Five critical parameters in Industrial Control Systems

There are five categories involved in integrating different Industrial control systems. Control systems integration is fundamental to Industrial Automation. In fact, control system integrator provides maximum value to the client by designing the system following these parameters including higher levels of control that manage personnel, materials, and equipment across all factory production areas. A good Control system integrator will follow all these parameters and all ISO standards.

There are five factors involved in integrating different control systems:

  1. Software infrastructure
  2. Process database
  3. Users Interface
  4. Alarm management
  5. Network security

Software infrastructure: A automation system requires that the application must be integrated into the systems.  It is the main reason why software infrastructure is important for system integration.

Process database: Database is a collection of data. These data are organised in the way that the data can be accessed in different ways for the users.

Users Interface: The human-machine interface (HMI) allows users to monitor the production. The information of the HMI is shown using graphics, reports, historical activities, and alarms.

Alarm management: Alarm systems help to identify critical issues on time, Plant operation requires alarms to take a timely effective decision. Alarm management is critical when integrating different control systems to monitor different function in the production.

Network Security: Integrated control and safety systems (ICSS) share information between industrial systems and management systems. Industrial systems include programmable logic controllers (PLCs), process control systems, safety systems. Automation is not only about control of the equipment, it also includes higher levels of control that manage personnel, materials, and equipment across all factory production areas.

The Functional Design Specification is a critical document that helps the client to have a clear understanding of the project and it also minimises the risks of misunderstanding during the building and commissioning phases. Check out more details on our website.

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New technology IOT 4.0 Robot Monitoring

Robotic Industrie 4.0 technology

Robotics has helped manufacturers to increase productivity. Robots can perform complex tasks that require accuracy and repeatability.

Today’s trends are towards harnessing new technologies, for example using smartphone interfaces to enable customers to monitor their robot’s performance. Industrie 4.0 will help the manufacturer to monitor data in real time, production activities and gather production details such as a number of units produced by each robot for a specific period.

Having accurate data will allow the creation of charts that will help smaller to mid-size manufacturers to take timely decisions and focus more on the production needs.

You can be in any part of the world and at the same time monitor what is happening on the production line. It is not just largely integrated factories or the larger original equipment manufacturers who can benefit from this new and powerful trend in robotic technology.

New Robot or Used Robot Installation

Whether you opt for new or used robots, robot integration can be a simple straightforward process or more involved in the case of complex production systems. Some robot applications are less straightforward than others, possibly requiring modification to existing equipment, re-design and the use of a robot software simulation package for better results.

We can adapt the new or used robot to integrate into the existing production line including setting up of the robot, programming of the trajectories, and commissioning of the complete system. It is important to carry out design studies and introduce any changes to future proof the installation.

It is always recommended that an experienced engineer review the design study to ensure nothing is overlooked. Also, CAD/CAM robot software is used particular where very long tool paths are involved in the case of milling cells.

How to program or modify a Robot Programming language?

Robot manufacturers each have their own specific programming language, even though, they have some similarity, it is important that the programmer has an in-depth knowledge of each specific robot type.

Most of the time modifications to existing programs are straightforward, for example, if you need to update from one robot cutting process to two cutting processes, it requires less programming work than if you were looking to perform two types of different tasks in the one production line operation.

Robotic technology has advanced and it provides a more structured code and well-organized patterns. A robot programmer should be able to understand where the limitations are and how the programming is affecting the whole process.

New robot technology IOT 4.0 for Robotics

Robotics has helped manufacturers to increase productivity. Robots can perform complex tasks that require accuracy and repeatability.

Today’s trends are towards harnessing new technologies, for example using smartphone interfaces to enable customers to monitor their robot’s performance. Industrie 4.0 will help the manufacturer to monitor data in real time, production activities and gather production details such as a number of units produced by each robot for a specific period.

Having accurate data will allow the creation of charts that will help smaller to mid-size manufacturers to take timely decisions and focus more on the production needs.

You can be in any part of the world and at the same time monitor what is happening on the production line. It is not just largely integrated factories or the larger original equipment manufacturers who can benefit from this new and powerful trend in robotic technology.

New Robot or Used Robot Installation

Whether you opt for new or used robots, robot integration can be a simple straightforward process or more involved in the case of complex production systems. Some robot applications are less straightforward than others, possibly requiring modification to existing equipment, re-design and the use of a robot software simulation package for better results.

We can adapt the new or used robot to integrate into the existing production line including setting up of the robot, programming of the trajectories, and commissioning of the complete system. It is important to carry out design studies and introduce any changes to future proof the installation.

It is always recommended that an experienced engineer review the design study to ensure nothing is overlooked. Also, CAD/CAM robot software is used particular where very long tool paths are involved in the case of milling cells.

How to program or modify a Robot Programming language?

Robot manufacturers each have their own specific programming language, even though, they have some similarity, it is important that the programmer has an in-depth knowledge of each specific robot type.

Most of the time modifications to existing programs are straightforward, for example, if you need to update from one robot cutting process to two cutting processes, it requires less programming work than if you were looking to perform two types of different tasks in the one production line operation.

Robotic technology has advanced and it provides a more structured code and well-organized patterns. A robot programmer should be able to understand where the limitations are and how the programming is affecting the whole process.

Why is important to choose a system integrator on your automation process?

System integrators’ expertise includes engineering experience such as electrical design & installation, PLC/HMI/SCADA programming, testing, commissioning and after sales support. They provide control, automation, robotic systems and data information to help to manufacture to take an important decision. The robotic and system integrators integrate from multiple suppliers to provide the best integration solutions to the clients.

  1. An Integrators know the best and most cost-effective because of their expertise and years of experiences.
  2. They follow all regulations and standards on the industry
  3. Project Manager will get the right equipment for the project
  4. Production uptime and easy troubleshooting when components fail
  5. Project delivery on time
  6. An Integrator can also help you to get the best control panel
  7. They ensure an effective thermal management in the panel to reduce damage to the components
  8. They make sure the panel is being thoroughly tested to avoid future problems.
  9. Integrator will identify possible issues and provide automation solution
  10. Providing proper documentation of the project.

The system integrator brings their knowledge of mechanical, robotic, experience in process and modern business technology. They experience to allow them to identify issues and knows how to integrate into a functional system.

How do you identify a good system integrator?

A good system integrator is certified by well-known associations, some of them are National Inspection Council for Electrical Installation Contracting, SafeContractor, ISO, Contractors Health and Safety Assessment Scheme.

They should have a track record of their experiences with real cases studies.

Phoenix will provide their expertise on System Integration and Robotic Automation.

Robotics Vs Composite Advanced Technology

The composite material is made by combining two or more materials, some of these materials used are fiberglass, carbon fibres or carbon nanotubes.  Composites made with carbon fibres are lighter and stronger than fiberglass but more expensive to produce.  Carbon nanotubes are even lighter and stronger than composites made with carbon fibres but they are still extremely expensive. It has been used for making lighter cars and aircraft structures.

Robotic automation has been implemented in the composite manufacturing processes, it demands extensive experience allied with a deep understanding of the subject.

What can robotics bring to the table in the Composite manufacturing process?

  • Robots are able to handle fabric sheets, lifting and placing them into a mould.
  • Composite drilling and trimming of the completed structure.
  • Loading and unloading the cured product.
  • Material removal including grinding and sanding
  • Spraying paints, varnishes and other coatings

Where do you find composite technology:

  • Automotive – Chasses and components
  • Communications – Satellite antennas
  • Aerospace & Defense – Aircraft interiors, flooring, cargo liners
  • Alternative Energy – Wind turbine blades
  • Sports Equipment – Helmets, boat hull components
  • Consumer Goods – Medical device components, seatbacks
  • Others

20170523_152805The Composite bonding and finishing processes are inevitably repetitive, dull and the environment along with the materials used potentially hazardous. The Implementation of robotic systems for these operations protects workers whilst also greatly improving quality and consistency of product.

The new Airbus A380, the world’s largest passenger airliner, makes use of modern composites in its design. More than 20 % of the A380 is made of composite materials, mainly plastic reinforced with carbon fibres. The design is the first large-scale use of glass-fibre-reinforced aluminium, a new composite that is 25 % stronger than conventional airframe aluminium but 20 % lighter.

Phoenix Control is present in all industries helping our customers to get the most out of their business.  We contribute and support our customers with our highly experienced staff in Control Systems and robotic automation. The main advantage of modern composite materials is that they are lighter and stronger than others materials.

Contact Us to help you in your own project or we can put in direct contact with one of our client if you want to know more about composite materials. Our customer’s success is our success.

How to win new business with Robotic Trimming?

Global sales of industrial robots rose significantly and it expected to double to 400,000 a year by 2018.  Industrial robot pricing will continue to decline over the next decade by more than 20 percent

trimming robotRobotic Trimming refers to the process of removing excess material from a part that has been fabricated for example removing the flashing from a part that has been removed from a thermoforming process.

Industrial robots are both flexible and precise while maintaining consistency and accuracy.  However, the biggest advantage of using robots for trimming is the ability to overcome a skills shortage.  Using robotic trimming enables you to speed up your production cycle and to deliver a high-quality product.

We always read that industrial robot improves Productivity, Safety, Quality and Cost Competitiveness, if this holds true, the return of investment is the first roadblock keeping many manufacturers from moving forward with robotic systems.

In fact, we will be answering the following question in our series of articles titled: How to calculate the time before your investment is completely paid off due to the savings difference that has accumulated from your robotic production improvements?

Take your time to find a System Integrator that not only understands the requirements of your trimming applications but also that provides you with a complete automation solution starting with the robot itself to the commissioning of the full system integration.

We would like to help our customers to take the right decision. Do not miss our next article.

Robotic Systems main parts

Air Design Visit 1

Once you’ve decided it’s time to buy a robot, there are three main robotic systems components to consider to start. However, whether you get to robotic automation or not, you need to do something to stay competitive or or somebody else will take your place. Take your time in finding an integrator that knows industrial automation and robotic system.

As the digital economy continues most businesses realize they need to keep their company agile and flexible. Adding robotic systems is a great way to accomplish this, as it’s fairly simple to change the robot’s settings to do what you need it to do and remember that you want to overestimate your needs to allow for future expansion and changes in production. See also robotic welding.

Controller

Every robot has a computer, which keeps the pieces of the arm working together. This computer is known as the controller. The controller functions as the “brain” of the robot. The controller also allows the robot to be networked to other systems, so that it may work together with other machines, processes, or robots.

Robots have controllers that are run by programs – sets of instructions written in code. Almost all robots of today are entirely pre-programmed by people; they can do only what they are programmed to do at the time, and nothing else. In the future, controllers with artificial intelligence could allow robots to think on their own, even program themselves. This could make robots more self-reliant and independent, but the the true is that all robotic systems have to be programmed to do the work.

Manipulator Arm

Many robots resemble human arms, and have shoulders, elbows, wrists, even fingers. This gives a robot lots of options for moving, and helps it do things in place of a human arm.

In order to reach any possible point in space within its work envelope, a robot needs a total of 6 degrees of freedom. Each direction a joint can go gives an arm 1 degree. As a result, many robots of today are designed to move in at least 6 ways.

Teach Pendant for Robtic SystemsTeach Pendant

Teach pendants are typically handheld devices and may be wired or wireless. A Teach Pendant is used to program various models of the robotic industrial machinery the company makes.

What else do you need to know?  See  our next  post.