Energy Saving using Variable Frequency Drive

 

VFDs (Variable Frequency Drives) are basically a green energy savings product that matches the amount of work or load on a motor to the amount of energy it needs to power that amount of work.  This reduces excess energy from being wasted.

So what is a VFD?  Some of the different names that are used in the industry are a variable frequency drive, an adjustable frequency drive, a variable speed drive, or an adjustable speed drive.  The technology has been around for quite a few years but only has started to make some headway in   and pumping applications in the last several years.  The size and cost of electronics has made VFDs applicable to a wider range of motors and increased the opportunity for savings.

The basic concept with the savings for VFDs is your speed and your flow are more or less proportional.   But the energy consumption is cubed.    If you’re running your motor at full speed 60 Hertz, you don’t have any savings- but any reduction pays the reduction cubed.

At its core , energy conservation is the necessity of hour every unit of energy a kg of coal is burnt. Green energy is taking up the foot steps but we need to conserve what ever energy we can. Its a good practice using less energy in order to lower costs and reduce environmental impact. This can mean using less electricity , gas , or any other form of energy that you get from your with finite energy resources available on our planet.

Variable Frequency Drive Systems Vs Servo Drive Systems

  VSD Vs Servo Drive

What is Variable Frequency Drive?

A Variable-Frequency Drive ( VFD) is also a motor control unit, but it  works in a different way than a servo drive. 

The VFD is a type of motor controller that works in conjunction with an electric motor by varying the variables such as voltage and frequency supplied to the electric motor. While a servo drive needs a command signal given to the motor in order to compare the real and desired position of the motor, a VFD directly controls the voltage and frequency supplied to the motor. VFDs are also known by other names such as AC drive, adjustable-frequency drive, inverter( mainly a Japanese term).

When it comes to the motor’s speed (RPM), a variable that is directly related is the frequency in Hz. The lower the frequency is, the lower the speed of the motor is, and vice versa. Sometimes, the electric motor doesn’t need to run at full speed and VFD can come in handy since it allows you to manipulate the frequency and voltage. If you don’t need full speed, you can decrease the frequency and voltage of the motor to suit your needs. This will also save the electric motor from potential malfunction and extend its life. Generally, Variable-Frequency Drives are used for reducing energy consumption thus reducing the energy costs of an electric motor. These motor proved to be very good when it comes to tight process control and are used everywhere from small appliances to large electronic systems, for controlling electric motors.

What is Servo Drive?

A servo drive is an integral part of a servo system that consists of a motor, a controller, a feedback device, and of course – a servo drive. 

In a layman's language a servo drive is a part of the servo system that receives a particular command from a control system, amplifies it, and transmits the current to a servo motor in the system. The servo motor produces a motion, tailored to the command it has received. The command signal usually represents some of the physical variables such as torque, velocity, and the desired position.

The servo motor is equipped with a sensor( Encoder ) that reads the current position of the motor and reports it back to the servo drive. When the feedback is received, a servo drive compares the motor status and position with the commanded variables. If there’s a deviation from the given commands, the servo drive alters the frequency, voltage or any other variable to correct the deviations.

Variable Frequency Drive[VFD]  Vs Servo Drive

A servo drive system, as opposed to a variable frequency drive (VFD) or AC motor drive , has the ability to position with extreme precision and repeatability. While a VFD  can be configured for position control, it cannot attain the exactness of a servo drive. VFDs  are also available in much higher horsepower ranges than servo's. Selection of external feedback sensors such as encoders, resolvers, linear position sensors, etc., required to achieve closed-loop control and each having its own inherent precision, will enable the system accuracy accordingly. Your application requirements will always dictate which system configuration will give you the best results!

Many of today's VFDs are fully capable of doing positioning when using encoder feedback; as with many other things, the lines have become blurred. What separates servo motor from induction motors is their low inertia and their ability to accelerate and decelerate much faster, the trick is to decide when you need full servo performance.

Can VFD controls servo motor or act like one?

Using variable frequency drive (VFD) for the servo application is quite possible, provided the application is less demanding in critical positioning purpose.

Servo motors have different information on motor control, it includes rotor positioning feedback, VECTOR mode, requires motor recognition and not necessary and encoder for rotor feedback, it estimates it through output current. (which includes V/F also) Numerical Commands can set V/F setpoint on power modules usually.

When you have VECTOR and Torque control, you may have a torque setpoint, instead of speed setpoint, if there's no load on this mode, the motor speeds up fast and may damage mechanics. If you control Torque, with the same power, speed becomes uncontrollable, some applications combine torque and speed setpoints for different frequency / torque ranges.

The problem here is that we are trying to define a specific answer using very general terms. A servo motor can be an induction servo, a brushless servo, a reluctance servo a dc servo - each of these can be either linear or rotary and can come with a variety of feedback such as tachometer, resolver of various pole counts, incremental or absolute encoders discreet or serial interface with different bus options, laser feedback, halls etc.

Then you come to the term variable frequency drive. Brushless servo amplifiers are also VDFS. Do standard inverters have proper control of induction, and brushless motors. Some allow for a software switch, some allow for a firmware download, some don't. Will inverters accept feedback - some have it built in, most that allow it do so by option cards, many do not.

What is Common Industrial Protocol Safety?

 

CIP Safety – “Common Industrial Protocol” – is an architecture  designed to provide fail-safe communication between different nodes on a safety network, including safety programmable logic controllers or Safe PLC’s,  safety door switches, safety light curtains, and many more. 

With most safety networks, you must hookup EACH safety device (which, in the case of a robot, or a machine can mean multiple individual devices hooked up ) back to the safe PLC. Safety involves redundancy, which means that each device will have at least two wires, and installation will be a very time-consuming activity. 

Safety over CIP or Simply CIP Safety, on the other hand, can be run over most common network cabling, which in turn mean not creating a need for special hardware requirements , irrespective of the location of the controller . It doesn’t matter whether you have a centralized or decentralized safety system. Since it’s not necessary to wire devices point-to-point, CIP Safety dramatically reduces wiring time and effort. 

Furthermore, all communications go through a single standard Ethernet cable, easing it  than ever to acquire necessary information for managing complex interactions between humans and machines. 

CIP Safety over EtherNet/IP enables smart safety within a Connected Enterprise and provides rich data from the plant floor . Rockwell Automation CIP  Modules & Devices  are designed to improve productivity and increase efficiency while helping provide personnel safety ,and can help protect complex equipment's.

More Information and a big thank you to  https://www.rockwellautomation.com ,www.odva.org 

An Automation Era v2.0

 

Well it all began in the late 60’s when Mr Dick Morley known as the " Fathers" of Programmable of Logic Controller [PLC] had a concept which would replace relay logic with some sort of a computer .That idea that struck since then change the course of not jut the automotive industry but has brought up an industrial revolution of its kind.The chatters of the relay have long been moved from the Electro- mechanical sequencing and from pneumatic  and Hydraulic P&ID control to simple Zero’s(0) and One’s (1) .

The world and the industry has since changed a lot but the one thing common the ‘Data’ has been following the law of conservation of energy i.e. , in my context the data can eventually nether be created or if not intended it be destroyed ,it can be transformed from one form to another for best results . The ‘Data’ since then has been transformed just from parameterize and reporting to more value value based propositions for ROI and Business Intelligence .

The Era of Artificial Intelligence is in its mid and since its inception in late 70’s have gone in for tremendous reforms ., we are now in a era were we are in a IT based Automation solution ; by that I mean the office and the field is seamlessly integrated and communicated across the continents just like what we did across the plant in the early days . The controllers are fast , strong , and versatile to handle complex process and deliver predicted model based results to save on time and money . With all this advancements the software didn't lack and have quickly moved from that old black screen with tons of instructions to module based Function Block .All his has started to move to move the automation a level up . With all this enhancement the productivity has greatly increased in a value based preposition , and programming the logic controller to with higher level languages ; thus bridge the gap which  IT engineer and the automation engineer had since years . Raw data processing transmitting was a challenge in it self , controllers are now equipped with Web servers and FTP with direct ERP data table mapped thus simplifying and pacing the project need to the best extend .

Our new normal is driving client-demand to automate processes that eliminate repetitive, monotonous tasks and augment humans to produce super-human results more rapidly. To meet this demand,  automation turbocharging with artificial intelligence (AI) to enable enterprises to automate a broader set of tasks,which we declare to be Automation 2.0.

 AI-powered automation is defined as a continuous closed-loop automation process where data patterns are discovered and analyzed, such that decisions on insights from the data can be translated into automated actions, with AI providing proactive optimizations during each stage of the process. AI-powered automation uses actionable intelligence to deliver IT and business operations with speed, lower cost, and improved user experience. The next section examines these four stages, illustrating how AI is transforming at each of these stages.

We at Softcon , have been in the automation industry since late 90’s have experienced this wonderful journey and are committed to enhancing with proven solutions for the global IT based Automation market .

What Function does PLC plays in An Automation Industry ?

 

Programmable logic controller (PLC) is a digital system of automation, which is used on a very large scale in automation industries. In these industries, it is used for a very high plant. Basically, it is used to control the heavy machines to fire a large process for grading of food, separation of many big things and many other tasks. It is typically designed as real-time controllers, which means that when you give the input, it really gives the output in the same manner. It is called an area-time controller, which gives the exact output. It has less noise, which means that it has noise immunity that does not disturb the persons.

Every machine has two aspects : 

• Input 
• Output

 As you give the input, it gives you the output but the thing is that the output should come as your requirements so in this manner this is a real-time controller as the normal human beings have the senses to do such type of thing same like that of machines. 

The machines also have their sensors and actuators. The sensors perform the function of doing things and actuators perform the tasks as per their requirements.The sensors and actuators both have designed like that they can catch any type of thing. Programmable controllers are designed in a way that they can perform such type of tasks rather than numerous things fitted in a machine. It performs the tasks that any machines can do the automation system with a high amount of parts fitted in that.

The basic function of controllers is that they control many types of motions and the related process. It has the hardware attached to it. It is compatible to industries, so this is a type of logic controllers based on digital processes, which reads the digital readings. The most important thing is that it requires the few workers. They can also perform very difficult tasks. Basically the digital signals based on binary reading such as 0 and 1 these things are sent by using the voltage and current has delivered the message to the machines the by that they perform the tasks. It mainly receives the signals working in a proper manner.

PLC Based Control Systems In India are very common and are widely used in automation industry nowadays. Softcon Systems is one of the best PLC Automation Companies In Pune. This way you can get an idea about controllers, which help you a lot in choosing the right products for you.

Automation Technology Roadmap to Industry is Easier!

 

 

This sounds slightly abstract. During this case the advanced automation technology could be a whole manufactory that during a ton of cases is quite one kilometer long.

 

But why would you prefer to simulate a full steel plant? Well, as a result of a manufactory prices up to a pair of billion Rupees and you'll be able to lose an enormous quantity of cash once the beginning of such a plant is delayed or it's not operating right. During this case simulation will facilitate to scale back the danger.

 

Here the main focus is on the automation instrumentation. The simulation ensures that the automation programs together with the sensors and actors run swimmingly right from the start. Simply Associate in nursing impression: one manufactory consists of nineteen, 000 input and output signals that are controlled by PLCs and alternative automation instrumentation.

 

The whole automation instrumentation industry is build up during a take a look at center to program and simulate the entire automation system like controllers and therefore the HMI (Human Machine Interface).

 

As well it's wont to train the operators and maintenance individuals. The simulation and coaching takes between 3 to 6 months. SOFTCON supported the build of steel plants within the last few years and gained a close understanding of the desired tasks.
The benefits SOFTCON were able to come through along with their client are:

• High software package quality right from the start (these are for instance the PLC programs)
  
•  Reduction of your time throughout the vital start-up section
  
•  Short authorization time and quick ramp-up
  

 

SOFTCON is endlessly exploring the most recent technology as per market demand time to time and developing experience through their international expertise in process plants, oil & gas automation industry and Food And Beverages Sector with  extremely masterly workers and world leader partners to support customers to require advantage of such developments.

 

SOFTCON, being associate coming organization aims to attain the goals and objectives with its ability to alter with time and therefore the determination to perpetually explore and meet client necessities. Our Company and team area unit driven by such a vision altogether its growth plans.

 

Visit our site for more Information : https://softcon.net.in/ or Call Us.
 
 

 

Automation + Digital Transformation - A Key to Business Success

                         

Automation is a process of using computers to control machinery and industrial processes of an organization. Automation generally reduces the use of the power of humans as well as machines. Automation is playing the best role in increasing income as it saves time to help a person to do multiple things with complete ease and comfort. There are many things and factors involved in automation. Chemical process can also be made automated. Some tools are involved in Industrial Automation In India. 

They are listed as follows: 

• ANN - Artificial neural network 
  
• DCS - Distributed Control System
  
• HMI - Human Machine Interface 
  
• LIMS - Laboratory Information Management System
  
• MES - Manufacturing Execution System
  
• PAC - Programmable Automation Controller 
  
• SCADA - Supervisory Control and Data Acquisition
  
• PLC - Programmable Logic Controller 

On the other is Digital Transformation means  is the practice of using technology to radically change your business to pursue new revenue streams and business models and to avoid disruption.

Digital transformation involves more than simply moving everything to the cloud and adopting a variety of digital processes. 

Tools used by Digital Transformation:

• Collaborative Suites
• Communication Tools
• New Generation Intranet Platforms
• CRM Tools
• CMS Tools
• Cloud Storage
• Project Management Tools
• Recruitment Management Tools
• Digital Accounting Tools
• Payroll Management Tools

Digitalization often starts with Automation, and migrating your data from paper copies to a digital system is one of the first steps.. Once paperless, and with your data easily accessible, you’re closing in on our model of an agile transformation.

Currently, the available technology for automation still requires human interaction or supervision, so there’s no need to panic about job loss. On the other hand, innovation breeds its own set of needs that will create new jobs. 100 years ago, social media didn’t exist, so there wasn’t a need for a social media manager like there is today. In the same vein, we can’t anticipate the jobs of the future because we’re not there yet. Going back to the point of fear of how automation performs, it’s always said that machines don’t err, humans do. If the programs and processes are properly set up, automation will actually reduce the margin of error and increase efficiency, without a doubt. 

Automation is one of the most common goals of digital transformation. The biggest benefit of leveraging automation to digitally transform is that when the time comes to grow the business, automation allows for a more seamless transition into the new business model size, with fewer resources. Digital transformation is a surefire way to ensure that your business can not just survive but thrive during the next decade.

We at Softcon Systems having more than 15 years of experience in Industrial Process Automation will help your business to grow innovatively. Contact Us for more details.