P. 20 KMT Waterjet Design Efficient Solutions · Manufacturer of high pressure pumps for waterjet cutting systems reduces costs with SmartWire-DT ... focuses on developing advanced

SOLUTIONS29Getting to Grips with Energy and Efficiency: Interview with CTO Ramanath Ramakrishnan P.3 T-Connector: New architectures for the machine periphery P.5 | Success Worldwide: Eaton supports machine builders exporting to North America P.10 | Tunneling Machines: Tunneling towards Industry 4.0 P.12 Precision Work: Train lifting systems P.18 | At High Pressure: KMT Waterjet cuts with water P.20

CUSTOMER MAGAZINE EATON’S ELECTRICAL SECTOR EMEA

P. 20

KMT WaterjetDesign Efficient Solutions

Contents News... 5-11

Tunneling Towards Industry 4.0…12-13 More data transparency for tunneling machine thanks to SmartWire-DT and smart devices

Recycle More, Save More… 14-15 CDM relies on Eaton to make its extruders more powerful while at

the same time achieving savings

From A Single Source… 16-17 Hydraulics and electrical engineering from Eaton for friction welding machine from Eaton Vehicle Group

Trains Get A Lift With Eaton… 18-19 Controlling train lifting systems with 2mm precision

Sharpening Water… 20-21 Manufacturer of high pressure pumps for waterjet cutting systems reduces costs

with SmartWire-DT

It‘s the Tool That Really Counts… 22-23 Injection molding specialist shortens cycle times for cap production

with electrical control system

Intelligent Disposal… 24-25 Eaton automation helps filter and extraction system specialists gain the competitive edge

Power Supply on a Mountain… 26-27 Reliable power supply at 1,600 meters above sea level

Autonomy in Solar Power… 28-29 Innovative electricity storage devices give a boost to the solar power sector

Infoboard... 30-31

CoMPANy

1. A so-called QR code is shown at the end of some of our texts. These can be read with a QR code scanner on a smartphone.

2. A QR code scanner can be downloaded onto the smartphone as an app.

3. Once the scanner is installed, the QR code can be scanned with the smartphone camera. The smartphone then activates the corresponding page on the Internet.

Instructions. Scanning the QR code.

Select and scan QR Code

View additional information

Scan QR Code

P. 24 P. 26

P. 22 P. 20

In your role as CTO you are responsible for coordinating all technical development efforts across Eaton’s different business sectors – Electrical, Hydraulics, Aerospace and Vehicle. From your perspective, what are the key trends in overall power management?

As we prepare for the future we periodically assess megatrends. Energy demand and resource availability, regulation on emissions reduction, the rising middle class in emerging nations, robotics, information and nano technologies, just to name a few, are all key elements in our corporate and business strategy plans, which form the basis for our technology roadmaps.

But to me the most significant megatrend today is population growth. It is the key factor behind the growing consumption of Earth’s finite resources and why it is essential we reduce energy consumption and emissions. This is why Eaton is so focused on

Interview with Ramanath Ramakrishnan, Executive Vice President and Chief Technology Officer at Eaton

As major player in the power management market, Eaton focuses on developing advanced products and solutions to help customers manage electrical, hydraulic and mechanical power in a more efficient and sustainable way. Eaton CTO Ramanath Ramakrishnan explains what this means for various markets and provides insights into trends and innovations.

Getting to Grips with Energy and Efficiency

Eaton SolutionS 29 3Eaton SolutionS 292

Contents News... 5-11

Tunneling Towards Industry 4.0…12-13 More data transparency for tunneling machine thanks to SmartWire-DT and smart devices

Recycle More, Save More… 14-15 CDM relies on Eaton to make its extruders more powerful while at

the same time achieving savings

From A Single Source… 16-17 Hydraulics and electrical engineering from Eaton for friction welding machine from Eaton Vehicle Group

Trains Get A Lift With Eaton… 18-19 Controlling train lifting systems with 2mm precision

Sharpening Water… 20-21 Manufacturer of high pressure pumps for waterjet cutting systems reduces costs

with SmartWire-DT

It‘s the Tool That Really Counts… 22-23 Injection molding specialist shortens cycle times for cap production

with electrical control system

Intelligent Disposal… 24-25 Eaton automation helps filter and extraction system specialists gain the competitive edge

Power Supply on a Mountain… 26-27 Reliable power supply at 1,600 meters above sea level

Autonomy in Solar Power… 28-29 Innovative electricity storage devices give a boost to the solar power sector

Infoboard... 30-31

CoMPANy

1. A so-called QR code is shown at the end of some of our texts. These can be read with a QR code scanner on a smartphone.

2. A QR code scanner can be downloaded onto the smartphone as an app.

3. Once the scanner is installed, the QR code can be scanned with the smartphone camera. The smartphone then activates the corresponding page on the Internet.

Instructions. Scanning the QR code.

Select and scan QR Code

View additional information

Scan QR Code

P. 24 P. 26

P. 22 P. 20

In your role as CTO you are responsible for coordinating all technical development efforts across Eaton’s different business sectors – Electrical, Hydraulics, Aerospace and Vehicle. From your perspective, what are the key trends in overall power management?

As we prepare for the future we periodically assess megatrends. Energy demand and resource availability, regulation on emissions reduction, the rising middle class in emerging nations, robotics, information and nano technologies, just to name a few, are all key elements in our corporate and business strategy plans, which form the basis for our technology roadmaps.

But to me the most significant megatrend today is population growth. It is the key factor behind the growing consumption of Earth’s finite resources and why it is essential we reduce energy consumption and emissions. This is why Eaton is so focused on

Interview with Ramanath Ramakrishnan, Executive Vice President and Chief Technology Officer at Eaton

As major player in the power management market, Eaton focuses on developing advanced products and solutions to help customers manage electrical, hydraulic and mechanical power in a more efficient and sustainable way. Eaton CTO Ramanath Ramakrishnan explains what this means for various markets and provides insights into trends and innovations.

Getting to Grips with Energy and Efficiency


NEWS +++ NEWS +++ NEWSCoMPANy

the development of energy-efficient products. If you consider the amount of energy consumed in our daily lives it is clear that there is a great need and scope to do more to increase efficiency.

What type of solutions does Eaton offer to address this challenge?

There are numerous examples from all our business sectors. Looking at our vehicle business, car manufacturers are increasing their efforts to reduce fuel consumption. One of the innovations we developed to address this need is an engine air boosting technology: Our superchargers are helping downsize engines by 30 %, improve fuel economy by as much as 10 to 15 % and contribute to reduced emissions. Another innovation is a technology based on cylinder deactivation. Not all cylinders in a car have to constantly be engaged; in some cases two of four cylinders would be sufficient to deliver the same power. This, again, helps to reduce consumption and emissions.

In aerospace, where we offer high-pressure hydraulic and digital fuel management systems that are particularly lightweight and reliable, we are able to reduce the weight of the fuel management systems, but we are also ensuring that the tank contents can be reliably determined to a single gram. After all, every gram of fuel counts.

In many applications electrical drives are replacing hydraulic systems. Can we expect further improvements from this?

The electrification of aircraft has been going on for around 20 years. The trend here is towards decentralized compact hydraulic systems. This means that instead of one central hydraulic system there are now many smaller ones. Thus, the length of hydraulic lines required can be reduced. In addition, the hydraulic systems are combined with electric drives. This enables individual modules to be placed precisely where they are required allowing for them to be simply integrated into the control structures. We have deployed such new systems in the Airbus A380 and the Boeing 777. In doing so, we managed to reduce the weight for the A380 by one metric ton. That means we helped them save 450 kg in fuel on a transatlantic flight, while 1 kg less fuel burned reduces CO2 emissions by 3.5 kg.

Where does Eaton focus within the electrical sector?

In the electrical sector and for the MOEM market lean automation continues to be a big customer value driver for efficiency. Our lean solution strategy is all about eliminating waste; it starts with connecting the various “assets” such as machines, electro-hydraulic valves, electrical circuit breakers, switches, sensors and relays using the minimal wiring and simplified communications architectures. We also implement diagnostics and prognostics algorithms that sense various operating parameters such as pressure, position, temperatures, current flows as well as voltage and frequency variations. A major benefit of the new technology is the data

transparency from the controller to the actuator and sensor. All data related to electricity and energy consumption is made available to the entire machine and to the individual actuators.

What does that mean for the integration of electrical and hydraulic systems?

We are moving away from ‘dumb’ mechanics which execute simple movements and are developing smart components. These contain electronics, sensors and control systems. This is one of the most important trends in hydraulic engineering today. Our lean solution system is already a combination of electrical solutions, electrohydraulics and mechanical devices such as pumps and cylinders.

We have brought all this together using our proprietary SmartWire-DT communications technology that radically simplifies the wiring architecture of machines. This integration enables us to offer an energy efficient solution. It allows customers to see exactly how much energy is consumed and what can be saved because all machine parts are communicating with each other. In addition, it brings with it many very useful diagnostic functions for the entire process chain that can be used to carry out preventative diagnostics, streamline processes and increase the availability of machinery.

How important is innovation to Eaton?

We believe that innovation is crucial to the growth of our customers, crucial for business, and crucial to the growth of nations. We see innovation as ’monetizing valuable novelties’. A novelty is something new to the world or to our customers that provides great value, where the benefits outweigh the costs. This and the ability of our organization to monetize in a timely manner make our customers successful – because our customers’ success is our success. We want to be at the forefront in developing innovative power management solutions that are safe, efficient, reliable and sustainable to meet our customers’ most demanding energy management challenges.

What kind of innovations can we expect in the years to come?

One of the key areas we are focusing on is connectivity and the development of solutions which use as little energy as possible. We want to make sure that our devices are extremely efficient and can be connected with minimum complexity. An important priority will be the algorithms, the acquisition of information. While anyone can collect data, the question however is what you do to generate information from this data and derive the correct course of action. This is the role of the diagnostics and prognostics algorithms we use to minimize energy consumption and maximize asset uptime across the entire system. This continues to be one of our major areas of research and development – now and into the future.

Another key area is improving the safety of the devices. A large part of our work involves very high electrical and hydraulic powers that are packaged in very compact envelopes or footprints, and the safety of humans and systems that these electrohydraulic solutions protect is paramount to everything we deliver. Simplicity when it comes to installation is also an important issue. We are convinced that simpler hardware and operation results in a more reliable system. Designing things to be simple is not easy at all. The simpler the device, the more work has gone into its development and design. This is also a key focus of our daily work.

Eaton Presents the T-Connector for SmartWire-DT: New Architectures and Increased Flexibility for the Machine Periphery

Power management company Eaton is expanding the possibilities for using SmartWire-DT outside the switch cabinet. The T-Connector now enables users to integrate sensors and actuators in the field directly into the innovative communication system. This therefore provides machine builders with new possibilities, a greater degree of freedom, and improved diagnostic information for IP67 system architectures. Both the construction of new systems as well as the conversion of existing machines can now be implemented with reduced cabling effort and use of materials. From design to construction to assembly and disassembly, the user benefits in many cases from a significantly simpler system.

Conventional architectures for connecting sensors and actuators to machine controls frequently involve several challenges: With a central configuration and complex systems that are spatially extended, the cabling required normally involves a great deal of material and effort; with decentralized configurations using remote I/Os in remote switch cabinets or IP67 I/O modules on the machine, the granularity of the terminals often does not match the number or type of peripheral devices present, so that investments have to be made in unnecessary hardware. In most cases, expansions are often difficult.

For this Eaton is offering here just one solution: With SmartWire-DT up to 99 modules can be connected directly with the controller on a string of up to around 600 m in length. The T-Connector with protection to IP67 enables all standard sensors and actuators on the market to be connected via the standard M12 plug connector to the SmartWire-DT network. This cable is used to feed power to the sensors as well as to exchange data with the controller at the same time. The user can thus check his installation simply and determine whether a sensor is connected at all to the M12 interface. The T-Connector also indicates its network status locally from any mounting position and whether the connected sensor is active or not.

The T-Connector enables machine builders to integrate sensors and actuators of any manufacturer into a SmartWire-DT network via M12 plug connectors with a granularity of one to 16.

Scan QR Code

The benefits of this architecture are particularly clear for applications involving only a few sensors, different types of sensors and actuators, or many components that are distributed far apart in the installation: Machine builders can route their cables flexibly, install the individual sensors or actuators at the desired positions, and simply and quickly add or change components to the network. They only have to invest in the periphery actually required for the functionality since the T-connectors offer a high level of granularity of one to 16. They also allow digital and analog inputs/outputs to be combined as required.

The integration of SmartWire-DT in automation concepts normally gives users the choice: they can either use any PLC via gateways (Profibus-DP, CANopen, Modbus-TCP, EthernetIP, Profinet, Powerlink), or they can use one of Eaton’s controllers with an integrated SmartWire-DT interface such as the innovative HMI/PLCs of the XV100 series. Through the use of simple and streamlined concepts, this enables the creation of lean solutions with fewer components in line with Eaton’s Lean Solution strategy.


NEWS +++ NEWS +++ NEWSCoMPANy

the development of energy-efficient products. If you consider the amount of energy consumed in our daily lives it is clear that there is a great need and scope to do more to increase efficiency.

What type of solutions does Eaton offer to address this challenge?

There are numerous examples from all our business sectors. Looking at our vehicle business, car manufacturers are increasing their efforts to reduce fuel consumption. One of the innovations we developed to address this need is an engine air boosting technology: Our superchargers are helping downsize engines by 30 %, improve fuel economy by as much as 10 to 15 % and contribute to reduced emissions. Another innovation is a technology based on cylinder deactivation. Not all cylinders in a car have to constantly be engaged; in some cases two of four cylinders would be sufficient to deliver the same power. This, again, helps to reduce consumption and emissions.

In aerospace, where we offer high-pressure hydraulic and digital fuel management systems that are particularly lightweight and reliable, we are able to reduce the weight of the fuel management systems, but we are also ensuring that the tank contents can be reliably determined to a single gram. After all, every gram of fuel counts.

In many applications electrical drives are replacing hydraulic systems. Can we expect further improvements from this?

The electrification of aircraft has been going on for around 20 years. The trend here is towards decentralized compact hydraulic systems. This means that instead of one central hydraulic system there are now many smaller ones. Thus, the length of hydraulic lines required can be reduced. In addition, the hydraulic systems are combined with electric drives. This enables individual modules to be placed precisely where they are required allowing for them to be simply integrated into the control structures. We have deployed such new systems in the Airbus A380 and the Boeing 777. In doing so, we managed to reduce the weight for the A380 by one metric ton. That means we helped them save 450 kg in fuel on a transatlantic flight, while 1 kg less fuel burned reduces CO2 emissions by 3.5 kg.

Where does Eaton focus within the electrical sector?

In the electrical sector and for the MOEM market lean automation continues to be a big customer value driver for efficiency. Our lean solution strategy is all about eliminating waste; it starts with connecting the various “assets” such as machines, electro-hydraulic valves, electrical circuit breakers, switches, sensors and relays using the minimal wiring and simplified communications architectures. We also implement diagnostics and prognostics algorithms that sense various operating parameters such as pressure, position, temperatures, current flows as well as voltage and frequency variations. A major benefit of the new technology is the data

transparency from the controller to the actuator and sensor. All data related to electricity and energy consumption is made available to the entire machine and to the individual actuators.

What does that mean for the integration of electrical and hydraulic systems?

We are moving away from ‘dumb’ mechanics which execute simple movements and are developing smart components. These contain electronics, sensors and control systems. This is one of the most important trends in hydraulic engineering today. Our lean solution system is already a combination of electrical solutions, electrohydraulics and mechanical devices such as pumps and cylinders.

We have brought all this together using our proprietary SmartWire-DT communications technology that radically simplifies the wiring architecture of machines. This integration enables us to offer an energy efficient solution. It allows customers to see exactly how much energy is consumed and what can be saved because all machine parts are communicating with each other. In addition, it brings with it many very useful diagnostic functions for the entire process chain that can be used to carry out preventative diagnostics, streamline processes and increase the availability of machinery.

How important is innovation to Eaton?

We believe that innovation is crucial to the growth of our customers, crucial for business, and crucial to the growth of nations. We see innovation as ’monetizing valuable novelties’. A novelty is something new to the world or to our customers that provides great value, where the benefits outweigh the costs. This and the ability of our organization to monetize in a timely manner make our customers successful – because our customers’ success is our success. We want to be at the forefront in developing innovative power management solutions that are safe, efficient, reliable and sustainable to meet our customers’ most demanding energy management challenges.

What kind of innovations can we expect in the years to come?

One of the key areas we are focusing on is connectivity and the development of solutions which use as little energy as possible. We want to make sure that our devices are extremely efficient and can be connected with minimum complexity. An important priority will be the algorithms, the acquisition of information. While anyone can collect data, the question however is what you do to generate information from this data and derive the correct course of action. This is the role of the diagnostics and prognostics algorithms we use to minimize energy consumption and maximize asset uptime across the entire system. This continues to be one of our major areas of research and development – now and into the future.

Another key area is improving the safety of the devices. A large part of our work involves very high electrical and hydraulic powers that are packaged in very compact envelopes or footprints, and the safety of humans and systems that these electrohydraulic solutions protect is paramount to everything we deliver. Simplicity when it comes to installation is also an important issue. We are convinced that simpler hardware and operation results in a more reliable system. Designing things to be simple is not easy at all. The simpler the device, the more work has gone into its development and design. This is also a key focus of our daily work.

Eaton Presents the T-Connector for SmartWire-DT: New Architectures and Increased Flexibility for the Machine Periphery

Power management company Eaton is expanding the possibilities for using SmartWire-DT outside the switch cabinet. The T-Connector now enables users to integrate sensors and actuators in the field directly into the innovative communication system. This therefore provides machine builders with new possibilities, a greater degree of freedom, and improved diagnostic information for IP67 system architectures. Both the construction of new systems as well as the conversion of existing machines can now be implemented with reduced cabling effort and use of materials. From design to construction to assembly and disassembly, the user benefits in many cases from a significantly simpler system.

Conventional architectures for connecting sensors and actuators to machine controls frequently involve several challenges: With a central configuration and complex systems that are spatially extended, the cabling required normally involves a great deal of material and effort; with decentralized configurations using remote I/Os in remote switch cabinets or IP67 I/O modules on the machine, the granularity of the terminals often does not match the number or type of peripheral devices present, so that investments have to be made in unnecessary hardware. In most cases, expansions are often difficult.

For this Eaton is offering here just one solution: With SmartWire-DT up to 99 modules can be connected directly with the controller on a string of up to around 600 m in length. The T-Connector with protection to IP67 enables all standard sensors and actuators on the market to be connected via the standard M12 plug connector to the SmartWire-DT network. This cable is used to feed power to the sensors as well as to exchange data with the controller at the same time. The user can thus check his installation simply and determine whether a sensor is connected at all to the M12 interface. The T-Connector also indicates its network status locally from any mounting position and whether the connected sensor is active or not.

The T-Connector enables machine builders to integrate sensors and actuators of any manufacturer into a SmartWire-DT network via M12 plug connectors with a granularity of one to 16.

Scan QR Code

The benefits of this architecture are particularly clear for applications involving only a few sensors, different types of sensors and actuators, or many components that are distributed far apart in the installation: Machine builders can route their cables flexibly, install the individual sensors or actuators at the desired positions, and simply and quickly add or change components to the network. They only have to invest in the periphery actually required for the functionality since the T-connectors offer a high level of granularity of one to 16. They also allow digital and analog inputs/outputs to be combined as required.

The integration of SmartWire-DT in automation concepts normally gives users the choice: they can either use any PLC via gateways (Profibus-DP, CANopen, Modbus-TCP, EthernetIP, Profinet, Powerlink), or they can use one of Eaton’s controllers with an integrated SmartWire-DT interface such as the innovative HMI/PLCs of the XV100 series. Through the use of simple and streamlined concepts, this enables the creation of lean solutions with fewer components in line with Eaton’s Lean Solution strategy.


NEWS +++ NEWS +++ NEWS NEWS +++ NEWS +++ NEWS

New Series: High Performance Sensors for Special Applications

with the E75/E76 luminescence sensor at a distance of 8 – 20 mm from the sensor face. This is also suitable for both light and dark light conditions. A user-friendly setup routine enables both the contrast and also the luminescence sensors to be commissioned and maintained easily. Users can adapt the devices ideally to their applications in only three steps and thus save valuable time during the installation or later system adaptions.

Eaton has added the E75/76 series of high performance photo-electric sensors to its product portfolio. This series provides sensors with field-adjustable background suppression and a considerably extended sensing range for the first time. The key to this is the IntelliView technology: It enables a number of new sensing techniques for color, contrast and luminescence sensing for particularly demanding applications requiring increased precision over large distances in challenging conditions. The high precision combined with the improved background suppression make the E75/76 sensor series into a flexible, high performance solution for a wide range of applications. Through the small number of sensing errors, the devices contribute even in the most difficult environments to increasing the safety and productivity of machines and plants.

In the E75/76 series, Eaton is presenting for the first time a photoelectric sensor with field-adjustable background suppression. This detects objects precisely at a distance of up to 190 cm and suppresses at the same time, for example the edges or bottoms of boxes and cartons. Besides the broad application range, the sensor stands out on account of its simple installation. This enables users to put the device easily into operation and adapt automatically to the individual requirements at the site of installation.

Eaton has also developed laser distance sensors with increased sensing depth, especially for the E75/E76 IntelliView series. These distance sensors output a signal from 0 – 10 V which changes within the operating range proportionally to the distance between the face of the sensor and the target. The integrated class II laser detects objects in a range between 0.3 and 4 m. In addition to analog outputs, the sensors are provided with two PNP outputs that can be programmed so that they switch at the set distances.

Eaton‘s series E75/E76 photoelectric sensors are divided into color, contrast and luminescence sensors. The color sensors feature a new “chromaticity plus intensity” algorithm. This provides increased sensitivity for color tone variations and improves the differentiation of grayscale tones. The “chromaticity plus intensity” mode is recommended for detecting different colors on the same type of material with a target sensing range of 5 – 45 mm from the face of the sensor. Three color tones can be programmed as standard. An 8-pin M12 micro connector also ensures analog signal transmission. A version with a serial terminal (RS 485) is also provided for remote communication. The contrast sensors, on the other hand, are ideal for detecting grayscales (e.g. positioning marks) or differently colored objects, as well as the detection of targets at a distance of up to 10 mm from the sensor face. Thanks to the complementary outputs, they can switch both in response to light or dark. The 4-pin M12 micro connector integrated as standard also simplifies integration in existing installations. Objects with reflecting surfaces or luminescent targets can be detected

The E75/E76 IntelliView sensor series is suitable for a number of applications in which increased precision is required over large distances in challenging conditions

Scan QR Code Scan QR Code

Analog Inductive Proximity Sensors with Unmatched Sensing

The robust stainless steel barrel with a shock-resistant front cap, a polycarbonate endbell, and the impact-absorbing potting compound ensure reliable sensor operation even in harsh production conditions. This makes the AccuProx devices resistant to extreme temperature or high pressure spray. They are therefore ideally suitable for applications involving extreme ambient temperatures and vibrations or in high pressure washdown environments. A high noise immunity of 20 V/m also prevents any problems caused by electrical interference. The sensors are available with different current (4 – 20 mA or 0 – 20 mA) and voltage outputs (0 – 10 V).

Eaton offers a wide range of sensors worldwide for maximum precision and virtually any application. Besides mechanical limit switches, the sensor manufacturer offers around 1,000 different types of inductive, photoelectric and capacitive sensors. The sensor solutions are used primarily in machine building, in packaging technology, the food and beverage industry and in material handling.

Eaton‘s E59 AccuProx high-performance analog inductive proximity sensors offer a particularly large sensing range.Thanks to the innovative iProx technology, the AccuProx sensors offer an extended linear sensing range up to 25 mm and thus a three to four times greater distance than typical tubular inductive analog sensors – without any loss in accuracy. The proximity sensors are therefore optimally suited for demanding applications requiring precise position sensing and measuring, such as in parts positioning or when excluding material faults or measurement variances in the output material. In this way, users can prevent production faults so that the considerably increased output accuracy in the application helps to increase productivity. Users benefit from sensors with above-average values in terms of sensing range, linearity and resolution in a compact tubular housing.

Unlike standard inductive sensors, in which a contact is closed or opened when a target is present or not, the AccuProx analog sensors supply an electrical signal that changes proportionally according to the position of the metal target in the sensing range. Thanks to the extended linear sensing range, the AccuProx sensors offer a high output resolution and repeatability in applications requiring a precise sensing performance. This includes parts positioning, the measuring of distance, size and thickness, the checking of faulty locations or materials, general inspection, as well as the detection of center to center variations, absolute angles and different metals. Two mounting options guarantee maximum flexibility for designing applications.

Thanks to the innovative iProx technology, AccuProx sensors offer an extended linear sensing range up to 25 mm


NEWS +++ NEWS +++ NEWS NEWS +++ NEWS +++ NEWS

New Series: High Performance Sensors for Special Applications

with the E75/E76 luminescence sensor at a distance of 8 – 20 mm from the sensor face. This is also suitable for both light and dark light conditions. A user-friendly setup routine enables both the contrast and also the luminescence sensors to be commissioned and maintained easily. Users can adapt the devices ideally to their applications in only three steps and thus save valuable time during the installation or later system adaptions.

Eaton has added the E75/76 series of high performance photo-electric sensors to its product portfolio. This series provides sensors with field-adjustable background suppression and a considerably extended sensing range for the first time. The key to this is the IntelliView technology: It enables a number of new sensing techniques for color, contrast and luminescence sensing for particularly demanding applications requiring increased precision over large distances in challenging conditions. The high precision combined with the improved background suppression make the E75/76 sensor series into a flexible, high performance solution for a wide range of applications. Through the small number of sensing errors, the devices contribute even in the most difficult environments to increasing the safety and productivity of machines and plants.

In the E75/76 series, Eaton is presenting for the first time a photoelectric sensor with field-adjustable background suppression. This detects objects precisely at a distance of up to 190 cm and suppresses at the same time, for example the edges or bottoms of boxes and cartons. Besides the broad application range, the sensor stands out on account of its simple installation. This enables users to put the device easily into operation and adapt automatically to the individual requirements at the site of installation.

Eaton has also developed laser distance sensors with increased sensing depth, especially for the E75/E76 IntelliView series. These distance sensors output a signal from 0 – 10 V which changes within the operating range proportionally to the distance between the face of the sensor and the target. The integrated class II laser detects objects in a range between 0.3 and 4 m. In addition to analog outputs, the sensors are provided with two PNP outputs that can be programmed so that they switch at the set distances.

Eaton‘s series E75/E76 photoelectric sensors are divided into color, contrast and luminescence sensors. The color sensors feature a new “chromaticity plus intensity” algorithm. This provides increased sensitivity for color tone variations and improves the differentiation of grayscale tones. The “chromaticity plus intensity” mode is recommended for detecting different colors on the same type of material with a target sensing range of 5 – 45 mm from the face of the sensor. Three color tones can be programmed as standard. An 8-pin M12 micro connector also ensures analog signal transmission. A version with a serial terminal (RS 485) is also provided for remote communication. The contrast sensors, on the other hand, are ideal for detecting grayscales (e.g. positioning marks) or differently colored objects, as well as the detection of targets at a distance of up to 10 mm from the sensor face. Thanks to the complementary outputs, they can switch both in response to light or dark. The 4-pin M12 micro connector integrated as standard also simplifies integration in existing installations. Objects with reflecting surfaces or luminescent targets can be detected

The E75/E76 IntelliView sensor series is suitable for a number of applications in which increased precision is required over large distances in challenging conditions

Scan QR Code Scan QR Code

Analog Inductive Proximity Sensors with Unmatched Sensing

The robust stainless steel barrel with a shock-resistant front cap, a polycarbonate endbell, and the impact-absorbing potting compound ensure reliable sensor operation even in harsh production conditions. This makes the AccuProx devices resistant to extreme temperature or high pressure spray. They are therefore ideally suitable for applications involving extreme ambient temperatures and vibrations or in high pressure washdown environments. A high noise immunity of 20 V/m also prevents any problems caused by electrical interference. The sensors are available with different current (4 – 20 mA or 0 – 20 mA) and voltage outputs (0 – 10 V).

Eaton offers a wide range of sensors worldwide for maximum precision and virtually any application. Besides mechanical limit switches, the sensor manufacturer offers around 1,000 different types of inductive, photoelectric and capacitive sensors. The sensor solutions are used primarily in machine building, in packaging technology, the food and beverage industry and in material handling.

Eaton‘s E59 AccuProx high-performance analog inductive proximity sensors offer a particularly large sensing range.Thanks to the innovative iProx technology, the AccuProx sensors offer an extended linear sensing range up to 25 mm and thus a three to four times greater distance than typical tubular inductive analog sensors – without any loss in accuracy. The proximity sensors are therefore optimally suited for demanding applications requiring precise position sensing and measuring, such as in parts positioning or when excluding material faults or measurement variances in the output material. In this way, users can prevent production faults so that the considerably increased output accuracy in the application helps to increase productivity. Users benefit from sensors with above-average values in terms of sensing range, linearity and resolution in a compact tubular housing.

Unlike standard inductive sensors, in which a contact is closed or opened when a target is present or not, the AccuProx analog sensors supply an electrical signal that changes proportionally according to the position of the metal target in the sensing range. Thanks to the extended linear sensing range, the AccuProx sensors offer a high output resolution and repeatability in applications requiring a precise sensing performance. This includes parts positioning, the measuring of distance, size and thickness, the checking of faulty locations or materials, general inspection, as well as the detection of center to center variations, absolute angles and different metals. Two mounting options guarantee maximum flexibility for designing applications.

Thanks to the innovative iProx technology, AccuProx sensors offer an extended linear sensing range up to 25 mm


NEWS +++ NEWS +++ NEWSNEWS +++ NEWS +++ NEWS

Scan QR Code

Eaton Launches Informative “How-to” Videos for xEnergy Switchboards

assemblies with long reliable working lives. The versatility of the system means that users can choose between fixed, removable or full withdrawable technologies to produce switchboards that optimally match the requirements of the application. Designed with safety in mind, the xEnergy system also provides the best possible protection for people and equipment.

The videos in the new xEnergy series cover: XP power sections, including incomers, outgoers and couplers; XF fixed assemblies, such as power outgoers with circuit breakers and fuse switch disconnectors; XR removable assemblies, which are plug-in modules that can be replaced under live-line working conditions; XW fully withdrawable assemblies, which offer easy maintenance without the need for special tools; and XG general sections to accommodate miscellaneous equipment such as control devices and power factor correction capacitors.

Panel builders who are interested in becoming an xEnergy partner are encouraged to contact Eaton and apply on www.xEnergy-partner.com. Once qualified, they get full access to Eaton’s support system and the portal with comprehensive technical details, certificates, news, software etc.

A series of informative videos are now available that show panel builders, in a clear and readily understandable way, how to work with and get the best from Eaton’s modular xEnergy low-voltage main distribution switchboard system. There are five videos in the series. Each deals with one of the main assembly types available in the xEnergy system – which include fixed, removable and fully withdrawable assemblies – and illustrates how the key components fit together.

The videos can be accessed online by visiting the Eaton Europe website www.eaton.eu and following the links to xEnergy main distribution systems. Alternatively, a CD version of the videos, from which a step-by-step assembly guide for xEnergy can be printed, is available to xEnergy partners and to companies with an interest in exploring the many technical and business benefits that an Eaton xEnergy partnership provides.

“Our modular xEnergy system is exceptionally versatile,” said Berhard Gegenbauer, Product Line Manager at Eaton. “And it offers panel builders a convenient and cost-effective way of producing attractive and reliable main distribution boards rated up to 5,000 A, which comply fully with IEC 60439-1 and IEC 61439-2. Our new instructional videos make the xEnergy system even simpler to work with, allowing new users in particular to save valuable time on building the assemblies. The videos are an effective addition to the comprehensive support that Eaton already provides for its panel builder partners.”

The xEnergy system from Eaton gives panel builders a convenient solution to the challenge of producing design-verified switchgear

More Safety for the Switch Cabinet – with the Eaton P Switch-Disconnector

padlocks. The K Line series thumb-grips and handles also make it possible to lock the door in the Off position as well as with two 6 mm padlocks or a cylinder lock. Eaton also offers an optional special tool for the user to unlock the door also in the On position, e.g. for faultfinding without isolating the power supply.

Eaton is now offering its proven P1 and P3 switch-disconnectors with IP65 protection also as variants with metal extension shafts for mounting in the switch cabinet. It is now possible for machine builders to ensure load disconnections in the 25 to 100 A range in switch cabinets with a depth of up 600 mm and thus provide optimum protection for personnel and equipment.

The portfolio includes different switch, handle, and shaft options so that the right system can be assembled flexibly depending on the requirement. As complete packages that are also available with prefabricated and switchable neutral conductor and auxiliary contacts, they help the user to save time and costs for the order and the installation.

The manual operating mechanism on the P switch-disconnectors works in direct connection with the contacts. The compact and robust devices are designed for use as a main switch with or without an emergency-stop function, as an on/off switch as well as a maintenance, repair or safety switch. They ensure here a high degree of reliability and have a long lifespan as well as outstandingly low power losses.

To install them in the installation, the user can simply fit the switches on the mounting rail or into a mounting plate. The extension shafts for connecting the door are available for switch cabinets with depths of 400 mm and 600 mm. Suitable thumb-grips and handles enable the switch to be locked in the On position as a standard feature and thus protect the door from unauthorized opening under live conditions. The lockable main switch handles can also be used to lock the cabinet with up to three 8 mm

Scan QR Code



Scan QR Code

Eaton Launches Informative “How-to” Videos for xEnergy Switchboards

assemblies with long reliable working lives. The versatility of the system means that users can choose between fixed, removable or full withdrawable technologies to produce switchboards that optimally match the requirements of the application. Designed with safety in mind, the xEnergy system also provides the best possible protection for people and equipment.

The videos in the new xEnergy series cover: XP power sections, including incomers, outgoers and couplers; XF fixed assemblies, such as power outgoers with circuit breakers and fuse switch disconnectors; XR removable assemblies, which are plug-in modules that can be replaced under live-line working conditions; XW fully withdrawable assemblies, which offer easy maintenance without the need for special tools; and XG general sections to accommodate miscellaneous equipment such as control devices and power factor correction capacitors.

Panel builders who are interested in becoming an xEnergy partner are encouraged to contact Eaton and apply on www.xEnergy-partner.com. Once qualified, they get full access to Eaton’s support system and the portal with comprehensive technical details, certificates, news, software etc.

A series of informative videos are now available that show panel builders, in a clear and readily understandable way, how to work with and get the best from Eaton’s modular xEnergy low-voltage main distribution switchboard system. There are five videos in the series. Each deals with one of the main assembly types available in the xEnergy system – which include fixed, removable and fully withdrawable assemblies – and illustrates how the key components fit together.

The videos can be accessed online by visiting the Eaton Europe website www.eaton.eu and following the links to xEnergy main distribution systems. Alternatively, a CD version of the videos, from which a step-by-step assembly guide for xEnergy can be printed, is available to xEnergy partners and to companies with an interest in exploring the many technical and business benefits that an Eaton xEnergy partnership provides.

“Our modular xEnergy system is exceptionally versatile,” said Berhard Gegenbauer, Product Line Manager at Eaton. “And it offers panel builders a convenient and cost-effective way of producing attractive and reliable main distribution boards rated up to 5,000 A, which comply fully with IEC 60439-1 and IEC 61439-2. Our new instructional videos make the xEnergy system even simpler to work with, allowing new users in particular to save valuable time on building the assemblies. The videos are an effective addition to the comprehensive support that Eaton already provides for its panel builder partners.”

The xEnergy system from Eaton gives panel builders a convenient solution to the challenge of producing design-verified switchgear

More Safety for the Switch Cabinet – with the Eaton P Switch-Disconnector

padlocks. The K Line series thumb-grips and handles also make it possible to lock the door in the Off position as well as with two 6 mm padlocks or a cylinder lock. Eaton also offers an optional special tool for the user to unlock the door also in the On position, e.g. for faultfinding without isolating the power supply.

Eaton is now offering its proven P1 and P3 switch-disconnectors with IP65 protection also as variants with metal extension shafts for mounting in the switch cabinet. It is now possible for machine builders to ensure load disconnections in the 25 to 100 A range in switch cabinets with a depth of up 600 mm and thus provide optimum protection for personnel and equipment.

The portfolio includes different switch, handle, and shaft options so that the right system can be assembled flexibly depending on the requirement. As complete packages that are also available with prefabricated and switchable neutral conductor and auxiliary contacts, they help the user to save time and costs for the order and the installation.

The manual operating mechanism on the P switch-disconnectors works in direct connection with the contacts. The compact and robust devices are designed for use as a main switch with or without an emergency-stop function, as an on/off switch as well as a maintenance, repair or safety switch. They ensure here a high degree of reliability and have a long lifespan as well as outstandingly low power losses.

To install them in the installation, the user can simply fit the switches on the mounting rail or into a mounting plate. The extension shafts for connecting the door are available for switch cabinets with depths of 400 mm and 600 mm. Suitable thumb-grips and handles enable the switch to be locked in the On position as a standard feature and thus protect the door from unauthorized opening under live conditions. The lockable main switch handles can also be used to lock the cabinet with up to three 8 mm

Scan QR Code



Scan QR Code

the degree of protection to NEC/CEC (UL/CSA Type 12, 4X etc.) or the stating of the electrical specifications (in HP, Pilot Duties, AWG etc.) must also be taken into account. The market also distinguishes between “feeder circuits” – switchgear that is used in the power distribution system – and “branch circuits” for which test requirements with different degrees of severity apply.

Eaton supports machine and panel builders with the following services to avoid any possible traps in the exporting of electrical equipment to North America and any problems with the approval of equipment by the local inspector (AHJ) at the end customer: personal consulting services for engineering, special seminars (in training centers and partly in-house at the customer) as well as practical help in acquiring UL certification by the independent test laboratory I2 PS in Bonn (Institute for International Product Safety GmbH). The practically oriented one-day North America seminars entitled “Industrial Control Panels in accordance with UL508A and NFPA79“ are designed for anyone involved in the export of electrical systems to North America. Here North America expert Dirk Meyer, manager of industrial control division applications at Eaton, explains to course participants the differences to the IEC standards and uses practical examples to provide knowledge for the successful export of electrical equipment to North America.

This year three seminars will take place in the company‘s own training center in Bonn and one in Hamburg, Achern and Munich. The current seminar dates for 2014 can be obtained from the current Eaton training program at: www.eaton.de/training, Industrial Control Panels to UL508A and NFPA79. Experts explain what you need to follow in order to be successful in exporting electrical systems to North America, using a sample switch cabinet at the Eaton stand at the Hannover Messe 2014, Hall 11, stand C63/69 as well as at this year‘s SPS IPC Drives fair.

Eaton also offers several technical articles on the subject of North America. These can be found at: www.eaton.eu/veroeffentlichungen

Companies wishing to export machines or switch cabinets to the North American market have to answer a large number of questions. As a manufacturer of low -voltage switchgear with decades of experience in exporting worldwide, and a strong presence in the USA, Eaton is a genuine expert in the exporting of goods to North America. This in-depth knowledge is offered by the company in the form of regular training seminars organized at the customer‘s premises. Thanks to an independent test laboratory at the Eaton site in Bonn, which is an approved UL test center, the company can not only advise machine and panel builders but also support them with the certification of products or entire switch panel systems for the North American market. With advice and support in engineering, Eaton helps exporters to North America to save time and avoid any financial risks.

The number of approvals and certificates that exist worldwide is large. The special aspect of the North American market is the fact that it is also necessary to observe and apply special codes and standards, as well as market practices, which are considerably different to the IEC standards. Electrical components are tested and approved in the USA and Canada in several stages: First all products must comply with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC) which both have a legal character. In the second stage, the products are tested by approved test bodies (NRTL= Nationally Recognized Testing Laboratories) like the UL (Underwriters Laboratories) or CSA (Canadian Standards Association), which must be certified with the appropriate markings. Only components with an approval from an NRTL can be used in North America. Recognized inspectors (AHJ, Authorities Having Jurisdiction) then approve the systems. This means the following: Unlike in IEC countries, where the manufacturers themselves are responsible for the release of industrial switchgear for sale (documented by the CE mark), the approval of devices and systems by an independent body (third party) is obligatory in North America. A common testing and a description in a general report are also required for device combinations.

Besides requiring a good knowledge of the relevant codes and standards, exporters must also follow specific market practices. This includes for example UL/CSA approved components that must have somewhat larger creepage and clearance distances or must be suitable for specific AWG cable cross sections. Furthermore, differences in documentation and markings such as the stating of

Eaton Supports Machine Builders with Exports to North America

No Limits to Exporting Switch Cabinets

The planning of machinery for export to the North American market is a real challenge. Questions like “Why is there only limited use of internationally tried and tested motor-protective circuit-breakers? What are feeders or branch circuits? Which devices are suitable as branch circuit protective devices?” were some that also faced AZO Controls GmbH. The company based in Osterburken specializes in automation solutions and turned to Eaton for help.

An expert knowledge of the relevant codes and standards cannot be acquired easily. Apart from the time required, a knowledge of special practices can only gained from experience. Eaton‘s Electrical Sector has the expertise required for all aspects of exporting to North America.

Master industrial technician Marco Zimmermann at AZO explains: “Due to our expertise in panel building in Europe, it became time to do the same in the North American market. We then contacted our partner Eaton. Our first switchboard was accepted by UL Germany in as little as half a year. Thanks to the specialists at Eaton, we were able to successfully complete this and many other projects.”

The Art of Packaging Without Frontiers

The requirements placed on filling machines are constantly changing. The market requires fast and flexible systems. The downstream final packaging machines must meet the same requirements in order to be accepted in the North American market. That is why the meurer group based in Fürstenau relies on the know-how of Eaton.

Meurer has been producing final packaging systems for more than 40 years. The export share is high, of which a significant percentage goes to North America. Besides requiring the use of components with UL/CSA approval such as Eaton‘s circuit-breakers, miniature circuit-breakers and motor-protective circuit-breakers or contactors, the global sale of machines also requires a UL/CSA approved switchboard design with UL/CSA Type 4x protection.

In order to ensure that its machines can be exported, meurer uses the services of Eaton as a competent and reliable partner. “We aim to inspire our customers with tailor-made solutions,” explains Guido Gewo, team leader of electrical engineering at meurer. “This applies to all customers worldwide. When exporting to North America, we have relied for several years on the expertise of Eaton.”



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the degree of protection to NEC/CEC (UL/CSA Type 12, 4X etc.) or the stating of the electrical specifications (in HP, Pilot Duties, AWG etc.) must also be taken into account. The market also distinguishes between “feeder circuits” – switchgear that is used in the power distribution system – and “branch circuits” for which test requirements with different degrees of severity apply.

Eaton supports machine and panel builders with the following services to avoid any possible traps in the exporting of electrical equipment to North America and any problems with the approval of equipment by the local inspector (AHJ) at the end customer: personal consulting services for engineering, special seminars (in training centers and partly in-house at the customer) as well as practical help in acquiring UL certification by the independent test laboratory I2 PS in Bonn (Institute for International Product Safety GmbH). The practically oriented one-day North America seminars entitled “Industrial Control Panels in accordance with UL508A and NFPA79“ are designed for anyone involved in the export of electrical systems to North America. Here North America expert Dirk Meyer, manager of industrial control division applications at Eaton, explains to course participants the differences to the IEC standards and uses practical examples to provide knowledge for the successful export of electrical equipment to North America.

This year three seminars will take place in the company‘s own training center in Bonn and one in Hamburg, Achern and Munich. The current seminar dates for 2014 can be obtained from the current Eaton training program at: www.eaton.de/training, Industrial Control Panels to UL508A and NFPA79. Experts explain what you need to follow in order to be successful in exporting electrical systems to North America, using a sample switch cabinet at the Eaton stand at the Hannover Messe 2014, Hall 11, stand C63/69 as well as at this year‘s SPS IPC Drives fair.

Eaton also offers several technical articles on the subject of North America. These can be found at: www.eaton.eu/veroeffentlichungen

Companies wishing to export machines or switch cabinets to the North American market have to answer a large number of questions. As a manufacturer of low -voltage switchgear with decades of experience in exporting worldwide, and a strong presence in the USA, Eaton is a genuine expert in the exporting of goods to North America. This in-depth knowledge is offered by the company in the form of regular training seminars organized at the customer‘s premises. Thanks to an independent test laboratory at the Eaton site in Bonn, which is an approved UL test center, the company can not only advise machine and panel builders but also support them with the certification of products or entire switch panel systems for the North American market. With advice and support in engineering, Eaton helps exporters to North America to save time and avoid any financial risks.

The number of approvals and certificates that exist worldwide is large. The special aspect of the North American market is the fact that it is also necessary to observe and apply special codes and standards, as well as market practices, which are considerably different to the IEC standards. Electrical components are tested and approved in the USA and Canada in several stages: First all products must comply with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC) which both have a legal character. In the second stage, the products are tested by approved test bodies (NRTL= Nationally Recognized Testing Laboratories) like the UL (Underwriters Laboratories) or CSA (Canadian Standards Association), which must be certified with the appropriate markings. Only components with an approval from an NRTL can be used in North America. Recognized inspectors (AHJ, Authorities Having Jurisdiction) then approve the systems. This means the following: Unlike in IEC countries, where the manufacturers themselves are responsible for the release of industrial switchgear for sale (documented by the CE mark), the approval of devices and systems by an independent body (third party) is obligatory in North America. A common testing and a description in a general report are also required for device combinations.

Besides requiring a good knowledge of the relevant codes and standards, exporters must also follow specific market practices. This includes for example UL/CSA approved components that must have somewhat larger creepage and clearance distances or must be suitable for specific AWG cable cross sections. Furthermore, differences in documentation and markings such as the stating of

Eaton Supports Machine Builders with Exports to North America

No Limits to Exporting Switch Cabinets

The planning of machinery for export to the North American market is a real challenge. Questions like “Why is there only limited use of internationally tried and tested motor-protective circuit-breakers? What are feeders or branch circuits? Which devices are suitable as branch circuit protective devices?” were some that also faced AZO Controls GmbH. The company based in Osterburken specializes in automation solutions and turned to Eaton for help.

An expert knowledge of the relevant codes and standards cannot be acquired easily. Apart from the time required, a knowledge of special practices can only gained from experience. Eaton‘s Electrical Sector has the expertise required for all aspects of exporting to North America.

Master industrial technician Marco Zimmermann at AZO explains: “Due to our expertise in panel building in Europe, it became time to do the same in the North American market. We then contacted our partner Eaton. Our first switchboard was accepted by UL Germany in as little as half a year. Thanks to the specialists at Eaton, we were able to successfully complete this and many other projects.”

The Art of Packaging Without Frontiers

The requirements placed on filling machines are constantly changing. The market requires fast and flexible systems. The downstream final packaging machines must meet the same requirements in order to be accepted in the North American market. That is why the meurer group based in Fürstenau relies on the know-how of Eaton.

Meurer has been producing final packaging systems for more than 40 years. The export share is high, of which a significant percentage goes to North America. Besides requiring the use of components with UL/CSA approval such as Eaton‘s circuit-breakers, miniature circuit-breakers and motor-protective circuit-breakers or contactors, the global sale of machines also requires a UL/CSA approved switchboard design with UL/CSA Type 4x protection.

In order to ensure that its machines can be exported, meurer uses the services of Eaton as a competent and reliable partner. “We aim to inspire our customers with tailor-made solutions,” explains Guido Gewo, team leader of electrical engineering at meurer. “This applies to all customers worldwide. When exporting to North America, we have relied for several years on the expertise of Eaton.”


INFoCUSToMER SUCCESS SToRy

Products: SmartWire-DT, HMI/PLCs, PKE motor-protective circuit-breakers

Eaton Insight: Success Story – mts Perforator GmbH tunneling machine www.eaton.eu/Europe/mediathek

Company: www.mts-p.com

More information: www.eaton.eu

Contact: Jan Carls [email protected]

Scan QR Code

CoNCLUSIoN

As an innovative technology, SmartWire-DT is a trailblazer for Eaton in the development of the networked world of Industry 4.0. The company is thus pursuing the strategy of applying SmartWire-DT continually to all standard components and converting it to smart devices.

More data transparency for tunneling machine thanks to SmartWire-DT and smart devices

The Power of One: A complete system is being developed jointly by Eaton Hydraulics and Eaton Electrical, enabling both hydraulic and electrical components to be connected to SmartWire-DT and monitored centrally

mts had already experienced the benefits of Lean Connectivity with SmartWire-DT in several projects. Besides the inherent manipulation protection in the system, both the project engineering and the wiring effort for the control panels and the required costs could be considerably reduced.

With SmartWire-DT the data cable and the power supply are combined, thus enabling the standard communication of all modules with each other. Each function element in the system has its own address as well as the facility for self-diagnostics.

Inherently secure

The control panels of the mts machines use RMQ control circuit devices which are all networked as SmartWire-DT slaves via the green eight-pole ribbon cable. For mts it is important that any manipulation or impermissible operation by the drill operator is prevented. This is made possible with SmartWire-DT as the system does not allow any contacts to be bridged. Another key criteria for the machine builder was the fact that Eaton also provides worldwide service and support as well as a 24-hour delivery service for spare parts.

On account of its good initial experience, mts decided to work more intensively with SmartWire-DT and Eaton‘s Lean Solution philosophy. This is based on the consistent application of lean management methods to engineering and automation processes. The aim here is to reduce all forms of waste. This focuses the optimization of costs, materials and time. For this Eaton developed a solution consisting of products, technologies and processes with

which savings can be implemented along the entire value chain. Lean Solution combines three areas for which SmartWire-DT is the connecting element: Lean Connectivity, Lean Automation and Lean Power.

Detailed drive monitoring included

Lean Automation means fewer components and less engineering. The I/O level is integrated in the switchgear such as motor protective switches, soft starters, variable frequency drives or circuit-breakers, which now communicate directly with Eaton‘s HMI/PLC devices. These can handle all control, visualization and data management tasks as a single unit, so that lean automation solutions can be implemented which at the same time can be designed faster and easier. These Lean Automation systems eliminate the need for entire device layers such as the I/O modules of a central PLC, and consequently also the required acquisition and maintenance costs.

The next step towards Lean Automation was taken recently by mts with the integration via SmartWire-DT of the PKE motor-protective circuit-breakers with electronic overload protection and also the NZM circuit-breakers in the switch cabinets of the tunneling machines. The combination of PKE and SmartWire-DT now brings the benefit of implementing enhanced drive monitoring: Process relevant data such as the actual motor current, thermal load and operating states can be monitored continuously and analyzed without any costly analog I/O technology.

Expansion of Lean Solutions with smart devices

In this way, Eaton has managed to convert switchgear into intelligent components. Smart devices such as PKE, which are able to communicate with any PLC in an open architecture, are an important step for the company in order to offer complete Industry 4.0-capable solutions.

“Eaton‘s smart devices enable us to implement detailed data access worldwide down to the field level,” explains Norbert Simdon, working in electronic support at mts. “We are thus able to monitor the current states of the 50 tunneling machines presently in operation worldwide, i.e. with condition monitoring. We can thus carry out remote diagnostics quickly in the event of a fault, provide a remedy and therefore ensure improved system availability for end customers.

In the past the local machine operator could manually change tripping characteristics and therefore run a motor continuously at too high a load. However, as the SmartWire-DT concept stores all setpoints centrally in the controller, the machine is automatically shut down if the tripping values of the motor-protective circuit-breaker are manipulated, thus preventing any risks to the user and the machine.

Tunneling Towards Industry 4.0

The worldwide demand for innovative tunneling technologies is large, both for traffic systems and also in supply and drainage technology. The Valluhn-based company mts Perforator GmbH (mts) is part of the Schmidt-Kranz Group. The company develops and manufactures tailored solutions for trenchless tunneling, with a portfolio of technologies including auger systems, slurry systems and EPB systems.

Several pushbutton actuators and indicator lights which have to be connected with the controller are used for the operation of the tunneling machines via the assigned control panels. In its search for an economical solution that also met the demanding requirements of the tunneling experts with regard to reliability and manipulation security, the company came upon the SmartWire-DT communication system from Eaton. SmartWire-DT is an innovative connection and communication system which eliminates the need for any complex and error-prone point-to-point control wiring of components such as switching devices, sensors and actuators with the central controller.

Infrastructure projects are in progress all around the world. The earth to be excavated can vary greatly depending on the location, and so too the requirements placed on the tunneling machines involved. These have to be tailored for each customer and according to the soil characteristics at hand. However, regardless of whether drilling in sand, clay or rock the reliability of the machine has the highest priority. This is where tunneling experts at mts Perforator use Eaton technology to ensure greater safety and data transparency.

The tunneling machines of mts Perforator are used worldwide. Besides a drill head up to 3 m in diameter, each plant consists of a control panel, hydraulic power unit and different accessories.



Products: SmartWire-DT, HMI/PLCs, PKE motor-protective circuit-breakers

Eaton Insight: Success Story – mts Perforator GmbH tunneling machine www.eaton.eu/Europe/mediathek

Company: www.mts-p.com


Contact: Jan Carls [email protected]

Scan QR Code

CoNCLUSIoN

As an innovative technology, SmartWire-DT is a trailblazer for Eaton in the development of the networked world of Industry 4.0. The company is thus pursuing the strategy of applying SmartWire-DT continually to all standard components and converting it to smart devices.

More data transparency for tunneling machine thanks to SmartWire-DT and smart devices

The Power of One: A complete system is being developed jointly by Eaton Hydraulics and Eaton Electrical, enabling both hydraulic and electrical components to be connected to SmartWire-DT and monitored centrally

mts had already experienced the benefits of Lean Connectivity with SmartWire-DT in several projects. Besides the inherent manipulation protection in the system, both the project engineering and the wiring effort for the control panels and the required costs could be considerably reduced.

With SmartWire-DT the data cable and the power supply are combined, thus enabling the standard communication of all modules with each other. Each function element in the system has its own address as well as the facility for self-diagnostics.

Inherently secure

The control panels of the mts machines use RMQ control circuit devices which are all networked as SmartWire-DT slaves via the green eight-pole ribbon cable. For mts it is important that any manipulation or impermissible operation by the drill operator is prevented. This is made possible with SmartWire-DT as the system does not allow any contacts to be bridged. Another key criteria for the machine builder was the fact that Eaton also provides worldwide service and support as well as a 24-hour delivery service for spare parts.

On account of its good initial experience, mts decided to work more intensively with SmartWire-DT and Eaton‘s Lean Solution philosophy. This is based on the consistent application of lean management methods to engineering and automation processes. The aim here is to reduce all forms of waste. This focuses the optimization of costs, materials and time. For this Eaton developed a solution consisting of products, technologies and processes with

which savings can be implemented along the entire value chain. Lean Solution combines three areas for which SmartWire-DT is the connecting element: Lean Connectivity, Lean Automation and Lean Power.

Detailed drive monitoring included

Lean Automation means fewer components and less engineering. The I/O level is integrated in the switchgear such as motor protective switches, soft starters, variable frequency drives or circuit-breakers, which now communicate directly with Eaton‘s HMI/PLC devices. These can handle all control, visualization and data management tasks as a single unit, so that lean automation solutions can be implemented which at the same time can be designed faster and easier. These Lean Automation systems eliminate the need for entire device layers such as the I/O modules of a central PLC, and consequently also the required acquisition and maintenance costs.

The next step towards Lean Automation was taken recently by mts with the integration via SmartWire-DT of the PKE motor-protective circuit-breakers with electronic overload protection and also the NZM circuit-breakers in the switch cabinets of the tunneling machines. The combination of PKE and SmartWire-DT now brings the benefit of implementing enhanced drive monitoring: Process relevant data such as the actual motor current, thermal load and operating states can be monitored continuously and analyzed without any costly analog I/O technology.

Expansion of Lean Solutions with smart devices

In this way, Eaton has managed to convert switchgear into intelligent components. Smart devices such as PKE, which are able to communicate with any PLC in an open architecture, are an important step for the company in order to offer complete Industry 4.0-capable solutions.

“Eaton‘s smart devices enable us to implement detailed data access worldwide down to the field level,” explains Norbert Simdon, working in electronic support at mts. “We are thus able to monitor the current states of the 50 tunneling machines presently in operation worldwide, i.e. with condition monitoring. We can thus carry out remote diagnostics quickly in the event of a fault, provide a remedy and therefore ensure improved system availability for end customers.

In the past the local machine operator could manually change tripping characteristics and therefore run a motor continuously at too high a load. However, as the SmartWire-DT concept stores all setpoints centrally in the controller, the machine is automatically shut down if the tripping values of the motor-protective circuit-breaker are manipulated, thus preventing any risks to the user and the machine.

Tunneling Towards Industry 4.0

The worldwide demand for innovative tunneling technologies is large, both for traffic systems and also in supply and drainage technology. The Valluhn-based company mts Perforator GmbH (mts) is part of the Schmidt-Kranz Group. The company develops and manufactures tailored solutions for trenchless tunneling, with a portfolio of technologies including auger systems, slurry systems and EPB systems.

Several pushbutton actuators and indicator lights which have to be connected with the controller are used for the operation of the tunneling machines via the assigned control panels. In its search for an economical solution that also met the demanding requirements of the tunneling experts with regard to reliability and manipulation security, the company came upon the SmartWire-DT communication system from Eaton. SmartWire-DT is an innovative connection and communication system which eliminates the need for any complex and error-prone point-to-point control wiring of components such as switching devices, sensors and actuators with the central controller.

Infrastructure projects are in progress all around the world. The earth to be excavated can vary greatly depending on the location, and so too the requirements placed on the tunneling machines involved. These have to be tailored for each customer and according to the soil characteristics at hand. However, regardless of whether drilling in sand, clay or rock the reliability of the machine has the highest priority. This is where tunneling experts at mts Perforator use Eaton technology to ensure greater safety and data transparency.

The tunneling machines of mts Perforator are used worldwide. Besides a drill head up to 3 m in diameter, each plant consists of a control panel, hydraulic power unit and different accessories.



Products: SmartWire-DT, XP700 industrial PC, XV-152 HMI/PLC, Galileo visualization software, RMQ Titan control circuit devices

Company: www.cdmengineering.it


Contact: Massimo Bonzini [email protected]

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CDM Engineering/OMP Prealpina S.r.l. has chosen the innovative Eaton SmartWire-DT technology and the XP700 industrial PC for its new ES135C co-rotating twin screw extruder. Using a sophisticated co-rotating twin screw system, the ES135C optimizes processed material homogeneity. This increases product quality while at the same time guaranteeing sizeable energy savings.

CDM Engineering/OMP Prealpina is an Italian industrial enterprise that has been operating in the plastics recycling sector for 40 years and is dedicated to technological innovation and an efficient after-sales service. A national and international leader in the manufacture of extruders, CDM has always been committed to maintaining high standards of production quality and customer service. That is precisely why the company attaches great importance to the choice of components for its systems and has been equipping its extruders with Eaton devices for 20 years.

The company recently presented the new ES135C co-rotating twin screw extruder at the international K2013 fair in Dusseldorf. This system is capable of recycling more than 2500 kg of plastic an

hour and is used to extrude co-generating products such as PE, PS, PP, ABS, PA, PC and BAYBLEND with a hot cutting system. The granules obtained are then used to make other plastic products.

More diagnostics and less maintenance on the ES135C extruder

Because of its considerable size and power, the ES135C requires an electronic device capable of effectively supporting it. The extruder is equipped with more than twenty motors, partly used for system ventilation and partly to control the material loading line, and is therefore exposed to problems such as current overloads and short-circuits.

To prevent and solve these critical issues, CDM has consistently chosen Eaton products and solutions, using the PKZ0 motor-protective circuit-breakers connected to an XV-152 touch display PLC via SmartWire-DT. Thanks to the innovative Eaton Codesys software, the XV-152 touch display PLC shows detailed data on the current consumption status of each motor in real-time. For example, in the extruder heating area, the PKZ0 circuit-breakers signal any current overloads, in the cooling area whether a fan motor is malfunctioning. The user can thus intervene and prevent or correct faults simply by changing the settings and parameters via the touch screen. “The Eaton technology allows our customers

Recycle More, Save Moreto use the ES135C extruder with extremely low maintenance costs,” says Antonio Caprioli, technical manager at CDM, adding that “the PLC allows users of our extruders to prevent most errors, thus avoiding system faults and the related repair costs.”

In order to make ES135C even more efficient and prevent needless production stops, CDM has moreover decided to add a set of Eaton M22 pushbuttons to support the PLC, these too connected to SmartWire-DT. This means that in the event of failure of the touch display PLC screen, these pushbuttons can be used to manually control the machine without having to stop production. In addition, CDM has adopted an Eaton NZM circuit-breaker to protect the entire electric system of the extruder against short-circuits. This device supplies 1250 A current to the electric cabinet and in the event of a short-circuit protects the extruder by immediately cutting off the current flow.

Speed and remote diagnostics for further savings

The ES135C extruder not only features state-of-the-art electronic equipment but also runs software able to ensure a high execution speed. While for the earlier smaller models it would have been sufficient to install an Eaton touch display PLC equipped with Galileo software, this would not suffice for the ES135C extruder, as it would produce such a quantity of data, maps and drawings that the system would be slowed down. For this reason, CDM has chosen to install the Galileo software on an Eaton XP700 industrial PC. This solution makes it possible to view detailed data on the overall system status, eliminating any refreshes and production slow-downs. The Eaton XP700 industrial PC is moreover connected via a CANopen output to an XV 152 PLC

CoNCLUSIoN

“Eaton offers quality product which are, technologically advanced and easy to use,” says Caprioli, whose company has been an Eaton customer for over twenty years. “Having given us the possibility of providing remote assistance to our customers, Eaton has allowed us a 35 % to 40 % saving on management and maintenance costs.” Moreover, thanks to the Eaton technology, CDM has not only achieved remarkable management and maintenance results, but has also saved on extruder installation costs. “Because of SmartWire-DT, the electric cabinet of the ES135C has a lot less wiring than the earlier extruder models,” explains Caprioli, “so that we have saved 15 % to 20 % on wiring design, hardware installation and testing costs.”

CDM relies on Eaton to make its extruders more powerful while at the same time achieving savings

equipped with Codesys software, which allows the user to interface with the machine’s SmartWire-DT system.

Another major problem CDM was able to solve by the combined use of the Eaton XP700 industrial PC and the SmartWire-DT communication system is remote diagnostics. In the past, if one of the motors short-circuited, CDM sent out its technicians to assist its international clientele. This, of course, translated into higher costs for the customers. “Having the possibility of providing free remote assistance to our customers has become an absolute priority for our company, and Eaton is one of the few that provide this type of service,” Caprioli explains.

Via a VPN (virtual private network) connection, the XP700 industrial PC now allows the CDM technicians to view the data produced by the extruder and diagnose most problems from remote stations, providing free service to the clientele. “We can now even know if a bulb has blown without having to send our technicians to the site,” says Caprioli, adding, “for example, our technicians can remotely restart a motor, or if a circuit-breaker is faulty, explain to the customer what to replace and how to replace it.” The result is amazing: a considerable saving in time and costs for the user and for CDM.

The electric cabinet of the ES135C extruder includes PKZ0 motor-protective circuit-breakers connected to the XP700 industrial PC via SmartWire-DT cable

The XP700 industrial PC touch screen makes it possible to view the status of each component of the extruder, modify parameters and thus prevent faults



Products: SmartWire-DT, XP700 industrial PC, XV-152 HMI/PLC, Galileo visualization software, RMQ Titan control circuit devices

Company: www.cdmengineering.it


Contact: Massimo Bonzini [email protected]

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CDM Engineering/OMP Prealpina S.r.l. has chosen the innovative Eaton SmartWire-DT technology and the XP700 industrial PC for its new ES135C co-rotating twin screw extruder. Using a sophisticated co-rotating twin screw system, the ES135C optimizes processed material homogeneity. This increases product quality while at the same time guaranteeing sizeable energy savings.

CDM Engineering/OMP Prealpina is an Italian industrial enterprise that has been operating in the plastics recycling sector for 40 years and is dedicated to technological innovation and an efficient after-sales service. A national and international leader in the manufacture of extruders, CDM has always been committed to maintaining high standards of production quality and customer service. That is precisely why the company attaches great importance to the choice of components for its systems and has been equipping its extruders with Eaton devices for 20 years.

The company recently presented the new ES135C co-rotating twin screw extruder at the international K2013 fair in Dusseldorf. This system is capable of recycling more than 2500 kg of plastic an

hour and is used to extrude co-generating products such as PE, PS, PP, ABS, PA, PC and BAYBLEND with a hot cutting system. The granules obtained are then used to make other plastic products.

More diagnostics and less maintenance on the ES135C extruder

Because of its considerable size and power, the ES135C requires an electronic device capable of effectively supporting it. The extruder is equipped with more than twenty motors, partly used for system ventilation and partly to control the material loading line, and is therefore exposed to problems such as current overloads and short-circuits.

To prevent and solve these critical issues, CDM has consistently chosen Eaton products and solutions, using the PKZ0 motor-protective circuit-breakers connected to an XV-152 touch display PLC via SmartWire-DT. Thanks to the innovative Eaton Codesys software, the XV-152 touch display PLC shows detailed data on the current consumption status of each motor in real-time. For example, in the extruder heating area, the PKZ0 circuit-breakers signal any current overloads, in the cooling area whether a fan motor is malfunctioning. The user can thus intervene and prevent or correct faults simply by changing the settings and parameters via the touch screen. “The Eaton technology allows our customers

Recycle More, Save Moreto use the ES135C extruder with extremely low maintenance costs,” says Antonio Caprioli, technical manager at CDM, adding that “the PLC allows users of our extruders to prevent most errors, thus avoiding system faults and the related repair costs.”

In order to make ES135C even more efficient and prevent needless production stops, CDM has moreover decided to add a set of Eaton M22 pushbuttons to support the PLC, these too connected to SmartWire-DT. This means that in the event of failure of the touch display PLC screen, these pushbuttons can be used to manually control the machine without having to stop production. In addition, CDM has adopted an Eaton NZM circuit-breaker to protect the entire electric system of the extruder against short-circuits. This device supplies 1250 A current to the electric cabinet and in the event of a short-circuit protects the extruder by immediately cutting off the current flow.

Speed and remote diagnostics for further savings

The ES135C extruder not only features state-of-the-art electronic equipment but also runs software able to ensure a high execution speed. While for the earlier smaller models it would have been sufficient to install an Eaton touch display PLC equipped with Galileo software, this would not suffice for the ES135C extruder, as it would produce such a quantity of data, maps and drawings that the system would be slowed down. For this reason, CDM has chosen to install the Galileo software on an Eaton XP700 industrial PC. This solution makes it possible to view detailed data on the overall system status, eliminating any refreshes and production slow-downs. The Eaton XP700 industrial PC is moreover connected via a CANopen output to an XV 152 PLC

CoNCLUSIoN

“Eaton offers quality product which are, technologically advanced and easy to use,” says Caprioli, whose company has been an Eaton customer for over twenty years. “Having given us the possibility of providing remote assistance to our customers, Eaton has allowed us a 35 % to 40 % saving on management and maintenance costs.” Moreover, thanks to the Eaton technology, CDM has not only achieved remarkable management and maintenance results, but has also saved on extruder installation costs. “Because of SmartWire-DT, the electric cabinet of the ES135C has a lot less wiring than the earlier extruder models,” explains Caprioli, “so that we have saved 15 % to 20 % on wiring design, hardware installation and testing costs.”

CDM relies on Eaton to make its extruders more powerful while at the same time achieving savings

equipped with Codesys software, which allows the user to interface with the machine’s SmartWire-DT system.

Another major problem CDM was able to solve by the combined use of the Eaton XP700 industrial PC and the SmartWire-DT communication system is remote diagnostics. In the past, if one of the motors short-circuited, CDM sent out its technicians to assist its international clientele. This, of course, translated into higher costs for the customers. “Having the possibility of providing free remote assistance to our customers has become an absolute priority for our company, and Eaton is one of the few that provide this type of service,” Caprioli explains.

Via a VPN (virtual private network) connection, the XP700 industrial PC now allows the CDM technicians to view the data produced by the extruder and diagnose most problems from remote stations, providing free service to the clientele. “We can now even know if a bulb has blown without having to send our technicians to the site,” says Caprioli, adding, “for example, our technicians can remotely restart a motor, or if a circuit-breaker is faulty, explain to the customer what to replace and how to replace it.” The result is amazing: a considerable saving in time and costs for the user and for CDM.

The electric cabinet of the ES135C extruder includes PKZ0 motor-protective circuit-breakers connected to the XP700 industrial PC via SmartWire-DT cable

The XP700 industrial PC touch screen makes it possible to view the status of each component of the extruder, modify parameters and thus prevent faults



Products: XV400 HMI/PLCs, SmartWire-DT, relays, NZM circuit-breakers, DIL contactors, RMQ-Titan control circuit devices, control valves, cable glands, hose connections, filters


Contact: Alberico Pucci [email protected]

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CoNCLUSIoN

The machine is currently installed in production. The first test runs were success-fully completed to the full satisfaction of the future operators. This also pleased the developers in the field of special machine building in the Eaton Vehicle Group. “Our aim to use as many Eaton components as possible has led to a very powerful but also easy-to-operate machine. And – what is also very important – the costs stayed within the planned budget, although we could realize interesting additional functions,“ Bosco concludes.

In the industry, Eaton is known as a global player in hydraulics and as an international leader in switching devices and controls for industry automation. And beyond, in the automobile and utility vehicle world, Eaton is known in different circles: with production volume of 300 million valves, Eaton’s Vehicle Group is the world‘s largest manufacturer of valves for car and truck combustion engines.

High-performance valves for small and large combustion engines

Eaton has become an established supplier of valve solutions for large and small engines. However, there is still a demand for optimum performance. However, large or small, manufacturers require solutions that are specific to their need.

With compact downsizing engines, hollow valves with sodium-filled cavities are required. This has a cooling effect that reduces the operating temperature and increases the lifespan of the valve. Additionally, the lower weight contributes to the performance dynamics and energy efficiency of modern petrol and diesel engines. The Eaton Nordhausen production site in Germany specializes in manufacturing these valves.

As the scale of engines gets bigger, for example in utility vehicles, manufacturers call for heavy-duty valves, which are produced at Eaton’s Bosconero site in Italy. These valves are made of solid materials, which are made from two components – head and shaft – and are then welded together. The advantage for engine manufacturing is that the optimum material is used in each case. The head consists of highly durable austenitic steel, while the shaft is made from steel with a martensite structure. The components are combined by friction welding, which is where, two parts are moved against each other under pressure until the generated friction heat is so high that the material is plasticized and a permanent connection is created. One advantage of friction welding is that no third work material comes into play.

Special engineering in own house

The manufacturing technology of these valves was largely developed at Eaton. It is put into practice by a powerful special engineering unit in Bosconero, which also develops and manufactures tailored machines for the other sites of the Eaton’s Vehicle Group worldwide.

The current projects in Bosconero include a machine that will allow for friction welding of valves that will serve much larger applications. Existing friction welding machines can only combine valves of up to 200mm. So when Eaton received an order from a leading truck manufacturer to produce outlet valves that are 250mm long, a new machine had to be planned and built.

Automation technology from the company shelf

“For the older friction welding machines, we used the control technology of a Japanese manufacturer as standard,” said Filippo Bosco, Manager Machine Building Department Eaton Vehicle Group in Bosconero. “Thanks to the acquisitions in the last years, we can now resort to our own automation technology for the electric and electronic systems in machine construction.“

Electro-hydraulics and electronics make the operation “smart”

Likewise, with the Eaton hydraulics offering, the machine construction integrates the company’s own technology. The infeed movement of the two work pieces are friction-welded to Eaton’s KBF-DG4V5 control valve for combustion engines is regulated by a high-precision, programmable electro-hydraulic axle control.

The “brain“ of the machine also comes from Eaton. “A micro panel type XV400 with integrated PLC not only assumes the control function, but also the task of the central human machine interface (HMI),“ Bosco reports. With only one axis to control, a complex control function is not required.

For the production of valves for truck engines, Eaton has developed and built a new friction welding machine at the Bosconero plant in Italy. The aim was to use as many components as possible from the company’s Hydraulics and Electrical businesses. The result is convincing – technically and commercially.

The XV 400 ensures the touch panel is easy to operate; the TFT display ensures transparency so the operator is constantly informed about the machine’s state. Naturally, all other switching devices on the operating panel come from Eaton, as do the frequency converters of the controllable electrical drives.

In the switch cabinet, the SmartWire DT system of Eaton is used, which significantly simplifies the connection of the electronic components. CANopen is used as a bus system.

High performance, perfect function, manageable costs

In addition to these central products and assemblies, the operation relies on a number of Eaton products and solutions. For example, in the hydraulic system machine designers and builders included Eaton’s control valves, screw joints and hose connections and filters. In the cabinet, there are also relays, power switches, and contactors from Eaton’s Electrical business.

Hydraulics and electr ical engineering from Eaton for fr iction welding machine from Eaton Vehicle Group

From a Single SourceTwo in one: Valves in modern truck combustion engines consist of shaft and head, which are made from different high-performance steel and combined by friction welding.

At the plant in Bosconero near Turin, the Eaton Vehicle Group develops and builds special machines, using numerous products from the company shelf.

All components of the human machine interface interface come from Eaton.



Products: XV400 HMI/PLCs, SmartWire-DT, relays, NZM circuit-breakers, DIL contactors, RMQ-Titan control circuit devices, control valves, cable glands, hose connections, filters


Contact: Alberico Pucci [email protected]

Scan QR Code

CoNCLUSIoN

The machine is currently installed in production. The first test runs were success-fully completed to the full satisfaction of the future operators. This also pleased the developers in the field of special machine building in the Eaton Vehicle Group. “Our aim to use as many Eaton components as possible has led to a very powerful but also easy-to-operate machine. And – what is also very important – the costs stayed within the planned budget, although we could realize interesting additional functions,“ Bosco concludes.

In the industry, Eaton is known as a global player in hydraulics and as an international leader in switching devices and controls for industry automation. And beyond, in the automobile and utility vehicle world, Eaton is known in different circles: with production volume of 300 million valves, Eaton’s Vehicle Group is the world‘s largest manufacturer of valves for car and truck combustion engines.

High-performance valves for small and large combustion engines

Eaton has become an established supplier of valve solutions for large and small engines. However, there is still a demand for optimum performance. However, large or small, manufacturers require solutions that are specific to their need.

With compact downsizing engines, hollow valves with sodium-filled cavities are required. This has a cooling effect that reduces the operating temperature and increases the lifespan of the valve. Additionally, the lower weight contributes to the performance dynamics and energy efficiency of modern petrol and diesel engines. The Eaton Nordhausen production site in Germany specializes in manufacturing these valves.

As the scale of engines gets bigger, for example in utility vehicles, manufacturers call for heavy-duty valves, which are produced at Eaton’s Bosconero site in Italy. These valves are made of solid materials, which are made from two components – head and shaft – and are then welded together. The advantage for engine manufacturing is that the optimum material is used in each case. The head consists of highly durable austenitic steel, while the shaft is made from steel with a martensite structure. The components are combined by friction welding, which is where, two parts are moved against each other under pressure until the generated friction heat is so high that the material is plasticized and a permanent connection is created. One advantage of friction welding is that no third work material comes into play.

Special engineering in own house

The manufacturing technology of these valves was largely developed at Eaton. It is put into practice by a powerful special engineering unit in Bosconero, which also develops and manufactures tailored machines for the other sites of the Eaton’s Vehicle Group worldwide.

The current projects in Bosconero include a machine that will allow for friction welding of valves that will serve much larger applications. Existing friction welding machines can only combine valves of up to 200mm. So when Eaton received an order from a leading truck manufacturer to produce outlet valves that are 250mm long, a new machine had to be planned and built.

Automation technology from the company shelf

“For the older friction welding machines, we used the control technology of a Japanese manufacturer as standard,” said Filippo Bosco, Manager Machine Building Department Eaton Vehicle Group in Bosconero. “Thanks to the acquisitions in the last years, we can now resort to our own automation technology for the electric and electronic systems in machine construction.“

Electro-hydraulics and electronics make the operation “smart”

Likewise, with the Eaton hydraulics offering, the machine construction integrates the company’s own technology. The infeed movement of the two work pieces are friction-welded to Eaton’s KBF-DG4V5 control valve for combustion engines is regulated by a high-precision, programmable electro-hydraulic axle control.

The “brain“ of the machine also comes from Eaton. “A micro panel type XV400 with integrated PLC not only assumes the control function, but also the task of the central human machine interface (HMI),“ Bosco reports. With only one axis to control, a complex control function is not required.

For the production of valves for truck engines, Eaton has developed and built a new friction welding machine at the Bosconero plant in Italy. The aim was to use as many components as possible from the company’s Hydraulics and Electrical businesses. The result is convincing – technically and commercially.

The XV 400 ensures the touch panel is easy to operate; the TFT display ensures transparency so the operator is constantly informed about the machine’s state. Naturally, all other switching devices on the operating panel come from Eaton, as do the frequency converters of the controllable electrical drives.

In the switch cabinet, the SmartWire DT system of Eaton is used, which significantly simplifies the connection of the electronic components. CANopen is used as a bus system.

High performance, perfect function, manageable costs

In addition to these central products and assemblies, the operation relies on a number of Eaton products and solutions. For example, in the hydraulic system machine designers and builders included Eaton’s control valves, screw joints and hose connections and filters. In the cabinet, there are also relays, power switches, and contactors from Eaton’s Electrical business.

Hydraulics and electr ical engineering from Eaton for fr iction welding machine from Eaton Vehicle Group

From a Single SourceTwo in one: Valves in modern truck combustion engines consist of shaft and head, which are made from different high-performance steel and combined by friction welding.

At the plant in Bosconero near Turin, the Eaton Vehicle Group develops and builds special machines, using numerous products from the company shelf.

All components of the human machine interface interface come from Eaton.


CUSToMER SUCCESS SToRy INFo

Products: XC100 modular PLCs, XV100 HMI/PLCs Company: www.mechan.co.uk


Contact: Stuart Greenwood [email protected]

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CoNCLUSIoN

The key requirements for the train lifting systems were precision and flexibility. Eaton’s solution based on the XC100 and XV100 is not only versatile but can be expanded easily as required.

Controlling train lifting systems with 2 mm precision

Trains Get A Lift With Eaton

Eaton automation products are part of the new train lifting control systems of Jenkinson Electrical Engineering. With a synchronization accuracy of 2 mm or less, this application needed genuine precision work and reliable technology.

Some time ago Eaton was selected by Jenkinson Electrical Engineering, a specialist panel builder and system integrator, to supply automation products that form the basis of a new and exceptionally versatile train lifting system developed by Mechan, world leaders in the design, development and manufacture of mechanical handling equipment for use in rail depots and workshops. The new lifting system allows a virtually unlimited number of lifting jacks to be synchronised with an accuracy of 2 mm or better. This means that even the longest trains can be conveniently and safely lifted so that, for example, bogies can be removed easily for servicing.

In today’s cost-conscious rail industry, it is more essential than ever to maximise the in-service time for rolling stock. As a result, conventional approaches to train lifting, which is part of the routine maintenance of modern rolling stock, have largely been superseded by the use of sophisticated jacking systems. With these systems, four jacks are typically used per vehicle, allowing the whole train to be lifted as a single unit in a matter of minutes.

A key requirement for the success of these jacking systems is that the jacks must be accurately synchronised while they are lifting and lowering the train, so that the risk of distorting the vehicle bodies is eliminated, and the weight of the train, which may be as much as several hundred tonnes, is evenly distributed between the jacks. Also, to ensure that the system is fully compatible with current and future train types, the individual jacks must be physically separate units so that they can be positioned as required to suit different types of train body.

These were among the essential requirements presented to Jenkinson Electrical Engineering, a company with wide experience of developing specialised automation systems, by Mechan when it was looking for ways to upgrade the control systems used in its products.

The control system that Mechan was already using offered satisfactory performance but it was limited to controlling a maximum of 24 jacks simultaneously. Because it was based on proprietary electronic systems, developing it further to handle more jacks and to add other new features would have been both costly and time consuming.

After looking carefully at Mechan’s requirements, Jenkinson Electrical Engineering proposed a solution based on modern automation products that incorporate the latest technology and are readily available off-the-shelf. The key products chosen were Eaton XC100 programmable controllers (PLCs) and XV100 touch screen operator interface units.

“We’ve had long experience of working with Eaton products,” said Keith Atkins, General Manager of Jenkinson Electrical Engineering, “so we knew we could rely on them to provide excellent performance and value for money. We also knew that by using the XC100 and the XV100 we could produce a versatile control system that could be easily upgraded, should the need arise, simply by making software changes.”

Jenkinson Electrical Engineering selected the XC100 PLCs for the Mechan project as they are compact modular devices that can easily be expanded to meet future requirements, and because they support the CANopen fieldbus system without the need for additional hardware. The XV100 operator interface panels were chosen because of their robust construction, high quality colour screens and their ease of programming.

“The PLC software needed to for this project was quite complex, as we’ve built in a large number of options to cater for different configurations of jacks,” said Keith Atkins, “but Eaton’s XSoft-Codesys-2 programming system, which is IEC 61131-1 compliant, made the programs easy to develop and test. The result is a system that’s dependable, and that offers all of the flexibility and versatility that Mechan was looking for.”

Mechan has now used the new train lift control system based on automation products from Eaton on several train lift systems ranging in size from a small single-vehicle lifting system with just four jacks, to a full train lifting system with 44 jacks. In every case, it has performed flawlessly and delivered synchronisation between the jacks that easily meets the 2 mm accuracy requirement. In principle, any number of jacks can be synchronised using the new control system, and the Mechan is planning to use it extensively on future projects.

XV100

XC100

The XV 100 series from Eaton offers the machine and system builders compact operator interfaces with maximum performance. They can be used as combined HMI/PLCs and come with a fully graphical 3.5”, 5.7” or 7” wide screen touch display.

The XC100 series modular PLCs are universal automation systems for small to medium-sized applications. They stand out on account of their freely scalable design. A range of different CPU performance classes and expansion modules are available.



Products: XC100 modular PLCs, XV100 HMI/PLCs Company: www.mechan.co.uk


Contact: Stuart Greenwood [email protected]

Scan QR Code

CoNCLUSIoN

The key requirements for the train lifting systems were precision and flexibility. Eaton’s solution based on the XC100 and XV100 is not only versatile but can be expanded easily as required.

Controlling train lifting systems with 2 mm precision

Trains Get A Lift With Eaton

Eaton automation products are part of the new train lifting control systems of Jenkinson Electrical Engineering. With a synchronization accuracy of 2 mm or less, this application needed genuine precision work and reliable technology.

Some time ago Eaton was selected by Jenkinson Electrical Engineering, a specialist panel builder and system integrator, to supply automation products that form the basis of a new and exceptionally versatile train lifting system developed by Mechan, world leaders in the design, development and manufacture of mechanical handling equipment for use in rail depots and workshops. The new lifting system allows a virtually unlimited number of lifting jacks to be synchronised with an accuracy of 2 mm or better. This means that even the longest trains can be conveniently and safely lifted so that, for example, bogies can be removed easily for servicing.

In today’s cost-conscious rail industry, it is more essential than ever to maximise the in-service time for rolling stock. As a result, conventional approaches to train lifting, which is part of the routine maintenance of modern rolling stock, have largely been superseded by the use of sophisticated jacking systems. With these systems, four jacks are typically used per vehicle, allowing the whole train to be lifted as a single unit in a matter of minutes.

A key requirement for the success of these jacking systems is that the jacks must be accurately synchronised while they are lifting and lowering the train, so that the risk of distorting the vehicle bodies is eliminated, and the weight of the train, which may be as much as several hundred tonnes, is evenly distributed between the jacks. Also, to ensure that the system is fully compatible with current and future train types, the individual jacks must be physically separate units so that they can be positioned as required to suit different types of train body.

These were among the essential requirements presented to Jenkinson Electrical Engineering, a company with wide experience of developing specialised automation systems, by Mechan when it was looking for ways to upgrade the control systems used in its products.

The control system that Mechan was already using offered satisfactory performance but it was limited to controlling a maximum of 24 jacks simultaneously. Because it was based on proprietary electronic systems, developing it further to handle more jacks and to add other new features would have been both costly and time consuming.

After looking carefully at Mechan’s requirements, Jenkinson Electrical Engineering proposed a solution based on modern automation products that incorporate the latest technology and are readily available off-the-shelf. The key products chosen were Eaton XC100 programmable controllers (PLCs) and XV100 touch screen operator interface units.

“We’ve had long experience of working with Eaton products,” said Keith Atkins, General Manager of Jenkinson Electrical Engineering, “so we knew we could rely on them to provide excellent performance and value for money. We also knew that by using the XC100 and the XV100 we could produce a versatile control system that could be easily upgraded, should the need arise, simply by making software changes.”

Jenkinson Electrical Engineering selected the XC100 PLCs for the Mechan project as they are compact modular devices that can easily be expanded to meet future requirements, and because they support the CANopen fieldbus system without the need for additional hardware. The XV100 operator interface panels were chosen because of their robust construction, high quality colour screens and their ease of programming.

“The PLC software needed to for this project was quite complex, as we’ve built in a large number of options to cater for different configurations of jacks,” said Keith Atkins, “but Eaton’s XSoft-Codesys-2 programming system, which is IEC 61131-1 compliant, made the programs easy to develop and test. The result is a system that’s dependable, and that offers all of the flexibility and versatility that Mechan was looking for.”

Mechan has now used the new train lift control system based on automation products from Eaton on several train lift systems ranging in size from a small single-vehicle lifting system with just four jacks, to a full train lifting system with 44 jacks. In every case, it has performed flawlessly and delivered synchronisation between the jacks that easily meets the 2 mm accuracy requirement. In principle, any number of jacks can be synchronised using the new control system, and the Mechan is planning to use it extensively on future projects.

XV100

XC100

The XV 100 series from Eaton offers the machine and system builders compact operator interfaces with maximum performance. They can be used as combined HMI/PLCs and come with a fully graphical 3.5”, 5.7” or 7” wide screen touch display.

The XC100 series modular PLCs are universal automation systems for small to medium-sized applications. They stand out on account of their freely scalable design. A range of different CPU performance classes and expansion modules are available.



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Products: XV-102 HMI/PLC, DS7-SWD soft starters, RMQ Titan control circuit devices, DIL contactors, NZM circuit-breakers, SmartWire-DT

Company: www.kmt-waterjet.de


Contact: Johann Fischer [email protected]

Nowadays water has a permanent place as a cutting medium both in the manufacturing industry and in food production. KMT Waterjet is one of the technology leaders worldwide in this field and offers high pressure generators that can produce water pressures of up to 6,200 bar. In order to implement a cost-effective and powerful control system for the high pressure pumps, the company chose Eaton‘s HMI-PLC with SmartWire-DT.

The principle of cutting with water offers a host of benefits. It allows the use of precise cutting speeds with flexible contours; material loss is negligible and finishing is often unnecessary. Furthermore it is a technology in which the material does not suffer on account of heat.

In order to enable the cutting of multidimensional contours, the waterjet cutting systems are as varied as the different application areas. KMT GmbH (KMT Waterjet) based in Bad Nauheim is a company that has specialized in the field of high pressure supply for waterjet cutting systems for over 40 years. The core of all waterjet cutting systems are the high pressure pumps. These are state-of-the-art high performance products that have to be adapted to the application at hand.

Cost-efficient and intelligent networking

Particularly when implementing the high pressure supply of cutting systems operating simultaneously, it is normal for end customers to run high pressure pumps in a network. An optimum network operation ensures that if a pump is switched off or fails, a neighboring pump can take over its operation automatically. This synchronization was important for KMT Waterjet as far as the development of an economical networking of high pressure pumps and their automation were concerned. The company therefore decided to choose a solution with a modular PLC, Eaton‘s XC-201, as well as the XVH-340 for visualization and operation. Eaton controllers such as the XC-201 come with interfaces like CANopen and Ethernet integrated as standard, so that KMT Waterjet was able to implement the networking of pumps directly via CANopen.

When the controller concept was reviewed, the aim was to increase overall efficiency. “We have been following the developments of the Lean Solution philosophy and SmartWire-DT for quite some time. The concept is innovative and we liked it straight away,” explains Achim Lucka, responsible for pump control at KMT Waterjet.

Keeping components to a minimum

Together with Eaton, KMT Waterjet designed a new control concept which is used in all high pressure pumps of the company. The functionality of the previous two devices is now handled by the XV-102 HMI-PLC combination device. As a compact and powerful micro panel with resistive touch technology it offers a user-friendly solution for controlling pumps. The integrated interfaces include Ethernet and either CAN, Profibus, RS232 and RS485. The XV-102 can be programmed in compliance with the Codesys standard. Achim Lucka uses Eaton‘s Galileo software tool for the visualization, via which the web server integrated in the PLC can be configured for teleservice tasks.

The HMI-PLC communicates via SmartWire-DT with the control circuit devices of the pumps as well as with the DS7 soft starter which start up the main motors from 22 to 110 kW. Soft starters provide a compact alternative to the star-delta starter. Through a patented procedure, the startup is particularly smooth and yet at a

higher torque than with other solutions. The SmartWire-DT interface allows the devices to be parameterized from a central point. Besides having a fault memory like the one typically found on variable frequency drives, the DS7 soft starter is able to detect nine different device faults and offer another 35 messages for communication faults. The DS7 with SmartWire-DT can also send an early warning and show details of malfunctions so that the operator can intervene in good time. KMT Waterjet also uses the data to prevent operating errors on the DS7 since the controller prevents incorrect settings.

KMT Waterjet now keeps different programs for various hardware configurations for the machines on an SD card. With XV-102 the operator can call up the software on the touch panel. The controller then starts up and detects which machine configuration is active. This means that the operator no longer has to manually change addresses in the CPU via an external laptop. Consequently, employees no longer have to travel to the customer to install software updates, but simply send the program modifications by email.

Sharpening Water

CoNCLUSIoN

“Thanks to its compact design, SmartWire-DT enables us to save space and minimize our costs for materials and stock-keeping. We also make additional savings since considerably less time is needed for assembly. This helps us to keep our prices constant despite the continuously rising material prices. “All in all, we benefit not only from the optimized costs but also from the additional ease of maintenance gained.”

Manufacturer of high pressure pumps for waterjet cutting systems reduces costs with SmartWire-DT

Compared to the conventional solution (left), the amount of components and cabling in the switch cabinet with SmartWire-DT (right) is reduced

Eaton SolutionS 29 21


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Products: XV-102 HMI/PLC, DS7-SWD soft starters, RMQ Titan control circuit devices, DIL contactors, NZM circuit-breakers, SmartWire-DT

Company: www.kmt-waterjet.de


Contact: Johann Fischer [email protected]

Nowadays water has a permanent place as a cutting medium both in the manufacturing industry and in food production. KMT Waterjet is one of the technology leaders worldwide in this field and offers high pressure generators that can produce water pressures of up to 6,200 bar. In order to implement a cost-effective and powerful control system for the high pressure pumps, the company chose Eaton‘s HMI-PLC with SmartWire-DT.

The principle of cutting with water offers a host of benefits. It allows the use of precise cutting speeds with flexible contours; material loss is negligible and finishing is often unnecessary. Furthermore it is a technology in which the material does not suffer on account of heat.

In order to enable the cutting of multidimensional contours, the waterjet cutting systems are as varied as the different application areas. KMT GmbH (KMT Waterjet) based in Bad Nauheim is a company that has specialized in the field of high pressure supply for waterjet cutting systems for over 40 years. The core of all waterjet cutting systems are the high pressure pumps. These are state-of-the-art high performance products that have to be adapted to the application at hand.

Cost-efficient and intelligent networking

Particularly when implementing the high pressure supply of cutting systems operating simultaneously, it is normal for end customers to run high pressure pumps in a network. An optimum network operation ensures that if a pump is switched off or fails, a neighboring pump can take over its operation automatically. This synchronization was important for KMT Waterjet as far as the development of an economical networking of high pressure pumps and their automation were concerned. The company therefore decided to choose a solution with a modular PLC, Eaton‘s XC-201, as well as the XVH-340 for visualization and operation. Eaton controllers such as the XC-201 come with interfaces like CANopen and Ethernet integrated as standard, so that KMT Waterjet was able to implement the networking of pumps directly via CANopen.

When the controller concept was reviewed, the aim was to increase overall efficiency. “We have been following the developments of the Lean Solution philosophy and SmartWire-DT for quite some time. The concept is innovative and we liked it straight away,” explains Achim Lucka, responsible for pump control at KMT Waterjet.

Keeping components to a minimum

Together with Eaton, KMT Waterjet designed a new control concept which is used in all high pressure pumps of the company. The functionality of the previous two devices is now handled by the XV-102 HMI-PLC combination device. As a compact and powerful micro panel with resistive touch technology it offers a user-friendly solution for controlling pumps. The integrated interfaces include Ethernet and either CAN, Profibus, RS232 and RS485. The XV-102 can be programmed in compliance with the Codesys standard. Achim Lucka uses Eaton‘s Galileo software tool for the visualization, via which the web server integrated in the PLC can be configured for teleservice tasks.

The HMI-PLC communicates via SmartWire-DT with the control circuit devices of the pumps as well as with the DS7 soft starter which start up the main motors from 22 to 110 kW. Soft starters provide a compact alternative to the star-delta starter. Through a patented procedure, the startup is particularly smooth and yet at a

higher torque than with other solutions. The SmartWire-DT interface allows the devices to be parameterized from a central point. Besides having a fault memory like the one typically found on variable frequency drives, the DS7 soft starter is able to detect nine different device faults and offer another 35 messages for communication faults. The DS7 with SmartWire-DT can also send an early warning and show details of malfunctions so that the operator can intervene in good time. KMT Waterjet also uses the data to prevent operating errors on the DS7 since the controller prevents incorrect settings.

KMT Waterjet now keeps different programs for various hardware configurations for the machines on an SD card. With XV-102 the operator can call up the software on the touch panel. The controller then starts up and detects which machine configuration is active. This means that the operator no longer has to manually change addresses in the CPU via an external laptop. Consequently, employees no longer have to travel to the customer to install software updates, but simply send the program modifications by email.

Sharpening Water

CoNCLUSIoN

“Thanks to its compact design, SmartWire-DT enables us to save space and minimize our costs for materials and stock-keeping. We also make additional savings since considerably less time is needed for assembly. This helps us to keep our prices constant despite the continuously rising material prices. “All in all, we benefit not only from the optimized costs but also from the additional ease of maintenance gained.”

Manufacturer of high pressure pumps for waterjet cutting systems reduces costs with SmartWire-DT

Compared to the conventional solution (left), the amount of components and cabling in the switch cabinet with SmartWire-DT (right) is reduced

Eaton SolutionS 29 21


Products: XV-102 HMI/PLC with XI/ON and CAN communication module

Company: www.wppg.de


Contact: Helmer Lüken [email protected]

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CoNCLUSIoN

“With the successful development of an electrically operated capping device we are the first to offer it on the market. We have calculated that by changing from a hydraulic to a partially electrical system with the Eaton controller, it is possible to reduce energy consumption by 65 %,” states a delighted Günter Rieken, global manager for production at WPPG. “Through the outstanding price-performance ratio of the XV-102 and the wide range of benefits for daily operation the investment in the new system has been worth it. We are therefore keen to pursue the course we have taken and integrate other process steps in the Eaton controller.”

Injection molding specialist shortens cycle times for cap production with electr ical control system

It‘s the Tool That Really Counts

At its German headquarters, WPPG produces its own tools for its injection molding machines.

The switch cabinet also contains Eaton‘s XI/ON modular I/O system which handles the data exchange with the locking system of the guard door, the position sensors or between the tool and the injection molding machine.

WPPG is headquartered in Ween in North Germany and develops and manufactures innovative plastic packaging for a wide variety of markets and customer groups. The company is regarded as a specialist in customized solutions. This is particularly due to the fact that the East Frisian company is one of the few closure manufacturers that produces its own tools for injection molding machines at their German headquarters.

All a question of technology

A closure is produced in the following way: The injection molding machine presses the two-section product-specific mold firmly at contact pressures of around 350 t. The liquid plastic is then injected at a pressure of up to 2,000 bar. The last process step in which the finished open closures are closed precisely is particularly critical. This operation is particularly challenging since the material shrinks on account of factors such as temperature, air humidity or color. Material damage may even occur during the closing operation.

A special tool, the capping bar, is used for the closing operation. The actuation of the capping bar previously had to be implemented with energy-intensive and wear-intensive pneumatic or hydraulic

systems, which could only be moved to end positions. In order to ensure the clean closing of the cap, the capping bar must be adapted individually for each product. If the setup of the system is not perfect, this produces a high rate of rejects. With product adaptions or new production lines, WPPG was therefore previously forced to produce new molds each time and adapt them to the application through lengthy tests with different mechanical variants.

Due to the increasing demand of customers for more efficient and fully electrical machines, WPPG decided to gradually change its tools for use with electrical controllers. This began with the capping device. Eaton was engaged as a partner.

Now it‘s going electrical

The result of the joint development was very successful: Two electrical servo drives for positioning the capping bar are controlled simultaneously by Eaton‘s XV-102 HMI/PLC, which can be programmed by the globally established Codesys standard. One drive handles the vertical movement and one handles the rotation. The control and visualization unit can now set a target curve by which the drives carry out the closing operation at maximum

The successful manufacturing of plastic closures primarily depends on two things: speed and precision. In collaboration with Eaton, injection molding specialist Weener Plastik GmbH (WPPG) has developed a solution based on the XV-102 programmable controller, which enables a precise parameterization of the assembly tool for closing the freshly molded closures. This method enables the cycle time to be reduced as well as the reject rate.

speed and with great precision. The controller compares the target and actual positions of both drives at a cycle rate of less than 2 ms and determines the further positioning of the capping bar.

The 7” touch screen enables curve positions, accelerations, speed and braking to be specified for each position of the servo drives. In this way it is possible to create capping curves matched precisely to the application. This in turn ensures a greater precision in the positioning of the capping bar and thus a more efficient capping process.

operator and maintenance friendly

Eaton integrated a communication module in the XV-102 that enabled direct communication via CAN specially for the data exchange with both servo controllers. The data exchange with the guard door locking system, the position sensors, or between the tool and the injection molding machine was implemented with Eaton‘s modular XI/ON I/O system which is fitted with a CAN fieldbus coupler. Eaton developed the Codesys program in close collaboration with WPPG specifically for the application. This enables service technicians worldwide to operate and set parameters easily if any specifications such as for material or color of the plastic are changed.

The new controller has also simplified maintenance. For example, the status of the connected components can now be examined easily through color displays in a graphic overview. In this way, any mechanical and electrical faults can be identified more easily during the process. A cycle counter also enables the system to indicate the scheduled lubrication of the servo motors. Technicians then have ten days to complete the maintenance work. If this does not take place, the machine shuts down until the maintenance is carried out.

Saving costs, time and energy

The XV-102 is a lean automation solution that handles the demanding and simultaneous control of the high precision speed servo drives of the capping device: Cycle times, rejects and energy consumption are reduced, whilst flexibility and productivity have been increased. Machine wear has also been reduced and the application is oil-free. The Eaton controller has now become standard equipment in new machines for a wide range of applications in the entire Weener Group.



Products: XV-102 HMI/PLC with XI/ON and CAN communication module

Company: www.wppg.de


Contact: Helmer Lüken [email protected]

Scan QR Code

CoNCLUSIoN

“With the successful development of an electrically operated capping device we are the first to offer it on the market. We have calculated that by changing from a hydraulic to a partially electrical system with the Eaton controller, it is possible to reduce energy consumption by 65 %,” states a delighted Günter Rieken, global manager for production at WPPG. “Through the outstanding price-performance ratio of the XV-102 and the wide range of benefits for daily operation the investment in the new system has been worth it. We are therefore keen to pursue the course we have taken and integrate other process steps in the Eaton controller.”

Injection molding specialist shortens cycle times for cap production with electr ical control system

It‘s the Tool That Really Counts

At its German headquarters, WPPG produces its own tools for its injection molding machines.

The switch cabinet also contains Eaton‘s XI/ON modular I/O system which handles the data exchange with the locking system of the guard door, the position sensors or between the tool and the injection molding machine.

WPPG is headquartered in Ween in North Germany and develops and manufactures innovative plastic packaging for a wide variety of markets and customer groups. The company is regarded as a specialist in customized solutions. This is particularly due to the fact that the East Frisian company is one of the few closure manufacturers that produces its own tools for injection molding machines at their German headquarters.

All a question of technology

A closure is produced in the following way: The injection molding machine presses the two-section product-specific mold firmly at contact pressures of around 350 t. The liquid plastic is then injected at a pressure of up to 2,000 bar. The last process step in which the finished open closures are closed precisely is particularly critical. This operation is particularly challenging since the material shrinks on account of factors such as temperature, air humidity or color. Material damage may even occur during the closing operation.

A special tool, the capping bar, is used for the closing operation. The actuation of the capping bar previously had to be implemented with energy-intensive and wear-intensive pneumatic or hydraulic

systems, which could only be moved to end positions. In order to ensure the clean closing of the cap, the capping bar must be adapted individually for each product. If the setup of the system is not perfect, this produces a high rate of rejects. With product adaptions or new production lines, WPPG was therefore previously forced to produce new molds each time and adapt them to the application through lengthy tests with different mechanical variants.

Due to the increasing demand of customers for more efficient and fully electrical machines, WPPG decided to gradually change its tools for use with electrical controllers. This began with the capping device. Eaton was engaged as a partner.

Now it‘s going electrical

The result of the joint development was very successful: Two electrical servo drives for positioning the capping bar are controlled simultaneously by Eaton‘s XV-102 HMI/PLC, which can be programmed by the globally established Codesys standard. One drive handles the vertical movement and one handles the rotation. The control and visualization unit can now set a target curve by which the drives carry out the closing operation at maximum

The successful manufacturing of plastic closures primarily depends on two things: speed and precision. In collaboration with Eaton, injection molding specialist Weener Plastik GmbH (WPPG) has developed a solution based on the XV-102 programmable controller, which enables a precise parameterization of the assembly tool for closing the freshly molded closures. This method enables the cycle time to be reduced as well as the reject rate.

speed and with great precision. The controller compares the target and actual positions of both drives at a cycle rate of less than 2 ms and determines the further positioning of the capping bar.

The 7” touch screen enables curve positions, accelerations, speed and braking to be specified for each position of the servo drives. In this way it is possible to create capping curves matched precisely to the application. This in turn ensures a greater precision in the positioning of the capping bar and thus a more efficient capping process.

operator and maintenance friendly

Eaton integrated a communication module in the XV-102 that enabled direct communication via CAN specially for the data exchange with both servo controllers. The data exchange with the guard door locking system, the position sensors, or between the tool and the injection molding machine was implemented with Eaton‘s modular XI/ON I/O system which is fitted with a CAN fieldbus coupler. Eaton developed the Codesys program in close collaboration with WPPG specifically for the application. This enables service technicians worldwide to operate and set parameters easily if any specifications such as for material or color of the plastic are changed.

The new controller has also simplified maintenance. For example, the status of the connected components can now be examined easily through color displays in a graphic overview. In this way, any mechanical and electrical faults can be identified more easily during the process. A cycle counter also enables the system to indicate the scheduled lubrication of the servo motors. Technicians then have ten days to complete the maintenance work. If this does not take place, the machine shuts down until the maintenance is carried out.

Saving costs, time and energy

The XV-102 is a lean automation solution that handles the demanding and simultaneous control of the high precision speed servo drives of the capping device: Cycle times, rejects and energy consumption are reduced, whilst flexibility and productivity have been increased. Machine wear has also been reduced and the application is oil-free. The Eaton controller has now become standard equipment in new machines for a wide range of applications in the entire Weener Group.



Products: XV-102 HMI/PLC, easy821 control relays, PKZ motor-protective circuit-breakers, DIL contactors, RMQ Titan control circuit devices, CS series enclosures

Company: www.schuko.de


Contact: Christoph Heselmeyer [email protected]

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CoNCLUSIoN

“The Eaton concept has given us a cost-efficient two-stage solution,” sums up CEO Heiko Schulte Südhoff. “The short programming steps are implemented in the easy821, parameter functions such as recipe management are handled by the XV-102. With just a single operator unit and only one single program type required, we can efficiently control all machine types and press materials.“

Eaton automation helps filter and extraction system specialists gain the competitive edge

Intelligent Disposal

In the switch cabinet, the easy821 control relay, PKZ motor protective-circuit-breakers and DIL contactors ensure safe, reliable operation.

The disposal of waste is playing an important role in industry, both on account of the costs and the environmental aspects involved. Particularly in the wood processing industry, production processes accumulate large quantities of wood chips, for which the volume can be considerably reduced through compression. Wood chips shaped in briquettes allow users to then store and transport them in the smallest of spaces.

The Schuko group of companies, based in Bad Laer, specializes in the field of environmentally-friendly waste disposal. Schuko has been producing extractor and filter systems as used in the wood, paper and plastics processing industries for over 45 years. The company‘s Compacto series of presses are a particularly efficient briquetting solution. As a technological pioneer, Schuko wanted to make the press machines more intelligent and more flexible. The machine builder therefore asked for the support of Eaton with the development of an optimized automation solution.

Control concept – individual and fast

The briquetting presses of the Compacto series are hydraulically driven and can be fed with material manually, via a bagging or filter system or a cargo floor. Due to the wide range of application fields and the different press materials, Schuko wanted to expand the control functions of its Compacto briquetting presses. The aim

was to make the machines more user-friendly and flexible in terms of their adaptability. This called for an intelligent automation concept tailored to Schuko‘s needs.

The selected concept consists of the easy control relay in combination with the XV HMI/PLC. PKZ motor-protective circuit-breakers, DIL contactors and CS enclosures from Eaton are also part of the solution. The innovative XV-102 touch screen PLC, with display and PLC functionality, which can be programmed with the CoDeSys standard, forms the heart of the system and supports the operator extensively from commissioning to maintenance.

Press machines are therefore equipped with a variable controller hardware with a single universal software program that can be loaded easily onto the XV-102 via memory card. A Schuko employee configures the machine via the touch screen with the data required for the specific application and selects the machine type and the material to be compressed. Schuko uses Eaton‘s intuitive Galileo design tool for the visualization and offers three different operator levels with different function sets – each one password protected – for the machine manufacturer, the trading partners and the end user.

Simple operation, optimum flexibility

The easy821 control relay takes over the control of time-critical signals (in the hundredth of a second range), such as for the hydraulic cylinders of the briquetting presses, and thus ensures optimum operation. The communication between easy821 and XV-102 is implemented via easyNet, a CAN-based network for easy control relays. A green bar on the XV display also indicates any faults in the communication between the two devices. An additional I/O module is used for connecting the easy821 control relay to analog sensors for the hydraulic pressures.

The operational hours counter is used by the machine to determine when mechanical wear parts, hydraulic oil or electronic components have to be changed, and also automatically requests the necessary maintenance work. A practical service: In the event of a fault, a stored maintenance schedule shows the operator immediately the correct technical support contact including the telephone number.

Since all the functions of the machine can be represented in the HMI/PLC, individual display and operator devices that previously had to be integrated and wired in the control cabinet became unnecessary. Schuko thus benefited from the fact that the installation in the control cabinet housing, as well as material, installation and stock-keeping costs could be kept to a minimum.

The new controller concept also made it possible to integrate an electronic level monitoring of the hydraulic oil, which offered a safety shutdown in the event of an oil leak.

The woodworking industry produces large quantities of wood chips, sawdust and sanding dust every day. This often involves considerable costs for storage, transportation and disposal. A Compacto briquetting press from Schuko provides an efficient solution for compressing wood chips and other loose materials in order to save space and costs for their disposal. A new intelligent controller concept from Eaton extends functionality and simplifies operation.

Eaton‘s XV-102 simplifies servicing - the machine displays the required maintenance and the contact data of the responsible technician.



Products: XV-102 HMI/PLC, easy821 control relays, PKZ motor-protective circuit-breakers, DIL contactors, RMQ Titan control circuit devices, CS series enclosures

Company: www.schuko.de


Contact: Christoph Heselmeyer [email protected]

Scan QR Code

CoNCLUSIoN

“The Eaton concept has given us a cost-efficient two-stage solution,” sums up CEO Heiko Schulte Südhoff. “The short programming steps are implemented in the easy821, parameter functions such as recipe management are handled by the XV-102. With just a single operator unit and only one single program type required, we can efficiently control all machine types and press materials.“

Eaton automation helps filter and extraction system specialists gain the competitive edge

Intelligent Disposal

In the switch cabinet, the easy821 control relay, PKZ motor protective-circuit-breakers and DIL contactors ensure safe, reliable operation.

The disposal of waste is playing an important role in industry, both on account of the costs and the environmental aspects involved. Particularly in the wood processing industry, production processes accumulate large quantities of wood chips, for which the volume can be considerably reduced through compression. Wood chips shaped in briquettes allow users to then store and transport them in the smallest of spaces.

The Schuko group of companies, based in Bad Laer, specializes in the field of environmentally-friendly waste disposal. Schuko has been producing extractor and filter systems as used in the wood, paper and plastics processing industries for over 45 years. The company‘s Compacto series of presses are a particularly efficient briquetting solution. As a technological pioneer, Schuko wanted to make the press machines more intelligent and more flexible. The machine builder therefore asked for the support of Eaton with the development of an optimized automation solution.

Control concept – individual and fast

The briquetting presses of the Compacto series are hydraulically driven and can be fed with material manually, via a bagging or filter system or a cargo floor. Due to the wide range of application fields and the different press materials, Schuko wanted to expand the control functions of its Compacto briquetting presses. The aim

was to make the machines more user-friendly and flexible in terms of their adaptability. This called for an intelligent automation concept tailored to Schuko‘s needs.

The selected concept consists of the easy control relay in combination with the XV HMI/PLC. PKZ motor-protective circuit-breakers, DIL contactors and CS enclosures from Eaton are also part of the solution. The innovative XV-102 touch screen PLC, with display and PLC functionality, which can be programmed with the CoDeSys standard, forms the heart of the system and supports the operator extensively from commissioning to maintenance.

Press machines are therefore equipped with a variable controller hardware with a single universal software program that can be loaded easily onto the XV-102 via memory card. A Schuko employee configures the machine via the touch screen with the data required for the specific application and selects the machine type and the material to be compressed. Schuko uses Eaton‘s intuitive Galileo design tool for the visualization and offers three different operator levels with different function sets – each one password protected – for the machine manufacturer, the trading partners and the end user.

Simple operation, optimum flexibility

The easy821 control relay takes over the control of time-critical signals (in the hundredth of a second range), such as for the hydraulic cylinders of the briquetting presses, and thus ensures optimum operation. The communication between easy821 and XV-102 is implemented via easyNet, a CAN-based network for easy control relays. A green bar on the XV display also indicates any faults in the communication between the two devices. An additional I/O module is used for connecting the easy821 control relay to analog sensors for the hydraulic pressures.

The operational hours counter is used by the machine to determine when mechanical wear parts, hydraulic oil or electronic components have to be changed, and also automatically requests the necessary maintenance work. A practical service: In the event of a fault, a stored maintenance schedule shows the operator immediately the correct technical support contact including the telephone number.

Since all the functions of the machine can be represented in the HMI/PLC, individual display and operator devices that previously had to be integrated and wired in the control cabinet became unnecessary. Schuko thus benefited from the fact that the installation in the control cabinet housing, as well as material, installation and stock-keeping costs could be kept to a minimum.

The new controller concept also made it possible to integrate an electronic level monitoring of the hydraulic oil, which offered a safety shutdown in the event of an oil leak.

The woodworking industry produces large quantities of wood chips, sawdust and sanding dust every day. This often involves considerable costs for storage, transportation and disposal. A Compacto briquetting press from Schuko provides an efficient solution for compressing wood chips and other loose materials in order to save space and costs for their disposal. A new intelligent controller concept from Eaton extends functionality and simplifies operation.

Eaton‘s XV-102 simplifies servicing - the machine displays the required maintenance and the contact data of the responsible technician.



Products: Five panels of the expandable Xiria E switchboard (two load switches, three circuit-breakers)

Company: www.gemeindewerk-beckenried.ch


Contact: Markus Baumgartner [email protected]

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CoNCLUSIoN

“We are very pleased with the new Xiria E switchgear,” plant manager Peter Feldmann sums up. “Installation and commissioning could be completed quickly, the system is very compact and we are open for extensions.” The municipal utility will use this experience when conversions are due in the coming years.

Reliable power supply at 1,600 meters above sea levelPower Supply on a Mountain

Fully to spec: easy to expandCompact: five panel Xiria E switchboard of the Alpstübli transformer station

Difficult transport: The Xiria E reached the Klewenalp above Lake Lucerne. Difficult to access: The transformer station is situated underground at 1,600 m above sea level. It only has a very narrow entrance.

The core business of the municipal utility company is the production, distribution and sale of electricity. Beckenried offers a special feature: self-generated electricity. The Sustli hydroelectric power station as well as the Lätten and Lanzig mini hydropower stations. With an annual output of around 9.4 gigawatts per hour, they produce half of the electricity required in the municipality from a clean primary energy source.

SF6-free – environmentally friendly and durable

“Treating the environment responsibly has a high priority in the corporate philosophy of our utility company,” explains Peter Feldmann, manager at the Beckenried municipal utility company. “That is why only an SF6 (sulfur hexafluoride)-free solution could be considered for replacing the switchgear.” Xiria E meets these requirements exactly: Like all mediumvoltage switchgear from

Eaton, the Xiria E makes absolutely no use of environmentally harmful SF6 gas.

Thanks to the use of advanced vacuum circuit-breakers and innovative insulation technology, they are a particularly environmentally-friendly and durable alternative in the medium voltage sector. A positive side effect: The operating costs are also reduced, since regular examinations of the gas pressure and other routine work become unnecessary as the switchboard is maintenancefree.

Compact – and flexible

The Alpstubli transformer station is situated in the middle of a hiking and skiing resort. It supplies all the businesses and facilities of the Klewenalp tourist and holiday region, such as the mountain inns and restaurants, the holiday chalets and group hostels, as well as the ski lifts. The new installation therefore had to meet some particular requirements. This not only involved the challenging transportation over narrow mountain paths up to the remote alpine slope: “The installation is located in an underground station that can only be accessed through a very narrow entrance.

The compact design and flexibility of the switchgear was therefore one of the most important criteria in selecting the system.” With a panel width of only 500 mm the Xiria E is one of the most compact representatives of its class, requires only a small mounting footprint and can even be installed in the most confined spaces. “Although we had to extend the power line, the new switchboard in our station enabled us to gain space,” says Peter Feldmann delighted.

Beckenried is situated on the south bank of Lake Lucerne in the canton of Nidwalden, Switzerland. The municipal utility is responsible for the supply of electricity and water for the municipal district of Beckenried as well as the Klewenalp area situated at 1,600 meters above sea level. The transformer station located there was renewed and equipped with the new Xiria E medium voltage switchgear from Eaton. The compact design and the SF6-free solution of the extendable switchboard were key factors in the selection process.

Reliable, safe – and maintenance free

“The station is situated on the mountain side and is therefore covered with snow in winter. Access is therefore difficult in the truest sense of the word,” Peter Feldmann explains, “we therefore placed a great deal of importance on reliability and maintenance requirement when making our decision.” Both the live primary components as well as the drive mechanisms on the Xiria E are sealed for life, thus protecting the entire system from environmental influences and making it maintenance-free. The contact wear of the vacuum circuit-breakers is negligible and is also certified maintenance-free for up to 30,000 operating cycles.

Modular – and quickly installed

The Xiria E system has a modular design. This means that any combination and order of panels is possible. The number of panels that can be used in a system is unlimited since several panels can be interconnected without any problem. They can also be fitted and connected quickly thus ensuring the rapid commissioning of the switchgear. Cellpack Power Systems AG based in Villmergen (Switzerland) thus only needed one day to install the system. They also spoke about how pleased they were with the project on site. As the cable connection for the Xiria E is implemented from the front, it was not only possible to save on building costs but also to erect the system close to the wall of the building. A further benefit of the system given the limited space available in this project.

Easy to integrate – and extendable

The local operator panel of the Xiria E is arranged ergonomically at eye level. However, during normal operation the Alpstubli system is remotely operated from the control center in Beckenried: “The integration in our existing control system was completed without a hitch,” as Peter Feldmann confirmed. Like the protective and control devices, the equipment for the remote control functionality is installed in a fully separated low-voltage room.

An expansion of the snow production equipment of the skiing resort is planned in the near future. However, it is still not yet clear what the additional requirements the necessary pumping stations and snow cannons will have: “The fact that additional panels can be added to the Xiria E at any time is very useful here.”



Products: Five panels of the expandable Xiria E switchboard (two load switches, three circuit-breakers)

Company: www.gemeindewerk-beckenried.ch


Contact: Markus Baumgartner [email protected]

Scan QR Code

CoNCLUSIoN

“We are very pleased with the new Xiria E switchgear,” plant manager Peter Feldmann sums up. “Installation and commissioning could be completed quickly, the system is very compact and we are open for extensions.” The municipal utility will use this experience when conversions are due in the coming years.

Reliable power supply at 1,600 meters above sea levelPower Supply on a Mountain

Fully to spec: easy to expandCompact: five panel Xiria E switchboard of the Alpstübli transformer station

Difficult transport: The Xiria E reached the Klewenalp above Lake Lucerne. Difficult to access: The transformer station is situated underground at 1,600 m above sea level. It only has a very narrow entrance.

The core business of the municipal utility company is the production, distribution and sale of electricity. Beckenried offers a special feature: self-generated electricity. The Sustli hydroelectric power station as well as the Lätten and Lanzig mini hydropower stations. With an annual output of around 9.4 gigawatts per hour, they produce half of the electricity required in the municipality from a clean primary energy source.

SF6-free – environmentally friendly and durable

“Treating the environment responsibly has a high priority in the corporate philosophy of our utility company,” explains Peter Feldmann, manager at the Beckenried municipal utility company. “That is why only an SF6 (sulfur hexafluoride)-free solution could be considered for replacing the switchgear.” Xiria E meets these requirements exactly: Like all mediumvoltage switchgear from

Eaton, the Xiria E makes absolutely no use of environmentally harmful SF6 gas.

Thanks to the use of advanced vacuum circuit-breakers and innovative insulation technology, they are a particularly environmentally-friendly and durable alternative in the medium voltage sector. A positive side effect: The operating costs are also reduced, since regular examinations of the gas pressure and other routine work become unnecessary as the switchboard is maintenancefree.

Compact – and flexible

The Alpstubli transformer station is situated in the middle of a hiking and skiing resort. It supplies all the businesses and facilities of the Klewenalp tourist and holiday region, such as the mountain inns and restaurants, the holiday chalets and group hostels, as well as the ski lifts. The new installation therefore had to meet some particular requirements. This not only involved the challenging transportation over narrow mountain paths up to the remote alpine slope: “The installation is located in an underground station that can only be accessed through a very narrow entrance.

The compact design and flexibility of the switchgear was therefore one of the most important criteria in selecting the system.” With a panel width of only 500 mm the Xiria E is one of the most compact representatives of its class, requires only a small mounting footprint and can even be installed in the most confined spaces. “Although we had to extend the power line, the new switchboard in our station enabled us to gain space,” says Peter Feldmann delighted.

Beckenried is situated on the south bank of Lake Lucerne in the canton of Nidwalden, Switzerland. The municipal utility is responsible for the supply of electricity and water for the municipal district of Beckenried as well as the Klewenalp area situated at 1,600 meters above sea level. The transformer station located there was renewed and equipped with the new Xiria E medium voltage switchgear from Eaton. The compact design and the SF6-free solution of the extendable switchboard were key factors in the selection process.

Reliable, safe – and maintenance free

“The station is situated on the mountain side and is therefore covered with snow in winter. Access is therefore difficult in the truest sense of the word,” Peter Feldmann explains, “we therefore placed a great deal of importance on reliability and maintenance requirement when making our decision.” Both the live primary components as well as the drive mechanisms on the Xiria E are sealed for life, thus protecting the entire system from environmental influences and making it maintenance-free. The contact wear of the vacuum circuit-breakers is negligible and is also certified maintenance-free for up to 30,000 operating cycles.

Modular – and quickly installed

The Xiria E system has a modular design. This means that any combination and order of panels is possible. The number of panels that can be used in a system is unlimited since several panels can be interconnected without any problem. They can also be fitted and connected quickly thus ensuring the rapid commissioning of the switchgear. Cellpack Power Systems AG based in Villmergen (Switzerland) thus only needed one day to install the system. They also spoke about how pleased they were with the project on site. As the cable connection for the Xiria E is implemented from the front, it was not only possible to save on building costs but also to erect the system close to the wall of the building. A further benefit of the system given the limited space available in this project.

Easy to integrate – and extendable

The local operator panel of the Xiria E is arranged ergonomically at eye level. However, during normal operation the Alpstubli system is remotely operated from the control center in Beckenried: “The integration in our existing control system was completed without a hitch,” as Peter Feldmann confirmed. Like the protective and control devices, the equipment for the remote control functionality is installed in a fully separated low-voltage room.

An expansion of the snow production equipment of the skiing resort is planned in the near future. However, it is still not yet clear what the additional requirements the necessary pumping stations and snow cannons will have: “The fact that additional panels can be added to the Xiria E at any time is very useful here.”



Products: XV-100 with SmartWire-DT, DIL contactors, PKZ motor-protective circuit-breakers, RMQ Titan control circuit devices

Company: www.sia-energy.de


Contact: Klaus Kuginna [email protected]

Scan QR Code

CoNCLUSIoN

In future sia energy plans to provide an app to make the data of the energy storage device also available on a smartphone. “We are also very impressed by the DC24 and the Eaton HMI/PLC as this solution is really future-proof,” says Chris Wägerle gladly. “After all, we see good opportunities to generally integrate the system in the building automation system and the management of other consumers. Thanks to the various interfaces on the XV102 and the modular design, this can be done easily at any time.”

Innovative electr icity storage devices give a boost to the solar power sector

Autonomy in Solar Power

Nowadays, the feed-in tariff for solar electricity is no longer a major incentive for the installation of a photovoltaic (PV) installation. However, the fact that electricity prices will continue to rise in future is nevertheless obvious.

For the operators of PV installations, the use of self-generated solar power for one‘s own consumption it is increasingly becoming worthwhile.

Energy storage devices are some of the great beacons of hope in the industry, since they enable the user to increase the share of self-generated electricity consumption and thus become less dependent on the energy supplier and their price policy. Battery storage devices in particular are ideal for private households and smaller companies and have been eligible for state subsidies in Germany since May 2013.

Developing an innovation from personal experience

The company sia energy, based in Lindenberg in the Allgäu region, has made a name for itself as a specialist in all issues related to photovoltaics. The origins of the company are based on the rental

Even though the solar power industry hasn‘t had an easy time of it recently with the constantly reduced feed-in tariffs, an increasing number of consumers are nevertheless considering the installation of PV systems. After all, electricity prices continue to rise and alternative energy is still in demand. The possibility to store electricity intelligently on location is giving the sector new opportunities. sia energy is one of the technological trailblazers in this sector. This Allgäu-based company relies on Eaton for its control technology.

of extensive roof space for their own energy requirements. Drawing on their own personal experience with a wide range of products and technologies, the sia team was able to grow into becoming expert advisors and consultants on the subject. For many years, sia energy focused on the design engineering and installation of complete systems – from small applications for private households, right through to large-scale installations for industrial plants. Their recipe for success is based on individual and continuous customer support as well as the use of field-proven products.

The need for an effective energy storage device and the fact that there was nothing of this kind adequate on the market became clear to these experts already a few years ago. Together with a partner that had decades of experience in the battery and energy storage field, the company decided to develop an innovative, high quality and effective battery solution.

Loss-free transforming and flexible control

Due to their good knowledge of customer requirements and their practical experience, two issues became top priorities: The storage device had to operate as loss-free as possible and had to be flexible enough to support the expansion or modification of PV installations. The two previous concepts available on the market had not been able to combine these two features.

The most common type of storage device available operates on the consumer side of the power inverter and converts the direct current (DC) generated by the solar modules into alternating current (AC). Battery storage therefore needed two further transformations (AC-DC & DC-AC). These AC systems therefore involve considerable losses (approx. 20-30%). DC systems with a storage device that is charged directly with DC current directly from the solar modules have to date been difficult to use. This is because the battery voltage has to be adjusted precisely to the module voltage, so that only a very specific number of modules can be connected, thus also preventing a later retrofitting of the systems.

sia energy therefore took up these challenges and developed a new solution that stores the solar electricity directly on the DC side virtually loss-free with an efficiency of 93 %, and at the same time allows the flexible connection of string voltages between 200 and 1,000 V. The company decided to use Eaton technology for monitoring and controlling the demanding system.

Available and tested – patent pending

“For our new DC24 storage device it was important for us to use proven automation technology,” comments Thilo Andonovic, responsible for technology at sia energy. At the same time, the controller had to be compact, modular and flexible. Designed for visualization and for PLC functions for controlling small to complex machines and plants, the XV102 touch display PLCs were selected. The programming and visualization here is based on CoDeSys in accordance with IEC61131-3. “Thanks to the use of CoDeSys, we and our partners don‘t have to acquire any complicated software licenses or programming devices – in our view a considerable benefit,” the engineer explains.

Unlike many other solutions, the DC24 is now already available for delivery and is field tested. sia energy is currently having the system patented, but around 50 units have already been successfully in operation at end customers. One of the first applications to be

installed at the beginning of 2013 was in a private home in Vaihingen/Enz, which was built in compliance with the latest energy standards. As the heat pumps for the ventilation system operate round the clock, the architect and owner Thomas Gutjahr soon agreed that the PV installation had to be equipped with an energy storage device.

The PV specialists Buck Solar GmbH & Co. KG, based in Markgröningen, are important partners in the dealership network of sia energy. Buck Solar installed the PV installation with an output of almost 8 kWp and helped the operator to become “price autonomous“ so to speak. At night the battery storage device provides enough power to the heat pumps in the home so that hardly any additional electricity has to be purchased.

Everything under control with the XV102 touch display PLC

Thomas Gutjahr can view all actual values at a glance on the Eaton HMI/PLC: his generated solar power output to date, the electricity purchased, the electricity sold, as well as the total consumption of the building. He does not have to do anything else with the controller. This is delivered to the dealer pre-programmed by sia energy. The dealer just has to configure on the touch panel some important basic settings for the installation as well information about the power inverter.

“In our view, the DC24 is the leading product on the market and is around one year ahead of the competition – in terms of technology and in terms of its availability,” stresses Chris Wägerle, technical manager at Buck Solar. “The system works, and the customer soon realizes that this is really something different to the products of the competition. Having this unique selling point means a great deal to us.” He is currently retrofitting energy storage devices in the PV installations of many of his customers. For him, the fact that the energy storage device is maintenance free, has a long lifespan and that the integrated components are available at any time are important factors. “Eaton‘s HMI/PLC is industry-proven and I always get spares very quickly if any replacements are necessary. It is also useful that we can easily upload the software and updates quickly via a USB interface.” He also sees a great benefit in the fact that the XV102 can be operated completely via the touch screen, and that he can save a lot of time for any fine tuning because he never requires a laptop at the installation.

One standout feature of the DC24 is the fact that the PLC monitors every single battery cell in real time. A data logging of the cell temperature here is particularly useful for warranty issues. If a cell can no longer produce the necessary capacity, the entire battery bank switches off and an error message is output. In this way, it can never occur that a “bad“ cell infects the other cells in the battery bank. The error message of the system enables the installer to make a targeted replacement of the faulty cell.

The XV102 HMI/PLC can be operated easily via the touch screen, a laptop is not needed for the configuration

The Eaton HMI/PLC comes with several interfaces and the SmartWire-DT connection technology simplifies the wiring



Products: XV-100 with SmartWire-DT, DIL contactors, PKZ motor-protective circuit-breakers, RMQ Titan control circuit devices

Company: www.sia-energy.de


Contact: Klaus Kuginna [email protected]

Scan QR Code

CoNCLUSIoN

In future sia energy plans to provide an app to make the data of the energy storage device also available on a smartphone. “We are also very impressed by the DC24 and the Eaton HMI/PLC as this solution is really future-proof,” says Chris Wägerle gladly. “After all, we see good opportunities to generally integrate the system in the building automation system and the management of other consumers. Thanks to the various interfaces on the XV102 and the modular design, this can be done easily at any time.”

Innovative electr icity storage devices give a boost to the solar power sector

Autonomy in Solar Power

Nowadays, the feed-in tariff for solar electricity is no longer a major incentive for the installation of a photovoltaic (PV) installation. However, the fact that electricity prices will continue to rise in future is nevertheless obvious.

For the operators of PV installations, the use of self-generated solar power for one‘s own consumption it is increasingly becoming worthwhile.

Energy storage devices are some of the great beacons of hope in the industry, since they enable the user to increase the share of self-generated electricity consumption and thus become less dependent on the energy supplier and their price policy. Battery storage devices in particular are ideal for private households and smaller companies and have been eligible for state subsidies in Germany since May 2013.

Developing an innovation from personal experience

The company sia energy, based in Lindenberg in the Allgäu region, has made a name for itself as a specialist in all issues related to photovoltaics. The origins of the company are based on the rental

Even though the solar power industry hasn‘t had an easy time of it recently with the constantly reduced feed-in tariffs, an increasing number of consumers are nevertheless considering the installation of PV systems. After all, electricity prices continue to rise and alternative energy is still in demand. The possibility to store electricity intelligently on location is giving the sector new opportunities. sia energy is one of the technological trailblazers in this sector. This Allgäu-based company relies on Eaton for its control technology.

of extensive roof space for their own energy requirements. Drawing on their own personal experience with a wide range of products and technologies, the sia team was able to grow into becoming expert advisors and consultants on the subject. For many years, sia energy focused on the design engineering and installation of complete systems – from small applications for private households, right through to large-scale installations for industrial plants. Their recipe for success is based on individual and continuous customer support as well as the use of field-proven products.

The need for an effective energy storage device and the fact that there was nothing of this kind adequate on the market became clear to these experts already a few years ago. Together with a partner that had decades of experience in the battery and energy storage field, the company decided to develop an innovative, high quality and effective battery solution.

Loss-free transforming and flexible control

Due to their good knowledge of customer requirements and their practical experience, two issues became top priorities: The storage device had to operate as loss-free as possible and had to be flexible enough to support the expansion or modification of PV installations. The two previous concepts available on the market had not been able to combine these two features.

The most common type of storage device available operates on the consumer side of the power inverter and converts the direct current (DC) generated by the solar modules into alternating current (AC). Battery storage therefore needed two further transformations (AC-DC & DC-AC). These AC systems therefore involve considerable losses (approx. 20-30%). DC systems with a storage device that is charged directly with DC current directly from the solar modules have to date been difficult to use. This is because the battery voltage has to be adjusted precisely to the module voltage, so that only a very specific number of modules can be connected, thus also preventing a later retrofitting of the systems.

sia energy therefore took up these challenges and developed a new solution that stores the solar electricity directly on the DC side virtually loss-free with an efficiency of 93 %, and at the same time allows the flexible connection of string voltages between 200 and 1,000 V. The company decided to use Eaton technology for monitoring and controlling the demanding system.

Available and tested – patent pending

“For our new DC24 storage device it was important for us to use proven automation technology,” comments Thilo Andonovic, responsible for technology at sia energy. At the same time, the controller had to be compact, modular and flexible. Designed for visualization and for PLC functions for controlling small to complex machines and plants, the XV102 touch display PLCs were selected. The programming and visualization here is based on CoDeSys in accordance with IEC61131-3. “Thanks to the use of CoDeSys, we and our partners don‘t have to acquire any complicated software licenses or programming devices – in our view a considerable benefit,” the engineer explains.

Unlike many other solutions, the DC24 is now already available for delivery and is field tested. sia energy is currently having the system patented, but around 50 units have already been successfully in operation at end customers. One of the first applications to be

installed at the beginning of 2013 was in a private home in Vaihingen/Enz, which was built in compliance with the latest energy standards. As the heat pumps for the ventilation system operate round the clock, the architect and owner Thomas Gutjahr soon agreed that the PV installation had to be equipped with an energy storage device.

The PV specialists Buck Solar GmbH & Co. KG, based in Markgröningen, are important partners in the dealership network of sia energy. Buck Solar installed the PV installation with an output of almost 8 kWp and helped the operator to become “price autonomous“ so to speak. At night the battery storage device provides enough power to the heat pumps in the home so that hardly any additional electricity has to be purchased.

Everything under control with the XV102 touch display PLC

Thomas Gutjahr can view all actual values at a glance on the Eaton HMI/PLC: his generated solar power output to date, the electricity purchased, the electricity sold, as well as the total consumption of the building. He does not have to do anything else with the controller. This is delivered to the dealer pre-programmed by sia energy. The dealer just has to configure on the touch panel some important basic settings for the installation as well information about the power inverter.

“In our view, the DC24 is the leading product on the market and is around one year ahead of the competition – in terms of technology and in terms of its availability,” stresses Chris Wägerle, technical manager at Buck Solar. “The system works, and the customer soon realizes that this is really something different to the products of the competition. Having this unique selling point means a great deal to us.” He is currently retrofitting energy storage devices in the PV installations of many of his customers. For him, the fact that the energy storage device is maintenance free, has a long lifespan and that the integrated components are available at any time are important factors. “Eaton‘s HMI/PLC is industry-proven and I always get spares very quickly if any replacements are necessary. It is also useful that we can easily upload the software and updates quickly via a USB interface.” He also sees a great benefit in the fact that the XV102 can be operated completely via the touch screen, and that he can save a lot of time for any fine tuning because he never requires a laptop at the installation.

One standout feature of the DC24 is the fact that the PLC monitors every single battery cell in real time. A data logging of the cell temperature here is particularly useful for warranty issues. If a cell can no longer produce the necessary capacity, the entire battery bank switches off and an error message is output. In this way, it can never occur that a “bad“ cell infects the other cells in the battery bank. The error message of the system enables the installer to make a targeted replacement of the faulty cell.

The XV102 HMI/PLC can be operated easily via the touch screen, a laptop is not needed for the configuration

The Eaton HMI/PLC comes with several interfaces and the SmartWire-DT connection technology simplifies the wiring


INFo BoARD

Fair DatesIf you want to experience Eaton live, visit us at one of the several fairs that we will be attending. The latest fair dates and information about forthcoming fairs is provided on our website:

www.eaton.eu > Our Company > Fairs and Events

Info Board

Scan QR Code

Scan QR Code

Scan QR Code

ContactTo contact an Eaton salesperson or local distributor/agent, please visit www.eaton.eu/electrical/customersupport

FAX Reply: +49 (0)228 602-2275

Email: [email protected]

Internet: www.eaton.eu

ImprintSolutions is the customerpublication of Eaton’s ElectricalSector EMEA

Published: Eaton Electrical Sector EMEAEaton Industries GmbHHein-Moeller-Straße 7-1153115 BonnTel.: +49 228 602-0Fax: +49 228 602-2275E-Mail: [email protected] www.eaton.de/electrical

Editor in Chief:Dipl.-Ing. Christian Bücker

v.i.S.d.P: Dirk Bolz

Layout: buntebrause agentur

Translator: Terry Osborn TRANSTech Translations

No. of copies: 18,000

Languages: German, English

This customer publication is protected by copyright, applicable to all articles, diagrams and photos. Eaton reserves all rights.

© 2014 Eaton Electrical Sector EMEAAll Rights ReservedPrinted in Germany 03/14Publication Number: CS083018ENArticle number: 177241

Download Center: Easy Access to Extensive Documentation

Eaton always puts safety first! While it seems that many people just pay lip service to this issue, Eaton views it as one of our prime directives. Our company and its workers are dedicated to the health and safety of all people and the environment. But what exactly is ‘safety’?

The world of norms and standards defines safety as “freedom from unacceptable risk,” meaning on the one hand protection of an object from its environment (immunity) and on the other hand operational safety, meaning the protection of the environment from a potentially dangerous object. When an organization pays equal heed to all aspects of safety and pursues the issue through a targeted program of activities, this is referred to as Safety Management.

Safety Management – Safety Under Control

For prospects, customers and partners all important information is now available in a central Download Center. From product information, catalogs, and software downloads for manuals, installation instructions and instruction leaflets, right through to tender texts and design engineering documents, the right information can be found and downloaded with just a few clicks. In addition to a central search function, it is also possible to go through the offering according to application and product group.

The Download Center - Documentation belongs to customer support and can be accessed via the following we page:

www.eaton.eu/documentation

Targeted improvement of safety performance is of growing importance for companies. One driving force behind this was the decision to anchor safety management into quality standards like EN ISO 9000. Eaton supports customers in all aspects of Safety Management and delivers a variety of solutions to improve safety – within your company and for your customers – for manufacturers, operators and users alike.

These focus on solutions that minimize the risk of hazards from machines and low-voltage systems. The issue of arc flashes is also an important area covered. For this Eaton offers arc flash risk analyses and facilities to reduce the probability of arc faults.

For further information see: www.eaton.eu/safety

Scan QR Code


INFo BoARD

Fair DatesIf you want to experience Eaton live, visit us at one of the several fairs that we will be attending. The latest fair dates and information about forthcoming fairs is provided on our website:

www.eaton.eu > Our Company > Fairs and Events

Info Board

Scan QR Code

Scan QR Code

Scan QR Code

ContactTo contact an Eaton salesperson or local distributor/agent, please visit www.eaton.eu/electrical/customersupport

FAX Reply: +49 (0)228 602-2275

Email: [email protected]

Internet: www.eaton.eu

ImprintSolutions is the customerpublication of Eaton’s ElectricalSector EMEA

Published: Eaton Electrical Sector EMEAEaton Industries GmbHHein-Moeller-Straße 7-1153115 BonnTel.: +49 228 602-0Fax: +49 228 602-2275E-Mail: [email protected] www.eaton.de/electrical

Editor in Chief:Dipl.-Ing. Christian Bücker

v.i.S.d.P: Dirk Bolz

Layout: buntebrause agentur

Translator: Terry Osborn TRANSTech Translations

No. of copies: 18,000

Languages: German, English

This customer publication is protected by copyright, applicable to all articles, diagrams and photos. Eaton reserves all rights.

© 2014 Eaton Electrical Sector EMEAAll Rights ReservedPrinted in Germany 03/14Publication Number: CS083018ENArticle number: 177241

Download Center: Easy Access to Extensive Documentation

Eaton always puts safety first! While it seems that many people just pay lip service to this issue, Eaton views it as one of our prime directives. Our company and its workers are dedicated to the health and safety of all people and the environment. But what exactly is ‘safety’?

The world of norms and standards defines safety as “freedom from unacceptable risk,” meaning on the one hand protection of an object from its environment (immunity) and on the other hand operational safety, meaning the protection of the environment from a potentially dangerous object. When an organization pays equal heed to all aspects of safety and pursues the issue through a targeted program of activities, this is referred to as Safety Management.

Safety Management – Safety Under Control

For prospects, customers and partners all important information is now available in a central Download Center. From product information, catalogs, and software downloads for manuals, installation instructions and instruction leaflets, right through to tender texts and design engineering documents, the right information can be found and downloaded with just a few clicks. In addition to a central search function, it is also possible to go through the offering according to application and product group.

The Download Center - Documentation belongs to customer support and can be accessed via the following we page:

www.eaton.eu/documentation

Targeted improvement of safety performance is of growing importance for companies. One driving force behind this was the decision to anchor safety management into quality standards like EN ISO 9000. Eaton supports customers in all aspects of Safety Management and delivers a variety of solutions to improve safety – within your company and for your customers – for manufacturers, operators and users alike.

These focus on solutions that minimize the risk of hazards from machines and low-voltage systems. The issue of arc flashes is also an important area covered. For this Eaton offers arc flash risk analyses and facilities to reduce the probability of arc faults.

For further information see: www.eaton.eu/safety

Scan QR Code


The XP500 panel PC with capacitive multi-touch technologyZooming, scrolling, swiping with two fingers – the industrial world is finally able to enjoy intuitive ease-of-use thanks to Eaton‘s new XP500 panel PC. But capacitive multi-touch technology is not all that the XP500 has to offer to system and machine manufacturers.

With its slim design, open Windows 7 operating system, and extreme ruggedness, the XP500 can be used in a wide variety of industrial applications. Regardless of whether harsh conditions, hazardous applications, or extremely strict cleaning requirements are involved, the XP500 is perfect for all needs. Simply modern and modernly simple.

A New Era in Process Visualization:

XP500 – Tomorrow‘s Operator Controls Today

www.eaton.eu

Documents

P. 20 KMT Waterjet Design Efficient Solutions · Manufacturer of high pressure pumps for waterjet cutting systems reduces costs with SmartWire-DT ... focuses on developing advanced