Transform Your Operations with the WAGO Compact Controller 100: Your Gateway to IIoT Excellence

Corey Foster || Valin Corporation

Transform Your Automation with the WAGO Compact Controller 100


In the digital era, having a smart, connected device that bridges the gap between automation and IT is crucial. The WAGO Compact Controller 100 is more than just a PLC; it's a powerful IIoT information controller that brings your automation projects into the future. 

  1. Real-Time Linux® Operating System for Maximum Flexibility 
    The Compact Controller 100 runs on a real-time Linux® operating system, offering you the freedom to use a wide range of software, from CODESYS V3 to Node-RED, Python, and C++. This versatility allows you to tailor your control system to your specific needs.
  2. Gateway Functionality with Docker® Virtualization  
    Easily transform your Compact Controller 100 into a full-fledged IIoT device with gateway functionality by installing Docker®. This addition enables seamless integration of various applications, enhancing your system's capabilities and opening new avenues for innovation.
  3. Compact Design with Built-in I/O  
    Designed as a DIN-rail built-in installation device, the Compact Controller 100 fits perfectly into small distribution boards. Its compact enclosure houses both the controller and the I/O unit, saving space and simplifying installation.
  4. Enhanced Connectivity and Security  
    With two configurable RJ45 Ethernet ports, the Compact Controller 100 ensures reliable and secure connectivity. Built-in firewall and VPN support protect your network, while MQTT protocol enables easy cloud server configuration, making it ideal for digital transformation projects.
  5. Versatile Programming and Visualization  
    Take advantage of the market-leading CODESYS V3.5 development software to create sophisticated control applications. Develop user-friendly interfaces with HTML5 web visualizations, accessible via any web browser on PCs or mobile devices, ensuring operators and maintenance staff have the tools they need at their fingertips.
  6. Ready for the Future of Automation  
    The Compact Controller 100 is designed to meet the demands of modern automation. Its support for industrial protocols like MODBUS TCP, Ethernet/IP, and OPCUA ensures smooth communication with your existing systems, while the ability to expand memory and connect to a wide range of devices makes it a future-proof solution.


Embrace the future of industrial automation with the WAGO Compact Controller 100. This versatile, powerful, and easy-to-use IIoT information controller is your key to unlocking new levels of efficiency and connectivity in your automation projects. 


Learn more about the WAGO Compact Controller 100


Contact us at (855) 737-4716 to learn more, or fill out our online form.

Overcoming Cable Problems in Dynamic Motion Control Applications with Balluff's Wireless IO-Link

Corey Foster || Valin Corporation

Overcoming Cable Problems in Dynamic Motion Control Applications with Balluff's Wireless IO-Li

In the realm of industrial automation, some applications pose significant challenges that traditional wired IO-Link systems struggle to address effectively. One such application is dynamic motion control in robotics and transport systems. The constant movement and flexibility required in these environments make wired connections impractical due to the risk of cable fatigue, wear and tear, and the complexities involved in installation and maintenance.  This is where Cable Management Basics comes in.

Consider a robotic arm or gantry system that performs precise tasks across multiple axes of motion. Traditional wired connections can be a major hindrance in such scenarios. The constant bending and twisting of cables can lead to frequent breakages and signal loss. Additionally, the installation process becomes cumbersome and time-consuming, impacting overall productivity. This challenge is not limited to robotics; any application involving dynamic motion, such as automated guided vehicles (AGVs) or moving machinery, faces similar issues with wired systems.

The Solution: Balluff’s Wireless IO-Link System

Download Balluff IO-Link Performance Portfolio and Balluff IO-Link Introduction datasheet to learn more.

Call us today at (855) 737-4716 or fill out our online form and someone will get back to you.

Unlocking the Power of Modular Automation with WAGO’s Module Type Package (MTP)

Corey Foster || Valin Corporation

Modular systems have become essential to allow for quick expansions, reductions, and changes in manufacturing and process engineering. WAGO’s Module Type Package (MTP) is at the forefront of this revolution, offering a seamless way to integrate and optimize modular automation solutions. Whether in shipbuilding, pharmaceuticals, or any other industry, MTP ensures rapid, reliable, and efficient system deployment and management.

Similar to how a printer driver can connect printers from any manufacturer to a computer, WAGO’s MTP can connect the systems of different manufacturers to a central computer to form complex systems that do not have to worry about the compatibility of their respective interfaces. In the process, different modules will be created that can be swapped out or reused, allowing for quick and easy changes to the system structure.


 

Key Features of WAGO’s Module Type Package (MTP)


Key Features of WAGO’s Module Type Package (MTP) 

  • Standardized Interface: Ensures compatibility and integration across different manufacturers and technologies. 
  • Plug & Produce: Simplifies the adaptation and expansion of existing systems with minimal engineering effort. 
  • Dynamic Integration: Facilitates the rapid creation and modification of systems using reusable modules. 
  • Comprehensive Control: Includes descriptions of data objects, control images, and future service information. 


Benefits of Implementing MTP 

  • Efficiency and Flexibility: Modules can be quickly integrated or swapped, reducing downtime and enhancing productivity.
  • Cost-Effective: Minimizes engineering costs through reusable modules and standardized integration processes. 
  • Enhanced Security: Incorporates advanced security measures, ensuring safe and reliable operation. 
  • Future-Proof Technology: Leverages modern communication standards like OPC UA for real-time, manufacturer-independent communication. 


Applications of MTP in Modular Automation 

  • IIoT and Smart Factories: Enables intelligent integration and management of various Industrial Internet of Things (IIoT) devices. 
  • Pharmaceutical Manufacturing: Facilitates the production of highly specialized products in small quantities but can quickly and easily be ramped up for mass production. 
  • Shipbuilding: Ensures efficient integration of modular systems in complex shipbuilding projects. 


WAGO’s Module Type Package (MTP) is transforming the landscape of modular automation, making it easier than ever to create, adapt, and optimize industrial systems. By standardizing interfaces and providing a robust framework for integration, MTP empowers industries to achieve unparalleled efficiency, flexibility, and security. Embrace the future of automation with WAGO’s MTP and unlock the full potential of your modular systems.


Compatible products:

 

Contact us at (855) 737-4716 to learn more, or fill out our online form.

Mark Efficiently with the WAGO Smart Printer

Corey Foster || Valin Corporation

Download Free Printer Promo Flyer
Are you looking to streamline your marking process while saving both time and money? Meet the WAGO Smart Printer, the industry’s most versatile and economical printing solution. This powerhouse device is designed to handle all your marking needs with ease and efficiency.  

mark efficiently with the WAGO smart printer

Why Choose the WAGO Smart Printer?

Versatile Marking Capabilities  
The WAGO Smart Printer isn't just another printer; it’s your all-in-one marking solution. It can seamlessly switch between marking terminal blocks, relays, power supplies, and PLCs, to labeling control cabinet type plates, push-buttons, wire markers, and more. This versatility ensures you have one reliable tool for all your marking needs, reducing the hassle of managing multiple devices.


Smart Designer Integration  
Take advantage of WAGO’s free online configuration and ordering tool, Smart Designer. With full 3D capabilities, you can create and save custom assemblies complete with all accessories and markings. Export your designs into all standard CAD formats, ensuring a smooth transition from planning to implementation.


Cost-Effective Solution  
The WAGO Smart Printer is the industry’s most affordable printing solution, significantly lowering material costs and reducing marking time. Minimal maintenance means you can focus more on your projects and less on upkeep.


Comprehensive Marking Options

Terminal Block markingTerminal Block Marking  
WAGO terminal blocks can be labeled using two exclusive methods: the continuous marker strip for fast, multi-line marking and the WMB inline markers for single marking tags. Fit up to twelve characters of text per terminal block, making identification clear and efficient. 

Cable and Conductor Marking  
Choose from a variety of marking options including sleeves, self-laminating labels, thread-on wire markers, and heat shrink tubing. These options cater to different wire sizes, providing flexibility and ensuring clear labeling for all your cabling needs.

device markingDevice Marking  
The WAGO Smart Printer offers a broad selection of label types for the entire cabinet, including push-button markers and type plates. Available in various colors and sizes, these labels help maintain a clean, organized, and professional look for your control cabinets. 
 

The Power of Smart Script

Efficient Software Integration  
WAGO’s Smart Script marking software complements the Smart Printer perfectly, offering an efficient, cost-effective solution for all your marking needs. It allows you to generate all marking data directly, with seamless integration to the Smart Designer configurator, EPLAN P8, Microsoft Excel, and CSV.

Customization and Ease of Use  
With Smart Script, you can manage multiple printers simultaneously, customize print settings based on the material used, and ensure optimal management of your marking projects. The intuitive workflow and modern design make it easy to create and print custom marking solutions.

 

The Benefits for You

  • Modern Design and Intuitive Workflow: Fast and easy to use with integrated printer drivers and settings. 
  • Large Selection of Marking Media: Tailored templates for use with WAGO’s thermal transfer Smart Printer. 
  • Optimized Data Interfaces: Seamlessly import data from CAE systems like EPLAN, WSCAD, and ZUKEN, or via Excel.
  • Comprehensive Management: Smart Script enables easy project management, mirroring project structures from Explorer, and ensuring quick project discoverability.


Conclusion
The WAGO Smart Printer is not just a printer; it’s a transformative tool that enhances efficiency, reduces costs, and ensures precise marking for all your control cabinet applications. Visit www.wago.com/smartprinter for the installation package and software, or click here to learn more. 

If you have any questions or are just looking for some help, we're happy to discuss your application with you.  Reach out to us at (855) 737-4716 or fill out our online form.

How Yokogawa Took a Plant from Semi-Automated to Autonomous

Yokogawa

In 2017 Yokogawa started developing AI for control applications. In 2018 FKDPP (Factorial Kernel Dynamic Policy Programming algorithm) was jointly developed by Yokogawa Electric Corporation and the Nara Institute of Science and Technology (NAIST). FKDPP was run on a simulator of a vinyl acetate manufacturing plant (distillation column, decanter).  It was presented at the IEEE International Conference in August 2018 as a reinforcement learning technology that can be applied in plants (the world's first reinforcement learning technology to demonstrate high feasibility for use in plants).

 
How Yokogawa Took a Plant from Semi-Automated to Autonomous
 

Based on four valves and nine sensor values, FKDPP operated the valves to maximize the volume of products produced and ensured that quality values conformed to standards and safety standard values were within tolerances. Stable and optimized valve operation was achieved in just 30 learning trials.

In 2019 Yokogawa succeeded in an experiment using a control training device - a three tank level control system, via laptop PC. Although the system can be controlled with conventional PID control technology, it was shown that FKDPP can reduce the settling time by 50% to 70% while also preventing over-shoot.

In 2020 Yokogawa showed the potential for controlling an entire plant that was confirmed with a simulator. (Paper presented in April 2020).
 
The demonstration utilizing e-RT3 Plus (as a PLC) with FKDPP was unveiled in an exhibit at Measurement Exhibition 2020 OSAKA.

The experiment was successful and started practical use of minimized use of electricity and LPG for air conditioning control in semiconductor clean rooms in Komagane plant of Yokogawa, Japan.

In 2022, Yokogawa launches Autonomous Control AI Consultant Service and FKDPP controlled a chemical plant for 35 consecutive days (in a world first).

  • Reinforcement learning AI can be safely applied in an actual plant
  • Can control operations that have been beyond the capabilities of existing control methods (PID control/APC) and have up to now necessitated the manual operation of control valves based on the judgements of plant personnel.

In 2023  (in a world first), Yokogawa’s Autonomous Control AI  (FKDPP) is officially adopted for use at an ENEOS materials chemical plant!

  • Over two years of stable operation demonstrates this next-generation control technology can decrease environmental impact, achieve stable quality, and transform operations of control valves based on the judgements of plant personnel.
  • Yokogawa’s Autonomous Control AI Algorithm (FKDPP) Takes Highest Honor in Japan Industrial Technology Awards!    

In 2024 Yokogawa Launched Autonomous Control AI Service for Use with e-RT3

  • Optimizes control to improve productivity and save energy

The purpose of the original field test in 2022 was to demonstrate that reinforcement learning AI (FKDPP: Factorial Kernel Dynamic Policy Programming algorithm) can be applied safely in plants where safety is an absolute necessity and also to demonstrate that reinforcement learning AI can be used to control areas that existing technology cannot automate.

 

Success in “Controlling" an Actual Plant with AI 

Field Test Target Overview

AI directly controls the two heat  sources (waste heat utilization) in the revoir section of the distillation column.

Reason for choosing the target : Until now, the target location could not be automated by PID control or APC, so it was manually controlled. (This target was requested by the production department.) Manual control at regular intervals 24 hours a day, 365 days a year is very difficult!

FKDPP operates the MV and controls it directly! No changing of the SV! New control method!

Graph


Generate AI control model with a plant simulator

  • Plant model generated from design information for the relevant plant
  • Reinforcement learning-based AI (FKDPP algorithm) learned and generated a control model

Comprehensively assess AI control  model validity and reliability

  • Checked with past operating data
    • Was it stable?
    • What kind of control was performed when problems occurred?
  • Checked with real-time data
    • Was it stable?
    • Was product quality within spec?
    • Were veteran operators satisfied with FKDPP control instructions?

Ensure safety, then control a real plant

  • Ensured safety with existing interlocks and other safety functions
  • Integrated with CENTUM™ VP integrated production control system, and incorporated into plant operations 
  • Ensured safety in operations (planned responses and established system for dealing with AI system malfunctions)
 

What Did FKDPP Actually Control?

In processes where existing control methods (PID control / APC) could not be applied:

  1. Separate substances with similar boiling points were controlled
    1. Maintain liquids in the distillation column at an appropriate level to ensure all products are compliant
  2. Achieved high quality outputs and increased energy savings while taking into account sudden external disturbances (rain, snow, etc.)
    1. Operate valves to maximize use of waste heat for heating
 

Value for Society

Autonomous Control

Areas that previously couldn’t be controlled with PID control and APC were autonomously controlled by reinforcement learning-based AI (the FKDPP algorithm)

Over Two Years

Managed and controlled with CENTUM™ VP integrated production control system

Safe Operation and Improved Productivity

Simultaneously achieved safe operation and improved productivity, with stable quality, high yield, and energy saving

Reduced Cost and Time Loss

Only high-quality products were produced, so losses in the form of fuel, labor costs, time, etc. that occur due to production of off-spec products were eliminated

It was proved that next generation control technology using reinforcement learning-based AI ( FKDPP) can greatly contribute to the autonomization of production, ROI maximization, and environmental sustainability.

 

Conclusion

Until now, there have been many parts of the plant that have not been fully automated.

The next generation control technology using reinforcement learning-based AI ( FKDPP) will autonomize areas that could not be automated with existing control methods while ensuring safety and improving productivity. FKDPP is a disruptive innovation that allows for a different dimension of control, particularly in such areas. This AI technology can be applied in the energy, materials, pharmaceuticals, and many other industries.

The daily monetary value of operations in large-scale plants is in the range of tens of millions of dollars. Autonomous control AI (FKDPP) can greatly contribute to the autonomization of production around the world, ROI maximization, and environmental sustainability, and will have a major economic impact.

In order for our customers to fully understand this value, Yokogawa welcomes customers who are interested in these initiatives globally. We aim to swiftly provide products and solutions that realize industrial autonomy.

Be sure to read our blog: Autonomous AI Control Service for Edge Controllers

Would you like to speak to one of our technical specialists to learn more?  Just fill out the form below.

Discover the Future of Automation with Techman AI Cobot

Corey Foster || Valin Corporation

AI Cobot S Series from Techman RobotWelcome to the future of manufacturing, where efficiency meets intelligence! At Valin Corporation, we're thrilled to introduce the Techman AI Cobot series—a revolutionary family of collaborative robots that bring the power of AI and vision technology directly to your production floor. If you're a manufacturer looking to enhance productivity, boost quality, and stay ahead of the competition, the Techman AI Cobot is your ultimate solution. 

 

What Makes Techman AI Cobot Stand Out?

1. AI Vision Technology: Unlike traditional robotic arms, Techman AI Cobots are equipped with “AI Vision” technology, giving them the ability to see and understand their environment. This built-in vision system allows the cobots to dynamically adjust to changes, ensuring precision and flexibility in every task. Whether it’s recognizing objects, reading barcodes, or performing quality inspections, these cobots excel where others fall short.

2. Enhanced Productivity: The Techman AI Cobot significantly increases production throughput. By sensing their surroundings and interacting safely with human operators, they create a seamless workflow that enhances overall efficiency. Imagine a robot that can adapt to changes on the fly, and how much that would reduce downtime and maximize your output!

3. Cost-Effective and Flexible: Techman cobots provide a cost-effective automation solution suitable for businesses of all sizes, from small workshops to large manufacturing plants. Their user-friendly, flow-based programming and robust construction ensure they’re easy to use and maintain, offering exceptional value for your investment.

4. Built for Durability: Techman cobots are designed to last. With metal gearing instead of plastic, they stand up to high duty cycles and tough manufacturing environments. Most  cobots are still running strong after five years of rigorous use, proving their durability and reliability.

 

Unique Features of the Techman AI Cobot

Integrated Vision Applications: Techman cobots come with built-in vision applications that include positioning (eye-in-hand, eye-to-hand, upward-looking, conveyor tracking), recognition (barcode/QR code reading, optical character recognition), measurement (distance and angle measurement, object counting), and AI inspection (image classification, object detection, defect detection).

TM Landmark for Precision: The TM Landmark feature allows cobots to calibrate to the work surface rather than the robot’s coordinates. This means when the robot or surrounding objects move, all points are dynamically updated with just one glance, providing unmatched flexibility and accuracy.

Force-Related Features: From deburring and polishing to screw driving and assembly, the Techman AI Cobot’s force-sensing capabilities transform these tasks. By precisely controlling the force applied, the cobots enhance the quality and efficiency of each process, reducing the risk of damage and improving overall precision.

 

Why Choose Techman AI Cobot?

Smart Manufacturing Made Easy: The Techman AI Cobot is designed to help you achieve smart manufacturing with ease. Its advanced features and user-friendly interface make it simple to deploy and operate, ensuring you get up and running quickly without extensive training or costly setup.

Future-Proof Your Production: As the manufacturing landscape evolves, having a flexible and intelligent automation solution is key to staying competitive. The Techman AI Cobot not only meets today’s demands but is also equipped to handle the challenges of tomorrow, making it a future-proof investment.

Real-Time Quality Control: With the TM Image Manager, you can manage and track quality inspections in real-time. This software monitors inspection progress, records results, and archives images, helping you maintain high standards and reduce after-service costs.

 

Ready to Transform Your Manufacturing Process?

Join the ranks of forward-thinking manufacturers who have already discovered the benefits of the Techman AI Cobot. At Valin Corporation, we’re here to help you integrate these innovative robots into your production line, providing the support and expertise you need to succeed. Click here to learn more about Techman AI Cobots.

 

Talk to one of our automation experts today at (855) 737-4716 or fill out our online form to learn more.