Automation Magazine en

AUTOMATION&CONTROL
TECHNOLOGIES
TECHNICAL TOOLS
ISSUE 1
TRENDS/LEGISLATION
SCHNEIDER
ACTI 9
A safe, efficient and simple choice
for low-voltage modular systems
NEW
AUTOMATION
& CONTROL
EDITION
www.designspark.com/automationmagazine
SmartWire-DT Data
transparency as standard
Logic
Command
Sensor
Actuator
Power
PKE motor-protective circuit-breaker with SmartWire-DT

Always knowing the actual current consumption of each motor brings clear benefits.
Machines and plants can be run at their performance limits, and the pre-warning
function can prevent overload trips. Output and availability are increased. The
comprehensive data supplied by the PKE via SmartWire-DT enables energy
consumption to be optimized and diagnostics to be carried out effectively so
that faults can be rectified faster.
We call this Lean Power. This offers you the freedom you need for creative
and economical solutions.
The PKE motor-protective circuit-breaker offers you all these options when it is
fitted with a SmartWire-DT module. Contact Eaton for more information.
www.rs-components.com/eaton-smartwire
IN THIS ISSUE
INTRODUCTION
Glenn Jarrett, Global Head of Product Marketing
esignSpark and RS Components
Acti 9, that will help engineers build
provides for 3D printing.
are proud to present this new
new panel designs quicker and with
This and much more
digital format that will be
more safety built-in. We are also talking
is packed in this new
focussing on the interests of engineers in
about wireless connectivity as one of the
magazine...
the machine and panel building industry.
important trends in the industry which
To be as close to your heart as possible
opens up completely new design options
enjoy reading and as
we have worked together with reference
for engineers. One of our groundbreaking
always if you have
engineers from the industry and leading
solutions we have developed in 2013
feedback please come
manufacturers around the globe.
is DesignSpark Mechanical. Read our
over and talk to us on
latest news about this free 3D design tool
DesignSpark.com
In this edition we focus on a new

range from Schneider Electric, called
in this edition, as well as the options it
REGULARS
Schneider Acti 9
n Introduction
n FEATURE: Acti 9
n Product News
TECHNOLOGIES
Sensors in Automation
n Sensors in Automation
n PLCs & HMIs in Automation
We hope you will
12
03
12
38
17
17
21
TRENDS/LEGISLATION
Wireless Connectivity
n Energy Efficiency
n Wireless Connectivity
TECHNICAL TOOLS
DesignSpark Mechanical
n DesignSpark Mechanical
n DesignShare
n 3D Printing
08
04
08
25
25
32
33
DESIGNSPARK MAGAZINE
Available on iPad, Android Tablet, Kindle Fire and as an interactive PDF
Terms and Conditions: Terms and conditions of sale are set out here ( www.goo.gl/lQVFc ) This issue is valid from March 2014 to September 2014.
Published by: RS Components Limited. Registered office: Birchington Road, Weldon, Corby, Northamptonshire NN17 9RS. Registered No. 1002091.
RS Components Ltd 2013. RS are trademarks of RS Components Limited. An Electrocomponents Company.
DESIGNSPARK MAGAZINE A&C ISSUE 1
PAGE 3
TRENDS/LEGISLATION
REACHING FOR
HIGHER ENERGY
EFFICIENCY
T
he need to reduce energy

consumption overall and deliver
greater energy efficiency in
design, manufacturing, assembly and
distribution is greater than ever. The
worlds resources are becoming ever
more depleted, energy costs are rising
fast, and clearly there are serious and
well-known concerns over the future
global environment. The European
Union for example is aiming for a 20
percent cut in Europes annual primary
energy consumption by 2020. The
European Commission has proposed
several measures to increase efficiency
at all stages of the energy chain
including generation, transformation,
distribution and final consumption,
including the introduction of smart
meters to encourage consumers to
manage energy use better.
Increasing industrialisation worldwide
means the expansion of automation,
and in particular the increased usage of
electric motors. In fact, according to a
2011 report from the IEA (International
Energy Authority), electric motors and
the systems they drive were the single
largest electrical end use, accounting
for approximately 45% percent of all
electricity consumption globally. And
of course it is in industry that electric

motors dominate and account for the
largest amount approximately two
thirds of total electricity consumption
with use for pumping, fans, air and
liquid compression, conveyance and
many other forms of mechanical
handling and processing. So, the failure
to invest in more efficient motors,
products and machinery to gain shortterm cost savings could be a false
economy.
Motor Efficiency
The largest proportion of motor
electricity consumption is due to midsize low-voltage AC motors that deliver
an output power over the 0.75 to 375kW
range. The IEC 60034-30:2009 standard
defines efficiency classes for low-voltage
three-phase asynchronous motors over
this power range: IE1 is standard; IE2 is
high; and IE3 is premium. In 2010, the
IE4 classification was also added to the
standard and manufacturers are already
starting to launch motors that meet this
enhanced performance level.
Since 2011, only motors with a
minimum performance of IE2 have
been able to be sold in the European
Economic Area, and only a minimum of
PAGE 4
TRENDS/LEGISLATION
IE3 or equivalent will be permitted by

2017. More specifically: from 2015, IE3
will be the legally specified minimum
efficiency required for power ratings
from 7.5kW up to 375kW, or an IE2 motor
plus Variable Speed Drive (VSD); and
from 2017, the IE3 will be the minimum
efficiency mandatory for ratings from
0.75kW up to 375kW, or an IE2 motor
plus VSD. Therefore it makes sense in
the medium and long term to ensure all
new or replacement motors are either
IE2 or IE3 performance, and choosing to
fit these new motors instead of having
old motors re-wound can offer real
savings.
A key factor in the drive to reduce
energy costs and improve operational
efficiency is better motor control. While
there are several options for motor
starting, part of the solution increasingly
includes the use of soft starters and
Variable Speed Drives (VSDs), which
can dramatically reduce costs. There are
estimates that approximately 90 percent
of motors used in industrial applications
have no form of control other than
simple electromechanical switching,
which can result in large costs in terms

of maintenance and mechanical wear on
equipment.
Starting
Looking at the more traditional threephase motor starting methods, Directon-line (D.O.L) is a very simple and
common way of starting three-phase
motors that uses only a main contactor
and thermal overload to directly connect
the supply to the motor. It is of course
very cost effective, but disadvantages
include a very high starting current and
starting torque, which causes stress to
the motor and drive train. Also it does
not lend itself to remote control, as the
high in-rush current of large contactors
is unsuitable for direct control from
PLC (Programmable Logic Controller)
transistor outputs.
A second method, Star-Delta (SD),
changes the wiring of the three motor
windings from delta (230V across
each winding) to star (400V across
each winding) reducing the starting
current by 60% compared to a D.O.L
starter. Star-Delta starters comprise
three contactors, thermal overload and

a timer. The advantage is a reduced
starting current and torque lowering
mechanical stresses. The disadvantage
is that it is more expensive than a D.O.L
starter, it has multiple points of potential
failure, and also will prevent the starting
of motor loads that require more than
50% of the full motor rated torque.
Both these control methods have
disadvantages and while Star-Delta
starting does reduce in-rush starting
current and limits the torque, it cannot
be fine-tuned for the application and
does not lend itself to continuous start/
stop operation. However, savings can
be achieved by using a soft-starter
in a number of ways. For example,
by matching the start-up torque and
duration to the load, wear and tear is
reduced along with transmission and
drive train stresses, which in turn also
reduces maintenance and downtime.
Energy saving can be achieved as
integrating the soft-starter into the
machines automation and removing
elements of manual control, which
mean the motor can be left running
when not in use. A common application
is stopping out-feed conveyors when
there is no product. By using a simple
photoelectric sensor to detect product,
the conveyor can be quickly brought
up to speed when product arrives and
halted when no product is available.
Because soft-starters do not
use mechanical contactors with
moving parts, their operation life
is considerably longer and they
combine all the components found in a
traditional starting solution in a single
compact unit.
Variable Speed Drives

Many applications will have variable
loads and many industrial processes,
such as assembly lines, have the
requirement to adjust the motor speed.
By adapting motor speed and torque to
the required load, it is possible to make
large gains in efficiency via the use of a
Variable Speed Drive (VSD).
PAGE 5
TRENDS/LEGISLATION
Related Products
Variable Speed Drives: fan power versus nominal flux
Eaton DS7 Soft Starter

100%
Fan
Motor
Power
80%
50%
60%
BUY NOW
40%
Schneider TeSys Range

DOL Starters
20%
0%
20%
40%
Trational Direct on-line

fan motor control
Fan motor control with a
variable speed drive
By matching the speed and torque to

the current load, savings can be made
in many applications such as small
size cranes, car washes, conveyor,
elevators, drilling or woodworking
machinery. However, if the VSD is used
in a pump or fan-control application,
savings of up to 50% are possible. For
example, a fan running at 80% speed
only uses 50% of the energy, compared
to one running at full speed. Yet far too
many pumps and fans run continuously
at full speed with the output regulated
by inefficient throttling devices such as
dampers or valves.
Combined with these energy saving
opportunities Variable Speed Drives
also allow machines to run more
efficiently, and in some cases faster, as
the speed can be smoothly altered by
the PLC or logic controller to suit the
process requirements avoiding time
consuming, and mechanically stressful
stops and starts.
An Extensive
Energy-Efficient Range
A vast range of AC motors, DOL,
Star-Delta and Soft Start-up starter
60%
80%
100%
Nominal
Motor
Flux
devices and VSDs are available from

RS Components, representing many
leading brands including ABB, Eaton,
Mitsubishi, Omron, Schneider Electric
and Siemens among many others.
The increased need for energy
efficiency is also leading to the better
performance metrics in a range of
products and technologies aimed at
automation markets, including DIN rail
and panel-mount power supplies with
devices from Omron, Phoenix Contact
and PULS leading the way with everhigher efficiency ratings. In addition,
SMC continues to deliver high efficiency
products within pneumatics such as
KQ2 fittings and the AC range of FRL
(Filter-Regulator-Lubricator) units,
which also deliver improved installation
efficiency. And with the move to LEDs,
beacons and industrial pushbuttons are
now more efficient than ever before,
while electric linear actuators can
reduce running costs within pneumatic
installations.
For more information visit:

www.rs-components.com/
energy-efficiency
BUY NOW
Mitsubishi D720-SC
Single Phase Drives
BUY NOW
Siemens AC Motors
BUY NOW
PAGE 6
Solutions for
the future
Energy
Eff iciency
Renewables
Energy
Supply
with trend-setting
connection and
automation technology.
Traff ic
Infrastructure
Water
Supply
Smart Grids
E-Mobility
PHOENIX CONTACT 2013
With foresight and enthusiasm we

create electrotechnical products and
solutions for tomorrow's world.
For additonal information visit:
phoenixcontact
TRENDS/LEGISLATION
WIRELESS
CONNECTIVITY
IN CONTROL
O
ver time, many different wireless

technologies have evolved
to support flexible links for
industrial networking and process
control applications with a range of
capabilities from hardware-based realtime solutions to low cost. In the past,
concern about security and reliability of
wireless communication technologies
in the industrial arena has limited its
deployment. But more and more, the
latest technology can support robust,
reliable and secure industrial wireless
systems including Ethernet-based
wireless LAN solutions.
The use of industrial wireless
communication is now opening up
many new possibilities for highly
flexible and efficient automation
solutions. The benefits are many
not least of which are the savings in
the installation cost of cabling up a
wired network especially over long
distances. In addition to which there
are economies of scale with the easier
addition of nodes, operational savings
with better and faster monitoring, plus
potentially much safer operation in
hazardous environments that previously
may have required an operator to take a
reading or activate a valve for example.
The range of wireless frequencies
and protocols available for process
automation, coupled with the different
performance requirements down to
hard real-time responses, has created
a fragmented industry. There is a range

of unlicensed frequencies available,
varying from the sub-1GHz variants in
different parts of the world the 915MHz
band for the Americas, 868MHz in
Europe and 920MHz in Japan up to the
unified 2.4GHz ISM (Industrial, Scientific
and Medical) band.
Industrial Wireless LAN

In response to requirements for
significantly higher levels of data
and greater networking capabilities,
Industrial Wireless LAN (IWLAN)
technology is growing fast in the
industrial automation arena. The
technology is also especially suitable

for demanding industrial applications
that require end-to-end reliable and
secure radio communications. IWLAN
is an extension of the IEEE 802.11a/b/g
and n standards offering from 54-Mbit/s
upward to potentially hundreds of
Mbit/s. In addition to higher data rates
than other wireless systems, allowing
applications such as video streaming
for example, it also allows data
transmission with other mobile devices
leading to significantly improved
process efficiency. The technology is
also especially suitable for demanding
industrial applications that require
PAGE 8
TRENDS/LEGISLATION
end-to-end reliable and secure radio
communications. Existing Ethernet
networks can be upgraded by up to 96
access points without requiring any
changes to the network infrastructure,
which opens up completely new
options, such as the use of Voice-over-IP,
video or Internet access in one single
wireless network. Various services,
security requirements and access
criteria can thus be managed reliably
so that all can use the same wireless
network.
A leading player in IWLAN wireless
communications is Siemens, which also
offers a range of equipment for wireless
remote networks or WirelessHART
based solutions. All of its offerings are
suitable for indoor and outdoor use
under extremely harsh conditions and
also provide reliability, robustness and
security. The companys SCALANCE W
range of industrial Ethernet networking
components includes access points,
client modules and various accessories
such as antennas and power supplies.
For example, the SCALANCE W7862RR access point device enables the
establishment of very reliable wireless
networks with approval in the licensefree ISM bands at either 2.4GHz or 5GHz.
Siemens has numerous industrial
applications in the IWLAN area,
including crane control (see Figure 1)
and automated guided vehicle systems
in a container terminal (see Figure 2).
Figure 1 Automated crane control

using SCALANCE W devices
Figure 2 Controller-based IWLAN applications with a large

number of access points, such as in a container terminal
Bluetooth
Bluetooth is of course very well
known as a wireless data technology
in consumer markets, but it is also
gaining excellent traction in industrial.
Offering multiple megabit-per-second
data transmission capability, like
IWLAN it operates in the 2.4GHz ISM
band and delivers reliable wireless
communication with automation
components and also quick and easy
implementation. Several advantages of
the technology include: easy and safe
installation, thanks to largely automatic
configuration; extremely reliable and
rugged data transmission, due to
redundant transmission channels and
integrated error correction; interferencefree parallel operation of multiple
Bluetooth wireless paths or Bluetooth
wireless paths and WLAN systems,
due to the efficient use of frequency
gaps; and finally a transmission range
of potentially up to several hundred
meters. A major player in Bluetoothbased devices for industrial is Pheonix
Contact, which offers products such as
its PSI line of Bluetooth converters that
convert the RS-232, RS-422 and RS-485
serial interfaces to Bluetooth making

possible a point-to-point or multipoint
connection, or for use as an access point
for Bluetooth-capable devices such
as notebooks or other smart portable
devices to query operating status or
carry out programming or diagnosis.
WirelessHART
Low-latency solutions can be vital for
those applications that require a hard
real-time capability such as monitoring
critical processes. Wireless versions
of fieldbus-based protocols such as
WirelessHART which is a wireless
sensor peer-to-peer networking
technology adding wireless capabilities
to the Highway Addressable Remote
Transducer Protocol (HART) provide
a way to deliver real-time performance
in a more flexible manner with wireless
links. While it is based on the popular
unlicensed band at 2.4GHz used by
other technologies such as WiFi or
Bluetooth and also ZigBee it also
includes security and interference
protection to ensure that every packet
of information is delivered within a
certain time. The protocol enables users
PAGE 9
TRENDS/LEGISLATION
Related Products
Phoenix Contact Wireless

Point to Point - Profibus
BUY NOW
to quickly and easily gain the benefits of

wireless technology while maintaining
compatibility with existing HART
devices, tools and systems.
The WirelessHART protocol is an
open standard designed for devices
such as sensors connected over the
4-20mA analogue loop and offers a
data rate of 250kbps. It uses a timesynchronised, self-organising and
self-healing mesh architecture and
includes several features to provide
built-in 99.9% end-to-end reliability in
all industrial environments, such as
channel hopping to avoid interference
and provide coexistence with other
wireless networks. Clear Channel
Assessments test for available channels,
while blacklisting avoids frequently
used channels, optimising bandwidth
and radio time. Time synchronisation
provides on-time messaging for the
time-critical links to the interface, and
the self-healing network topology
means any breaks or failures do not
impact the data transfer. Each device in
the mesh network can serve as a router
for messages from other devices. This
means that a device does not have to
communicate directly with a gateway,
but can forward its message to the
next closest device, thereby greatly
extending the range of the network and
providing redundant communication
routes for increased reliability.
Security is also a key consideration
for an industrial network. In this,
WirelessHART employs the security

techniques to provide the highest levels
of protection available via 128bit AES
encryption and a unique encryption key
for each message, as well as device
authentication.
Siemens W-786-1PRO
Access Point
Extensive Wireless Range

And finally, also available via RS are a
range of wireless products including
pushbuttons from Schneider Electric,
wireless switches from companies such
as Honeywell and Steute, and wireless
LAN access point products from
Pheonix Contact. In addition, brand
new wireless industrial sensor products
now include those from JUMO such as
its Wtrans transmitter RTD (Resistance
Temperature Detector) temperature
probe. The Wtrans transmitter is
designed to be used with a Wtrans
receiver for stationary or mobile
detection of temperatures within the
operating range of 30 to +260C or
200 to +600C. The transmission
electronics of the probe are vibrationproof and the case is both oil resistant
and acid proof. The radio frequencies
of the Wtrans measuring system
(868.4MHz for Europe or 915MHz in the
US) are largely impervious to external
interference and allow transmission
even in a harsh industrial environment.

wireless-automation
BUY NOW
Honeywell Wireless Limit

Switch Top Roller Lever
BUY NOW
Schneider Wireless
Push Button
BUY NOW
PAGE 10
imagine a world without wires
What would you do with more freedom?

Its time to cut the cord. To retire the wire. To give your best
ideas free rein. Introducing Limitless Switches, a series of
wireless limit switches from Honeywell Sensing and Control
that allows you to go farther, work smarter and explore more
possibilities than ever before.
Theres a new way of doing things. A new way of working that
delivers more exibility, more uptime, more reliability and more
freedom. Its built on the principle that we dont need to be chained to the old way of doing
things. Wireless technology has already changed how we communicate and connect to our
world. And now Honeywell is using it to change how we design and operate a host of different
technologies and devices.
Freedom awaits. Its time to discover the possibilities. Its time to switch. Switch to wireless.
Switch to Limitless products.
To learn more about Limitless wireless limit switches, contact a Honeywell

representative today at 1-800-537-6545 or visit www.honeywell.com/limitless.com
2010 Honeywell International Inc. All rights reserved.
www.rs-components.com/honeywell-limitless
FEATURE
SCHNEIDER
ACTI 9
Pushing the Boundaries in Smarter

and Safer Power Distribution.
The Acti 9
Modular System
Launched last year by Schneider

Electric, the new Acti 9 range is a complete
modular low-voltage distribution system offering
protection, control, measurement and communication. The
range promises much, including unmatched efficiency and
total controllability, according to Schneider, along with the
ability to single-handedly transform control and electrical
distribution in modern commercial builds.
Next Generation
Designed to be the next evolution

of the companys well-known and
industry-leading Multi 9 system, the
Acti 9 Modular System represents
Schneiders fifth generation of modular
systems and is the culmination of 40
years of industry experience. Covering
all applications and implementing as
many as 21 new patents, several of
the Acti 9s features are exclusive to
Schneider. The Acti 9 range is especially
suited to demanding environments
and networks and offers high levels of
safety, zero maintenance and excellent

continuity of service. It also includes the
latest technology available in terms of
robustness, security, quality, reliability
and sustainable development.
Combined with the Smartlink
communication system, Acti 9 is a
complete and ready-to-connect system
that is compatible with any EMCS
(Energy Management and Control
System) architecture. It unites basic
control with optimum protection to
easily manage energy efficient solutions
in any environment using the flexible,
PAGE 12
FEATURE
reliable and easy-to-use Modbus
communication system. Offering
increased levels of safety, usability
and performance, the extremely
wide product range should meet the
requirements of manufacturers of
control panels, panel builders and
contractors among many others
includes miniature circuit breakers
(MCBs), residual current devices (RCDs),
switch disconnectors, DIN-rail-mounted
control and other switching products.
In addition, the range is designed to be
completely environmentally friendly
and is said to be the only industry
MCB system that is made from 100%
recyclable and recoverable components.
A highly flexible and comprehensive
system, Acti 9 based systems can
also evolve with the demanding
requirements of industrial and tertiary
electrical installations, in addition to
providing zero-maintenance installations
that are highly cost effective over time.
Safety
Safety is one of the major advantages
of the Acti 9 system. Its VisiSafe feature
provides reinforced insulation on the
iC60 miniature circuit breaker and ilD
residual current breaker ranges. This
guarantees that the downstream circuit
is always safe, regardless of overvoltage
conditions, wear, or contractor
experience, even in the most demanding
environments. Combined with its Class
2 front face, where clearances between
its surfaces and internal parts are more
than twice the industry standard.
Class 2 front-face IP40

Efficiency
The Acti 9 MCBs and residual-current
circuit breakers (RCCBs) operate using a
fast-closing mechanism, which reduces
wear and tear on the main contacts,
thereby increasing the lifetime of the
products especially when they are used
for protection and functional switching.
IP20 termination
Automatic Reclosing
Fast closing main contacts

In addition, the systems VisiTrip feature
enables users to identify a fault with
a single glance, enabling the quick
diagnosis, resolving and reclosing of
circuits for better building management
and reduced downtime. All power
connections are also designed to
provide an IP20-rated finger-proof
terminal using a built-in insulated
shroud, which also prevents incorrect
insertion of the conductor into the cable
clamp. Also, super immunisation of
RCDs guarantees a high level of service
continuity and electrical immunity
in even the harshest environments,
which may be subject to dust, chemical
pollution or humidity, as well as being
able to withstand higher levels of
impulse voltage.
VisiTrip
Through the use of an automatic

reclosing auxiliary (ARA), the Acti 9
system can be fully adapted to suit a
remote infrastructure site, making it
100% operational anywhere in the world
using the ARA/RCA (Remote Control
Auxiliary) operator or integrated Reflex
circuit breakers. The ARA automatic
reclosing auxiliary can perform
automatic reclosing of the associated
protection device after tripping, therefore
significantly increasing the availability of
installations that are isolated or difficult
to access and yet demand high levels of
availability. Application environments
could include mobile telephony systems,
pumping stations, airports, railways,
meteorological stations, service
stations, automatic teller machines or
public lighting systems, among many
others. Operators can select from
predefined reclosing programs that
allow both safety and availability
of facilities taking into account the
application environment. Essentially,
it allows the restoration of operation
without intervention by personnel in
the event of a transient fault due to
atmospheric disturbances or industrial
overvoltages, for example, potentially
negating the need to go on site a
major advantage in industries where
the cost implications of even a few
minutes of downtime are huge
unless of course the ARA recloser
cannot reset the circuit breaker, clearly
indicating the potential for a greater
problem to be resolved.
PAGE 13
FEATURE
n Sealable cover
n Indication of ARA
operating states
n Placing in safety configuration by

integrated padlocking device ( 3 to 6 mm)
n 4 Predefined
programs
n Manual control of
the circuit breaker or
residual current circuit
breaker always overrides
automatic control
n Manual remote control of

final reclosing (after inhibition
of automatic recloser)(Y2)
n Remote inhibition of
remote reclosing (Y1)
n Bistable operation: does not

change state in the event of
electrical power outage
n Inhibition of automatic
recloser (auto OFF) and
resetting (Reset)
Automatic Recloser Auxiliary (ARA) system
Monitoring and
Communication
The Acti 9 products can also be
directly integrated with a Building
Management System (BMS) or PLC
to gain full insight into energy usage.
Incumbent operators can benefit from
real-time data coming from panels
and circuits to fine-tune electrical
loads to reduce and allocate costs and
effectively manage energy.
Unlike traditional options, the
system easily connects to any facility
management system, even in the most
challenging of electrical environments
enabling simple, error-free installation,
performance and maintenance.
Complying with the IEC/EN 61131-2
standard for PLCs, the Acti 9 Smartlink

transmits data from Acti 9 devices
including MCBs, RCCBs, RCDs, remotecontrolled MCBs or power meters to
a PLC or a supervisory system via the
Modbus serial line communications
network. All data is stored in memory,
including number of cycles, power
consumption and period of operation
even in the event of a power failure.
Smartlink can also exchange data with
any device that has 24V DC digital
inputs and outputs. Using flexible
and robust Modbus communications
and pre-fabricated wiring for instant
error-proof connectivity, it could save
up to 40 per cent in time spent with
control wiring.
ECMS System Example

As an example, a typical energy
management system used by a shopping
centre operator to manage critical loads
and measure power usage could be built
using Acti 9 technology and products.
The Acti 9 Smartlink enables terminal
switchboards to be directly connected
to the site monitoring network; circuit
breaker auxiliaries such as iOF+SD24
types indicate any tripping or deliberate
opening; the RCA module and impulse
relays receive the on/off switching orders
and indicate their states; the RCA module
bistable operation ensures that it does not
open if power is lost; and finally energy
meters can be incorporated to make their
data available via the Modbus network.
PAGE 14
FEATURE
Acti 9 system example
All devices are connected to the

Modbus network via the Acti 9
Smartlink communication interfaces
and fully prefabricated connectors,
which means that cabling is quickly
installed without risk of error and
during maintenance operations
and the fine wire links inside the
switchboard can be identified
immediately. No handling tools are
required, due to the use of plug-in
connectors. Other benefits include
a single RS485 link connecting
the switchboards to the PLCs and
monitoring system, high reliability
of data and indications, including
IEC 60947-5-4 compliant low-level
signal contacts for the iOF+SD24,
and a high level of electromagnetic
compatibility of the Acti 9 Smartlink
modules. In addition, functionality
such as protection-device trip
and operating time metering
integrated within Acti 9 Smartlink
communications makes it possible to
plan preventive maintenance.

schneider-acti-9
Availability
A major distributor of products from Schneider Electric, RS Components

offers approximately two thousand Acti 9 products globally with local
and regional variations taken into consideration.
In a process that began in 2013, and continuing on to the end of 2014, the existing
Multi 9 system products will be migrated to Acti 9, with the possible exception of some
products designed for specific applications. Acti 9 product availability and up-to-date
pricing information is available via the RS website, in addition to technical hotlines and
the availability of its global sales force to provide further support to customers.
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PAGE 15
Reliable and easy operation - worldwide

S8VK power supplies
Omron has developed a new and exciting family of compact power

supplies with the same high quality and practical design that made our
previous series safe, reliable, and easy to install. The S8VK series is even
tougher, more compact and easier to use.
To ensure that we provide the perfect solution to match every
customer need, Omron has launched 3 different families:
the cost effective S8VK-C, the standard S8VK-G, and the S8VK-R
redundancy unit.
Key features
The most compact design on the market
Stable operation in extreme temperatures
High vibration resistance & long product life
Easy and fast installation
www.rs-components.com/omron-powersupplies
TECHNOLOGIES
SENSORS
IN AUTOMATION
Sensors surround us all: in
the consumer world of smart
and mobile devices such as
the capacitive or resistive
based touchscreens on our
smartphones and tablets or
the motion accelerometers in
gaming platforms; or in the home
automation world with pressure
and proximity sensors among
many others in our dishwasher;
and certainly they are a vital
component in the fast developing
future that is the Internet of
Things, which is taking many of
the headlines these days, and in
the so-called Industry 4.0 drive to
make manufacturing smarter.
Sensors have also long been the
virtual eyes, ears and nose and
also the instruments of touch
in industrial automation and
control machinery. They inform
the systems brain usually the
programmable logic controller
(PLC) in an industrial context
with what it needs to know to
make decisions. When integrated
with PLCs and control products,
sensors form a key part of the
control and communication
system and need to be a major
consideration at the early stages
of system architecture design.
Environment
In the industrial environment, sensors
are used to measure an extremely wide
range of environmental factors including
temperature, motion, positioning,
acceleration, weight, humidity, chemical
composition, gases or pressure or liquid
flow. Typical examples include ultrasonic
liquid-level transmitters for continuous
level measurement and alarm switching
at a water treatment plant; or pressure,
temperature and level sensors in the
monitoring of hydraulic fluids and
coolants in machine tool applications;
or inductive proximity switches in
automotive assembly lines. In fact
today, there is virtually nothing that
cannot be measured or sensed and used
as an input to a system.
Sensors and transducers are designed
Equally important
as acquiring the
signal is conditioning
and transmission.
for a wide range of environments, but

equally important as acquiring the
signal is conditioning and transmission
to ensure it is safely conveyed to the
central processing unit. For example,
often a signal needs to travel over
a distance and usually via cables.
To increase the signal-to-noise ratio,
PAGE 17
TECHNOLOGIES
twisted-pair cable with shielding is
typically used to cancel out induced
noise. Depending on the surrounding
environment and the distance of cable
run, amplification of weak signals may
be required, which can affect the type
of signal chosen in the first instance.
For example, 4-20mA is the de facto
signal for long distances over hundreds
of meters because it is immune to volt
drop and induced noise. Millivolt and
small-resistance signals such as those
from thermocouples are generally
weak signals and therefore need
to be amplified prior to being sent
over distance to controllers. Signal
conditioners are therefore employed
and fitted near to the sensor.
One of the fastest growing areas

in automation is machine vision
technology, employing digital camera
sensors and advanced image processing
technology and widely used in many
industries to automate the production,
increase production speed and also
improve quality. However, more
traditional sensor types have also
evolved rapidly. For example, one of
the most important functions is position
sensing and a vast range of linear and
rotary position encoders is available.
While some offer absolute encoding,
retaining memory of the last position
of the system following powerdown,
the vast majority of applications can
be served by incremental encoders.
Encoder outputs need to be chosen
carefully according to the electrical
environment, application and external
signal conditioning apparatus.
Manufacturers such as Baumer
therefore offer a range of configurations
specifically designed to cope with these
different requirements. Other major
manufacturers in this area include
Hengstler, Omron and SICK.
used in a huge variety of positioning

applications, ranging from hoisting
in the factory environment to mobile
lifting, automatic livestock feeding
systems and automation in the food and
beverage industry. The trend here is to
provide improved performance using a
traditional underlying technology with
advances in specifications such as sensor
speed, robustness and smaller size. One
type of proximity sensor is the inductive
proximity sensor, which uses magnetic
induction to detect ferromagnetic
metallic material. Suitable for use in
dirty and wet areas, it is commonly used
in traffic lights, car washes and many
industrial automation processes, and
while it is immune to dust, it is also
limited to sensing distances of up to
about 50mm. An example of this type
of sensor is Schneiders OsiSense XS8
range, which is designed for use in
many industrial applications including
packaging, materials handling and
assembly. Key features of these
sensors are that they can be installed
quickly and easily on any machine or
equipment due to the unique one-click
mounting and the rotating detection
head. They enable maintenance to be
simplified due to the quick mounting
and removal of LED status indicators
that are clearly visible from any
direction and from long distance.
A second type is capacitive proximity
sensing, which detects objects that are
conductive or simply have a dielectric
different from that of air. This means
the technology can detect both metallic
and non-metallic material, which is a
primary difference from induction-based
proximity sensors. The technology
is commonly used in applications to
detect and measure position, humidity
or fluid levels among others. Again, it is
suitable for use in dirty and wet areas,
and is immune to dust, but is limited to
sensing distances of up to 40mm.
Proximity
Light
Non-contact proximity sensing is

another key area in automation and is
Photoelectric sensors are also

employed widely in industrial
Position
Related Products
Mobrey MSP400
Ultrasonic Level Sensor
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SICK Photoelectic
Sensor DS50
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Omron E3JK Sensor
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Telemecanique
Inductive Sensors
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PAGE 18
TECHNOLOGIES
Level
Level sensors are another important
kind of sensor for automation and
control: essentially they detect the flow
level of substances, usually liquids,
slurries and powders. One example level
sensor that uses ultrasonic technology
is the MSP400 level transmitter from
Mowbrey, which is designed to be
mounted above a liquid and will
measure the distance to the surface
of the liquid. When programmed with
details of the vessel, sump or open
channel, the MSP400 calculates the
level, content or flow and provides
a 4-20mA signal proportional to the
chosen variable. Two relays are provided
for control functions and programming
is achieved using integral push buttons
or by remote communication using
HART (Highway Addressable Remote
Transducer Protocol).
Conclusion
automation, using light to detect the
distance, absence, or presence of an
object by using a light transmitter, often
infrared, and a photoelectric receiver.
There are many types available that
detect an object when the light beam
is interrupted such as through-beam
sensors, in which a receiver is located
in line-of-sight of the transmitter and,
or retro-reflective sensors, in which the
transmitter and receiver are placed at
the same location and use a reflector
to bounce the light beam back from
transmitter to receiver.
An example through-beam sensor
is the E3JK series of photoelectric
sensors from Omron, which also have
a built-in power supply for greater
system integration. This series of
sensors have a high power and visible
red LED for all models enabling easy
alignment and long sensing distance.
Another example of light-based
devices, the DT50 and DS50 series
of phototransistor distance sensors

from SICK, uses either infrared or red
light and provide a high degree of
reliability and reliable measurement
detection including in strong light
conditions and on shiny targets.
Typical application areas include steel
and metal production, print and paper,
automotive, warehousing and many
more. And finally, when position and
presence detection is required on a
much smaller scale, fibre-optic and
RGB colour sensors are becoming
increasingly popular. In addition to
small size and their ability to detect
small object and movements, they are
also resistant to electrical noise and
can function at higher temperatures.
Finally, one of the fastest growing
areas for light sensors is the dramatic
increase in the use of visual information
as a system input, particularly machinevision technology, which today is being
heavily used in manufacturing.
These are just a few from hundreds

of different sensor types available,
and this is without even including
pressure sensors, or RFID and
barcode readers/scanners, which
again come in a vast array of different
types. Major manufacturers of
proximity, light and pressure sensors
and a huge range of accessories
all available via RS include
Telemecanique, Omron, Pepperl
+ Fuchs, Baumer, IFM Electronics,
SICK Banner. In summary, the
continuing development of sensor
technology is vital to the flexibility
and sophistication of both simple
and complex control and automation
systems in a multitude of industrial
process and manufacturing industries.

sensors
PAGE 19
IN UNSURE TIMES, NOTHING BEATS OPTIMISED PRODUCTIVITY.
When industrial systems have to deliver high productivity, engineers dont rely on gut instinct. Instead, they rely on sensor technology
from SICK. Our solutions ensure optimal processes. They stop expensive machine failure and downtime. They reduce changeover
times. They provide your every industrial sensor need. In every industry and every area of factory automation. With photoelectric
sensors, proximity sensors, light grids, uid sensors, distance sensors, vision sensors, and registration sensors and services from
SICK. When it comes to reliable production, the whole world draws on the engineering spirit of SICK.
We think thats intelligent. www.rs-components.com/sick-sensors
TECHNOLOGIES
Programmable
Logic Controllers
Human-Machine
Interfaces
&
I
he use of programmable logic

controllers (PLCs) continues
across a diverse range of
automation and industrial control
applications including vending machines
or high-speed packaging apparatus
or many kinds of factory automation
equipment such as materials handling
and automated assembly. PLCs are
also sometimes known by other names
such as logic controller, programmable
controller, programmable automation
controller (PAC) and machine
automation controller (MAC). Despite
continuous evolution they are still
clearly recognisable as descendants
of the original PLCs that emerged
40 years ago or so, and continue
to excel in applications that involve
managing a sequence of control tasks
in a predictable and timely fashion in
response to a number of input signals.
Prior to the creation of the PLC, most
machine control and automation tasks
were controlled using a combination
of simple relay logic, timers, counters
and other discrete control components.
While early PLCs were simple with
limited functions and memory, their
capabilities have significantly increased
over time. The original Boolean-type
operations such as AND and OR
A T
functions have been supplemented with

mathematical functions and higherlevel output capabilities such as preconfigured pulse-width modulation
(PWM) blocks, in addition to an
increase in input/output (I/O) count
and significantly improved external
communications options.
Categories of PLC
PLCs have become increasingly
differentiated and a number of
categorisations of product are now
in common use. Historically, the
simplest applications are covered by
logic controllers, which are sometimes
called smart relays and typically
provide a relatively small number of
I/O, implement basic Boolean logic
control and do not require high-speed
operation. They are generally used for
processes that follow a pre-defined
sequence with limited or no deviation
in applications such as car park barriers,
car washes, vending machines and
simple packing equipment.
The second more complex type
is the compact or brick PLC, which
offers increased processing speed and
I/O capability. There is also support
for additional I/O expansion and a
more flexible sequence of operation
PAGE 21
TECHNOLOGIES
for instance in response to operator
intervention or as a result of monitoring
external conditions. Typical applications
include programmable cutting machines
and batch control of bottling equipment.
The third category is the advanced
PLC, which services more complex
applications involving large amounts
of data, requiring a modular build
approach and needing to function at
high speed with further increased levels
of I/O. One example is RFID-based
sorting and routing of products in a
conveyor system and high-speed
label printing.
A fourth and much more recent
category is the programmable
automation controller (PAC), which
has become a largely interchangeable
term with PLC, or advanced PLC. In
many ways it combines capabilities of
a PC and a PLC and offers many of the
benefits of both in a single package. PLC
vendors are increasingly positioning
higher-end PLCs as PACs as these
products tend to offer greater flexibility
in programming, larger memory
capacity, better interoperability and
include more connectivity options and
broader control capabilities than their
PLC product lines. Generally, a PAC is
more suitable for complex automation
system architectures that are often
composed of a number of PC-based
software applications, including HMI
(Human Machine Interface) functions,
asset management and advanced
As PLCs have become

more capable and
differentiated, the task
of programming has
become more complex.
process control requirements.

The choice of logic controller or
a compact or advanced PLC or PAC
will ultimately be determined by the
application, but lines between all the
above are becoming increasingly
blurred with the functions and capability
of logic controllers growing every
year. Most logic controllers now offer
expansion up to 28 I/O and often
accommodate AC or DC inputs and
transistor or relay outputs over many
voltage ranges. In addition, integrated
PWM output for motor-control tasks is
now a common feature. Example logic
controller devices include the Siemens
Logo! and Mitsubishi Alpha 2, which
also have evolved to incorporate the
ability to integrate with HMI panels
providing operation messages and other
status information, a function which a
few years ago was only the preserve of
compact or advanced PLCs.
Programming
As PLCs have become more capable and
differentiated, the task of programming
has become more complex. Originally
designed to be easy to program, early
devices were programmed directly
via a front panel or a special-purpose
terminal. The restricted range of

functions meant it was often possible
to include a dedicated key to represent
each logical element of the program.
The traditional programming language
associated with PLCs is ladder logic,
a simple system that depicts the
program graphically based on an
equivalent circuit diagram of relay
logic hardware. Unfortunately, the
ladder logic languages of individual
manufacturers are incompatible and it
is rather misleading to think of ladder
logic as a language as it is closer to a
programming style or family of rulebased languages.
Software has played an increasingly
important role in progressively complex
industrial automation over the years,
and increases in software cost can mean
it is even becoming the most expensive
part of the system. To control these costs
and achieve higher efficiency during
application development, while also
increasing software quality, attempts
have been made to introduce a degree
of standardisation to PLC programming
systems via the IEC 61131 standard in
which the PLCopen organisation has
been a driving force. The intention of IEC
61131 part 3 is to harmonise the design
PAGE 22
TECHNOLOGIES
and operation of industrial controls via
standardisation of the programming
interface, allowing a team-based
approach to project specification,
design, implementation, testing,
installation and maintenance. The
standard recognises four programming
languages: ladder diagram (LD)
and function block diagram (FBD)
programming are both graphical styles;
while structured text (ST) and instruction
list (IL) are textual types. In addition, IEC
61131-3 defines a sequential function
chart (SFC), which includes elements to
organise programs for sequential and
parallel control processing.
A related trend in the PLC market is the
move towards the use of more familiar
and often consumer-market driven
communications interfaces such as USB.
In the past most PLCs were programmed
via the RS-232 or RS-485 serial port,
but with most if not all modern mobile
computing devices not incorporating
these legacy communication ports,
PLC manufacturers are responding by
enabling programming via serial, USB
and increasingly Ethernet.
Human-Machine Interface
A massively important element in
the evolution of PLCs over the years
has been the growing integration
of Human-Machine Interface (HMI)
technology, which is providing
significantly increased logic and graphic
processing capabilities. While there are
many aspects to this, perhaps most
striking of all is the increased use of
high-resolution graphics displays and
rugged-environment touchscreens in
panels as a substitute for traditional
devices such as indicators, displays
and switches. Many logic controller and
PLC ranges also now include graphical
user interfaces that have more in
common with desktop PCs than with the
simple buttons and meters of the past.
Automation and industrial control is
becoming more and more reliant on HMI
capabilities to deliver accurate and realtime control and monitoring information
on industrial processes, enabling faults

to be quickly identified, for example.
Developments in consumer electronics
markets are increasingly being applied
in HMI design for industrial automation
and control panels and all-in-one PLC/
HMI units are now widely available in
the market. Suppliers are developing
increasingly innovative solutions that
deliver ever-higher functionality and faster
processing speeds enabling many more
possibilities in industrial applications.
Related Products
Mitsubishi FX3G and FX3U
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Extensive Selection
of Leading Brands
To enable panel builders to make
informed, creative and reliable choices
about the right solution to build new
installations and also maintain and
upgrade existing equipment, RS stocks
a wide range of equipment from
leading brands in the market such as
Mitsubishi, Omron, Schneider Electric,
Siemens and Eaton, including all
the control devices and components
required to build a complete system
such as control (CPU) units, I/O
expansion and displays and other HMI
devices, in addition to providing a very
high level of technical support.
Omron CP1L
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plc-and-hmi
Related Products
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PAGE 23
AF contactors
Connect to Control
Featuring the AF Contactor technology as ABBs
new standard global offer (replacing ABBs former
A-Line series contactor range). The electronically
controlled coil of the AF Contactor allows for a
much wider operating voltage in either AC or
DC with the same contactor; as well as offering
multiple benefits over conventional alternatives.
Now expanded up to 370A via RS Components:
- Up to 200 Kw / 370A, 400V AC-3 / 3-phase motor rating
- Up to 600 A, 690V AC-1 / general use rating
Simplify design
Access global support
Secure uptime
Optimize logistics
Coordination tables, lowered energy consumption and

smaller units are some reasons to why the AF contactor helps
simplify your design.
The AF contactor ensures distinct operation in unstable

networks thanks to a wide operating voltage and an
electronically controlled coil.
www.rs-components.com/abb-contactors
ABBs AF contactors meets all major international and

national standards and can be used in applications in Europe
or Asia as well as in North America.
The total number of product variants has been reduced by up

to 90% while offering increased functionality.
TECHNICAL TOOLS
DESIGNSPARK
MECHANICAL
Some Useful Techniques
The new DesignSpark Mechanical 3D modelling
software from RS allows the creation of 3D
models quickly and easily without needing
previous CAD expertise.
While it is a very easy tool to use, it is always useful to learn a few
shortcuts to become even more productive. Here are a few techniques,
also described on the DesignSpark blog site, that should aid and
accelerate 3D design using DesignSpark Mechanical.
PAGE 25
TECHNICAL TOOLS
Resizing Solids
Creating a new solid is quick and easy using the Sketch
andPulltools. Once a shape has been created, it can
be resized with reference to the original dimension.
In Figure 1, when some simple cylinder shapes were
originally created, the right-hand cylinder was 25mm
tall. This can be reduced to 20mm by clicking on
thePulltool and dragging down the top surface; the
tool indicates how much the surface has moved. At any
time during this action, the keyboard can be used to
provide the precise dimension required. The Pulltool
can also be used to resize with reference to the overall
height. Selecting the top surface, a small menu appears
(see Figure 2). Selecting the Ruler tool allows the pull
action to be performed, but with reference to any
chosen point.
Figure 1: Reducing the

height of a cylinder
Figure 3: Pull tool menu

showing size of cylinder
Figure 4: Cylinder resized

using the Pull tool
Hollow Bodies
There are a couple of ways to create hollow bodies,
but the simplest method is to turn a solid into a hollow
body by selecting theShellbutton (Figure 5), and
then choosing a surface for removal. The default wall
thickness is 1mm, but this can be changed following
surface selection. TheCompletebutton (Figure 6) can
then be used or another tool selected to finalise the
changes. TheShellbutton will also work on more
complex shapes, such as that shown in Figure 7.
Figure 2: Pull tool menu

For example, if the ruler is anchored to the bottom
surface it will show the overall height of the cylinder
25mm (Figure 3); the required height of 20mm (Figure
4) can also be entered to complete the action.
PAGE 26
TECHNICAL TOOLS
orientation of the section plane can be selected by
clicking on one of the surfaces of the object, followed
by use of the Move Gridbutton. The Move tool can then
be used to move the section plane to show the internal
structure of the design, as in Figure 10.
Figure 5: Shell button
Figure 8: Component
Structure Tree
Figure 6: Complete button
Figure 9: Section Mode
Figure 7: Using Shell for complex shapes

Hollow solids can also be created without removing a
surface. Following creation of a solid, the component
can be selected in the Structure Tree (Figure 8), rather
than clicking on the object. TheShellbutton can be
selected to change the wall thickness, as before. The
only difference is that once the operation has been
completed, the changes will not be shown on the
screen. The solid is now hollow, but all surfaces are
intact. SelectingSection Modeon the toolbar (Figure
9) provides a view of the design in cross-section. The
Figure 10: Move tool
PAGE 27
TECHNICAL TOOLS
Move up to
The Move - up totool is very useful in placing one part
or feature accurately against another surface. A typical
example could be populating devices on a DIN rail at
the back of an enclosure. Trying to place the part in
the conventional way by dragging into position with
theMove anchoris difficult because the sides of the
enclosure will obscure the view of the parts, even if the
design view is revolved. Touse Move up to, theMove
anchoris placed so its hub is located on the intended
mating face of the object to be moved, as in Figure 11.
This can be achieved either by selecting and dragging
the hub of theMove anchor, or using theAnchor
placement tool,which is in the design frame to the left
hand side while the Movefunction is selected, Figure 12.
Figure 11: Move anchor placed

on the mating face
The axial arrow should be selected in the direction the

object is to be moved (although sometimes the arrow
will be pointing in the opposite direction, it will still
work as long as the correct axis is selected). A command
menu will appear following selection of the anchor
arrow, as in Figure 13. Selecting the up to icon and then
selecting the target surface enables the components to
be mated, as in Figure 14.
Figure 13: Mating components using anchor

arrow command menu
Figure 14: Components mated

using Move up to
Moving dynamically
within a plane
Figure 12: Mating components

using Anchor placement tool
TheAlt key can be used to move an object dynamically

within a plane. When inMove mode, and theMove
anchoris visible, the Alt keycan be pressed and heldto
generate webs between the axial arrows of the anchor
(Figure 15). By selecting and dragging on a web, the object
can be moved freely in two axes but will be restrained to
move within the plane as indicated by the web.
Figure 15: Moving dynamically

within a plane
PAGE 28
TECHNICAL TOOLS
Zoom - extents
This is a very useful tool that is accessible from
theZoom drop down menuon theRibbon barand from
theZoom select menuat the bottom right of the design
frame (the shortcut is key z). It is especially helpful when
working on small details within a larger model as it will
zoom in and centre on theselectedportion of the model
(if nothing is selected it will centre on the whole model).
It is doubly useful because it zooms without changing
the orientation of the model, whereas using theHome
toolto centre the model will return it to its original
orientation when it was opened.
Figure 16: Duplicating devices

using the structure tree
Tumbling Models
Tumbling the model(or multiple selected models) can
be difficult, especially when trying to reset the view
in an orderly fashion, for example with axes aligned
with the design frame. Attempting to manoeuvre the
model in all three dimensions at once is very tricky and
confusing. A useful technique is to revolve the model
in only one axis at a time until step-by-step the model
moves to its desired orientation.
Duplicating Devices
Duplicating the devices within an assembly is achieved
using Ctrl Move Drag. Moving along the axis of the
DIN rail in an enclosure will mean the new devices will
only need to be positioned for a suitable clearance
from the next device.The way the device is selected
prior to moving is crucial. To copy the device details in
theMoveoperation,the selection must be done either
by selecting the device in the structure tree (Figure 16)
or by using the Select Component tool(Figure 17) from
the top left of the design screen. Triple clicking a device
will select and copy it as a solid, but will not copy across
the device details required for Bill of Materials lists for
example.
Figure 17: Duplicating devices using

the select component tool
Deleting Components
Deleting componentsshould be done wherever possible
by editing the structure tree, as this will be reflected in
the model and in the Bill of Materials. If components
are deleted by triple clicking, an empty componentwill
be left in the structure tree and will still appear in the
BOM. To ensure this does not happen, it is best toright
clickon the file name at the top of the structure tree
and select Delete empty components (Figure 18). Empty
components will show no additional content when the+
signis clicked on in the structure tree.
Figure 18: Deleting empty components
PAGE 29
TECHNICAL TOOLS
Adding components
for BOM listing
If components do not need to appear in the model but
are needed for the Bill of Materials listing, they can
be added byright clickingon thefile nameat the top
of the structure tree and clickingNew Component. An
appropriate name and other details can also
be allocated.
Shelled Solids
These can be confusing to work with especially when
attempting to pull a sketch through the shell to create
an opening in the surface. TheMaintain offsetsoption
is selected as default and will help to maintain the
coherence of the shelled structure as the model
is modified and developed. In doing so, Maintain
offsetswill prevent thePull toolfrom cutting an opening
in the shell. To override this restrictioneither deselect
the Maintain offsets optionin the menu to the left of the
screenor Ctrl Select the edges of the shape to be cut
outbeforePullingto create the opening.
And finally
A few general tips that could help
further in projects:
Before starting a project, mock up the idea in a simple
material such as cardboard. This will create more
awareness of the physical requirements and should
shorten design time and also help to make a better
design.
Print out a scale drawing of the design to get a better
visualisation of its proportions and print as many
iterations as feasible during the design.
Avoid CAD eye there is a temptation to
thinksomething is plausible and adequate because
it appears so on screen. Importing a reference part
will allow checking whether walls are thick enough or
buttons can be pressed and will provide reassurance
that the design will work.
DOWNLOAD DESIGNSPARK
MECHANICAL FOR FREE NOW
Have a look...
Click to find tutorials for
PAGE 30
THATS WHY LEADING INDUSTRIAL COMPANIES

COUNT ON CONNECTIVITY.
The unique demands of todays networked manufacturing facilities count on
reliable connectivity solutions to deliver performanceand to do so faster,
more economically and within smaller spaces. In the factories of the future,
intelligence needs to be available in all devices, resulting in a large amount
of data that needs to be transported and communicated quickly and reliably.
Count on TE Connectivity to deliver all this in your most environmentally
demanding industrial applications. te.com/industrial-communications
www.rs-components.com/teconnectivity
EVERY CONNECTION COUNTS
TECHNICAL TOOLS
DESIGNSPARK
DESIGNSHARE
T H E H O M E O F O P E N S O U R C E P R OJ E C TS
DesignShare was created in June 2013 to host open-source project sharing, collaboration and
concept discussions within the online DesignSpark engineering community. Six months on, the
site has become a popular destination that engineers visit to connect and cooperate via the two
main areas: Projects and Ideas. The companys DesignSpark Mechanical customer challenge was
recently hosted on the site, drawing in many interesting, and often quirky, ideas from users testing
the new free 3D design software.
Projects
The Projects area is where users can
browse, share, create, collaborate
and download projects. The individual
project pages include details of how
the project developed at each stage,
along with a collection of assets that
enable users to build the project
themselves. At each of the five stages
of the development of a project Brief,
Proposal, Design, Prototype, and
Evaluation/Test status updates are
posted sharing the design challenges
along the way. Project assets may
include PCB schematics and layout
files for DesignSpark PCB, for example,
along with mechanical blueprints,
software code and/or machine code,
mechanical drawings, and CAD files.
Additionally, there is a plug-in to the
main RS website where users can
purchase the kit of parts.
Ideas
The Ideas section is the area where the
DesignSpark community is invited to
post project proposals, generate debate
and elicit feedback on the validity of
proposals. Users can vote for the ideas

they would most like to see adopted and
turned into real projects by DesignShare
partner, Elektor. DesignShare is intended
as a collaborative space for engineers
of all levels, embracing the full gamut
of hobbyist or fun concepts through
to professional projects. All projects
are available as open-source and are
downloadable free-of-charge. In some
cases, RS may develop the most popular
or highly rated projects and take them to
market as commercial products.
on DesignShare
A prime example of collaboration
through DesignShare, and one that
spurred engineers from diverse
backgrounds and disciplines into creative
action was the hosting on the site of
the DesignSpark Mechanical customer
challenge. Participants were invited to
submit an original design using the
intuitive new 3D design software, taking
into account the principles of mobility,
accessibility or green living as key
features of the end product.
One of the favourite designs as voted

for by the DesignSpark community,
and which illustrates innovation and
teamwork, was a conceptual wheelchair
that enables the operator to move from a
seated to a standing position. The project
collaborators drew on research and
experience to create the optimal design
for a manually operated chair that would
be light and affordable while remaining
as manoeuvrable and comfortable as
standard manual chairs. On a slightly
more fun note, another team devised a
water rocket aimed at educating children
about the power of water as an alternative
to fossil fuel.
These are just a couple of the many
examples of how DesignShare is inspiring
engineers to work creatively together
using free, simple-to-use design tools.
DesignShare is available to everyone.

To view the many projects in progress,
or to add one of your own, visit
http://designshare.designspark.com
PAGE 32
TECHNICAL TOOLS
.3D Printing A Self-Replicating

.Design for Rapid Prototyping
.and Inspiring Innovation
3D printing is fast becoming an essential part
of the design process. Increasing numbers of
companies are beginning to see the benefits
of using this technology to create quick-turnaround prototypes and save months in the
design cycle.
PAGE 33
TECHNICAL TOOLS
...3D printing is
moving from a niche
technology used
primarily by larger
companies into a mass
market for consumers
and small businesses.
arriers to adoption in the past

have been the cost of hardware
and a lack of easy-to-use design
software for non-CAD specialists. Now,
the RepRap open-source self-replicating
3D printer initiative has culminated
in the latest Ormerod 3D printer. In
conjunction with the DesignSpark
Mechanical 3D modelling software tool,
it presents companies and developers
with a massive opportunity both to
shorten the product development
process and inspire innovation, writes
Mark Cundle, Head of Technical
Marketing at RS Components.
Three-dimensional (3D) printing, or
additive manufacturing as it is also
called,is revolutionising product
development, and also production in
some cases. It is the process of making
asolid object from acomputer-aideddesign (CAD) model, achieved using
anadditive manufacturing process,
essentially building up successive
layers of materials such as plastic or
metals that are laid down in different
shapes. The more traditional machining
technique of course uses a subtractive
process, involving the removal of
materials in an approximately similar
way to that adopted by sculptors
chopping off whatever they didnt need
from their chosen block of marble, to
paraphrase Auguste Rodin.
While 3D printing has really come to

the attention of the general public over
the past year or so (some partly due to
headlines about weapon manufacture
unfortunately), it has actually been
around since the 1980s. Many 3D
printing methods have been used
such as Fused Disposition Modelling
(FDM), which is the most common
process used today in low-cost 3D
printing, along with Stereo Lithography
(SLA), Electron Beam Melting (EBM),
Laminated Object Manufacturing
(LOM), among many others. These
technologies are increasingly being
used for rapid prototypingandalso
some manufacturing across a myriad
of industries including engineering,
construction, automotive, defence and
aerospace, medical applications and a
number of consumer industries such
as fashion.
Increasing Ubiquity
Since the turn of the millennium, there has
been a significant growth in sales for 3D
printers, which are becoming increasingly
attractive with substantial reductions in
price mass-market models are now being
priced at less than $2500 and below. A
recent market research report, published
by analyst Markets&Markets, forecasts a
CAGR of 23% for 3D printers from 2013
to 2020, eventually reaching $8.41 billion.
3D printing is moving from a niche
technology used primarily by larger
companies into a mass market for
consumers and small businesses.
In fact, there is a now an increasing
line of thought that says a 3D printer
could even eventually find a corner
in our homes enabling us to avoid
costs associated with purchasing
common household objects. The
technology is fast becoming available
to all and individuals will be able to
make small numbers of products that
are comparable to those from large
companies.
PAGE 34
TECHNICAL TOOLS
There is a rather good quote related
to all this, made a few months ago
by dotcom pioneer Joe Kraus on the
BBC Radio 4 programme In Business,
essentially delivering a high level
view on the current revolution in
manufacturing and production: The
20th Century was about dozens of
markets of millions of consumers.
The 21st Century is about millions
of markets of dozens of consumers.
There is every chance that 3D printing,
in conjunction with other technologies
and movements such as open source,
is destined to play an important part in
a future that is likely to see uniqueness
and increased customisation rather
than the one-size-fits-all manufacturing
approach of old.
Rapid Prototyping
Hours Not Weeks
3D printing is certainly making
an impact in mainstream product
manufacturing in many industries,
especially in low-volume or highly
customised applications, but technology
has its limits for high-volume
production. 3D printing technology,
which is used to create products
in layers means that the structural
integrity of components may not be
strong enough to be used in production
parts. 3D printing is therefore unlikely
to replace manufacturing involving
moulded liquid metal, at least any time
soon. But perhaps the critical point, at
least for volume manufacturing, is 3D
printings ability to build prototypes
rapidly. It is revolutionising product
development machine skills are not
required to deliver prototypes, enabling
huge time-to-market benefits as well as
delivering a significant increase in
design freedom.
There has been significant
improvement in the productdevelopment process across a wide
range of industries, including car
manufacturing, consumer electronics
and medical devices. 3D printing
technology is being used to design
and test new concepts in companies

both large and small as an alternative
to employing custom machine tools
to make early prototypes of new parts
or components. The method allows
product developers to have a prototype
in a matter of hours or days compared
with weeks or months previously.
But the process offers more than just
saving time and cost; rapid prototyping
using 3D printing is producing more
innovative and higher quality products.
Product developers no longer have
to wait for tools or parts to come
back from outside machine shops or
injection-moulding houses. 3D printers
allow the physical testing and further
refining and improving of prototypes
before committing a product to mass
production.
What if a 3D printer
could create a
duplicate of itself?
RepRap and Self-Replication

A major dynamic in 3D printing is the
movement for open source and 3D
printer self-replication: what if a 3D
printer could create a duplicate of itself?
The Replicating Rapid Prototyper
project, also known as RepRap, was
founded in 2004 by Adrian Bowyer,
a former Mechanical Engineering
professor at Bath University in the UK,
as an attempt to put 3D printing into
the hands of everyone at low or at
least reasonable cost. Very simply, the
RepRap project is an initiative to develop
a low-cost 3D printer that can print most
of its own components. RepRap printers
employ Fused Disposition Modelling
(FDM) based 3D printing methods: using
a computer-controlled plastic-glue gun
and a spool of plastic fed into a heated

chamber. The plastic material is squirted
out via a small nozzle to make the first
layer on a baseplate, which is then
lowered by a small amount ready for the
second layer, and so on.
According to presentations given by
Bowyer, there is a symbiotic relationship
between machines and people within
the RepRap project: the machines
are the flowers that provide goods
and people are the insects that will
help replicate the machine. While the
machine will be able to make all of its
plastic parts, RepRap specifies that all
the remaining components required
for the construction of a duplicate
machine, such as the electric motor,
electronics assemblies and various other
components such as metal threaded
rods, must have two properties: they
must be relatively cheap and simple to
obtain; and they must be easily available
to everyone everywhere in the world.
A fundamental motive of RepRap is
to make 3D printing available for all
and therefore a central tenet of the
project is that it must be open source.
Anything that can copy itself is subject
to the laws of evolution; and because
its a machine that is manufacturing
its own parts, the design files need
to be readily available. However, the
machine will not evolve primarily by
random mutation, it will be much closer
a selective breeding process similar
to the development of Linux and open
source software. Those in the RepRap
community will inevitably change the
design to improve it, perhaps making
it more accurate or easier to build, and
naturally many of these improvements
will be posted to the web. And if a user
has an older RepRap machine, it can be
used to make a new machine based on
the improved design.
The project has met with much
success: there are now a handful of
low-cost printers on the market and
most of them are based on the RepRap
project. In a recent survey on 3D printing
(Manufacturing in Motion, Moilanen, J.
PAGE 35
TECHNICAL TOOLS
The first RepRapPro 3D printers available

were called Huxley and Mendel, both
selling at a cost of a few hundred pounds.
& Vadn, T), the RepRap project took the

largest share of the market. In addition, to
further proliferate the concept, RepRapPro,
the commercial arm of the RepRap project,
was launched in 2011. The first RepRapPro
3D printers available were called Huxley
and Mendel, both selling at a cost of a
few hundred pounds (sterling) as a kit of
parts, with or without the printed plastic
components. And now, the next generation
RepRap is here the Ormerod.
RepRapPro Ormerod
Available at low cost, the new
RepRapPro Ormerod complete 3D
printing kit is now available from RS.
When used in conjunction with the free
DesignSpark Mechanical 3D design
software, the printer will enable design
engineers around the world to develop
sophisticated concepts and products
incredibly quickly and inexpensively.
Also suitable for small production runs,
the Ormerod is one of the most versatile
3D printers available: it is easy to
expand in functionality, fast to replicate
and fast to assemble.
Like its predecessors, the Ormerod
uses the FDM process, also known
as fused filament fabrication, to build
3D objects in a range of plastics and
eventually in a variety of colours.
This process enables the user to
create almost any shape that can be
modelled on a computer, including
some that cannot be produced by
traditional manufacturing techniques
at all. While the Ormerod is actually a

monochrome 3D printer that has been
configured to work with one type of
plastic at a time, the devices head is
fundamentally designed to work with
three-colour deposition; an upgrade
kit is to be made available soon. In
addition, the Ormerods electronics
has been redesigned and now enables
connectivity via a web browser. In
addition, its construction is far simpler
compared to the Mendel, which took
two days to put together, on average;
whereas the Ormerod only takes two
hours, making it significantly more
accessible to non-engineers.
The RepRapPro Ormerod is shipped
as a kit of parts containing all the
required components, ready for
assembly. The complete kit includes: all
printed parts; all hardware, including
threaded and smooth rods, screws,
nuts, washers, belts and bearings; presoldered and programmed electronics;
MicroSD card and adapter; heated PCB
build surface; motors; nozzle assembly
and extruder drive mechanism; 100m of
1.75mm-diameter PLA (polylactic acid)
filament material (approximately 300g);
power supply (for EU, UK, US and
Australia); and finally, software to run
the machine, including firmware for the
electronics. Other specifications of the
Ormerod include accuracy of 0.1mm,
resolution of 0.0125mm, build speed of
1.8mm per minute and deposition rate
of 33cm3 per hour.
In summary, the availability of

low-cost 3D printing technology
with the RepRapPro Ormerod
in conjunction with the free
and intuitive DesignSpark
Mechanical and the ModelSource
library of 3D component models
means that 3D design and rapid
prototyping is now available to a
much wider universe of users and
not just CAD specialists, enabling
increased innovation and faster
time-to-market.
The RepRapPro Ormerod is
available via the RS website at
rswww.com/RepRapPro
and DesignSpark Mechanical is
available for free download via
the DesignSpark website at
www.designspark.com
Related Products
RepRapPro Ormerod
BUY NOW
PAGE 36
Thermal
Management
System
(TMS) highly configurable fan speed
controller from ebm-papst
Market leader ebm-papsts Thermal

Management System (TMS) is
a highly configurable fan speed
controller. Its well known that
using speed controllable fans to
provide the airflow an application
requires can give substantial energy
saving, noise reduction and fan
life enhancement. The ebm-papst
Thermal Management System
(TMS) fan controller is able to speed
control up to four fans, based on
independent temperature profiles,
providing fan speed control for a
wide variety of applications.
The TMS has been developed for
use with four wire fans (Power, 0V,
Speed control, Tachometer) on 12V,
24V or 48V systems. It can also be
used to control mains powered EC
fans. Each fan may be configured
using a PC interface for a different
speed/temperature profile.
www.rs-components.com/ebmpapst
The TMS can also

provide visual or relay alarm
functionality which is configurable
via a PC interface. If a PC is left
connected the TMS can provide data
logging which is useful during test &
development stages.
James Cooper, Product Manager,
comments: Speed control is
often overlooked when specifying
fans, however significant energy
savings can be made by the use
of the correct controller and fan
combination, not just direct savings
in energy consumed by the fans
but indirect savings from ancillary
equipment. The addition of a
controller can add extra functionality
to products enhancing their usability
and safety.
Related Products
TMS EC DC fan controller
BUY NOW
REGULARS
PRODUCT NEWS
OLS/OLF Obstacle Marking Beacons
Cost effective longlife LED beacons from
MoFlash in dust and weatherproofed
housing. Ideal for use with photocell control.
PanelPilot - Smart Graphics Displays

This innovative software platform from
Lascar Electronics allows configuration and
customisation of a range of compatible
colour displays.
The PanelPilot series range of colour TFT
graphics meters allow users to program and
display meter styles previously provided by
a traditional panel meter.
Colours, text labels, splash screen and
input scaling can all be customised by
the user through the software and then
uploaded to the meter through the
USB connection.
Once programming is complete, the
user can save all selections to the meter
and computer, detach the unit and mount
in their panel as they would any standard
display.
This range of Obstacle Lights have been

designed to offer a more cost effective
option for compliance to the low intensity
ICAO regulations. The 10 and 32 Candela
both incorporate low consumption Red
LED arrays. A power rating of 8 watts for
the 10Cd and 12 watts for the 32Cd lend
themselves for use with photocell control if
required. The typical application is marking
fixed objects in or around aerodromes
where the object is a less extensive one and
its height above the surrounding ground
is less than 45m. These beacons can be
used in conjunction with medium and high
intensity lights.
RS Search Term: moflash ol
These Photoelectric Sensors help achieve

a total cost reduction with a wide AC or
DC power supply range.
The E3JK series of photoelectric
sensors from Omron have a built-in
power supply and a high power visible
red LED enabling easy alignment and
long sensing distance. They provide
improved operability due to an enlarged
sensitivity adjuster and operational
selector. With a freely selectable
power supply input from 24 - 240 V
AC/DC this range allows the highest
flexibility during installation. Prewired
(2m) through-beam, retro-reflective
and diffuse versions are available.
RS Search Term: E3JK
RS Search Term: panelpilot
BUY NOW
E3JK Photoelectric Senors with

Built-in Power Supply
BUY NOW
BUY NOW
Level sensors, MHF15 Optical Point Level Switch

Small, compact sensor also suitable for difficult limited space installations.
Quick commissioning saves time and costs.
A range of easy to install level sensors requiring no calibration and suitable for
installation in confined or difficult to access areas. SICKs MFH15 series of optical
level switches are robust and simple in construction and manufactured from
stainless steel and polysulfone with a casing rated to IP67. Optical Level sensors
operate using a LED light and the principle of refraction.
RS Search Term: MHF15
BUY NOW
PAGE 38
REGULARS
PRODUCT NEWS
Thermofit heat-shrinkable
cable glands
Thermofit heat-shrinkable boot
feedthroughs provide a watertight and
fumetight seal wherever cables need to
enter connection boxes, enclosures or
bulkheads. Offering a real alternative to
conventional cable glands, the adhesivelined heatshrink ensures a secure seal
around the cable. In addition, the multientry versions provide a solution for the
problem of fitting several cables through a
single gland, with two-, three- and four-entry
options available. The heatshrink boots are
flame retardant, and the feedthrough is
fixed to the bulkhead using a rigid plastic
nut and O-ring. Suitable for a large number
of applications, they are approved for
marine and ship-board use.
RS Search Term: te fts ces
SMT D-Sub Connectors

Now available from RS Components, the
new range of straight SMT mounting D-sub
connectors from HARTING is optimised for
automated assembly. Designed from the
ground up as a surface mount connector, the
entire range can withstand common solder
reflow techniques, and locating pegs allow
accurate positioning with low insertion forces.
Die-cast fixing brackets combined

with precision made contacts ensure a
secure termination. The connectors are
provided with a removable mounting
plate to enable automatic placement, and
the open design allows post-assembly
inspection. The result is a high reliability
connector installed at a very low cost.
RS Search Term: harting smt dsub
BUY NOW
Ebm-papst IP68 Protected

Compact Fans
Ebm-papst ingress protected IP68 fans
are ideal for operation in the harshest of
environments. These fans are designed
to perform subject to high dust, high
humidity and direct water exposure both
in and outdoors. They are ideal for washdown situations and cannot be damaged
BUY NOW
by continuous immersion in water

making them suitable for a broad range of
applications. With a construction based on
the entire motor (winding and PCB) being
completely coated in plastic, the integrated
operating electronics of ebm-papst IP68
fans are completely encased and the cable
connection is specially sealed.
RS Search Term: ebm-papst ip68 axial fan
BUY NOW
PAGE 39
D-Sub SMT
Perfect for automated
Pick & Place processing.
Large surface area for

vacuum pipette
Optimized for SMT processes
9 to 37 contacts
Optional grounding pins for even

greater mating and demating forces
Locating pegs for reliable fixation

without a press-in force
The straight D-Sub SMT connector from HARTING.

This product range expansion supports swift and smooth Pick & Place processing thanks to an
SMT-compatible design that features a removable gripper plate. Locating pegs hold the connector in
place during the soldering process and optional grounding pins ensure the highest level of mechanical
robustness. This SMT connector consequently uniquely combines longevity and process reliability in
the PCB assembly.
Find more information, phone +49 5772 47-97100 or send an e-mail to electronics@HARTING.com
www.HARTING.com
www.rs-components.com/harting
har-flex
Straight, angled and

with IDC termination
People | Power | Partnership
1.27 mm grid
6 to 100 pins
Ready for
automatic pick-and-place
100 % coplanarity
check
har-flex even more universal

Whether straight or angled HARTING har-flex is always a good choice.
Connect your circuit boards in parallel, at right angles or with ribbon cables.
Various designs, from 6 to 100 pins, ready for automatic pick-and-place what else do you need?
HARTING: Pushing Performance to innovative solutions.
Nehmen Sie Kontakt auf: HARTING Deutschland GmbH & Co. KG

Simeonscarr 1 | D-32427 Minden | Tel +49 571 8896-0 | Fax +49 571 8896-990604 | de@HARTING.com
www.HARTING.com

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AUTOMATION&CONTROL

PKE motor-protective circuit-breaker with SmartWire-DT

Glenn Jarrett, Global Head of Product Marketing

esignSpark and RS Components

Acti 9, that will help engineers build

provides for 3D printing.

are proud to present this new

new panel designs quicker and with

This and much more

digital format that will be

more safety built-in. We are also talking

is packed in this new

focussing on the interests of engineers in

about wireless connectivity as one of the

the machine and panel building industry.

important trends in the industry which

To be as close to your heart as possible

opens up completely new design options

enjoy reading and as

we have worked together with reference

for engineers. One of our groundbreaking

always if you have

engineers from the industry and leading

solutions we have developed in 2013

feedback please come

manufacturers around the globe.

is DesignSpark Mechanical. Read our

over and talk to us on

latest news about this free 3D design tool

In this edition we focus on a new

in this edition, as well as the options it

We hope you will

DESIGNSPARK MAGAZINE A&C ISSUE 1

he need to reduce energy

DESIGNSPARK MAGAZINE A&C ISSUE 1

of course it is in industry that electric

IE3 or equivalent will be permitted by

which can result in large costs in terms

three contactors, thermal overload and

Variable Speed Drives

Variable Speed Drives: fan power versus nominal flux

Eaton DS7 Soft Starter

Schneider TeSys Range

Trational Direct on-line

By matching the speed and torque to

devices and VSDs are available from

For more information visit:

PHOENIX CONTACT 2013

With foresight and enthusiasm we

ver time, many different wireless

a fragmented industry. There is a range

Industrial Wireless LAN

technology is also especially suitable

Figure 1 Automated crane control

Figure 2 Controller-based IWLAN applications with a large

serial interfaces to Bluetooth making

Phoenix Contact Wireless

to quickly and easily gain the benefits of

WirelessHART employs the security

Extensive Wireless Range

For more information visit:

Honeywell Wireless Limit

imagine a world without wires