Electricity and Control September 2021

FEATURES: · Control systems + automation · Drives, motors + switchgear · Measurement + instrumentation · Transformers, substations + cables

COMMENT

INDUSTRY 4.0 + IIOT

In an automated world, it’s people who keep plants working A s I was reflecting on the focus for this month’s comment with our editor, Leigh

something, really, it is. It’s far harder to control it, and harder still to control it automatically. This last mentioned requires a real understanding of the process, what its performance depends on, what needs to be measured, and what must be done with the information gleaned from the measurements. And in many cases this falls upon an operator. Indeed, in times of crisis, quite often it is the operator who takes control, who figures out what all the data means – and what needs to be done to stabilise the situation. This applies as much in an industrial setting as, quite frankly, it does in a leadership one. In many such cases people need to make decisions based on limited information and usually in a very short space of time. Unless they have a deep understanding of what it is that they are doing, and why, the implications of an error can be dire indeed. For this and other reasons, operating procedures are always put in place, people are trained on how to react, and decision- making is coded (as it were) by very careful scenario planning. In most cases this is not complex; in others it can be. My sense is that, whatever the findings ultimately are around the very unfortunate Medupi incident, we should all take heed that on our own plants there are procedures and processes that simply must be managed by people. Sometimes this is part of the normal proceedings, and sometimes it is only during times of crisis. But it happens. Use this as the moment to refresh your procedures, to renew training, to realign everyone on your site. We have traversed remarkably difficult times, and my sense is that the human factor needs some special attention as, slowly (but hopefully), we return to a more normal time again. Enjoy this edition.

Darroll, we obviously considered the content of this edition of Electricity+Control – and the context then of the initial good news regarding Medupi, and the expectation around gazetting the regulations relating to embedded generation. The announcement of 100 MW now being on the table has been, by all accounts, very well received – especially during these times of severe energy uncertainty. (More on this in Write @ the back in this issue.) As we have noted in the past, the devil always seems to be in the detail. This month we cover a variety of topics, from Control systems and automation, to Drives, motors and switchgear; from Measurement and instrumentation to Transformers, substations and cabling – all good staples of a successful industrial sector. Energy security is critical to our industry as well. And while crafting this comment, we received the incredibly bad news about an explosion at Medupi. A phenomenal event; and one that would surely not be expected in such a new and benchmark-setting station. Much has been written and said about what happened – but we should pause to reflect that similar events could happen on any of our plants. What causes them, and how can we avoid them? Without for a moment suggesting any- thing, we need to consider that no matter how much we automate, instrument and control our plants, at the end of the day it is us, people, who keep the lights on. Whereas motors are no longer the largest consumers of energy in industry – that accolade has now apparently moved to data centres – we are reminded how easy it may seem to take people out of the loop, as it were. We live in a data-centric environment; we live in an automated world; but is it really controlled? It is worth reminding ourselves, for instance, of the fundamental difference between automating a process versus controlling it. It’s easy to automate

energy + information in industry

ArmCoil highlights the capabilities of South African manufacturers of trans- formers and mini substations, equipped to supply packaged and customised technical solutions to renewable energy

development projects. (Read more on page 3.)

Editor: Leigh Darroll Design & Layout: Darryl James Advertising Manager: Heidi Jandrell Circulation: Karen Smith Editorial Technical Director: Ian Jandrell Publisher: Karen Grant Deputy Publisher: Wilhelm du Plessis

Audited circulation Quarter 2 (April-June) 2021 Total print and e-editions 9868

Published monthly by: Crown Publications (Pty) Ltd Cnr Theunis and Sovereign Sts, Bedford Gardens, PO Box 140, Bedfordview 2008 Printed by: Tandym Print Telephone: +27 (0) 11 622 4770 E-mail: e-mail: ec@crown.co.za; admin@crown.co.za Website: www.crown.co.za/electricity-control

CROSS PLATFORM CONTENT INTEGRATION: * Electricity+Control Magazine * Online Edition * Weekly e-Newsletter * Website* LinkedIn

Publisher of the year 2018 (Trade Publications)

Electricity+Control is supported by

Ian Jandrell PrEng IntPE(SA), BSc(Eng) GDE PhD, FSAAE FSAIEE SMIEEE

1 Electricity + Control SEPTEMBER 2021

The views expressed in this publication are not necessarily those of the publisher, the editor, SAAEs, SAEE, CESA or the Copper Development Association Africa

CONTENTS

INDUSTRY 4.0 + IIOT

Features

CONTROL SYSTEMS + AUTOMATION

4 Baking the perfect loaf Delta Industrial Automation Solutions

6 Easier data searches in system engineering EPlan

4

7 Products + services

DRIVES, MOTORS + SWITCHGEAR

10 Customised finish under servo control Bernhard Fischer, Beckhoff Automation

13 Products + services

MEASUREMENT + INSTRUMENTATION

6

17 Products + services

TRANSFORMERS, SUSBSTATIONS + CABLES

22 Advantages raise demand for dry-type transformers Leigh Darroll, Electricity + Control

24 Products + services

Regulars

10

1 Comment In an automated world, it’s people who keep plants working

3 Cover article Locally produced transformers for renewable energy plants

29 Reskilling, upskilling + training International cooperation and technology in training youth

30 Cybersecurity Insider threat detection for security and compliance

31 Engineering the future Printed/flexible electronics in evolving automotive technologies

22

32 Write @ the back Amended Schedule 2 of ERA widely welcomed

2 Electricity + Control SEPTEMBER 2021

COVER ARTICLE

Locally produced transformers for renewable energy plants

A rmCoil, among other South African transformer man- ufacturers, is involved or ready to become involved in the renewable power producer market, especially now that there will be more renewable projects coming up over the next few years for South Africa and neighbouring countries. At ArmCoil we recognise that smart costing and packaged technical solutions are in high demand for these producers, for inverting dc to ac voltages. Such solutions typically include a transformer, inverter and various protection and monitoring devices, packaged as a unit mounted onto a steel structure or inside a weather-resistant container. Depending on the size of the plant, applications will vary in power ratings for PV or wind driven generation plants. The rated power range required in transformers for PV self-generation plants ranging in scale from 10 MW to 100 MW is typically designed to be 2.5 MVA, 3 MVA and 6 MVA at 33 kV. Hence for a 10 MW application, there are standardly four 2.5 MVA distribution transformers. The num- ber of distribution transformers is also dependent on their locations, cable lengths and grid layout, as the cables play an important role in determining costs and other factors. Renewable energy plants convert power from dc to ac by means of inverters, to feed into the utility grid. The trans- formers and inverters required for PV and wind generation plants have been and can be manufactured in South Africa, to meet high technical specifications and project comple- tion demands. Energy storage for renewable power producers in South Africa is largely non-existent or rare and would rely mainly on battery energy storage systems. For large renewable power producers, one of the more favourable storage facilities could be in hydropower, in pumped storage schemes, where during the day water is pumped into a top dam and, during peak times, the water is released to drive power generation turbines, when the renewable power producers are effectively off-line. However, in most cases, renewable power plants are quite remote and seldom close to any pumped storage scheme. They are reliant on natural weather conditions – clear, sunny and windy days. When the weather is overcast, PV plants do not produce much power. ArmCoil is well positioned in the medium voltage market and has gone from strength to strength over the past 20 years in terms of product, skills and service development where the company boasts its niche transformer and miniature substation manufacturing capability, fully equipped repair facility and on-site maintenance division. There are not many service providers in South Africa who can offer centralised manufacturing supply, instal- lation and commissioning of transformers and miniature substations on a national and international level. ArmCoil has been doing this for years with a proven track record of success across the African continent.

Most large renewable power producers are in remote areas with logistical challeng- es to access their plants; some are situat- ed in harsh climatic environments where temperatures are quite extreme. ArmCoil is technically and commercially capable and fully equipped to assist with on-site main- tenance and parts for these remote areas and to offer medium- to long-term service level agreements which can increase the duration of product life expectancy and de- crease or prevent downtime. It is not uncommon for ArmCoil to be involved in replacing, maintaining and up- grading various OEM equipment across South Africa and Africa. This is due to many large OEMs not having local offices to sup- port their imported products such as trans- formers, protection devices for different types of transformers and other protection or monitoring devices.

Morne Bosch, General Manager - Sales & Marketing at ArmCoil.

It is important for large power producers who are in- vesting in the country to take advantage of South Africa’s competitive local transformer and miniature substation manufacturers, repairers and on-site maintenance service providers. We offer in depth expertise and support. ArmCoil holds three ISO accreditations – on environ- ment, quality and health and safety management systems – which confirm our commitment to our clients. □

Over the past 20 years ArmCoil has established itself as a well- respected local manufacturer of transformers and miniature substations.

For more information contact ArmCoil. Email: morneb@armcoil.co.za Visit: www.armcoil.co.za

3 Electricity + Control SEPTEMBER 2021

CONTROL SYSTEMS + AUTOMATION

Baking the perfect loaf Bread could be considered a staple food, globally, and the baking of bread a process fundamental to daily life around the world. Bread likely brings to mind your favourite bakery. But baking the perfect loaf, and in large enough quantities, demands ovens that accurately control the process from beginning to end.This was the task faced by Mechatronics Ltd., a system integrator and official distributor of Delta Motion, Drive, Control, and Robotics products based in Bulgaria.

T he requirements for the bread baking machine defined four temperature zones. The first zone is especially powerful to compensate for the cooled conveyor belt and the relatively cool loaf entering the oven. At this step, steam is also injected into the oven to give the bread a freshly-baked sheen. It is followed by three temperature-controllable baking zones, carefully controlled to bake the optimal loaf. The conveyor belt of this travelling oven design also needs to be kept at the correct speed throughout the process. And the final element of the specifications was a human-machine interface (HMI) to configure the baking process, deliver temperature status of each zone, and output any error status information. For the HMI, the team selected the Advanced HMI DOP-107WV from the DOP-100 Series. This touch-based control panel features a 16:9 7-inch colour TFT screen with a narrow frame. With multilingual support it was well-suited for this market, and user-friendly editing software makes the final user interface easy to navigate. With several RS-485 COM ports, it could be integrated easily with the other components selected for the project. Considering the operating environment, the flat, wipeable surface of the DOP-107WV also made it a suitable choice for a dusty bakery. Control for the conveyor was implemented using an MS300 Series inverter. This ac motor variable frequency drive (VFD) also supported the RS-485 Modbus interface and is ideal for open-loop control of induction motors (IM) and permanent magnet (PM) motors.

Temperature control But it is the oven that defines the quality of the bake. Special attention was given to selecting the optimal control approach for the seven heating elements used. After careful deliberation, the DTC1000 Temperature Controller was selected as the main controller, with DTC2000 controllers used in parallel for the remaining six heaters. These are also connected to the Modbus. The selection of established, reliable components, as well as careful programming, were critical in delivering a low-maintenance design that could be operated 24/7. To provide optimal temperature regulation, the auto- tuning function of the DTC1000/2000 was used. The inputs are acquired from third-party PT100 temperature sensors and control of the heating elements is implemented with solid-state relays. Auto-tuning uses a training process to configure the closed-loop PID controller once the sensors and heaters are installed in this 250 kW oven. Further complicating the implementation was the dual heating and sensing of the last three baking zones. With one heater above the conveyor and the other below, each needs to be set to a different temperature. Spare outputs available from the Delta Temperature Controllers were linked to relays for audible and visible alarm signals. These signals were also replicated in the DOP-107WV HMI. Conveyor speed Closely linked with the quality of the bake is the speed con- trol of the conveyor belt. The MS300 VFD is linked to an inductive proximity sensor that is easy to clean and remains accurate in the dusty baking environment. Installed close to the gears, the built-in programmable logic controller (PLC) of the MS300 is configured to monitor and calculate the conveyor speed. This is continuously compared to the set- point defined in the HMI. Thus, the customer only needs to set the desired baking time, the required temperature, and then press run to start baking. The Mechatronics Ltd. team benefited from the broad range of industrial automation solutions in the Delta portfolio. Integration of the VFD, HMI, and Temperature Controller was simplified by the out-of-the-box interoperability and connectivity of the components selected. “Most people would assume that baking bread is very simple. On the contrary, the bread oven project has highlighted the skill required of both bakers and engineers to create a machine that delivers the perfect loaf. The auto-

In industrial ovens accurate temperature control through the different process zones is critical to the quality of the bake.

4 Electricity + Control SEPTEMBER 2021

CONTROL SYSTEMS + AUTOMATION

At a glance  The control system for the bread baking oven meets three specific requirements: - temperature control across four different temperature zones - speed control on the conveyor carrying the loaves through the oven - and an HMI to monitor the process.  The selection of established, reliable components and careful programming, were key in delivering a low-maintenance design.

Speed control on the conveyor belt is also closely linked to the finished quality of the bread. tuning function of the DTC1000/2000 played a large part in ensuring that bakers can deliver a quality product in every batch, by providing excellent temperature control,” said Victor Ogedegbe, Field Application Engineer at Delta. Toma Draganov, Automation Engineer at Mechatronics Ltd, said: “Construction of the bread furnace was simplified by the availability of components that are interoperable and fulfilled the requirements set out by our customers. Accurate temperature control was most critical for us, and the Delta team’s support was essential in configuring the DTC1000/2000 auto-tuning function. This assistance contributed to the project moving from the initial design stage to full production in just seven months.” □

This project highlighted the skill required of bakers and engineers in creating a machine that delivers the perfect loaf in every batch.

For more information visit: www.delta-emea.com

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

New graphic operation terminals

Mitsubishi Electric has launched two new Graphic Operation Terminals (GOTs) as the latest addition to its GOT2000 Series Wide Model line-up. The 12.1-inch widescreen models, which feature narrow bezels and frame colours of smart silver (GT2512-WXTSD) or cool black (GT2512-WXTBD), will help meet customers’ needs for a wider screen to show more information in factory, process, utility and other automation applications. The models also feature various interfaces, including two Ethernet ports which facilitate the connection of

12.1, 10.4 and 8.4 inch sizes. The sheets help reduce the need for disinfection by adopting SIAA-certified sheets (evaluated in accordance with ISO 22196 and ISO 21702 standards). The sheets, which use RIKEN TECHNOS’ RIKEGUARD ® , are proven to inactivate 99.99% of viruses and reduce bacterial growth to less than 1/100, with 10+ years of performance in typical environments.

For more information visit: www.eu3a.mitsubishielectric.com/fa/

Ethernet cables. Additionally, they can support remote connection in cases where user access may be restricted. Remote connection functions such as SoftGOT enable remote maintenance via access to the local GOT screen and operators can obtain live data using GOT Mobile. Another benefit to support safe working practices, is the option of including new antibacterial, antiviral protection sheets for standard GT27 and GT25 GOTs in

[Source: Mitsubishi Electric Corporation]

The new graphic operation terminals: left, smart silver frame and right, cool black, have a wider screen to show more information.

5 Electricity + Control SEPTEMBER 2021

CONTROL SYSTEMS + AUTOMATION

Easier data searches in system engineering Selecting the appropriate components and related data in engineering is often time consuming. However, the new EPLAN Data Portal, with a new user interface and improved search algorithms, has been developed to make it easier and faster.

T he new EPLAN Platform is soon to be released and will see the EPLAN Data Portal available for use exclusively in the EPLAN ePulse cloud environment. The platform’s updated user interface offers numerous enhancements in searching for and finding device data. Improved search algorithms and parameters make it much easier for users to find and download the appropriate components quickly. Improved system performance also ensures greater speed when selecting components. And another new feature is the integration of the Lenze product configurator. Streamlined product selection Lenze Director of Team Processes and Data, Bernd Spiegel explains: “The direct integration of our product configurator into the new EPLAN Platform lets customers very quickly find the product they need. There’s no need to search for devices in extensive lists and customers get the devices that match their requirements. This cooperation also benefits Lenze as a manufacturer of many products and variants. Maintaining the data for the configurator in EPLAN Electric P8 is much easier for us than doing that for all the distinct variants of a product series.” As an example, a user looking for a frequency inverter, using the Lenze Easy Product Finder, needs just a few steps to find a suitable device from the company’s i550 series of devices. The defining characteristics such as

rated power, supply network type, and the type of fieldbus network are included as selection criteria. Once users have decided on a particular device based on these parameters, the associated EPLAN data can be generated in the detail view and then imported into the CAE solution’s device management. Around three million data sets available The configurators of other manufacturers, including Endress+Hauser, Bosch Rexroth and Rittal, all work in a similar way. This makes each manufacturer’s portfolio easily accessible to design engineers. Selecting devices and acquiring high quality data is easy and intuitive. The data is up to date and can be transferred directly into projects. Similarly to configuring features for a new car, users are guided through the various product families of the different manufacturers. Integrating configurators as it does, the portal expands the data available (more than 1 million data sets) by some two million configurable variants, and it makes it easier for users to compile high quality device data. In addition, there are selectors from Aventics, IPF and Schneider Electric that ensure fast product selection. The targeted narrowing of selections via search parameters ensures that the data is correct. The portfolio will soon be expanded with the inputs from two more well-known global players.

The Data Standard More than one third of the data on the portal already conforms to the new, high quality Data Standard, and EPLAN has set further goals: it aims to see half of all the device data meet the Data Standard by the end of 2022. This calls for further commitments from device manufacturers, many of whom are recognising the benefits of having 100% digital data. Big players that have been pioneers in this in the international arena include Chint (China), IFM, Pilz, Rittal and SMC (Europe), Numatics (USA) and Omron (Japan). Pilz Vice President Customer Support International, Arndt Christ says: “We’re pleased that we can now offer our

More than one third of all the data in the EPLAN Data Portal – for instance, that from Rittal – already conforms to the new, high quality Data Standard.

6 Electricity + Control SEPTEMBER 2021

CONTROL SYSTEMS + AUTOMATION

customers high quality engineering data. In 2020, we decided to create our Pilz product macros to conform to the EPLAN Data Standard. The data standardisation that is currently possible, which makes using the macros easier, benefits our in-house engineering departments in our affiliated companies and, externally, our customers around the globe. “While macros previously had to be inserted into designs using value sets, today it can be done using a functional template. The benefits include improved networking of data – for instance between 2D and 3D, fewer errors because the wiring connections are precisely defined, and time savings above all, because the macros are standardised. “The new Data Standard, particularly the functional template, is a mark of quality for our macros and meets our expectations for high quality data. We have a dependable partner for the future in EPLAN, someone we can work with to continue advancing this approach.” EPLAN Director Cloud Business Master Data, Timm Hauschke says: “The aspiration for high quality from the manufacturers coincides with the demands of our users. Only comprehensive, integrated, end to end data forms the foundation for the digital twin, which provides information for processes and to machines along all the stations of the process, from design engineering to manufacturing. Since its introduction the EPLAN Data Standard is being implemented worldwide. Our goal is for device data to be available 100% digitally, providing the ideal foundation for highly efficient engineering.” □ The DXM1200E Series wireless controller from Turck Banner integrates wireless radio, cellular and Ethernet connectivity, and local I/O, making it easy to connect de- vices on a local wireless network with cloud webservers and local host systems. The DXM1200E can collect, log, or analyse data from sensors and other input devices. It can communicate status updates directly to other devices on the network, and/or send email notifications for user-defined events. For additional monitoring, analysis and visualisation, the data can also be sent to a cloud webserver, SCADA sys- tem, HMI, or PLC. DXM applications can be optimised to make data‑ driven decisions using Banner’s Cloud Data Services for data storage, condition-based alerts, and visualisation. Data can be accessed anywhere and anytime with the powerful tools built into the software. These make it easy to view and analyse data from each device in the net- work, establish performance baselines and thresholds, identify trends and issues, and make timely and action­ able decisions about your equipment and assets. The robust, IP67 rated housing of the DXM1200E means it can be installed easily in most environments Data management via wireless controller

At a glance  The new EPLAN Data Portal incorporates configurators from multiple manufacturers, making each manufacturer’s portfolio easily accessible to design engineers.  Comprehensive, integrated, end to end data forms the foundation for the digital twin.  The EPLAN Data Standard aims to see device data available 100% digitally.

Portal users need only a few steps to find a suitable i550 series device using configurators such as the Lenze Easy Product Finder.

For more information visit: www.eplan.co.za

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

without the need for an addi- tional enclosure. With peel- and-stick implementation, the DXM can be placed into challenging environments to increase productivity, reduce downtime, or gain insight into valuable applications with ease. The DXM1200E wireless controller supports:

- Predictive maintenance - Remote condition moni- toring - Productivity and OEE improvements - Kitting and order fulfilment.

The DXM1200E makes it easy to collect, log, or analyse data from sensors and other connected input devices.

For more information contact Brandon Topham at Turck Banner. Tel: +27 (0)11 453 2468 Email: brandon.topham@turckbanner.co.za Visit: www.turckbanner.co.za

7 Electricity + Control SEPTEMBER 2021

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

Digital transformation in plant operations

From oil refineries to food and beverage plants, process engineers are being asked tomanage increasingly complex systems – and to do more with less. This is a challenge that Blair Wilson, PlantPAx Marketing Manager for Rockwell Automation, is ready to take up: “The good news is that the latest distributed control system (DCS) platforms have kept pace with technological developments. And more DCS users are now considering upgrading and modernising their systems for optimal performance.” How can a DCS modernisation help manage system complexity and improve productivity? Wilson explains that producers are adept at navigating the complexities and challenges of staying competitive. “This is true in industries ranging from pharmaceuticals, consumer packaged goods, and food and beverages to mining and chemicals. This is why it’s important to implement the latest technological advances to continue the evolving digital transformation journey.” System features positively impact plant operations by

designed to meet plant-wide applications, and more, as well as to help reduce the overhead required for automation infrastructure while delivering improved diagnostics and analytics. This latest iteration of the popular DCS has a reduced footprint. New process con- trollers extend the Logix

Blair Wilson, PlantPAx Marketing Manager for Rockwell Automation.

family capabilities with cutting-edge processing power and capacity to reduce the complexity of PlantPAx archi- tectures. This footprint reduction also reduces total cost of ownership of the system throughout the lifecycle. In addition, it drives consistency. With native process instructions embedded in the controllers, project teams can adopt approaches to control strategies that drive consistency for individual projects or multi-site deployments. With its streamlined workflows, development teams can realise savings in the configuration of instrumentation, alarms, and diagnostic system elements. Operators have the extended ability to view underlying control logic in a safe and secured way. Further, to help mitigate risk, the PlantPAx 5.0 system architectures are TÜV certified to the international standard ISA-99/IEC 62443-3-3, which provides guidance on the implementation of an electronically secured system. The provides a unified multidisciplinary design environment for production systems engineering. NX Automation Designer and NX Industrial Electrical Design provide new functions for efficient electrical and automation design of industrial equipment. Electrical en- gineers can complete their work faster making use of the enhancements to connection handling and reporting, new OOTB symbols for IEC, ANSI and fluidics and 2D cabi- net dimensioning. Automation engineers benefit from the extended software generation capabilities for sequences and safety programs. The latest release enables customers to move into the world of functional design by starting their electrical and automation design work without Teamcenter. Customers not looking for a complete PLM system can benefit from the electrical and automation design capabilities. By boosting engineering productivity with a new level of multi- disciplinary collaboration, NX Automation Designer lowers IT costs and addresses manufacturers’ need to meet grow- ing demand for product variety from consumers. Karl Stieler, owner of STiMA GmbH & Co. says, “Today, in order to maintain profitability we have to realise more projects with the same number of employees. Furthermore, we

The PlantPAx 5.0 DCS is designed to meet plant-wide applications, help reduce automation infrastructure overheads, and more.

ensuring that plant-wide and scal- able systems drive productivity, improve profitability, and reduce overall risks. The newest release of PlantPAx offers new valuable techni- cal features. The next generation DCS PlantPAx 5.0, the next generation DCS from Rockwell Automation, is

Facilitating electrical and automation design

The NX™ Automation Designer software and NX™ Industrial Electrical Design software recently released by Siemens Digital Industries Software, introduce a new suite of solutions that provide a central design application for industrial electrical and automation design. The new tools can help manufacturers of production systems to manage design complexity, shorten development lifecycles and increase the quality of their designs. Direct integration with Teamcenter ® software for product lifecycle management (PLM) and the entire NX design software portfolio

The NX Automation and Electrical Design software suite enables quicker design development and improved quality in production systems engineering.

8 Electricity + Control SEPTEMBER 2021

CONTROL SYSTEMS + AUTOMATION : PRODUCTS + SERVICES

An accelerated shift in industrial automation

PlantPAx 5.0 release has purpose-built frameworks that easily connect live and historical data from the DCS into reporting and analytical tools. This allows extended experiences, such as Augmented Reality, and easy integration with scalable analytics packages. Wilson adds that, from the control room to the board room, process system users face the constant challenges of balancing productivity against budget and resource constraints, as well as proactively addressing evolving operational risks. “It’s important to meet these challenges and experience real productivity gains in all areas of the plant, which can be done with the PlantPAx DCS. “Digital transformation isn’t going away – at some point, every manufacturer and producer will have to start the journey. For many, it’s considered the new normal. Embracing new technologies will fundamentally change how you do business – for the better. “Evaluate your legacy DCS to see if the latest DCS platform can help in your digital transformation journey. This decision can allow flexibility so you can better meet customer needs, and provide data and insights to help you improve performance, decision-making and profitability. It doesn’t have to be difficult or disruptive. With the right solutions in place, you can embrace tomorrow’s challenges with confidence,” Wilson advises. For more information contact Rockwell Automation. Email: mjunius@ra.rockwell.com Visit: www.rockwellautomation.com need to react quickly to different and complex customer requirements. This means we need the close interaction of mechanical design, electrical design and automation technology. With this solution by Siemens we are well prepared for the future and the challenges of the market.” STiMA chose the NX platform to combine various dis- ciplines – mechanical, electrical and automation – into one environment to manage projects more efficiently and improve quality. With the help of NX and particu- larly NX Automation Designer, STiMA has reduced its engineering time by 45%, facilitated by consistent data across the different areas and a more efficient workflow. The scalability of NX benefits customers like STiMA by allowing them to start with a single module or to combine different modules with each other. The NX AutomationDesigner andNX Industrial Electrical Design applications can work natively (without Teamcenter) or in managed mode with Teamcenter in the background. “With this integrated toolchain from Siemens, digital- isation becomes possible in small and medium sized enterprises,” says Wolfgang Schloegl, Vice President Digital Engineering at Siemens. “It provides for greater efficiency, particularly in realising new products.”

Black swan events like the pandemic may be unpredictable, but they leave a long- lasting impact. Through the turmoil, there is a pressing need and much opportunity to reassess, reconfigure and rebuild in more future-oriented ways. While the conversation around industrial automation has been centre stage for some time, Covid-19 has caused a rapid change in how organisations approach and manage their operations. It has led to many employees working from home and limiting in-person professional interactions, fundamentally changing the way we work. Workforce automation, for example, which has been ramping up in recent years, is likely to accelerate as a result. This is the view of Christo Potgieter, Director at PCMP, a leading industrial systems integrator. As a supplier of industrial automation

Christo Potgieter, Director at PCMP, an industrial automation supplier and systems integrator.

systems PCMP provides turnkey automation solutions, from instrumentation to MES (manufacturing execution systems) and ERP (enterprise resource planning) integration. The company designs, manufactures and installs complete electrical systems, including automation, power, energy and configured software components. Key focus industries include the automotive, packaging, food and beverage, mining, chemical, water and waste industries. All these industries incorporate high levels of automation from the start of the design phase. “The food and beverage sector has taken up the most of the new initiatives and technologies in this space,” says Potgieter, “followed by the mining industry, which is really driving the adoption of state-of-the-art tech to bring itself up to date with new realities.” He adds that more business decision makers are learn- ing the advantages of automation. “Now they know that em- ployees can work from home and you can control a facility or machine remotely. This is only a small part of what we offer.” Potgieter says through the past year PCMP has been in a fortunate position. “We have longstanding relationships with many big businesses. The only negative impact we felt was due to the alcohol sales ban, given that SAB ABInBev is one of our VIP clients.” Commenting on projects recently executed, he highlights PCMP’s installation of a turnkey solution on a new blending facility to produce flavoured alcoholic beverages at one of its VIP clients in South Africa. That was during 2020 through the lockdown. The project was delivered ahead of time and within budget.

For more information contact PCMP. Tel: +27 (0)12 665 0802 Email: christo@pcmp.co.za Visit: www.pcmp.co.za

For more information visit: www.sw.siemens.com

9 Electricity + Control SEPTEMBER 2021

DRIVES, MOTORS + SWITCHGEAR

Customised finish under servo control Bottle caps serve as protection and decoration in one. On one hand, they shield wines and other beverages outwardly, and on the other they act as a decorative design element, lending bottles an individual touch.The design options open to Pinggau-based BT-Watzke are close to endless – because the Styrian company operates its own in-house engineering department and machine shop, which allows it to control how it implements customer requirements – no matter how varied. Servo drive technology from Beckhoff Automation also plays an important role.

T he roots of the Watzke capsule factory date back to 1892. Originally founded as a forge, the traditional company based in Pinggau, in Styria, Austria, has developed into a premium supplier of bottle caps. It has a customer base ranging from small wine producers to mass bottlers. The export quota is around 85%. “We distribute our products to more than 40 countries, including Germany, Scotland, South Africa and Tanzania. We even have our own headquarters for the North American market, located in Sherwood, in the US state of Oregon,” says Christian Stanzel, Managing Director of BT-Watzke GmbH. The customisation options offered by the manufacturer for wine, sparkling wine, spirits and fruit juice bottles, range from “simple” top and side printing to sophisticated foil embossing and other typical design features for caps, such as breathing or cork ventilation holes, spherical or

grid graining, tear-off perforations, or tear-off strips. “Many customers come to us with a template and ask whether we can reproduce the particular design. The fact that we have our own engineering department is tremendously beneficial as it allows us to cater to individual customer requirements in terms of shape, colour, logo, font, and other features. If we don’t have the right tools for a pending order, we carry out a feasibility check and, if necessary, upgrade or convert the existing equipment accordingly,” says Stanzel, highlighting the company’s comprehensive manufacturing expertise. A further attribute of BT-Watzke is that it acts as a one-stop supplier – from low-cost heat shrink capsules to high-quality tin capsules. Other options include capsules made from polylaminate film or aluminium. “There is no other producer in the world that can manufacture the complete range of

closing products at one location. With our Vinotwist twist caps, which we have been producing since 2007, and an ever-growing assortment of caps, we have developed a range of solutions for closing the most varied types of bottles,” says electrical engineer, Daniel Wolf, pointing out the many “facilitator” qualities that characterise the business. It is usually up to him and his colleague Gerhard Schuller to fulfil the required underlying technical conditions to output around 350 million caps a year, working with Workshop Manager Franz Reifbäck and his team. BT-Watzke only rarely purchases ready- made standard machines. “We build almost everything ourselves – and in the way we need it,” Reifbäck says. “It is important for us to be able to respond flexibly to different customer requirements.” Perfectly controlled synchronisation

[Picture: © Beckhoff]

An EL5151 incremental encoder interface records the position of the transport chain as a virtual master axis. All subsequent motion sequences are aligned automatically using the cam disc function available in TwinCAT.

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At a glance  BT-Watzke recently integrated a third machine into the painting process for caps that require up to three coats, in order to increase throughput rates.  For Beckhoff, the project involved three individual systems that operate independently but have to run synchronously.  The use of servo drive technology to transport the blanks, rather than a pneumatic solution, was a key optimisation measure in the process.  Collaboration started at the concept phase and enabled an open exchange of ideas and views throughout the project.

[Picture: © Beckhoff]

The cam disc function makes synchronisation easy: regardless of the speed the system is running at, the AM8000 servo motors align themselves solely to the curve they are given. Some 100 self-built systems are currently in use in the capsule factory in Pinggau – including 14 that “simply” paint. One of these machines was recently extended by an additional part. “Because the lateral surface areas of our twist caps require up to three coats, depending on the colour, we decided to integrate a third machine into this production process in order to increase throughput rates,” says Reifbäck, explaining why they decided to give this running system a helping hand. Another optimisation measure, in particular, also helped to increase the performance significantly: it was decided to use servo drive technology from Beckhoff to transport blanks, rather than a pneumatic solution that had been used until then. “The project involved three individual systems that operate independently but have to run synchronously – because they form a unit together with the drying kiln through which every blank to be painted is fed,” says Bernhard Fischer, a member of the sales team at Beckhoff, describing the task they faced at BT-Watzke. The transport chain acts as the time base for this application, determining the nominal speed for all manipulations that have to be carried out in the individual machine parts. “We use an EL5151 incremental encoder interface for this purpose, which records the position of the transport chain as a virtual master axis. All subsequent motion sequences are aligned automatically using the cam disc functionsavailable inour TwinCATautomationsoftware,” says Fischer, pointing out a simple synchronisation feature that the maintenance department at the factory soon came to appreciate. The behaviour of the drives at maximum output of up to 200 cycles per minute can now be tested at slow speed after every reprogramming. “Regardless of the speed the system is running at, the AM8000 servo motors focus solely on the curve set for them,” says Wolf, commenting on the perfectly controlled synchronisation between the newly added machine part

[Picture: © Beckhoff]

Servo motors from the AM8000 series are used for attachment and detachment of capsule blanks at the revolver that is synchronised with production cycles. They also manage the movements of the turntable. and the existing units of the lateral surface painting system. Having to perform reference runs each morning is no longer required. “That was another aspect Beckhoff took into consideration in designing the drive technology. We wanted to be able to start immediately in the morning,” says the electrical engineer, outlining one of a number of small additional requirements BT-Watzke specified in this project. Up to 200 cycles per minute “We communicated what we wanted and indicated that in general a solution for up to 200 cycles per minute would be needed. We relied to a large extent on the experts at Beckhoff, however, when it came to the finer points of the implementation. They know best what their products can do,” says Wolf. Collaboration started as early as the concept phase and enabled an open exchange of ideas and views throughout the project. Workshop Manager Reifbäck first used his CAD program to design how the additional third machine part needed might look. He then had these proposals assessed and double-checked by Beckhoff employees. Some refinements and deliberations took place alongside this process. “I remember when Beckhoff’s drive specialist, Leo Büchinger, and I sat together in front of the screen.

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DRIVES, MOTORS + SWITCHGEAR

Trust reduces complexity The collaboration between BT-Watzke and Beckhoff was intensive from the outset and built on trust. “Because my colleague Gerhard Schuller and I have to cover a broad range of activities as industrial electricians – from lamp replacement, maintenance and repair to drawing plans and (re)programming – we clearly needed more support with this first project with a technology provider who was new to us than someone who already has more experience of such matters. In this regard, proximity to the Styrian sales office was a great benefit to us, especially with two of our main contacts – Bernhard Fischer and Thomas Maierhofer – living not far away. They were on hand immediately if needed,” says Wolf, recognising the quick response times of the Beckhoff team. Some joint activities are planned for 2021. Discussions are under way in relation to an extension of the twist cap side face painting unit with the addition of energy measurement, the connection to the ERP system, and numerous other conversion or upgrade activities. “Our engineering department always has its hands full because there is always something new to design or construct, and existing equipment to maintain or, if necessary, modernise with the latest electronics,” says Christian Stanzel, confirming more orders soon to be placed with Beckhoff. “Perhaps in future we will want to process data in real time or incorporate image processing,” says Wolf, looking ahead. With Beckhoff the Pinggau-based manufacturer has an implementation partner at its side with numerous “facilitator” qualities, like BT-Watzke itself: on one hand, PC-based control technology is, by nature, finely scalable – in terms of both hardware and software; and on the other, because the Beckhoff team invests all its know-how in exceeding and not just meeting the expectations of the customer. For BT-Watzke, it was primarily the interaction between the “small and large drive technology” in synchronisation with production cycles, which at first glance for Reifbäck and Wolf did not seem so easy to control. However, with the cam disc functionality recommended by Fischer, even this highly complex task could be solved easily with one software switch for everything. All actual and target positions are transmitted via EtherCAT to the EL72xx servo motor terminals and AX5000 servo amplifiers involved, thus allowing an electronic cam disc to be implemented on the AM8000 servo motors. “We watched closely how several motion sequences are synchronised in TwinCAT 3. Next time we will be able to do it ourselves,” say Wolf and Schuller, pleased with how much they learned through the collaboration with Beckhoff. □

[Picture: © Beckhoff]

I gave him the weights and diameters relevant at certain points and the associated speeds and, as I looked on, he worked out which components could be considered,” says Reifbäck. The corresponding CAD data was sent directly to his computer. “The design process couldn’t have gone more smoothly. I didn’t have to call anywhere or send further information; everything was done here on site. It was complete within just a few hours,” he adds. In addition to numerous EtherCAT input and output terminals, the EL5151 incremental encoder interface, EL72xx servo motor terminals, and an EL9576 brake chopper terminal, the lateral surface painting process at BT-Watzke is now also supported by a CX5130 embedded PC with an Intel® Atom™ multicore processor and four servo motors from the AM8000 series. The latter ensure attachment or detachment of capsule blanks at the revolver that is synchronised with production cycles. In addition, they manage the movements of this turntable. “The probability that the attachment would immediately work as we had envisaged was almost 100%, but the removal from the turntable was the greatest unknown. Would everything really work as calculated beforehand? Would the mechanics and electrical drive technology interact properly? As we had not done anything similar in this way before, there was some trepidation before the first real test run,” Wolf confesses, adding: “Simulations are one thing, but everyday production has proven us wrong on many occasions. A few snags can arise very quickly here and there.” “Capsules are not all alike,” says Reifbäck. “Depending on whether a matt or gloss paint is applied, or the products being transported are black or green, they behave slightly differently. And the drive technology has to respond to these small, subtle differences,” he says, highlighting that the Beckhoff solution used has to offer maximum adaptability and flexibility. In addition to the servo drive technology, the lateral surface painting process at BT-Watzke is supported by numerous EtherCAT input and output terminals as well as a CX5130 Embedded PC with an Intel ® Atom™ multicore processor.

For more information visit: www.beckhoff.co.za

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