Archive for December 2011

Application Note: Going From DC Motors to a Synchronized System of AC Motors and Drives

December 27, 2011
by Kat Trick, Applications Engineer, Innovative-IDM

Overview:  At one company, there is what they call a brine box. There is a saltwater tank setup that slows an electric motor saw. Within this setup, they use three DC motors. They decided they would like to change the DC motors to AC motors. In addition to changing from DC to AC, they would like to implement speed control between the motors including the ability to decelerate the motors at the same time, and at the same rate.

The Solution: We selected the AC motors to match the required speed and torque needed for the application. This information was obtained by analyzing the load conditions and from the specifications at which the DC motors were running the application. For speed control, the simple solution was to daisy chain Yaskawa drives. This allowed the drives to communicate with each other, as well as synchronize their deceleration.

The Results:  The AC motors can be rated to give the same performance, or higher performance, as the DC motors.The AC drives can provide for controlled acceleration and deceleration rates. Connection between the drives allows for the synchronization of the acceleration and deceleration rates.The Yaskawa drives have the ability for the parameter setting to be extracted. This would make programming the drives to be easier by setting the parameters in one, and just copying the parameters from that one to the other two.

Merry Christmas from Innovative-IDM

December 23, 2011

Man are we lucky…all these greeting cards from our friends, customers and vendors; a great year of growth for our company and our employees; tons of new customers to serve. We at Innovative-IDM have been blessed. Like Brianna at our front desk exclaimed earlier today, “Merry Christmas!”

Customer Testimonial: Another Happy Customer

December 23, 2011

Well, it happened again. Another written testimonial from a customer complimenting one of our customer service staff: this time, Cyrus Jahani. Read for yourself why Innovative-IDM is the home of LEGENDARY customer service.

Jeff,

As you know we are in the process of building several machines at [our company].  As we are new to this process there are always items that are missed on the original BOM.  I can not even begin to explain how much Cyrus has meant to our success.  He sends emails to me before 8am, is always there late and never makes any mistakes.  I am always 100% confident that I can take what he tells me to the bank.  As you know I am kind of a jerk and mainly only work with vendors that give me a quick and precise response, so Cyrus fits my needs/wants very well.

If you can pass my appreciation onto Cyrus Jahani’s manager I would greatly appreciate it.

Andy

Hydraulic Presses Improved With PLC and HMI

December 22, 2011
by Rami Hassouneh, Innovative-IDM Application Engineer

Overview:

A plastics manufacturer suffering from poor productivity, inefficiency and a large number of operator errors acquires an automated solution to alleviate the problem. Using a simple setup with an Omron PLC and Omron HMI, the manufacturer reduces wasted time and material and utilizes his hydraulic presses to their full potential.

The Challenge:

The process in question was a fully manual process. It consisted of an operator filling a mold with resin, setting the pressure, and activating the hydraulic press. The operator would wait for a given time as indicated in the “recipe”, then increase the pressure setting. The operator, again, would wait for a given time, and then disengage the hydraulic press. The mold is flipped over and the process repeated. The total time of production for one part could run from 30 minutes to 300 minutes depending on the resin composition and size of the finished product.

This type of process, while simple in nature, is actually inherently prone to productivity issues. The process relies completely on the operator to accurately set and control variables such as pressure and pressing time. Human error, and unfortunately a lack of care by the operator, was resulting in these variables being inaccurate and ultimately many parts were rendered useless. On a typical day the manufacturer had 10 presses running, and was losing 2 parts a day due to operator error, at an average of $175 per part.

The Solution:

Our solution was to automate the process by installing an Omron CP1H PLC and an Omron NS series Industrial Touch Screen HMI on each press. The operator from then on would only need to select the “recipe” from a user friendly menu on the HMI, and press start. The PLC from them on would control the process by starting the hydraulic press, setting the pressure required, and time to hold. It would alert the operator when the process was completed either to flip the part over, or to remove the product. It also would trigger an alarm if a mechanical failure had occurred in the press and the set pressure could not be achieved.

The total cost for setting up the system, allowing for programming, hardware, and installation was $130,000.

 

The Results:

The manufacturer eliminated the losses due to defective products coming out of the presses. While that alone would have covered the cost of the automated solution in approximately one year, and directly increased his revenue by $127,750/yr from then on, there were also added benefits that became apparent. Productivity was increased as now a visual alarm allowed the supervisor to quickly see when a press was sitting idle, and the situation corrected immediately. The solution provided also reduced the manpower required to run the ten presses from five operators to two.

Materials Used:

OMRON CP1H Series PLC with Ethernet Interface.

OMRON NS Series Industrial Touch Screen HMI, 8” with Ethernet Interface

OMRON CJ1G/CJ1H CPU Units will be Discontinued March 31, 2012;

December 21, 2011

DISCONTINUATION NOTICE: OMRON CJ1G/CJ1H CPU Units will be Discontinued March 31, 2012

Replace with CJ2M/CJ2H CPU Units
The CJ1G/H CPU units will be discontinued at the end of March 2012. Replacing them with CJ2M/CJ2H CPU units requires minor changes to the system design such as PLC programming, unit setting, and wiring. Please refer to P068-E1-01 Replacement Guide for more details regarding converting CJ1G to CJ2M controllers.

Omron will provide repair and maintenance service for seven years after product discontinuation.

Product Discontinuation and Recommended Replacement
CPU units
Discontinued model (CJ1x Series) Recommended model (CJ2 Series)
CJ1G-CPU42H       CJ2M-CPU12
CJ1G-CPU43H       CJ2M-CPU13
CJ1G-CPU44H       CJ2M-CPU14
CJ1G-CPU45H       CJ2M-CPU15
CJ1H-CPU65H       CJ2H-CPU65
CJ1H-CPU66H       CJ2H-CPU66
CJ1H-CPU67H       CJ2H-CPU67
CJ1H-CPU64H-R   CJ2H-CPU64
CJ1H-CPU65H-R   CJ2H-CPU65
CJ1H-CPU66H-R   CJ2H-CPU66
CJ1H-CPU67H-R   CJ2H-CPU67
Hand-held programming console cannot be used with CJ2 CPU units.

Yaskawa G5 and P5 AC Drive Obsolescence Notice

December 16, 2011

The A1000 600V was introduced in July 2009 and the many features and current technology have made for a successful transition to this new product platform.

Given the age of the G5/P5 600V drives there is limited availability of components. At this time, we are announcing that the G5/P5 600V drives and all variations will be discontinued effective March 1, 2012.

Key Events and Dates

  • Stock returns will not be accepted after February 1, 2012
  • Orders for non-stocked drives will be accepted until February 1, 2012
  • The remaining G5/P5 600V stock will be sold until it is depleted
  • G5/P5 600V drives and all variations will cease production on March 1, 2012
  • Marketing documents (price book and flyers) will be discontinued March 1, 2012
  • Replacement parts will be available until September 15, 2019 (subject to availability)
  • Repair will be available until September 15, 2019 or while components are available to support these services

Phone support will continue to be available, as it is for any legacy product. Innovative-IDM is one of the most reputable distributors for Yaskawa drives, as well as being a factory authorized service center. Call us at 877.906.2100 or email info@innidm.com, or visit http://www.innovativeidm.com and we can help.

Customize Omron Sensors with Factory Molded Connectors

December 15, 2011

Beginning this week, we can now offer our customer factory molded connectors onto their OMRON sensors. We can add a molded IP67-rated M8 or M12 Connector and custom-length cable onto most Omron 3-wire and 4-wire DC Photoelectric or Proximity
Sensors.

This new program from OMRON lets our customers have a choice of affordable custom sensors with their choice of straight connector type. Ordering custom connectors is  simple
1. Call Innovative-IDM at 877.906.2100 or go to http://www.innovativeidm.com
2. Relax, we’ll take care of the rest.