tool frame.

For our example, we jogged in the Joint System, so that we could show moving each Joint separately.

2. The jog speed is shown in the green box at the top right on the teach pendant screen – the jog speed defaults to 10%.

3. Turn the ON/OFF SWITCH to ON

4. From this point press the DEADMAN switch on the back of the teach pendant until you hear/feel one click, and hold throughout the jogging process.

You will notice that the DEADMAN Switch has three positions: unclicked, one click, and two clicks. You need to listen or feel for the first click and hold the switch here. If you compress the DEADMAN Switch to two clicks (fully), the robot will not move and there will be an error. To clear this error, completely release the DEADMAN Switch, press in again for one click and press the RESET button

5. To change the jog speed, press the -% or +% button and the speed changes by percent, you can watch the speed increase/decrease in the green speed box at the top right.

6. Now you are ready to start moving the robot at each joint, press and hold the SHIFT key as you use the JOG KEYS to move each joint to the needed position. You can move each joint into position by selecting the direction and joint key and holding the key down until the joint is in position.

• What happens if you get a Fanuc Robot Alarm JOG-007? This means that you stopped holding down the SHIFT key will moving the robot with the JOG Keys. Simply stop moving the robot with the JOG keys and press and hold the SHIFT Key. Then continue moving robot to desired position.
• What if you get a “In singularity” error? You need to Jog Joint J5 +/- at least 10 degrees.

If you need to quickly stop robot movement, release the DEADMAN Switch

7. Once you finish jogging the robot, you can select Auto HOME button to return the robot to position and beginning cycling.

Purchase in: https://plccompany.com.mx/

Information source : https://motioncontrolsrobotics.com/jogging-the-robot/

This guide is intended to help you configure and install the Q3X Sensor. For detailed information on programming, performance, troubleshooting, sizing, and accessories, refer to the instruction manual at www.bannerengineering.com. To view the manual, look for product number 181485. Use of this document assumes prior knowledge of industry standards and practices.

WARNING: Not to be used for personal protection
Never use this device as a detection device for personal protection purposes. Doing so could result in serious injury or death. This device does not include the redundant self-monitoring circuits necessary to enable its use in personal safety applications. A malfunction or sensor failure may result in a live or dead sensor output condition.

Features

1. Output indicator (amber)

2. Screen

3. Buttons

Display and indicators

1. Stability indicator (STB = green)

2. Active TEACH indicators

DYN = Dynamic TEACH mode selected (amber)

WND = Symmetrical window thresholds are active (amber)

In Run mode, the 3-digit, 7-segment display provides real-time information on signal strength for all models and target position for models with a fixed background suppression distance. The numeric value from 0 to 990 represents the amount of light received divided by the threshold, and represents the excess gain of the detection event expressed as a percentage of the switching point. This value is called the normalized signal power (NSS). If the NSS value is 999, it indicates that the received light signal is saturated, so low-contrast detection is not possible.
In single-threshold teach modes (static two-point, dynamic, light level setting or dark level setting), the output switches to a value of 100 (with excess gain of 1.0).

For models with a specified background suppression distance, it indicates that an object is at a greater distance than the background suppression distance and is suppressed. In light mode operation, the output turns off when displayed. For LD50 models, the status of the sensor output when it is displayed can be controlled using the menu. By default, the sensor regards an object in the background as a dark signal and respects the LO/DO selection (light/dark mode operation).

In window configuration teach mode, the value 100 represents the learned signal strength. The displayed value is the percentage of received light divided by the learned signal strength. The output switches according to the displayed values above and below 100, as determined by the percentage window shift selected by the user.

Output indicator
– Ignition: conductive outputs (closed).
– Off: non-conductive outputs (open).

Stability indicator (STS)
– On: stable received light signal.
– Flashing: Light intensity is within the switching threshold hysteresis band.
– Off: No light signal is received.

Active TEACH indicators (DYN and WND)
– DYN and WND off: TEACH static two-point mode, light level setting or dark level setting selected (default is TEACH static two-point).
– DYN and/or WND flashing: Sensor is in TEACH mode.
– DYN on: Dynamic TEACH mode selected.
– WND on: Symmetrical window thresholds are active. The switching points are above and below 100 as determined by the percentage deviation.

Buttons

Use the (-)(MODE) and (+)(TEACH) buttons to program the sensor.

(-)(MODE)
– Decrease the gain: Press once (-)(MODE) then press and hold (-)(MODE) to decrease the gain quickly.
– Enter Setup Mode: Press and hold (-)(MODE) for more than 2 seconds.
– Scroll through the sensor menu: press (-)(MODE)
– Change the configuration values: press and hold (-)(MODE) to decrease the numeric values.

(+)(TEACH)
– Increase the gain: Press once (+)(TEACH) then press and hold (+)(TEACH) to increase the gain rapidly.
– Start selected TEACH mode: press and hold (+)(TEACH) for more than two seconds (static two-point TEACH mode is the default).
– Scroll through the sensor menu: press (+)(TEACH)
– Change the settings: press and hold (+)(TEACH) to increase the numeric values.

(-)(MODE) and (+)(TEACH)
– Select menu items in Setup mode: press (-)(MODE) and (+)(TEACH) at the same time.
– Select and save a parameter and return to Run mode: press (-)(MODE) and (+)(TEACH) at the same time for more than 2 seconds.
When navigating through the menu systems, the various items are displayed sequentially.

Laser description and safety information

CAUTION: Adjusting controls or procedures other than those specified in this document may result in hazardous radiation exposure. Do not attempt to disassemble this sensor for repair. If a unit is defective it should be returned to the manufacturer.

Laser wavelength: 655 nm Output: < 0.42 mW Pulse duration: 5 µs

Installation

Placement of the safety label

Q3X sensors used in the United States must carry the safety label.

NOTE: Place the label in the position on the cord where you receive the least exposure to chemicals.

1. Remove the protective cover of the label adhesive.
2. Place the label around the cable of the Q3X as shown in the illustration.
3. Stick the two halves of the label together.

Sensor orientation

Proper orientation between the sensor and the object is important for correct detection. For reliable detection, orient the sensor as shown in relation to the detected object.
For models with background suppression, make sure that the target is within the contrast detection range and that the background objects are located outside the background suppression distance.

Mounting the sensor

1. Mount the sensor on a bracket.
2. Mount the sensor (or sensor and clamp) in the desired location on the machine or equipment. Do not tighten yet.
. 3. Check the alignment of the sensor.
4. Tighten the screws to secure the sensor (or sensor and clamp) in the aligned position.

Wiring diagram

1 = Brown
2 = White
3 = Blue
4 = Black
5 = Grey

NOTE: Open connections must be connected to a terminal block.

The user can select the function of the input cable; for more information, see the User’s Manual. The input cable function is disabled by default.

Cleaning and maintenance

Proceed with care when installing and using the sensor. If the sensor lenses have fingerprints or are dirty with dust, water, oil, etc., scattered light may be emitted that can degrade the maximum performance of the sensor. Inject filtered compressed air onto the lens, then clean it with a cotton swab soaked in 70% isopropyl alcohol or water and a soft cloth.

Sensor programming

Program the sensor with the sensor buttons or the input cable (this system offers limited programming options, see the Instruction Manual for more information).
The input cable also serves to disable the buttons for safety reasons, preventing accidental or unauthorized modification of the programming. For more information, see the User’s Manual.

Setup Mode

Press and hold MODE for more than 2 seconds to enter Setup mode from Run mode.
2. Press the or buttons to scroll through the main menu.
Select the desired submenu by pressing and together.
4. To view the options contained in the submenu, press or .
5. Select an option from the submenu.
– To select and save a submenu option and return to the main menu, press and at the same time.
– To select and save a submenu item and return to Run Mode, press and together for more than 2 seconds.

Basic Learning Instructions

Follow these instructions to facilitate learning about the Q3X sensor. The instructions that appear on the sensor display vary depending on the type of TEACH mode selected. Two-point TEACH is the default mode.
Press and hold TEACH for more than 2 seconds to initiate the selected TEACH mode.
2. Present the object.
3. Press TEACH to learn the object. The object is learned and the sensor waits for the second object, if the selected TEACH mode requires it, or returns to Run mode.
Follow steps 4 and 5 only if requested by the sensor for the selected TEACH mode.
Present the second object.
5. Press TEACH to learn the object. The object is learned and the sensor returns to Run mode.
Refer to the instruction manual for more information and how other TEACH modes work.

Manual adjustments

Increase or decrease the gain manually by pressing – or + .
1. In Run Mode, press – or + once. The value of the signal strength flashes slowly.
2. Press – to decrease the sensor gain or + to increase the gain, – or + press and hold or to decrease or increase the gain quickly. After one second, the normalized signal strength flashes rapidly, the new setting is confirmed, and the sensor returns to Run mode.
Locking and unlocking sensor buttons
The lock and unlock function prevents unauthorised or unintentional changes to the programming.
To lock or unlock the sensor using the buttons, hold down and immediately press four times.

Operating curves

The efficiency is based on a white card with 90% reflectance.

NOTE: At high sensitivity, excess gain is increased by a factor of 1.5. At low sensitivity, excess gain is decreased by a factor of 0.75.

Q3XTBLD models

Models Q3XTBLD50

NOTE: At high sensitivity, excess gain is increased by a factor of 1.5. At low sensitivity, excess gain is decreased by a factor of 0.75.

(The detection cutoff distance of a 6% black card will be 95% of the cutoff distance of a 90% reflective white card).

Models Q3XTBLD100

NOTE: At high sensitivity, excess gain is increased by a factor of 1.5. At low sensitivity, excess gain is decreased by a factor of 0.75.

(The detection cut-off of a 6 % black card shall be 95 % of the cut-off of a 90 % reflective white card).

Specifications

Sensing Beam: Class 2 visible red laser, 655 nm

Supply Voltage (Vcc) 10 to 30 V dc Power and Current, exclusive of load

Supply Power: < 675 mW

Current consumption: < 28 mA at 24 V dc

Power protection circuits:  Reverse polarity and transient overvoltage protection

Repeatability 60 µs

Delay at Power Up 1 s

Maximum Torque

Side mounting: 1 N·m (9 in·lbs)

Nose mounting: 10 N·m (88 in·lbs)

Connector 5-pin M12 Integral Connector

Construction

Housing: Nickel-plated zinc die-cast

Side cover: Nickel-plated aluminum

Lens cover: Scratch-resistant PMMA acrylic

Lightpipes and display window: Polysulfone

Adjustment buttons: 316 stainless steel

Input Wire

Allowable Input Voltage Range: 0 to Vcc

Active Low (internal weak pullup—sinking current): Low State < 2.0 V at 1 mA max.

Output Configuration Bipolar (1 PNP & 1 NPN) output

Output Rating Discrete Output: 100 mA maximum (protected against continuous overload and short circuit)

Off-state Leakage Current: < 10 µA

NPN On-state saturation voltage: < 200 mV at 10 mA and < 1.0 V at 100 mA

PNP On-state saturation voltage: < 1 V at 10 mA and < 2.0 V at 100 mA

Ambient Light Immunity > 5000 lux

Response Speed User selectable:
• : 250 microseconds
• : 1 millisecond
• : 5 milliseconds

Operating conditions

Temperature: -10 °C to +50 °C

Humidity: 35% to 95% relative humidity
Degree of protection

IEC IP67 for IEC60529

IEC IP68 for IEC60529

IEC IP69K for DIN40050-9

 vibration

MIL-STD-202G  method 201A (10 to 60 Hz, 0.06 in. double amplitude) 1.52 mm] double amplitude in the X, Y and Z axis directions, 2 hours respectively), with the sensor in operation.

 Shock

MIL-STD-202G method 213B, condition I (100 G 6 times in X, Y and Z axis directions, 18 shocks in total), with the sensor in operation.

Storage temperature

-25 °C to +75 °C

Certifications

UL protection class: Type 1
Over-amperage protection must be provided in the application of the final product as indicated in this table. Over-amperage protection can be provided by external fuses or a class 2 power supply. Supply cables < 24 AWG cannot be spliced. For more product information, visit http:// www.bannerengineering.com.

Limited warranty from Banner Engineering Corp.
Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year after shipment. Banner Engineering Corp. agrees to repair or replace, free of charge, any product of its manufacture which, at the time of return to the factory, has any defect during the warranty period. This warranty does not cover damage or liability for misuse, abuse, or improper application or installation of the Banner product.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), ARISING OUT OF OPERATION, SALE OR COMMERCIAL USE.
This warranty is exclusive and limited to repair or, at Banner Engineering Corp’s discretion, replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO THE PURCHASER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOST PROFITS OR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES ARISING FROM ANY DEFECT IN THE PRODUCT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETHER ARISING IN CONTRACT OR WARRANTY, TORT, STRICT LIABILITY, NEGLIGENCE OR OTHERWISE.

Sensor Menu Scheme

Fuente: http://info.bannerengineering.com/cs/groups/public/documents/literature/181486_es.pdf

Workplace? Oh, no! Wait. Let’s start over.

The fourth industrial revolution, or Industry 4.0, is already changing our daily lives for the better.

You may be working in an organization that is immersed in this revolution and you may be lucky enough to see the industrial evolution that it brings to the working life of individuals and companies.

Or perhaps you sense that something is changing around you, technological changes: in your city, on the TV you have just bought.

However, as a company, you either adapt to industry 4.0 or you can hardly reap its benefits.

In this post we are going to understand what is the industry 4.0, what technologies it uses to generate the current industrial revolution we live in and in which areas it affects our current business.

What is Industry 4.0

Even if you don’t know exactly what industry 4.0 is, I imagine you must sense that it has to do with technology and the digital transformation of companies. And, yes, you’re right.

There was talk of this concept in Germany, referring to smart factories. This concept referred to communication between machines, to enhance it. But it didn’t go beyond that, it didn’t extrapolate and it didn’t come out of that factory.

It was the 4.0 concept and Digital Marketing that led to this new interpretation of the industry.

It’s a term we could define as such:

Industry 4.0 is an efficient model of production that
involves the integration of new technologies for maximum benefits.

What does industry 4.0 have to do with the 4th industrial revolution?

Industry 4.0 revolutionizes our understanding of manufacturing. It is the fulcrum of the 4th Industrial Revolution.

Basically, we seek to develop programs that allow the analysis of Big Data to provide useful and valuable information for the manufacture of industrial products. It seems logical to think that incorporating values improves decision-making, right? We confirm this a few lines below.

The automotive, pharmaceutical and electronics industries are surely the most sensitive to this digital mobilization.

The 5 technologies affecting the industry 4.0

Without a doubt, the penetration of new technologies in the manufacture of products represents a profound change. That is why we talk about the 4th industrial revolution.

But what are the technologies that have turned the model of industry we had until now around?

#1. Internet of Things (IoT).

I like to talk about the Internet of Things as an invisible superhero. You don’t see it, but you feel its effect.

If we apply it to the business world we are faced with a new concept, the Industrial Internet Of Things (IIoT). If you already know the power of the IoT in people’s daily lives, you understand the IIoT. We refer to its application in the productive processes of companies.

It is based on the fact that the M2M model, the machine to machine communication, takes advantage of all the data available to the company and combines it with technological innovation. We are looking for intelligent machines that optimize business efficiency.

#2. Big Data

If you’re thinking you’re hearing about Big Data again and you don’t have that much data, I have an answer for you today.

If you’re an SME.

Of course you have databases! Confirmed orders, offers sent, shipments made (if you are a logistics company), registrations in your blog and, in general, don’t you have a customer history? Use it.
If you are an entrepreneur: I understand that your listings are shorter than those of a company. But have you considered using LinkedIn or Twitter as Big Data? Think about Social Selling.
Of course, you need to analyze that data and interpret it in a beneficial way for your company. You can give it a focus to improve your:

Supply Chain

If you segment that huge information and analyze it in smaller packages, you can apply improvements in the supply chain.
Internal and external online communication. The first one has an impact on the improvement of the working environment, because it takes place between people. But also in the optimization of resources, when you direct it towards the IIoT. External because, with this data, you detect the doubts and concerns of your clients, so that you can respond to them by providing solutions through the blog and social networks.

Internal training

A few lines above we talked about using social networks as data sources. Consider training in Social Selling for your sales team. But the Big Data in the industry 4.0 allows you to improve the training of all departments.

#3. Artificial Intelligence

It could not be otherwise: Artificial Intelligence appears as one of the technological pillars of the 4.0 industry.

Applications such as Microsoft’s “Cortana” show us that we can design intelligent machines that learn automatically from the given inputs. In fact, they are already used in production lines.

#4. Cobots

Cobots are the new generation of collaborative robots that work together with people. They are easy to program and very flexible, providing extra support in industrial production. They are designed to act safely with humans, so that they stay still when they detect arms or any other part of the body.

They are currently helping to install the Ford Fiesta’s shock absorbers at the factory in Cologne, Germany.

#5. Virtual and augmented reality

Both are helpful in optimizing industrial processes. The first, adding a virtual environment. The second, virtual elements to reality.

There are sectors whose evolution and progress require the construction of expensive prototypes. This technology allows them to be made at much lower costs. BMW already uses it to visualise vehicle interiors.

It is common to hear that this new industry model generates more unemployment. However, experts are already explaining that this is not what happens. New professional profiles are needed that are capable of managing this change that is taking place. Engineers and programmers are the most in demand.

Above all, the automotive and pharmaceutical sectors are the ones that incorporate the most automation in their processes.

3 leading companies in the industry 4.0

In this post we have already mentioned the powerful Ford and BMW as references of the industry 4.0.

Which is the group of companies that accompany them in this leadership?

/*/ SEAT

Seat is one of the most recent examples of a company determined to become an industry 4.0. Its logistics building in Martorell is on its way to becoming the highest automated warehouse in Spain.

It is scheduled to open at the end of 2018 and will have a capacity of 199,999 boxes.

/**/ Lego

Lego is an example of evolution. Video games began as a strong threat to his classic pieces. But they have managed to reinvent themselves and are currently participating in gamification programs for companies and universities.

They have also managed to develop it on a virtual plane.

/***/ John Deere

John Deere is a name we’ve stamped on the tractors we’ve seen all our lives.

They too have been able to offer the farming world a plus, taking advantage of new technologies. Today we see how these vehicles have built-in weather sensors or crop advice.

How does industry 4.0 affect Digital Marketing?

When we look at any company that is heading towards digitalization we see that there is one element in common: the commitment to digital marketing.
Not only do users use the Internet to solve their doubts or satisfy their needs. Also in the B2B model is used to find suppliers or strategic partners to help develop our business.

They are not impulsive purchases, but decisions are meditated and assumed after a negotiation. And, with this environment, having a solid brand with a good reputation is the first step to being chosen.

There are 15.4 million residents in Spain who use social networks. And we can reach them thanks to the implementation of an appropriate Social Media Marketing Plan.

With a specific strategy aimed at achieving business objectives, we manage to attract our potential client in a non-intrusive way. This is Inbound Marketing.

But our work in Digital Marketing does not end there. Once we have attracted them, we must convince them that we are their best answer. And to do that, keeping an active blog and a good conversation in social networks are essential.

Conclusion

The path towards the digitalization of companies seems inevitable.

I would be satisfied if after reading this post you have many more doubts than before about the 4.0 industry. That means that I’ve been able to transmit you some clear idea about what it is and what tools it is based on.

Obviously, when we take a first step into a new field, 1,000 doubts are opened. And that’s great because it means you’re concerned about how it can make you better.

Go ahead. Take that first step and don’t hesitate to ask for external collaborators, if that helps you grow and find new business opportunities for your company to become a 4.0 industry.

Fuente: https://soniadurolimia.com/que-es-la-industria-4-0/?utm_source=blogsterapp&utm_medium=twitter

Let’s look at five important considerations that must accompany any light curtain specification.

1. What are the specifications? 

Certain basic standards must be observed for all safety products, including ISO 13849-1, IEC 62061 and IEC 61508. These standards emphasize control reliability, diagnostic capabilities and safety system architecture.

In the case of light curtains, you should also look for additional safety information, such as the Performance Level (PL) provided by the safety device.

2. What is its detection capability? 

The resolution or detection capability of a light curtain refers to the separation between its laser beams. There are many different resolution options. For example, a resolution of 14mm is suitable for finger detection and is used when the curtain is placed very close to the source of hazardous movement. Hand detection is achieved with a resolution of 25mm to 30mm.

3. What is the minimum safety distance?

According to ISO 13855, the minimum distance must always be calculated to determine where to install a safety light curtain. This ensures that once a person activates the light curtain when crossing the detection area, the machine stops operating before the person reaches the source of danger.

4. What’s the resistance? 

Many manufacturing facilities present environmental challenges, such as temperature, excess humidity and other issues that can easily damage equipment. Light curtains must be resistant to these pressures. For example, Omron’s F3SG-SR series has a wide operating temperature and stands up well to food processing and steel applications.

5. What is control architecture? 

Light curtains are a measure specifically designed for machine safety, but in reality they simply represent a fraction of the overall safety system around a machine and an information point for that system. To develop a satisfactory solution, it is necessary to connect the light curtains to safety monitoring equipment, such as safety relays or safety controllers, that meet the mandatory specifications.

Fuente: https://automation.omron.com/es/mx/programacion-blog/how-to-select-a-safety-light-curtain

– Mech Value
– Mech Line
– Mech Line Force
– Mech Line Plus – Extreme

AW’s linear actuators are ideal for replacing hydraulic and pneumatic systems. They feature a high-performance and highly durable ball screw for loads up to 120kN. The Mech Value series, is focused on solving applications where small size actuators are required, with available sizes of 16, 25 and 32.

The entire Mech Line range is compatible with ISO 6431, offering maximum performance in minimum space. It has an interface for direct or relayed step-by-step or brushless monitoring.
The Mech Line Force actuator, an evolution of the Mech Line range, maintains compatibility with ISO 6431, while offering high modularity and flexibility for dynamic applications with high force. Available with in-line or biased monitoring, as well as optional epicyclic gear.

The Mech Line Plus & Extreme, is a series of linear actuators that combine extreme force with high precision. Compatible with ISO 1554.2, they are specially designed for applications where high forces are required, being a real and effective alternative for hydraulic and pneumatic cylinders. In addition to this, an anti-rotation system generates a low noise level while maintaining high productivity.

AW has a flexible manufacturing service depending on the needs of the application (stroke, engine arrangement, gearbox, mountings, etc.).

As in its other product ranges, AW offers a solution for the execution of movement in a simple manner, by means of software applied to its control solutions, in this case the EasyLin software, which allows a quick and simplified configuration of the application.

Fuente: https://www.infoplc.net/noticias/item/108010-gimatic-actuadores-lineales-mech-line-extreme-de-aw

The fourth industrial revolution is creating a faster, smarter and more efficient manufacturing process. Known as Industry 4.0, this stage that is spreading to manufacturing plants has taken automation to the next level. Using the Industrial Internet of Things (IoT), manufacturers can connect the physical world with the digital world and fully control all systems like never before. In addition, they can leverage data to reduce costs, improve performance, and increase productivity by using an open IoT operating system.

Although a digital transformation may seem somewhat overwhelming, the transition can be carried out in just four phases, called pillars: connectivity, control, digitalization and augmentation. Although few companies (4%) are fully integrated today, more than 70% have completed at least one IoT project or are looking for and implementing one. Almost 90% of those who have completed a project are looking for new plans.

Those who have completed an IoT project report reduced downtime, lower operating costs, increased productivity and a better understanding of the equipment (see graph below) and how to optimize it.

The following steps detail how to make the digital transition and take advantage of the opportunities offered by Industry 4.0.

Pillar One – Connectivity: connecting and controlling assets

Connectivity means connecting physical devices and business systems to the IoT to promote systems integration, increase transparency and improve remote processes between plants.

The first step of the digital transformation is to connect physical devices and systems to the IoT. Even companies with older equipment can do this with investments in sensors and hardware. Plants in several locations can be connected and then controlled remotely. Once the machines are connected, data can be collected in real time, and alarms can be set up to notify the manufacturer when an asset is not working properly. This reduces the chances of an expensive and urgent repair.

This control minimizes downtime and offers manufacturers the opportunity to continuously improve machine performance using real-time asset data. Siemens’ MindSphere customers, for example, report reducing service costs by 30%, decreasing downtime by 15% and increasing production by 8%.

Pillar two – Control and transparency: optimising performance predictability

Control allows an enterprise to use data from connected devices for full transparency and control of asset performance. The second step of the digital transformation is to use the data collected to optimize machine performance, using predictive and descriptive maintenance. This involves replacing traditional maintenance methods (reactive and scheduled maintenance) with evolving, data-driven approaches.

Predictive and prescriptive maintenance means carrying out maintenance on machinery at the right time to prevent any service failure. This eliminates untimely maintenance, reduces unnecessary downtime and allows the manufacturer to remotely monitor machines and identify the root cause of production problems.

Predictive maintenance saves 12% in costs compared to scheduled repairs, reduces maintenance costs by 30% and decreases breakdowns by 70%, according to an operational efficiency report conducted by Pacific Northwest National Laboratory for the U.S. Department of Energy. Customers using MindSphere report a 15% reduction in downtime.

Third Pillar – Digitization: Closing the Circle with Digital Twins

The scanning process uses data to create a digital copy of a product or system to search for efficiencies, resolve issues, test solutions and improve product development. Later, real-time data from the field is incorporated into the digital twin for continuous innovation.

There are three types of digital twins: product, production and performance. A digital product twin allows the manufacturer to test several versions of a product before creating the physical prototype. This can shorten development cycles, allow more innovation and eliminate costs in product development.

A digital production twin recreates the entire manufacturing process. This allows the manufacturer to search for defects in the process without affecting the manufacturing outcome. A digital performance twin collects real-time data from operational products and the production line so that manufacturers can identify new ways to improve the product or process. Data can also be incorporated into the digital twin of the product or production for continuous improvement.

Fourth Pillar – Augmentation: extending results

In this phase, the IoT and artificial intelligence combine to create intelligent machines that can use data to function independently of human influence. The final step of the digital transformation is to use data from the IoT to report on the operation of the machine without human interference. Artificial intelligence uses the IoT data using automatic language to predict the results and act accordingly.

By automating the operation of machines, manufacturers can increase productivity, reduce errors and gain a competitive advantage over others with less operational efficiency. Bringing artificial intelligence to manufacturing plants provides companies with a way to stop using current business models and look for new opportunities.

As the industry moves at full speed toward digitalization, manufacturers need to be prepared for disruption. Industrial IoT can completely transform the way a company does business. 70% of companies have already completed at least one IoT project or are considering one, and 4% of companies are fully integrated with IoT. Continuing with traditional ways of operating while competitors move to Industry 4.0 will leave manufacturers behind in that race for better operational efficiency.

The industrial IoT allows companies to take control of their factories like never before. By connecting devices and systems, manufacturers can learn more about their machines and how to manipulate them to work smarter, reducing costs and errors.

Fuente: https://www.infoplc.net/plus-plus/blogs/item/108000-opinion-siemens-iiot-cuatro-pilares

Despite this, industry estimates suggest that 80-90% of the roughly 150 million lighting units installed in industrial facilities in the United States continue to rely on energy-draining High Intensity Discharge (HID) sources, specifically metal halide, mercury vapor, and high-pressure sodium lighting. Worse yet, fluorescent and incandescent lighting remains commonplace. LED luminaires create the same or better illumination as conventional lighting sources yet use less than half of the energy, making their higher upfront cost recoupable within months. Industrial facilities that install LED luminaires also realize lower maintenance and repair costs since LED lighting typically operates at full capacity for more than 60,000 hours, or in some cases, up to 100,000 hours. That is two to four times as long as most metal halide, or even sodium vapor lights, and more than 40 times the lifespan of the average incandescent bulb.

Alongside financial benefits, the environmental case for LED luminaires is strong. Consider the following list of ways LEDs help businesses shrink their environmental footprint while improving their bottom-line.

Almost half of our carbon footprint is due to electricity, generated by coal, gas, or nuclear power plants. First and foremost, LED lighting consumes significantly less power per lumen than any other lighting source. LED lights are up to 80% more efficient than traditional lighting, such as high-pressure sodium and metal halide, with 95% of the energy in LEDs converted into light and only 5% released as heat. LED’s “Instant-On” capability is especially energy saving in industrial settings where HID lights are left on around-the-clock to avoid their long warm up-period. HID lighting requires a warm-up period because the lighting intensity is dependent on, and changes as, the material inside the bulb is evaporated into plasma. Additionally, as the HID heats up, it requires additional voltage to operate. Worse yet, HID lights become less efficient over time. They must use more and more voltage to produce the same lumen output as the light degrades. Roughly 17% of the typical U.S. industrial building’s electricity usage is devoted to lighting. This takes a bite out of a company’s profits and out of the ozone layer.

Less energy use by LEDs translates into reduced demand from power plants and decreased greenhouse gas emissions. Greenhouse gases trap heat in the atmosphere, making the planet warmer by thickening the Earth’s blanket. Greenhouse gases include Carbon Dioxide that enters the atmosphere through burning fossil fuels; Methane emitted during the production of coal, natural gas, and oil; and Nitrous Oxide released in the combustion of fossil fuels and solid waste. Each of these gases can remain in the atmosphere for different amounts of time, ranging from a few years to thousands of years.

Due to their low energy consumption, LED luminaires contribute the least amount of carbon dioxide into the atmosphere of all lighting sources. For example, use of a simple incandescent bulb results in 4,500 pounds of CO2 annually, while LED bulbs contribute only 451 pounds of CO2 per year. Retrofitting HID fixtures with LED luminaires can have a huge environmental impact by reducing greenhouse gases. IHS Markit, a London-based company that analyzes information and provides solutions for corporations, released a study that shows 570 million tons of carbon dioxide emissions were eliminated in 2017 thanks to the use of LED bulbs. This is an amount similar to shutting down 162 coal-fired power plants around the world. Since LED lighting can last up to 20 years in some cases, this longer life also decreases the production of more luminaires and bulbs, and therefore reduce the greenhouse emissions created by the manufacturing process. Despite growing concern about global warming, U.S. emissions rose over 3% in 2018 and global emissions reached an all-time high. While commercial and household use of LED lamps is helping, far greater impact could be affected by full conversion of the industrial sector to LED.

Example Using Retrofit Calculator
Along with the economic benefits, the environmental contribution of retrofitting HID and other legacy lighting with high-efficiency industrial-grade LED lighting can be quantified using Emerson’s Retrofit Calculator. A typical refinery, processing 100,000 to 150,000 barrels per day might have approximately 3,500 70W high pressure sodium task lights and 100 400W high pressure sodium or metal halide flood lights. The table pictured is reported from the calculator and shows the yearly environmental impact of retrofitting this example refinery to new LED luminaires. The energy savings in this one facility would be equivalent to the usage of 229 American households. Power Plants, Petroleum and Natural Gas Plants, and Petroleum Refineries are the three largest emitters of greenhouse gases, and improvements in these facilities can have the biggest impact on overall U.S. emissions.

Fewer Luminaires Needed
LEDs exhibit far superior light distribution by focusing light in one targeted direction as opposed to other types of lighting that waste energy by emitting light in all directions. As a result, fewer LED luminaires are required to achieve the same level of brightness given off by HID, fluorescent, or incandescent lights. Fewer lights reduce energy consumption and therefore benefits the environment in many ways.

LEDs Run Cooler
LEDs give off very little heat. And what heat is produced is dissipated by metal heat sinks that wick away the heat from the light source. Lowering the facility’s temperature naturally reduces the power load on heat-sensitive systems, like air conditioning and refrigeration. Adding dimming, sensors, or smart controls to LED fixtures can also reduce energy usage, while extending service life.

LEDs Don’t Contain Mercury
LED luminaires are mercury-free. Therefore, from cradle to grave, they are not toxic to the environment and are 100% recyclable, helping to reduce the amount of waste materials delivered to landfills. Both fluorescent and mercury vapor lights contain mercury internal to the bulb and thus require special handling at the end of their service life. While mercury is effective at enabling white light, it is also highly poisonous and is especially harmful to the brains of both fetuses and children. None of these health considerations are linked to LED technology.

Zero UV Radiation
Most HIDs emit a significant amount of UV radiation and require specific UV-blocking filters to meet safety standards in industrial spaces. When an industrial sized space is lit by many powerful HIDs, it becomes a safety concern for employees. Health problems include skin damage, energy depletion, eye damage, and worsening existing conditions such as lupus. Unlike HIDs, LEDs do not emit ultraviolet radiation. LEDs represent a healthier, cleaner source of lighting that doesn’t harm employees or the ozone, plus it is ideal where there are materials stored that are highly sensitive to UV. This is why museums around the world, including the Van Gogh museum in Amsterdam, have retrofit their lighting with UV-free LEDs and are preventing damage to priceless paintings.

Durable, Long-lasting Design
Today, LED luminaires are rugged and much more likely than their predecessors to survive harsh vibrations, corrosion, or moisture on a plant floor during production. Even in the face of carelessness or accidents, the risk of damage is minimal. Not only does this keep employees safe, it also reduces a company’s contribution to landfill crowding, manufacturing, and resource use.

Several factors combine to give LED the smallest environmental footprint of any lighting source. The benefits it provides simply can’t be ignored, either by end-users or manufacturers.

Helm is Director of Product Marketing at Emerson Automation Solutions (www.emerson.com), providing leadership for its Appleton® brand lighting products. She has dedicated nearly 20 years to marketing, product management, and new product development in roles focused on lighting technology and electrical products within industry leaders including Emerson, Simpson Electric, and Martin Marietta Aerospace. She is a strong advocate for LED lighting, striving to provide needed customer education to encourage safely illuminated environments where customers benefit from LED’s energy efficiency and cost savings. She have a BSEE from Valparaiso University and an MBA from the University of Colorado. 

Fuente: https://www.rockwellautomation.com/es_ES/news/blog/detail.page?pagetitle=Diez-sugerencias-de-seguridad-y-productividad-del-a%C3%B1o-2020-%7C-Blog&content_type=blog&docid=426724fbd3fd22e891381867414f025c&utm_source=Twitter&utm_medium=Social-Organic&utm_content=blog

We live in an era where technology is rapidly transforming the security landscape. Our access to information is broader than ever, but obtaining this information brings new risks. In addition, how we use this new information to understand why and when safety outages occur and how to improve safety and productivity dramatically transforms our operational arrangements.

Unlike previous generations of workers, a changing workforce of younger and less experienced workers often exhibits a difference when it comes to how they perceive risks and use information, and have different expectations of their environment of work. This poses the challenge of finding, training and retaining these younger workers.

As we enter the year 2020, we’ve put together a list of 10 tips to help you overcome these challenges and realize immediate improvements in safety and productivity.

Focus on improving security maturity

Security maturity is a combination of culture (behavior), compliance (policies and procedures), and use of capital (technologies). Numerous studies have shown that 20 percent of manufacturers achieve greater than 5 to 7 percent OEE, less than 2 to 4 percent unscheduled downtime, and less than half the injury rate of average manufacturers. And the best manufacturers are expanding their lead.

Best-in-class manufacturers view safety as a key facet of their quest for operational excellence. To achieve it, they take advantage of modern security methodologies. For example, an LNS research survey revealed that 75 percent of industrial companies responded that they had achieved operational improvements as a result of using advanced security technology. This allows us to understand why these companies have also confirmed that they are willing to pay for more connected, intelligent and secure machines.

Security maturity is the result of evolution rather than revolution. It is the result of progress related to the improvement of culture, procedures and processes in the area of ​​security, as well as the use of technology to achieve greater productivity and security. It’s the result of realizing that security and productivity are not mutually exclusive, but complementary, and taking steps to improve both.

How do you improve security maturity? First, assess your own security maturity and determine where improvements are needed to reach your goals. Knowing your level of performance and areas that need improvement is essential to optimizing security.

Protection risks are security risks

Very often security is considered “an IT issue”. It is not.

As industrial operations become increasingly connected, attack surfaces inherently increase. Hackers are increasingly attracted to industrial control systems, and a disgruntled employee who gains access to their systems can wreak havoc on them.

An overpressured pipeline, misaligned valves, or an unforeseen change in machine operation present a safety risk to personnel, the environment, and your company’s reputation.

Safety and security assessments should be carried out as part of any comprehensive management program. Security professionals (EHS and engineers) must collaborate with IT to ensure risks to physical assets are mitigated to help protect workers, equipment, and intellectual property residing in industrial control systems. Unfortunately, the inherent consequences of security with respect to protection risks are too often neglected.

Improve collaboration

A key aspect of many important business aspects of security includes a collaborative approach to security.

The primary responsibility of the EHS team is employee safety, but this team only directly controls important, though less effective, methods of machine safety: awareness, training, procedures and personal protective equipment. Engineers focus on technical standards, but are also in control of more effective machine safety methods: design to eliminate hazards, guarding, monitored access, and interlock devices. These two departments often view each other with suspicion, resulting in reduced safety and productivity.

A key element of the aforementioned security maturity is the collaboration between these two departments, along with the operations department. In fact, a recent LNS research study showed that in organizations where there is collaboration between these three departments, the median incident rate is 15 percent lower.

Perform Risk Assessments Early in the Design Process

The design process is a critical stage for machinery that optimizes safety and productivity. Specifically, designing a machine to eliminate risks, rather than building it and then trying to improve it to make it safer, is an essential aspect of these goals.

While most companies conduct a risk assessment at a certain point in time, timing is key. Should it be done during the design process when risks can be eliminated? Or once it’s designed, built and ready to ship?

It is essential to perform a risk assessment early in the design process and later after it is installed on site to help verify compliance, safety and productivity. Studies have revealed that between 60 and 70 percent of security incidents occur outside of normal operating mode (during maintenance, repairs, etc.).

Ergonomic machinery design

The changing workforce in our industry demands new considerations when it comes to safety. Younger workers with less experience suffer a higher rate of acute injuries. Older workers experience a higher rate of musculoskeletal and repetitive strain injuries, which often become chronic or career-destroying. A more diverse workforce means machinery must be able to accommodate a variety of workers.

Learn how to mitigate risks and improve labor productivity for an evolving workforce.

To get the most out of every available worker, you need to build machines to suit a wider range of workers. This includes ambidextrous features and configurations geared towards reducing repetitive motion, lifting, and awkward body positions.

As the global workforce continues to evolve, modern machinery design techniques and safety systems must be taken into account not only to mitigate risks, but also to increase worker productivity.

Find out how to design your security system for more uptime.

Use of alternative measures to reduce LOTO and improve productivity

Security doesn’t have to come at the expense of productivity. Modern machinery design allows for minor lockout tagout (LOTO) service exceptions when procedures are routinely and repetitively performed and are essential to operating the equipment. This is critical to optimizing both security and productivity.

When used correctly, alternative measures can improve productivity by reducing LOTO-related downtime while maintaining regulatory compliance. In some cases, these measures can mean the difference between simple regulatory compliance and operational excellence.

Inclusion of security in The Connected Enterprise

The power of the Industrial Internet of Things (IIoT) can greatly improve security performance and compliance.

Digital transformation gives security professionals the ability to understand in real time the behavior of workers, the regulatory compliance of machinery, the causes of interruptions or stoppages for security reasons, as well as anomalies and security trends. It can also help you recruit, train, and retain employees.

Security: an integral element of your control system

Your control system must include safety-classified inputs, logic, and output devices to mitigate risk, improve productivity, and provide feedback to key stakeholders.

It can be challenging to design effective security systems that improve productivity. But security design tools can speed development and help confirm and document compliance.

For example, RASWin software can help to consistently manage and document the security lifecycle. Safety Automation Builder® software can help you design your safety system.

Safety functions documents can also help you implement machinery safety functions and include calculations for safety performance, wiring, programming, verification and validation.

The Safety Automation Builder software tool is now integrated into the RASWin evaluation software to help engineers through the steps of the machine safety life cycle in a single environment, providing documentation showing regulatory compliance with international standards.

Implementation of intelligent security systems

New designs and smart safety devices can reduce wiring, design costs, and unscheduled downtime. For example, they allow you to capture smart device interactions to create predictive maintenance feedback and other information.

Intelligent systems control every layer: from intelligent sensing, safety and motor control devices that predict their own maintenance, to flexible control systems that optimize safety, protect intellectual property, improve operations and provide information to customers. analytical systems that provide detailed insight to help leaders make decisions and set the right course for their organization.

Smart systems help restrict access to machines to only authorized and trained personnel to improve productivity, safety and security.

Intelligent systems control each layer.

Expanding your knowledge in the area of security

You need engineers, system integrators, and machine builders with experience in today’s safety standards, a proven track record in safety system manufacturing, and in-depth knowledge of safety system design processes and technologies that improve productivity.

If your plant staff does not have this experience, turn to our partners. Rockwell Automation employs almost half of the security professionals certified by TÜV Rheinland.

Our alliances include recognized system integrators and solution partners with security expertise. These organizations have met rigorous requirements, including a rigorous multi-month evaluation and training process, to become members of our PartnerNetwork™ program. Read more about the Rockwell Automation® Security System Integrator Program.

Fuente: https://www.rockwellautomation.com/es_ES/news/blog/detail.page?pagetitle=Diez-sugerencias-de-seguridad-y-productividad-del-a%C3%B1o-2020-%7C-Blog&content_type=blog&docid=426724fbd3fd22e891381867414f025c&utm_source=Twitter&utm_medium=Social-Organic&utm_content=blog