You've probably checked out Engineered Automation's home page to find that they have just completed a new project and if you haven't taken the time to see the new Custom Automation video, please do.
While you're watching the system in action, I've taken the opportunity to explain just how the folks at EAM go about doing this. As most of you will know, a machine such as this is usually many weeks in the making.
I was informed early on, that they were about to take this project, and they kept me informed of progress at various stages. When they first began working with the client, they didn't even have a contract. It was just a good faith effort on the part of both EAM and the client to "buckle down" and study the requirements and to fully understand even such fundamental questions as, why did they feel they needed this? What sort of schedule or urgency were they facing? Was their new product even finalized and stable as a design or was there a possibility of changes along the way?
After exploring the possible answers to all the questions both parties could imagine at the time, they proceeded to try to visualize the type of machine that needed to be built. This started with many sketches, both paper and white board. The next stage; preliminary drawings that help define the steps in the automated process, size of machine, features, etc.
It's an amazing process folks. Meetings, phone calls, meetings, emails, changes, re-drafts, and finally! The folks at EAM know just what needs to be built, and the customer (more of a partner by now), knows what they are committing to and what to expect when it's all done.
I had the opportunity to check in from time to time to see frames in place, people building sub-assemblies, wire bundles, controls enclosures (basically a fortified case to house the computers), and finally, the functional tests of the machine.
By the time I got there with a camera, they made it look easy; I set up the lights and they pushed the Start Button. So what you are seeing in those three minutes of video is the product of many weeks of work by both EAM and their customer, oh, and, a few hours of work on my part!
Enjoy!
http://youtu.be/YzHhjYQlod0
As I mentioned earlier, I visited EAM to get some video of their latest project and I realized I was looking at a system that was being controlled by a very intelligent and super-fast computer. Peter Robbins, Manager of EAM's Controls Department, was kind enough to spend some time explaining to me just exactly what he had done here. Please be sure to let me know if you find this as interesting as I did.
The following is from my conversation with Peter;
Roland Wyman: "Good morning Peter. I've just spent a few minutes watching this machine and, even for me, it didn't take long to see that this machine is controlled by something pretty clever. What is the actual controller you used for this machine?"
Peter Robbins: "The controller I used in this project is Schneider Electric’s LMC058 Motion Controller. It is marketed as a motion controller with logic capabilities as opposed to a PLC with motion capabilities."
Roland Wyman: "Was this the first time you incorporated this controller in a project?"
Peter Robbins: "This was EAM’s first project using this controller. I knew we were going to need a controller that would tightly integrate the machine logic with the servo motion required to operate a machine at the rate we were looking to achieve and fit into a budget that the customer could accept. The LMC058 boasts a scan time of under 3 milliseconds for up to eight axes of motion. We’re running 4 axes of motion and we are just over 2 milliseconds for the servo process control. The main control for the rest of the machine is running under 10 milliseconds."
Roland Wyman: "Pretty impressive specs! How did the design and integration go in comparison to earlier projects?"
Peter Robbins: "There was a slight learning curve to deal with but the controller is designed around the I.E.C. 61132 specification which made most of the programming structure very similar to the controllers I have been using."
Roland Wyman: "You've already established that you needed to move to this controller in order to achieve the scan times while controlling all those servos. Are there also added capabilities this offers as opposed to earlier controllers you used?"
Peter Robbins: " As I mentioned, the motion functions in this controller are tightly integrated into the rest of the controller functions and are very fast. The unit also offers built in CANOpen Bus and CANMotion bus so attaching the servo amplifiers and remote I/O was very simple."
Roland Wyman: "I'm told that a technology that is also available with your systems allows you to log onto the machine, no matter where it is installed. If that's so, then this means you are providing some form of ongoing service or support to your client. Can you tell me a bit about that?"
Peter Robbins: "E.A.M. has been encouraging customers to opt for our ‘Remote Administration’ package for some time now. With the advances in the complication of machine function and controls structure it is very helpful for E.A.M. to have access to the controller of the machine to aid the customer in troubleshooting the machine. This ability more times than not allows E.A.M. personnel to ‘log onto’ the machine and see firsthand what the machine is doing. This saves both the customer and E.A.M. time and money."
Roland Wyman: "I would guess your clients see this as an ongoing value to them. That's very impressive. You're obviously incorporating all the latest technologies into these projects and it would seem that you find the right technologies for the specific project requirements both in functions, budgets, etc. What do you, as a pro in your field do to keep up with all this? You're obviously self motivated to know what's out there in order to offer it to your clients. After all these years, what's your secret? How do you maintain your enthusiasm?"
Peter Robbins: "The way I explain my position at E.A.M. is that I go into the office each day and play with my toys. In order to be able to supply control systems that meet the customer’s needs it has always been my first priority to listen to what the customer is looking for in the equipment we are trying to build for them. Being able to boil down what the customer is looking for and then deliver it is an art. To accomplish this I stay current on my suppliers offerings, there are many trade shows, webinars, and distributor tech sessions that lend access the this information. I read the current trade publications for controls as well as other industry aspects of machinery, and foremost, I don’t accept “you can’t do that” from anyone."
Roland Wyman: "Thanks Peter for your time, your information, and your insights. After reading this, I'd be very surprised if some folks might not want to ask follow-up questions or start a thread. Is it okay if they post in the comments section below?"
Peter Robbins: "I would welcome pertinent questions to our product line."
I recently spent a morning at EAM getting some video of their latest machine as it was going through its shakedown time. Since I was not familiar with the project yet, some of the people who were instrumental in producing this new machine took the time to explain what it was all about. Although the machine as a whole was impressive, what really struck me was how sophisticated the control system was. You'll see that I spoke to Peter Robbins briefly in the video. Peter manages EAM's controls department and he is actually one of EAM's original employees. Unlike some of us (yes, I'm referring to myself!) who've become walking, talking museums, Peter has managed to keep the company at the forefront of technology as far as what makes these machines tick.
He explained that, unlike the traditional controllers that step through the various functions and have been in use for many years, this master controller is actually a computer overseeing many servo-controlled motions. Picture them as dedicated robots. Another interesting thing about this technology that Peter just casually mentioned (but got my attention!) is that these units actually have their own web address and he can log into them no matter where they are being used. This way, he can help the user in real time to analyze what's happening and help the user improve his efficiencies.
Rather than try to explain this all myself, I am compiling a transcript of the question and answer session that I had with Peter and so he will be able to explain this in his own words. That's what's coming up in the next post!
Peter Robbins
I think everyone can relate to this:
Your parents or grandparents have lived nearby you for almost as many years as you can remember while you've gone about living your life, maybe raising a family, building a career, and going through the highs and lows that most of us encounter. They've lived near enough so that you see each other on a regular basis and, although you may or may not need to, you know they can be there in a crisis or share in a celebration.
The time comes and they decide to move to say, Florida for their "golden years" and then things change. You can see they really need to stay in touch. They want to know what's going on with you and your family. They call, they email, and it seems they are always planning their next trip home as if they were exiled instead of just retired.
Well folks, I can tell you now that when it comes to Engineered Automation, I am those grandparents! I stopped working at EAM over a year ago now and I am always looking forward to the next phone call, the next email or visit. I'm always fascinated by news of who is traveling where. I want to know all the details about their current projects and how they are progressing.
As you can probably tell, I was grateful for the chance to blog here and hopefully to bring you news about the folks at EAM from a somewhat unique prospective. You'll be getting the latest scoop but "psst, not the company line from just an employee"!
Please be sure to subscribe if you'd like updates as I post them.