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.

Creating the Future of Manufacturing in an Automation World

 

Industrial services involve the different types of services that are used to processes a company. Industries differ in mutual due to their manufacturing products. The industrial services are divided into different categories and these include as follows: 

• Management services involve different techniques and tools that are used to manage not only different processes but also the employees of the company. Over time, the different techniques are evolved like benchmarking; six sigma and total quality management which are the latest techniques in order to comfort the management teams. These management services provided to the top management help in taking the company towards the journey of success. Management services vary from company to company as different companies need different techniques. Team industrial services are the one in which the team working is enhanced to increase the productivity level. 

• Manufacturing services require different machines and technologies in order to make the process more productive and hold minimum fault in it. With the passage of time, the manufacturing services are taken by the automotive technology from the labor due to the efficient and effective services of these industrial automation manufacturers .Usually, these technologies involve the use machines, which create a huge difference in giving the flexible performance. Different business industrial goods and services packaging is taken on contract basis as to enhance the each step of the product. Industrial goods and services are now more dependent on the automotive technology services.

Machining involves different types of machines that are used on an industrial basis. These machining processes require different technologies advancement in order to provide maximum quality at each step. Therefore, now innovative automotive technologies are in use by the industrial automation in India for machining purposes. 

Benefits of Automation Systems

 

Automation is the creation and application of technology to monitor and control the production and delivery of products and services.

       There are a lot of benefits of automation systems. 

we can say that it minimizes a lot of work that can be done by hand and man dependency on a system is reduced. 

These systems are portable that can be moved from one place to another. 

The automated software systems available today are used to manage different working tasks in companies and homes. 

There is another form of automation that is used to test the application manually. It is called the test automation. It performs tasks by using direct automation techniques. Thus, automation directs the equipment to do their work exactly in a correct way. There are many automation techniques out of which one is Rockwell integrator automation. This type of automation is providing very advanced and up-to-date methods for carrying out different tasks. They provide resources for the problem-solving activities that can be very cost effective. It is not a huge type of thing. We at Softcon are official partner of Rockwell integrators  provides cost-effective solutions to the problems.

In the process of automation, there are lots of lab safeties supplies involved, which make our work easy and reliable. They also facilitate to do the work smoothly done. As the name indicates, lab safety supplies provide the security in the automation processes. They provide flammable reactive things so that in case of fire, we can remain safe from fire-related damages. They also provide bottles for the safety of chemicals. Sharpie Marker is a type of ink that is used to resists different solvents to remain safe from automation errors. As we know that automated systems also need construction safety supplies that are used to perform reliable work during the construction of a building. Thus, Industrial automation in India is very important in today’s time and without it, organizations cannot expect to survive in this agressive competition.

 

Different Types of Automation Systems

 Not everyone can easily do it, but an automation system helps employers to perform different tasks, and it gives convenience to the users and the workers in their fieldwork. It needs a permanent setup because it is mainly used on a daily basis. So without moving it from one place to another, it is not possible to take proper work from it, and the most important thing about it is its reliability. Therefore, this process has reliability and it does not cause any major damage or the deaths of a person while drifting.

Industrial automation companies in India  includes many things such as software automation, factory tools automation and robots, Weather automation and many other things give us a variety of range of automation systems in every field. In software, marketing for business tools is a global incorporation providing these types of things. For many years, industrial automation in India has greater efficiency and reliability in the market, as every company wants the best. 

Automation companies in Pune incidentally offer highest grade software tools in the Indian market related to software such as quick surf, computer aided software’s to enhance the speed of the systems in a larger manner. Pharma Industrial Automation  is also providing the medicines for the patients as per their requirements. Every vendor wants to provide the right thing to his/her customers Building automation is the system that can perform many things. Advanced automation also provides cylinders and many other things related to cylinders

 

The broadcast communicating system is the system to provide many things in the broadcasting field, shipping corporation marine vehicle control, the pressure in the sea control, and the burner management control to note down the analog and digital values. Food & Beverages Industrial Automation provides the system of beverages; the companies provide everything that can help achieve your goals successfully. 

Home automation performs many things to integrate weather flow and control of lights i.e. on and off. 

Software automation improves the effectiveness of the things and saves the time.

Business automation is to reduce the amount of labor and do the work in a better way. It is designed to have less user interface underlying. In a database field, it has to be automated because the users commit many mistakes at a lime, as they are using the system that poses few drawbacks in it at a time of performing major tasks. Automation, on the whole, is a process of using power and learning about power; how it can be used efficiently in various ways. 

 

Automation Solutions and Instrumentality Modernization

 Now-a-days one can notice vary of automation system manufacturers giving automation solutions from getting down to end. Agreeing to this belief, “automation solutions embrace PLCs, automation controllers, human machine interface (HMIs), distributed I/Os, communication and management networks, power monitors, variable frequency drives, servo system, sensors and instrumentation like flow meters, transmitters, etc. Even new laptop (Windows) based code area unit getable for varied functions of automation like vogue and configuration, observation and dominant SCADA, info management, production management, quality management and quality and compliance. The companies need to offer complete vary of merchandise and solutions covering the full electrical and automation wants of any F&B plant. This includes solutions for technique and packaging areas like technique instruments, automation systems, HMI, DCS, fail safe systems, MES–Simatic IT, automation solutions for breweries, dairy, sugar, etc, solutions for filling & packing lines, low voltage switchgear, AC/DC drives and hearth detection systems. For the utility/electrical area, there area unit HV solutions for power transmission, MV drives and motors, casing for motors, solutions for switch yard and sub-station.

F&B legislation does not permit any compromise. the most focus is to protect the client and his interest, whereas giving consistent vogue. Hence, consistent high quality along-with complete transparency of the tactic is of nice importance throughout this business.

 

Automation solutions can promote a stronger understanding of production and business processes in addition to creating certain quality through precisely made public recipes. This ensures that consistent quality is formed and predefined parameters area unit strictly determined.“As risks and costs associated with food quality and safety have up dramatically, whereas automating associate F&B plant one ought to guarantee all operations area unit up to speed and in compliance with the business rules and standards . this wants the automation system provider implement reliable management and safety system that fits GMP, HACCP, ISO, and different quality and safety standards. This includes automation hardware vogue, code development as per standards.

 

 

 

Softcon Systems - Package of Entire Life Cycle Services

 

Softcon Systems designs and develop life cycle services for their business customers. We are continuously exploring the latest technology as per market demand time to time and developing expertise through their global experience and highly skilled staff and world leader partners to support customers to take advantage of such developments.

Softcon provides Design, Engineering, procurement, FAT (Factory Acceptance Test), SAT (Site Acceptance Test and Commissioning), Trial Run, training of customer staff and handing over.

Softcon‘s facilitates increased productivity at the desktop level by providing integrated pc support services for customers. we have got designed, developed,installed,operated and maintained major networks and work facilities. We tend to still offer operational system availability at the very best level for our customers.

Softcon‘s IT personnel have intensive expertise in maintaining and enhancing application systems. Their expertise includes maintaining and upgrading systems further as conversion and re-engineering of these systems exploitation the newest technology tools and methodology. 

Our system migration expertise focuses on commercial-off-the-shelf integration, the appliance of the new and evolving technologies with existing systems, and therefore the development of custom system.

Softcon offers "One Stop Shop Tailored made Services  for our clients".

       

 

Softcon Systems Company - Vision and Mission

 

 Chandrakant Kulkarni , the Director of Softcon System Pvt. Ltd, holds a Master of  Business Administration [MBA] degree as he takes care of the complete operations of the corporate . He has domain expertise in this field having more than 15 years of experience, taking care of the industries like oil & gas, power management, metals & minerals, pharma, waste management and different industries. The superior combination of administration  with technical & industrial  management.

Our Vision 

To be an globally recognized  as the best industrial automation solutions in all the Industrial sectors.

Our Mission 

Provide technically excellent and innovative solutions, for adding value for all customers and operate globally as professional company.

Our Values

• Customer satisfaction and loyalty
• Employee dignity and self respect
• Technical excellence with professional ethics
• Organizational and individual growth
• Responsibility to society

Our Team 

Every Softcon Engineer goes through technical training for development process and rigorous test covering business objectives and automation life cycle including :

•  Company Business
•   Ethics
•  Code of conduct
•  Worldwide standard and design practices
•  Health , Safety and Environment
•  Project activities and deliverables
•  Multi discipline approach in design
•  Projects Implementation procedures
•  Testing & Commissioning
• Project close out Documentation
• After sales support

Contact Us

Softcon Systems - Who We Are?

 

Softcon Systems is a Pune based ISO certified Industrial Automation Company in India & Overseas. We provide specialized technical consulting services and custom built merchandise to the oil & gas, power, energy and offshore industries applying advanced ways and technologies.

 The multi-disciplinary nature of the solutions to comes within the marine and industrial environments demands experience in a very big selection of fields.

Softcon Systems is one of India's leading manufacturers of automation and monitoring equipment.

Our team of dedicated engineers,  service architects,  programmers and technicians possess extremely specialized skills in a very broad vary of fields. Our production spectrum includes each parts and systems, that assist the crew in fulfilling their task and also the operators in optimizing the oil gas trade operation running.

Softcon Systems is a diversified global automation manufacturing and technology company. It’s offer a wide range of industrial services in the oil gas, power, food & beverage, pharma,  water treatment , metals & minerals, automobiles and other industrial sector etc. We are  recognized widely for our automobile engineering capabilities and management excellence.