Answer our April's "Real Answers" question.
We integrate multiple machines into a complete manufacturing process line. The operator has to physically attend to all of the machines. Rather than have an HMI at each machine, we're thinking about handheld HMIs, maybe wireless, that the operators would carry with them. We would like to hear about experiences with this approach.

Help!

We have a mixed customer base with regard to preferences for permanent magnet motors or standard induction motors. Have induction motors reached the end of their efficiency improvement road? But we still periodically hear about the potential for magnet material shortages. We'd like to standardize where we can. Anyone else having thoughts about the direction to take?

More of the automation we install on our machines has Ethernet and web-based connections. This helps with remote troubleshooting and enterprise reporting, but some customers worry that their connected factory floor is vulnerable to internal input mistakes that can cascade through an entire process. What kind of prioritized operator and technician HMI access can protect the process, but still give us the links needed to the outside?

For better or worse, some manufacturers used screw-clamp terminal blocks for connections. Now, they have customers that prefer and sometimes specify insulation-displacement connectivity. The customers argue that IDC mean lower installation costs and reduced cabinet space as a result. That's fine, but we would like to hear what real users know about increased likelihood of having to run down loose connections in the field later on. Let us know.

We want to save cabinet space and money by using IEC motor starters instead of NEMA. Yes, they're global standards, but we're concerned about resistance to IEC outside of Europe. What's the real state of acceptance of IEC motor starters right now?

E-CAD seems like a perfect application for the concept of "software as a service." There's tons of data to be stored, the data needs to be accessed by multiple users, there has to be tight version control, and nothing has to happen in real time. The software itself is very complex and requires frequent updates, so this also seems to fit the software-as-a-service model. Does anyone have experiences they can share about E-CAD software as a service?

To improve performance, we need to upgrade our multi-axis metal cutting machines to servo motors. But before we can even begin the selection process, we need to know if we should buy the controller, the amp and the servo motor from one supplier--or should we mix and match? We feel like the mix-and-match approach will result in the lowest upfront cost, but we're wary of integration issues. Do other OEMs have experiences they can share?

We farm out most of our repeat-design panel building work, but we often do the specials ourselves. It's been getting more crowded in many of these panels. Sometimes the simplest and shortest wiring arrangement means more heat generation around the controller and other sensitive components than might be wise. Any tips, best practices or software tools to share for optimal placement of components?

Our machines use a variety of proximity switches to detect presence or absence. These switches have been hardwired to local I/O at our central PLC. We think it might be time to upgrade and move to switches connected to our PLC via a digital network to cut wiring costs and add diagnostics. Our concerns are the complexity of adding a network and, most importantly, real-time performance because we'll be depending on the network for speed of execution and ultimately the safety of our machine. What's been the experience of others in a similar situation to ours--machine builders that have made the upgrade from hardwired to networked proximity switches?  read more »

The capability (and complexity) of packaging machine designs have evolved over time and use multiple power supplies. A Control Design reader thinks that upgrading to newer, higher-efficiency power supplies that his company has heard about would be a good option. He understands that overall machine power consumption will be reduced, but are there any drawbacks in terms of cost, heat generation, form factor, flexibility or other areas?