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CTRL F3: Factory Explosion Field Study

CTRL F3: Factory Explosion Field Study

The CTRL F3 series reviews field studies and failures in the field focused on control fails, fixes, and facts. This article covers an explosion at an industrial sawmill.


Negative Effects of Grounding (Earthing) a DC Power Supply

Negative Effects of Grounding (Earthing) a DC Power Supply

DC voltage systems exist to provide controllers and field devices with stable power, but it is not always clear when these systems should be bonded with the earth ground of the AC line voltage supply.


Singularity in Robotics: What Is It and How Can We Avoid it?

Singularity in Robotics: What Is It and How Can We Avoid it?

Singularity in robotics can be problematic for programmers and manufacturers alike. We will investigate the cause of singularities and how prevention can be considered in the design of a robot cell. 


Understanding PLC Program Commands: Comparison Instructions

Understanding PLC Program Commands: Comparison Instructions

​​​​​​​We will show you how to recognize, utilize, and efficiently operate your comparison instructions in Rockwell Automation’s Studio 5000 and Automation Direct’s Productivity Suite to make your program flow smoothly.


Working With Legacy Systems—Why Use Serial to Ethernet Converters?

Working With Legacy Systems—Why Use Serial to Ethernet Converters?

One common challenge when working with legacy control systems is establishing communication with old devices that use old protocols like RS232 and RS485. Learn about the importance of converting from serial to Ethernet.


Configuring a Network With Pneumatic Valve Manifolds

Configuring a Network With Pneumatic Valve Manifolds

There are many distributed fieldbus capabilities for valve manifolds that can save on network overhead and wiring. In this article, we will look at PLC programming of fieldbus manifolds highlighting Festo's CPX layout.


Understanding PLC Program Commands: Trigonometry Instructions

Understanding PLC Program Commands: Trigonometry Instructions

We will show you how to use the basic trigonometry functions to build ladder logic in a PLC, allowing for a clean, well-organized, and easy-to-use code that allows you and other users to troubleshoot your programs.


Methods of Performing Robot Tool Center Point Calibration

Methods of Performing Robot Tool Center Point Calibration

Industrial robots are a valuable investment because of their speed and accuracy. However, failing to establish the tool center point (TCP) can decrease the accuracy, effectiveness, and ROI for a robot workcell.


Predictive Maintenance: Defect Analysis Using Electrical Current

Predictive Maintenance: Defect Analysis Using Electrical Current

Electrical signal analysis has come to the forefront of predictive maintenance, helping to reduce downtime in industrial manufacturing by remotely identifying problems with electric motors and generators.


Data from Control System to Cloud - Industry 4.0 Communication Protocols

Data from Control System to Cloud - Industry 4.0 Communication Protocols

Communication protocols are a key component for an industry 4.0 compliant facility and are used to enable communication back and forth between cloud servers to transmit data or receive instructions.


Migrating PLC Software

Migrating PLC Software

Software obsolescence poses a threat in industrial automation equal to hardware obsolescence and should not be overlooked. Many PLC OEMs offer tools to migrate upgraded software projects to the newest controller revisions.


Successful Obsolescence Mitigation

Successful Obsolescence Mitigation

Designing an obsolescence mitigation plan to detect and solve mitigation risks before they occur is key to avoiding costly downtime and a potential catastrophe in control environments. 


Clarifying Misconceptions About Theoretical vs Physical Circuits

Clarifying Misconceptions About Theoretical vs Physical Circuits

Control engineering is integrally woven together with electricity and electrical circuits. Even so, sometimes the most basic scenarios become misunderstood through lack of training or experience.


Controlling Hydraulic Devices with Open and Closed Loop Systems

Controlling Hydraulic Devices with Open and Closed Loop Systems

What if you could control the end position and the speed of a hydraulic actuator accurately with just a simple signal? Some systems use simple open/close valves, but others require far more precision.


Comparing Mechanical vs Hydraulic Forces

Comparing Mechanical vs Hydraulic Forces

In honor of May the 4th, Star Wars Day, we compare the sources and applications of the two most common force-delivery systems - mechanical and hydraulic.


Up Close and Personal With Automated Ag Equipment

Up Close and Personal With Automated Ag Equipment

Our Control Automation engineering staff got the chance to visit a commercial farm in North Dakota and learn the hardware and software making these huge automated tractors ready for high-tech ‘field’ work.


Siemens SIMATIC PLCs - Hardware History

Siemens SIMATIC PLCs - Hardware History

In this first of an upcoming series, we investigate Siemens as a major PLC manufacturer, learning about the hardware, software, and key applications of each product lineup.


Circular Economy - Manufacturing to End User… And Back

Circular Economy - Manufacturing to End User… And Back

‘Reduce-reuse-recycle’ is a common slogan for promoting reduction of waste associated with end use of materials. But a circular economy model includes manufacturing processes and raw materials as well.


Introduction to Safety Relays

Introduction to Safety Relays

Redundancy and safety are often seen together in industrial safety systems. Safety relays monitor emergency devices to switch contacts based on status - but what makes them different from normal relays?


Mechanisms of Linear Sensing and Linear Encoding

Mechanisms of Linear Sensing and Linear Encoding

Linear sensors use electrical means to determine their position. Common linear position sensors are resistive, inductive, capacitive, and many rely on a property called magnetostriction.