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September 2005
The name says it all with the new Smart industrial PC from SIGMATEK. Smart because of ultra modern Pentium M technology with a processor speed of 1.4 GHz. Its maintenance-free compact construction and robust technology make the Smart Industrial PC optimal for challenging industrial applications. For operating conditions with extreme reliability requirements, the operating system can be installed on a Compact Flash card. |
Since a fan is not required for temperatures up to 50°C, no moving parts are needed for this version. The Smart IPC communicates over a number of interfaces which cover all current standards and important field buses.
High integration density means reduced space requirement
The Smart Industrial PC (S-IPC) is a very compact power package that combines high computer performance with low current consumption. The heart of the S-IPC is a Pentium M processor whose performance capabilities are comparable to its consumer counterpart, the Pentium IV. Its affiliation with the Embedded division from Intel ensures the safety of its availability.
An optimized construction concept ensures that for the S-IPC passive cooling is sufficient for environmental temperatures up to 50 °C. For operation at 60 °C a further design highlight can be employed: an industry compatible dual fan module can be simply mounted under the chassis. No cables are required as the connection is made automatically over the connector plugs provided.
Another interesting feature: in addition to the hard drive and/or Compact Flash, the S-IPC can also be booted over the USB interface.
S-IPC: Equipped for all applications
Special attention was given to ensure that all connections could be made from the front and all expansion and exchangeable modules are also accessible from the front. This makes installation, refitting and upgrading easier as well as servicing in restricted space.
A newly designed drive change assembly module allows two IDE devices (hard drive, CD, DVD) to be mounted. Two Compact Flash cardholders expand the storage capability and enable operation without a hard drive.
With a number of standard integrated interfaces and 2 additional PCI slots, all external modules and networks can be connected.
2x Ethernet 10/100, 2x RS232 (RS485), 3 x USB 2.0, PS/2 and an LPT connection are available and displays can be connected over VGA, DVI or S-DVI (for displacement up to 15m). In addition, a CAN bus and the SIGMATEK real time DIAS bus are integrated. Therefore the S-IPC can be used as a high performance control with integrated visualization.
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Customer specific or serial modular expansion
The Smart Industrial PC was designed by SIGMATEK as a trend setting machine and through in-house production, the complete technology is available at SIGMATEK. This ensures a long availability of the system and therefore the customer’s investment. The system integrity is further increased through the monitoring of internal and processor temperatures. Changing the battery is possible when the S-IPC is shut down. This means the data in the CMOS RAM and the clock time are not lost.
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August 2005
Precise rivet technology is a continuous topic for automotive suppliers. HPS Innovation GmbH, located in Anthering, has been dedicated to this topic for years. With the C-DIAS IPC from SIGMATEK, the Salzburg company is now implementing their “Smart Power NT1”control concept that will be used for rivet machines and presses as well as screw, bore and threading units. |
HPS Innovation GmbH is a young dynamic company, founded by Engr. Günther Ausserdorfer and has focused on pneumatics and hydraulics. As HPS Innovation GmbH began representing the Swiss company Bodmer Küsnacht in 1996, rivet technology along with the connected automation was added. This type of joining technology can be implemented over a variety of applications. Through the numerous rivet forms, a multitude of connections can be made. Even plastic can be riveted.
“Bodmer is long established manufacturer of rivet machines that are operated worldwide”, says Günter Aussendorfer. “We’ve been the general representative in Austria for a fairly long time and work very closely with the headquarters in Küsnacht.
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HPS designs a new rivet control
In the course of this close cooperation, Ausserdorfer and his team began to develop the existing rivet machine further. The project was successful and today, this control technology is also built and operated by the Swiss machine manufacturer. Such a project alone would already be an extensive program for a company like HPS, who are also active in other areas: “ We build complete automation for production and everything having to do with hydraulics and pneumatics. We have our own block manufacturing and produce special machines as well as extensive system solutions”, reports the manager over his program. This program is implemented within a company network: an electronics company is housed in the plants belonging to HPS and at the company Pichler & Stobl GmbH, mechanical production using the newest technology is provided. |
“Here, we at least have the same capability as a larger company”, says Günther Aussendorfer, who values cooperation. Günther Aussendorfer also works with the automation company MSRA Technik whose Managing director, Engr. Kurt Totz, he has known for many years: “HPS was searching for a new control system that could be used for rivet machines. Totz developed the necessary hardware requirements and designed for us, the control software for the rivet machine.”
“The problem with the machines used at the time was the complex application control and complicated menu navigation”, explains Gerhard Neuhofer, the technical manager at HPS. “It was very difficult and time consuming when the machine parameters had to be changed. With our graphic Touch display, image screens are constructed that only show what’s relevant. This is less confusing than when all functions, including those not required for the control, are displayed.”
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The perfect basis: An IPC from SIGMATEK
For the new “Smart Power NT1” controller, HPS was looking for a high performance control, reports Gerhard Neuhofer: “As we developed the specifications for the new “Smart Power NT1” controller together with Mr. Totz, he mentioned the years of good experiences he’s had with the automation systems from SIGMATEK. We then turned to SIGMATEK as well because we needed an extremely fast control for our standard procedure. With the low control cycle time of the C-IPC, it was possible to position a hydraulic or pneumatic cylinder with the target precision of 1/100 mm even when moving with a maximum rate of 40 Km/h. From then on, we’ve had a close cooperation with SIGMATEK.” |
The control is still not fully utilized as Helmut Fritz of SIGMATEK reports: “The analog input used is a long way from being overloaded. If even faster machines are available in the future, The C-IPC could be used to control them without exceeding its performance limits.”
Gerhard Neuhofer agrees: In this case, it was important to have such a fast controller. The, mechanical parts, however, follow the electronics and the operational limits are reached rather quickly. The control can certainly do more but there are no mechanical parts that can react as fast.”
With Ethernet to In Service
The Smart Power NT1 controls the rivet machine but can also be used to control the movement of a CNC machine and for PLC functions. For example, it can take over the adjustment of pressure pads. Many other functions are also possible, for example, the cycle data can be easily recorded for quality management.
If the rivet machine is used in a machine network rather than a stand-alone module, the user has two options. As Gerhard Neuhofer explains: “Either we connect the control over a CAN bus system or we offer a simple and logical connection with digital in/outputs. We can enter or read all the parameters relevant for high-level controls. Implementation in a machine network is simple. Even when an Ethernet bus system is used, we are the best possible position; the C-IPC is equipped with an Ethernet connection and we are completely open to this type of communication.
We already use the Ethernet interface for servicing. We can log into the customer control over the Internet with a PC and check for problems, which is a service that our customers really appreciate. When a rivet machine in a production area fails, quick action is demanded, which we guarantee with our 24-hour service Austria wide. However, we can test whether the problem is simply a false parameter input that can be corrected before we send a technician. If a technician must be deployed, we can determine which replacement parts he will need to take along.”
Experiences with the Compact Industrial PC
HPS is extremely satisfied with Sigmateks price-performance ratio. According to Engr. Günther Ausserdorfer: “ We’ve now managed to place a CNC machine on the market that costs a third less than a conventional CNC machine. This was only possible through the use of the new control and our good programming.”
When modifications were needed during development, a call to SIGMATEK was all it required to make them possible: “In two or three hours we had our solution on the table and could continue working. SIGMATEK was an important partner for us during this project. With the DIAS automation system, we could realize our control concept for the Smart Power NT1 exactly as we envisioned it.”
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April 2005
The “protective module” from SIGMATEK is a new design for the time proven automation system DIAS. The IP 67 I/Os are simply connected to the real-time capable DIAS bus for decentralized application. The highlights of the P-DIAS: No additional software is needed for the module configuration. The module also offers numerous diagnosis possibilities and is equipped with the new revolutionary Ultra-Lock connector. |
Modular, flexible and compact
The new P-DIAS module is the perfect compliment for the decentralized I/Os of the DIAS line. The modules are designed for the protection type IP67 and suited for the optimal expansion of modular decentralized assemblies. They are fully compatible with the existing DIAS PLC system. Communication occurs over the real-time capable DIAS bus. A great deal of attention was focused on flexibility. Therefore the digital module was equipped with eight channels that can be freely used as in or outputs.
LEDs show the actual status of each individual sensor or actuator and make an exact diagnosis possible. In addition, every connection has a red LED, which indicates when an error occurs, that means it monitors overloads and short circuits. With the project software, LASAL, this information can be linked in the user program and analyzed.
New connector system
The new M12 Ultra-Lock connector locks automatically when connected and unlocks when the locking clasp is pulled. The Ultra-Lock systems unique quick connect technology offer the users clearly faster and simpler possibilities for installation than the usual screw system. As a result, reduced costs, higher productivity as well as less labor are achieved.
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February 2005
A considerable number of cycles, which the lower Austrian machine builder SBT Die Form Engineering has achieved at its production center for manufacturing die form parts used in contact welding. The high precision of the produced parts that must be guaranteed simultaneously, especially in the electric /electronic industry, doesn’t make the automation of the corresponding machines simple.
Here, a manufacturer needs a dependable partner that can grasp the concept of synchronizing electrical axes as well as the control and visualization technology from which a high degree of availability can be expected.
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SBT has found just such a competent and dependable partner in the village of Lampechtshausen. Because the mid-sized machine builder has experienced the impeccable product quality and complete technical support with the Salzburg automation company SIGMATEK that was unavailable in previous suppliers, SBT Die Form Engineering’s distribution and quality manager, Peter Buxbaum stated at the beginning of an interview with AUTlook: “ We’ve been working with SIGMATEK for about two and a half years. With Our previous suppliers, from which we ordered all of our automation and drive components, we couldn’t deal with the manner which we were treated has relatively small customers. |
We were often left waiting despite delivery times having been agreed upon. We must however, guarantee our customers replacement part delivery times. Therefore we need a supplier that we can depend on completely.” Today, SBT Die Form Engineering has been in operation for almost 25 years in Wöllersdorf and Schöbach in Lower Austria. At first the company founder worked as a machine dealer when he began constructing his own Die forming tools. The design of the first contact welding machines followed and shortly thereafter, the establishment of his own die shop. “ Today we’re involved mainly in machine and tool building for precision manufacturing. Our specialty is contact welding, the welding of silver and silver alloy to different nonferrous metals and nonferrous heavy metals as well”, explained the son of the company founder, Peter Buxbaum. In the mid 80s, the first contact welding machines were designed. In the 90s, the product spectrum grew into a quick-change system that enabled the company to expand internationally and add a further contact welding machine as well as the current company flagship the SBTM-300 system.
This flexible production center was especially designed for the manufacturing of die form parts for contact welding, thread molding, rivet feeding and also for the assembly of metal and plastic parts. The machine can be equipped with one to six press, welding, rivet, assembly or die forming modules as required. The tools are set up and tested without having to use the production machine. After production is complete, the modules are simply exchanged. Thus, minimizing down time. “Our machines process band material five hundredths of a millimeter thick and work with cutting clearance of 5 µm and a production speed of 500 parts per minute”, explains Peter Buxbaum; not without pride over the considerable features.
The clients for this high performance machine are found in the electric and electronic industry and especially in household electrics. STB has supplied parts in the entire EU as well as the United States, Asia and even Australia. Exporting accounts for over 95 percent of the entire business.
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Control and Drive technology
Back to the automation technology of the precision machines: “An essential factor is the relatively high, 500 parts per minute, clock cycle. Because our machines run with up to 10 separate servo axes, each module is driven by its own servomotor. These are electronically synchronized and must operate under angular synchronism at high clock cycles”, says Peter Buxbaum about the complex challenges. “It’s also a question of very time critical automation.” The SBT technician had, at the beginning of the cooperation with SIGMATEK, very concrete ideas about the product results Salzburg automation experts were to achieve. “Naturally, we already had experience with controls and drives we used earlier and new exactly what was needed for our applications”, according to Peter Buxbaum.
In a relatively short time, the SIGMATEK crew customized the applications in its own portfolio. The product model conversion was first implemented on the smaller machines and then gradually expanded, so that soon all STB products were equipped with SIGMATEK controls.
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With the SBTM-300-NC, comes an industrial PC, a 15“ touch screen and up to ten servo axels as well as I/O modules from SIGMATEK in Lamprechtshausen. The “DIAS servo system” ensures the optimal interaction between the servo axels and the industrial PC. Communication is made over the field bus “DIAS bus”. As previously mentioned, the synchronization and monitoring have a special meaning. SIGMATEK technician Alexander Holzner gives the details: “For monitoring, Interrupt capable inputs are used so that even at high speeds we can record correctly. Because of the high-speed requirements, we work with a one millisecond Real-time task. The data rate of 11 Mbd on our DIAS bus guarantees an update of 2,4 million I/Os per second and a byte access time of 3.24µs. Thus, the possibility exists to implement positioning tasks and fast processing of analog values without local intelligence in the module.”
On the industrial PC, Sigmateks own multitasking operating system runs along with project software LASAL All in One. With the individual tools LASAL Class, Screen, Text and Motion; automation task such as project development, visualization and motion control are solved from a single source that supports all SIGMATEK products such as CPUs, terminals and IPCs. An essential attribute of the software is the object oriented programming with graphic representation, project building and debugging. A complete overview of the project, functions, data transfer and interfacing is available at a single glance. Complex connections are therefore simple to recognize, change and monitor.
Partnership with flexibility
“Our advantage is that we, unlike other special machine builders, have no prescribed controls producer. Our customers require a complete, functioning solution for which we’re responsible”, commented Peter Buxbaum on the unique features of the precision parts manufacturing branch. Therefore, on can concentrate on one supplier and develop a corresponding partnership. “ We have to try to design our machines as flexible as possible to give our customers the broadest possible product spectrum in their manufacturing process. Our strength lies in machine and tool making; in control technology, we’re no specialists. Therefore we need an accordingly flexible partner on our side and the flexibility from SIGMATEK is what I especially appreciate”, says Peter Buxbaum about his satisfaction. Meanwhile the technicians on both sides already work together perfectly. At the Euroblech trade fair that took place at end of October 2004 in Hannover , the technical control applications were already running very fast in the new SBT equipment presented and above all smoothly.
“We are currently in the process of building a third product line. This machine is called the “Mini stamper”. It is a small punch machine for precision parts manufacturing that is placed in a more cost saving price range as our larger production center. It is especially suitable for smaller and mid-sized precision parts for use in injection molding machines or for direct integration in assembly lines. Also on the control side, these machines are offered with several special features because when it comes to speed and production safety, we don’t want to take any short cuts”, concludes Peter Buxbaum.
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