We use a micro PLC to control our metal-cutting machines with good results. When customers see that we use a PLC, they want to specify brand, causing us multiple headaches in design, programming and after-sales support. There's very little variability in the operating parameters from machine to machine, so we're actually thinking of switching to a preprogrammed relay that would be set up and delivered by the vendor ready to go with its own part number. If a machine needed something a little different, we would order it preprogrammed accordingly. Are we mortgaging future versatility for fewer headaches right now?

We've added open connectivity to our machines via an Ethernet port on our industrial PC. Now, some of our customers are inquiring about wireless connectivity to pull some operating data from places that would be cost-prohibitive with a wired solution. There are many "standards" on the wireless side. What's analogous to wired Ethernet in terms of widespread industrial acceptance?  read more »

We think it makes sense to have a zero-tolerance policy toward energized work in the panels and MCCs in our new machine designs since our technicians are more involved in customer-site troubleshooting. NFPA 70E is a challenge to work through, but it appears we can do things such as restrict high voltage to one access door and employ non-contact test points through the enclosure door and have everything else at 24 V. It seems we then can lock out panels without the time and involvement of live-dead-live tests in full PPE for the technician.  read more »

We always used stepper motors in our semiconductor processing machinery with great success, but we're looking to cut costs. I've heard that it's possible to combine some of the newer VFDs with standard induction motors and attain performance close to stepper levels for less money. Does anyone have any experience with this type of an application? If so, what are the pluses and minuses?

The safety system we include on our machines has been a combination of a programmable safety controller with some regular distributed I/O to achieve a baseline SIL 3. Are we missing the boat by not trying to push the idea of safety I/O for better fault detection and diagnostics despite the cost hit?

We build some pretty basic machines that have only limited need for variable speed control of 240/480 Vac motors from 5 to 20 hp. That's going to change as we expand the machines' capabilities and design them to integrate into systems. We're arguing about whether to switch from full-voltage starters to either VFDs or soft starters. We think we could save energy costs with VFDs because we sometimes run at faster speeds than we need to, but that's not a big deal at the moment. Soft starts would clearly be easier on the system at startup. Cost can't be ignored.  read more »

Customers in our industry traditionally insisted on multiple-light, audible-horn, annunciator-type panels for alarming and operator notification. We want to move forward with up-to-date HMI touchscreens and to incorporate alarming and important operating notifications there. We'd like this to be part of the normal HMI configuration with screens that look as much like the old annunciator boards as possible. What are some possibilities?  read more »

To encourage more builder, integrator and user participation in our Real Answers section, we'll award a $100 gift card every quarter to the best, most experience-based builder, integrator or user answer, as chosen by the Control Design editors, that we print and post during each three-month period. Vendors aren't eligible, and all entries must be posted in the Comments section here and emailed to RealAnswers@putman.net. This quarter’s award will be made in June.  read more »

To encourage more builder, integrator and user participation in our Real Answers section, we'll award a $100 gift card every quarter to the best, most experience-based builder, integrator or user answer, as chosen by the Control Design editors, that we print and post during each three-month period. Vendors aren't eligible, and all entries must be posted in the Comments section here and emailed to RealAnswers@putman.net. This quarter’s award will be made in June.  read more »

To encourage more builder, integrator and user participation in our Real Answers section, we'll award a $100 gift card every quarter to the best, most experience-based builder, integrator or user answer, as chosen by the Control Design editors, that we print and post during each three-month period. Vendors aren't eligible, and all entries must be posted in the Comments section here and emailed to RealAnswers@putman.net. This quarter’s award will be made in June.

Here’s our first question from a machine builder.  read more »