More and more companies are focusing on the digitalization of industrial production. The aim is to use sensors, decentralized control and IT to monitor and control even complex production processes in near real time in the future. This creates greater transparency in the processes and reduces storage costs as 'just-in-sequence' material can be ordered and processed. At the same time, processes will become more flexible, making the production of very small batch sizes down to individual parts (batch size 1) more economical. Manufacturers of individualized products can retool and adapt their production more quickly and easily according to the motto 'Plug & Produce'.

Sensor data is the raw material for production systems of the Industry 4.0 generation. The acquisition of measurement data and its further processing and transmission to higher-level control systems is becoming ever faster. Measuring amplifiers ensure that the sensors can communicate with the decentralized controllers in real time via industrial communication using fieldbus protocols. Measurement technology software, in the form of innovative integrated web servers, manages the innovative balancing act between the simplest possible operation and the realization of increasingly complex functions.

Manufacturers have further optimized their products to meet the increased demands placed on measurement technology in the age of Industry 4.0: HBM, for example, provides the entire measurement chain for the digitalization of production. As its latest innovation, the measurement technology manufacturer has developed the ClipX dynamic measurement amplifier, which not only amplifies the sensor signals in an interference-free manner and transmits them to the controller, but also pre-calculates and summarizes the measured values - thus reducing the load on the higher-level controllers.

Accuracy class of 0.01

It should be clear to all machine operators that the entire measuring chain is only as precise as its weakest link. However, high-precision sensors are often used with less precise measuring amplifiers, which leads to a low overall accuracy of the measuring chain.

The responsive design of the web interface allows the measuring amplifier to be parameterized and measured values to be visualized.

© HBM

ClipX has an accuracy class of 0.01 and an integrated calibration certificate. Users of the industrial measuring amplifier therefore benefit from increased accuracy, as linearity errors, hysteresis and temperature influences are less than 0.01 % relative to the final value. This leap forward in measuring accuracy enables users of machines or test benches to manufacture products faster and more cost-effectively. More precise measurements allow further measurement tolerances, which leads to significantly lower reject rates.

Industrial measuring amplifiers are also exposed to numerous external sources of error. They often work alongside large motors, generators and converters, which generate strong electromagnetic and electrostatic fields and interference. This interference has a direct effect on the measuring amplifiers. Errors also emanate from the measuring cables between the sensors and the measuring amplifiers. If they are not shielded, they can act like antennas and conduct interference into the measuring amplifier. Measuring amplifiers must therefore be equipped with appropriate interference suppression elements so that the measuring accuracy is maintained even in the event of interference. These properties should always be documented in the technical data of the industrial measuring amplifiers, as HBM does for all its devices.

Intuitive web interface

A special feature of the new measuring amplifier is the intuitive web interface integrated into the device, which enables quick and easy commissioning. With the web interface, the measuring amplifier is immediately ready for operation without the need for software installation or training. This not only saves time, but also reduces costs and simplifies operation, as only a browser connection is required. Annoying software updates are no longer necessary, as the server always adapts automatically to the hardware.

ClipX can be used to implement individual measurement chains and measurement systems with up to six quasi-synchronized devices at millisecond intervals - optionally with a fieldbus connection. This means that several fieldbuses can be operated in the application.

© HBM

Due to stricter security regulations, software installations are often no longer permitted without the approval of the IT department. ClipX avoids this hurdle: The device is connected to the Internet via a simple Ethernet connection - the interface standard in offices and factories. No additional adapters are required. The device can also be accessed remotely from anywhere in the world via the Internet, allowing it to be parameterized via 'Remote Control', for example.

The web interface, which was developed on the basis of the globally used 'Google Material Design', is also responsive, i.e. it recognizes the resolution of the PC, smartphone or tablet and therefore enables optimum display on all browser-based end devices.

However, the web interface not only enables complete parameterization of the measuring amplifier, but also direct visualization of measured values and processes as well as a diagnostic display. This so-called 'health monitoring' detects errors and reports them to the operator via alarm functions. Errors can therefore be rectified quickly, resulting in fewer machine downtimes and more efficient processes. Data management is also no problem thanks to the backup and restore function. The files can be saved on a computer and transferred to other devices if required (device cloning).

Measurement technology in industrial applications must be seamlessly integrated into automation systems. ClipX is therefore equipped with functions and features that simplify the integration of measurement technology into the production process. The measuring amplifier has all common automation interfaces such as Profinet, Ethercat, Profibus, Ethernet/IP, analog (V/mA,) digital I/O and Ethernet (TCP/IP).

As data volumes and transmission speed requirements have increased dramatically, fast Ethernet-based fieldbuses are becoming increasingly popular as communication protocols in automation technology. In the past, these were simple fieldbuses such as CAN or Profibus. Today and in the future, data acquisition systems must support the real-time Ethernet protocols Ethercat, Profinet or Ethernet/IP, which can also transmit large amounts of data very quickly.

Smart Functions create relief

Unlike conventional measuring amplifiers, ClipX does not require a separate head module to process data directly. Whether single-channel or multi-channel applications in machines for manufacturing or production monitoring - the new HBM measuring amplifiers can be used to implement various measuring tasks. For example, up to six devices can be plugged together modularly via 'Plug & Play' and measurement data can be pre-calculated. In addition, one or more different system controllers can access the system via the fieldbus interfaces. Especially in applications with a very high degree of automation, the decentralized intelligence of the measurement technology is crucial in order to reduce the failure frequency and system load of the control system. In order to create faster production processes, the measuring amplifier can take over calculations or control functions that go beyond the actual measuring function, which relieves the higher-level control system (PLC). Thanks to so-called 'smart functions', the measured signals can already be processed internally and evaluated in real time. This allows the measuring amplifier to perform some of the tasks that would otherwise have to be carried out by the PLC itself - for example averaging, peak value detection and other mathematical calculations as well as PID control.

Parameterizing instead of programming

As the calculation channels run in real time, tolerance tasks with good/bad detection can be performed. The calculation channels only need to be parameterized by the operator and not programmed themselves. Instead of writing complex software code, parameters and input signals can simply be inserted into the ready-made functions. This saves the user an enormous amount of work.

With modern measuring amplifier systems, not only can the manufacturing costs of products be reduced, but the quality and speed of production can also be increased.

Author:
Michael Guckes is product manager for industrial measuring amplifiers and software at HBM.