- 1. Benefits to the general manager
- 2. Benefits for department managers
- 3.the benefits of material control and production management
- 4.the benefits of quality control
- 5. the benefits of the system to accounting
- 6. the benefits to the business
- 7.the benefits to the project
- 8. Benefits to the warehouse management department
- 9. Benefits to the Purchasing Department
- Many automation engineers are meeting fieldbus applications for the first time and Mike O’Neill discusses some issues, and explains how to deal with them.
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According to industry legend, Liu Chuanzhi has a famous saying: “Don’t die if you go to ERP. If you go to ERP, you will die.” Many companies think that ERP (Enterprise Resource Planning) can bring enterprise management to a higher level, in line with international standards, and realize informatization. And the whole process of monitoring, so he did not hesitate to spend a lot of money, but often the effect is not good. But this is a thing of the past. Now most companies have used ERP systems to improve their management effects by leaps and bounds. The following will share the benefits of implementing Fangtian ERP system to the management of various departments of the company.
1. Benefits to the general manager
- 1. The company’s operating status can be grasped at any time from the data in the system.
- 2. Establish the company’s management system and operation specifications, which will be operated by the system management company.
- 3. Establish a database for company operations, accumulate the company’s management experience and knowledge, and will not be lost due to personnel changes.
- 4. The integration of system information can improve the company’s response speed, without the need for manpower statistics, which can reduce errors and save manpower.
- 5. A large number of computing functions provided by the system can strengthen the company’s production flexibility and improve the ability to receive orders.
- 6. The system can integrate the data of each unit, can settle at any time, and understand the company’s current operating costs.
- 7. The system complies with fiscal and taxation regulations and may achieve the goal of internal audit and internal control.
- 8. The system complies with the specifications for listing and listing, and can assist companies in listing and listing operations.
- 9. The system can reflect various abnormal conditions and provide relevant information to facilitate problem solving.
- 10. The system can provide the functions of electronic sign-off and work flow, which can achieve the goal of paperless.
- 11. The system can remotely operate and query online, which is convenient for cross-border management and is not restricted by region.
- 12. The system can be used for fund management to improve the efficiency of fund operation.
2. Benefits for department managers
- 1 Check the fluctuations in the unit price of all raw materials purchased by the company at any time, and respond according to market conditions.
- 2. Analyze the total purchase amount of the supplier in a certain period of time, and negotiate discounts with the bulk raw material supplier based on the valid digital amount.
- 3. In the sales part, customers can be divided according to the sales amount within a certain period of time. Determine A-level customers.
- 4. Analyze customer orders, make a trend chart for the order volume of goods shipped, focus on control, analyze its cost, and reduce its cost of sales as much as possible, thereby increasing profits. It can also make a forecast of product sales.
- 5. Analyze inventory abnormalities and inventory errors, and formulate corresponding processing plans. Feedback information to relevant departments to optimize inventory.
- 6. The project can be audited and controlled for the project part, analyze its project profit and loss, and evaluate its feasibility.
- 7. A budget can be made for the whole year’s expenses, and then compared with the actual occurrence, the difference part is analyzed, and the corresponding strategy is formulated.
- 8. The purchase unit price can be electronically signed and controlled, so that the purchaser must use the purchase unit price signed by the supervisor when placing a purchase order.
- 9. Regarding the account receivable part, the system reflects the length of the account age, which can quickly understand and track the account receivable in real time.
- 10. Perform statistical analysis on the sales performance of business personnel, formulate corresponding reward and punishment mechanisms, mobilize the enthusiasm of employees to a greater extent, and create greater benefits for the company.
- 11 Keep abreast of the scrapping situation in the production process, analyze the abnormal work orders of scrapping, and formulate corresponding strategies.
- 12. Analyze the operating ability, financial structure, and profitability, and analyze the various abnormal coefficients.
- 13. In the process of using workflow message management, timely and quickly understand the delays of purchase orders and sales orders, and make corresponding adjustments to abnormal parts.
3.the benefits of material control and production management
- 1. It can keep track of the sales order quantity, shipment quantity, undelivered quantity and customer demand date in time.
- 2. Can control the purchase and arrival status of materials at any time.
- 3. The inventory status of materials and products can be grasped at any time, and production and shipment arrangements can be made in time.
- 4. Carry out delivery forecast analysis and material analysis to customer needs, so as to determine whether production capacity and materials can meet customer needs, and quickly feedback information to the business.
- 5. Through the product master plan, work orders for finished and semi-finished products can be issued at one time, reducing the workload.
- 6. Material requirements can list the inventory, allocated, in-transit, estimated inventory, and missing materials of the materials needed to produce the current product, which are checked by the material control, and can be directly transferred to the procurement system to generate purchase orders .
- 7. When opening a manufacturing order, you can know the inventory, allocated and requisite quantities of each material.
- 8. You can set the completion plan of the dispatch order, and query the completion status of the plan through <
> to control production. - 9. The production schedule of the machining center can control the ultra-short load situation of various resources at any time, so as to make the corresponding deployment.
- 10. Performance analysis of the machining center, which can understand the actual man-hour consumption and production efficiency of the machining center, the rate of good products, and the rate of defective products.
- 11. Product master plan progress tracking table, you can inquire about the production schedule, the number of sets that have been picked, the number of sets that have not been picked, and the number of warehousing according to the sales order.
- 12. The progress of the manufacturing order and the progress of the order are reflected at any time.
- 13. Production line work-in-progress transfer control and input, output, and in-process analysis of each station.
- 14. Transfer and storage over-quantity control and storage time control.
- 15. The overdue and unfinished manufacturing order data tracking table can deal with the overdue manufacturing order in time.
- 16. Over-requisition restrictions and replenishment procedures control.
4.the benefits of quality control
- 1. Use quality control operations to make the entire operation process more rational and complete.
- 2. The record of incoming materials is more complete, which is convenient for traceability, analysis and subsequent improvement.
- 3. Able to make detailed records of the entire production process to facilitate subsequent analysis and improvement.
- 4. Able to uniformly analyze the quality of the materials provided by the supplier for us, so that the operation can be adjusted accordingly.
- 5. Be able to concentrate on analyzing the links that need to be resolved in the products produced within the company.
- 6. Ability to cancel a large number of manual inspection reports, improve efficiency, and reduce unnecessary human errors.
- 7. Multi-link quality control operations can perform multiple certifications on products and reduce unnecessary repetitive operations in the follow-up.
5. the benefits of the system to accounting
- 1. The monthly financial statements are timely settled: such as the balance sheet and monthly profit and loss statement provided by the financial staff every month. The financial staff of the system operation no longer need to laboriously check for unbalanced loans.
- 2. The detailed account management is clear at a glance: As a factory, no matter how many clients you have, they can be managed by the system, and you can always keep track of their receivables and unpaid amounts. Financial staff also don’t have to worry about the unevenness of the general ledger and detailed accounts.
- 3. Control and deployment of capital flow: inquire about factory capital occupation and balance situation in time, and make capital forecast, and provide reasonable plan for the leader’s capital operation.
- 4. All departments are linked to each other in system operations, and the final documents are reviewed and kept by financial personnel to facilitate the internal supervision and internal control of the internal management of the factory.
- 5. Cost settlement is easily completed. The monthly system transactions are normal, the documents are complete, and the cost calculation is easy to settle.
- 6. The financial staff has a characteristic when checking out: the front is loose and the back is tight, that is, nothing happens at the beginning of the month, and there is no time at the end of the month. The system operation focuses on the timely entry of daily operations and the check of the correctness of the documents. As long as the data is entered correctly at ordinary times, the system calculates the report data at the end of the month, which is conducive to the rational use of enterprise human resources.
- 7. The system operation is not only to provide the report data of the current month, but also to provide the comparison of the data between different months to facilitate the analysis of various financial data.
- 8. The use of budget function provides analysis between budget and actual.
- 9. Provide multi-angle analysis and statistics functions: such as sales (purchase amount) statistics by customers, statistics by customers, statistics by salesmen, statistics by inventory, statistics by inventory classification, etc.
- 10. For the operating factories in the three places, this system provides the most convenient and efficient method for data exchange between databases, business exchanges, and financial and account consolidation.
6. the benefits to the business
- 1. Provide complete customer basic information files, record various detailed information of customers and related transaction conditions with customers, so as to facilitate future data inquiries.
- 2. You can enter sales orders conveniently and quickly, control the customer’s order quantity, and provide daily orders at any time.
- 3. The system automatically deducts the accounts that have been shipped, and provides the details of unpaid orders in real time, so that it is convenient to check P/O with customers.
- 4. Provide online production status analysis of orders, which can accurately understand the current production status and quickly reply to the delivery date of customers.
- 5. Provide approved unit price management, provide transaction history unit price query, and understand the status of unit price changes.
- 6. Provide an order forecast usage analysis table, which can calculate the material requirements of the forecast part of the customer, and prepare the materials in advance.
- 7. You can provide the shipping reconciliation schedule of the shipped part at any time to facilitate reconciliation with customers.
- 8. Provide credit line control, which can ensure the timeliness of fund return, reduce the occurrence of bad debts of the company, and reduce the company’s operating risks.
- 9. Provide a comparison table between the company’s material number and the customer’s material number, and you can directly use the customer’s material number for order processing, shipping list printing, query management, etc., which greatly improves the work efficiency.
- 10. Provide order version control, which can trace back the modified content of the customer’s order and the original order information according to the version change.
- 11. Can provide sales trend analysis reports by period, inventory, and customers to understand sales trends and market trends, and provide first-hand information for future production and sales plans.
- 12. For the export part, Invoice and Packinglist can be automatically provided according to the delivery order, which can meet the needs of export customers without repeating operations.
- 13.Resource sharing is truly achieved. As long as you have the authority, you can enter the system and check all the relevant information about the customer’s order and shipment at a glance. It will not be because the staff responsible for a customer is not available and others will not understand the situation and cannot be timely. Respond to and handle customer issues.
7.the benefits to the project
- 1. You can design multiple BOM versions for the same product.
- 2. The BOM with similar product structure can be directly copied to reduce input.
- 3. Through the BOM structure tree, the multi-level relationship of the product can be clearly printed.
- 4. It is possible to compare the BOM structure between different products.
- 5. The substitution relationship of materials can be maintained.
- 6. You can change multiple product BOMs at once.
- 7. You can maintain the co-by-product data of the main product.
- 8. The same product can maintain multiple processing techniques.
- 9. Various resources and individual resources can be maintained.
- 10. The production capacity of various resources can be adjusted at any time.
8. Benefits to the warehouse management department
- 1. Quickly check the warehouse inventory and related material status, such as the material in transit, allocated, purchased, etc. The quantity is more comprehensive.
- 2. Inventory query methods are flexible and convenient. For example, you can check the historical inventory at a certain point in time, you can check the inventory of a certain category or warehouse, and you can only check the inventory that has transactions on the day.
- 3. You can quickly check the safety stock status of common stocks and know whether materials should be purchased in time to ensure production needs.
- 4. Can quickly check the status of sluggish materials in the warehouse to deal with it in time, reduce the occupation of funds due to inventory backlog, and improve capital operating capacity.
- 5. Warehouse management is simple, easy, timely and accurate. Warehouse data can be generated in a variety of formats according to the needs of the leader, which is beautiful and generous, fast and flexible.
- 6. The monthly inventory data is generated quickly and conveniently, and the system automatically counts the inventory profit and loss figures of the warehouse account and the accounting account.
- 7. The documents made by the warehouse can be automatically transmitted to the financial and other related departments by the system, which is timely and accurate.
- 8. The warehouse data can be shared with other departments in real time, so there is no need to always receive calls to check inventory for people all day long.
- 9. There are special report statistics for abnormal inventory, so that the warehouse staff can check it in a targeted manner.
- 10. In order to meet financial needs, there is a separate interface for the inventory received at the end of the month for which there is no invoice for temporary inventory estimation.
9. Benefits to the Purchasing Department
- 1. Resource integration. The procurement system resources are integrated with other human, financial, and material resources in a database, which is conducive to the sharing of corporate resources.
- 2. Once the information is uploaded and the purchase receipt is entered, the system will automatically send a short message to notify the supervisor for review.
- 3. When the order is issued, the purchase order will be automatically transferred to the warehouse department to facilitate the inspection and storage of items.
- 4. Financial accounting, purchase warehousing documents will be automatically transferred to the accounting system, which is convenient for financial staff to reconcile and keep accounts.
- 5. The purchase can be arranged directly according to customer orders received by the business department.
- 6. The system will calculate the raw material requirements according to the production order issued by the production management department, and can automatically convert it into a purchase order.
- 7. It can maintain the supply chain management (SCM) of upstream and downstream manufacturers.
- 8. Unified management of suppliers and their quotations, which is convenient for evaluating suppliers and comparing and analyzing purchase prices.
- 9. According to actual needs, the scope of purchased items can be divided according to different purchasing personnel.
- 10. When the purchase order is entered, the system automatically brings in the approved price of the supplier, which is convenient for entering the order.
- 11. Record the requisition status of raw materials in each department in the requisition operation, and it can be automatically converted into a purchase order for purchase.
- 12. When the supplier delivers the goods, the temporary receipt information is directly related to the quality control. If the inspection is qualified, it will be stored in the warehouse, otherwise it will be returned.
- 13. Provide various query forms to keep track of purchase orders, purchase unit price, vendor delivery, warehouse acceptance, purchase follow-up, purchase reconciliation, accounts payable and other information.
Link to this article:The benefits of Fangtian cloud ERP system for management enterprises
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Not so long ago, erecting a wind turbine farm in deep water would have seemed…
The post Floating wind farms showing signs of a promising future first appeared on Walker Machining.
Not so long ago, erecting a wind turbine farm in deep water would have seemed a futuristic idea, but not anymore. Pilot floating wind turbine projects are showing positive results and they may become a cost and energy effective solution in areas lacking the appropriate geological conditions for the construction of conventional offshore wind farms.
Floating turbines can be placed in areas with the best possible wind conditions rather than primarily basing the location selection on the depth of the waters (max. 50m for conventional offshore wind turbines) or the quality of the seabed. Japan, the US and some parts of Europe, for example, could benefit from the development of floating offshore wind turbines due to their lack of shallow waters.
It was in 2009 that the first full-scale floating pilot platform Hywind, featuring a. 2.3 megawatt Siemens turbine, was deployed 10 km off the south-west coast of Norway and has since produced 32.5GWh of energy. Since then, several other successful full scale pilot projects have been given the green light in different regions of the world.
On 3 November 2015, the Scottish Government gave approval to the Norwegian energy company Statoil, who is behind the Hywind project, to start a second project off Peterhead in Aberdeenshire, Scotland. It is set to become the largest floating wind turbine farm in the world. The 30 MW pilot project will consist of five 6 MW floating Siemens turbines operating in waters exceeding 100m of depth at Buchan Deep, 25 km offshore Peterhead. The wind farm is expected to provide electricity to around 20,000 households. Production is planned for 2017. The turbines will be attached to the seabed by a three-point mooring spread and anchoring system. An export cable will transport electricity from the pilot park to shore at Peterhead.
Five km off the coast of Aguçadoura, Portugal, another pilot project, known as the Wind Float Atlantic project, is being tested under plans set out in November 2015. The project is planned to be operational in 2018 and will consist of 3 or 4 wind turbines on floating foundations, accounting for a total capacity of 25 MW. The project is led by a consortium of companies including French gas and power group Engie, Portugal’s EDP Renewables (EDPR), Japan’s Mitsubishi Corp and Chiyoda Corp, along with Spanish energy group Repsol. According to the consortium, the aim of the project is to demonstrate the economic potential and reliability of this technology, advancing it further in the path towards commercialisation. During phase one, a semi-submersible wind generator carrying a 2 MW Vestas turbine had produced more than 16 GWh over almost four years of operation, during which time it withstood extreme weather conditions.
Off the coast of Fukushima in Japan another project launched in 2013 is also seeing the huge potential of floating wind farms. The demonstration project (Fukushima FORWARD) is led by a consortium of universities and heavy industry companies, including Nippon Steel & Sumitomo Metal Corporation, and is funded by the Ministry of Economy, Trade and Industry. In this project, three floating wind turbines and one floating power sub-station will be installed off the coast of Fukushima. The first phase of the project was completed in November 2013 and consisted of one 2MW floating wind turbine. Phase II began in June 2015 and should see two of the world’s largest 7-megawatt wind turbines being installed by the end of the year.
The technologies enabling the wind turbines to stay afloat typically consist either of a single central floating cylindrical spar buoy or a triangular platform moored by catenary cables. So far, both technologies have shown promising results even in severe weather conditions.
The commercial development of this new technology could help further boost the use of renewables in lieu of fossil fuel energy.
Steel plays a vital role in wind power generation. Steel represents on average 80% of all materials used to construct a wind turbine. The main advantage of generating energy from wind turbines is that the technology emits no C02.
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Guest contributors are welcome at the Alloy Wiki.It is a weekly wiki and guide on alloy information and processing technology, while also about the vast array of opportunities that are present in manufacturing. Our team of writers consists of a Machining Material Supplier / Machinist / Tool and Die Maker, a Biomedical Engineer / Product Development Engineer, a Job Development Coordinator / Adjunct Professor, and a President and CEO of a manufacturing facility.
Link to this article:Floating wind farms showing signs of a promising future
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Many automation engineers are meeting fieldbus applications for the first time and Mike O’Neill discusses…
The post How to cope with fieldbus for the first time first appeared on Walker Machining.
Many automation engineers are meeting fieldbus applications for the first time and Mike O’Neill discusses some issues, and explains how to deal with them.
Many automation engineers are coming face to face with real fieldbus applications for the first time Fieldbus (the use of digital communications networks for distributed instrumentation and control) is a wonderful technology with many benefits, but fieldbus installation requires some additional considerations over and above normal 4-20mA projects
In this article, I will discuss some of those issues, and explain how to deal with them.
* Choosing a ‘Fieldbus’ – don’t get ‘into a dilemma about which fieldbus to choose.
Fieldbus is a generic term for a variety of communications protocols using various media, but all are simply a means to an end.
What is wanted at the end of the project is a satisfactory and functional control system, and practically every installation will use multiple fieldbuses to accomplish the many tasks required.
For example, one can use FOUNDATION fieldbus in the process plant, DeviceNet for a PLC network, and PROFIdrive to run motor drives.
Every DCS can easily integrate all these functional plant buses into the Ethernet-based control room bus.
In process control engineering, ‘fieldbus’ normally means FOUNDATION fieldbus H1 (H1) or PROFIBUS PA(PA).
Both of these fieldbuses are perfectly adequate and widely used around the world in refineries and process plants as modern day enhancements to 4-20mA, two-wire devices.
This article focuses on H1 and PAphysical layer implementation.
* Fieldbus power supplies – a fieldbus segment begins at an interface device at the control system.
On a FOUNDATION fieldbus H1 system, the interface is called an H1 card; on a PROFIBUS PA system, it is a PROFIBUS DP/PA segment coupler.
In terms of signal wiring and power requirements for the segment, H1 and PA are identical, as follows.
* Minimum device operating voltage of 9V.
* Maximum bus voltage of 32V.
* Maximum cable length of 1900m (shielded twisted pair).
* Communications at 31.25kHz, Manchester encoded.
The DC power required by devices on the bus is normally sourced through a fieldbus power supply or ‘power conditioner’, which prevents the high frequency communications signal from being shorted out by the DC voltage regulators.
Typical power conditioners make 350 to 500mA available on the bus and usually The interface experts incorporate isolation to prevent segment-to-segment cross talk.
In H1 segments, the power conditioners are separate from the H1 interface card and are often installed in redundant pairs to improve the overall reliability.
For PA systems, the DP/PA segment coupler usually incorporates the power conditioning component.
There is no absolute requirement for the DC source to be independent per segment, but most designs provide segment isolation via DC/DC converters.
Note that fieldbus power conditioners are not the same as COTS (Commercial Off-The-Shelf) power supplies, which if connected straight onto any segment, will immediately damp out all segment communications.
* Installing Fieldbus – H1/PA systems carry both DC power and digital communications on the same wire pair, and a standard 24V DC power pack would effectively short-circuit the communications signal.
The power supply therefore requires low pass ‘conditioning’ to filter out that signal, and this conditioning may be ‘active’ (notch filters, etc) or ‘passive’ (series inductance).
Fieldbus power supplies can fail while in service so it is usually a good idea to specify power supplies, as follows.
* Are redundant (one unit can continue delivering power when the other one fails).
* Can be ‘hot swapped’ (a new one can be replaced without shutting down the segment).
* Has some sort of alarm that notifies maintenance or operations when a problem occurs.
* A good feature is built-in surge protection to protect the DCS system from lightning impulses from the field.
Redundant supplies can be constructed as needed for FOUNDATION fieldbus H1 segments, but PROFIBUS PA segments are constrained by the standard DP/PA segment coupler design which incorporates field power conditioning within the DP/PAprotocol converter and only allows redundant power conditioning in the fault-tolerant version.
* Segment calculations – when calculating how many devices can fit on a fieldbus segment, the primary factors to be taken into account are as follows.
1 – The maximum current requirement of each device.
2 – The resistance of the segment cable (because of voltage drops along the length).
The calculation is a simple Ohm’s law problem, with the aim of showing that at least 9V can be delivered at the farthest end of the segment, after taking into account all the voltage drops from the total segment current.
For example, driving 16x 20mA devices requires 320mA, so if the segment is based on cable with 50 Ohms/km/ loop and a 25V power conditioner, the maximum cable length is 1000m to guarantee 9V at the end.
Note that many users also specify a safety margin on top of the 9V minimum operating voltage to allow for unexpected current loads and for adding additional devices in the future.
Some users also allow a safety margin in case one or more fieldbus devices fail from a short circuit.
It will be discussed below.
The calculations must be done for each segment.
An engineer must add up all the power requirements of all the fieldbus transmitters, valve controllers, and other devices on the segment, and then factor in the length and resistance of all the cables to make sure that 9V can reach the farthest devices.
Fieldbus devices can require anything from 10mA to 25mA, with 20mA a reasonable estimate for mental calculations.
In most cases, the fieldbus device manufacturer will supply the necessary data, but be wary: sometimes they are mistaken.
In one case, a customer found that valve controllers specified to draw 10mA actually required 25mA when configured in a particular way.
When the plant powered up the segment, they found that discrepancy the hard way, and had to add an entire segment to accommodate the high-powered controllers.
Advice – be certain the power requirements are known of every device planned for installation on a segment.
* Terminators – in FOUNDATION fieldbus H1 and PROFIBUS PA, the communications signal is current modulated at 31.25kHz, 20mA peak-to-peak (p-p).
Terminators are required at each end of the segment cable to prevent line reflections (which may otherwise result from open-ended cables) and to source/sink the communications current.
The terminator circuit is very simple: 100 Ohm resistor and 1 microFarad capacitor in series across the segment.
The end-of-line resistor provides a nominal load for the communications signal, and the capacitor stops the DC supply draining through the resistor.
Two terminators at 100 ohm gives a nominal 50 ohm load for the communications current (20mA p-p) and a signal voltage for receiving devices of 1V p-p.
* When instruments work in the laboratory (lab), but not in the factory – if instruments worked during lab or staging tests, but don’t work in the field, in many cases it’s an installation problem.
Simply put, the technicians didn’t set the segment terminators properly.
Instruments can behave erratically, drop off the segment mysteriously, and Terminators must be turned on at the beginning and at the end of each segment.
Two terminators are required per segment, one at each end.
With one terminator, the signal will be higher, and with three or four terminators, the signal will be lower.
Many field devices won’t accept signals at 2V p-p and may unexpectedly reset.
With three or four terminators, the signal can be so low it is unusable.
The absolute minimum signal that devices must be able to recognise is 150mV p-p.
Some users may test a segment in a lab, or at the vendor site.
In such a case, under carefully controlled conditions, the segment may actually work with incorrect terminators.
However, they rarely work in the field when not terminated properly.
Careful installation management to ensure the correct number of terminators is essential.
It is unfortunate that many installation subcontractors pay little heed to the terminators and either forget them completely or enable them all if they are part of the device couplers, neither of which allows the segment to operate properly.
Often, physical inspection of junction boxes and field enclosures is the only way to locate and correct the terminator position, which is a significant delay to the commissioning process.
* Device couplers – most device couplers use manual on/off DIP switches to terminate couplers.
In a segment, the last device coupler should contain the terminator, and all couplers between the last coupler and the H1 card should have their terminator switches set to off.
Diagnosing the problem often requires physically examining each device coupler to determine if the switches are set properly throughout the segment.
Automatic segment termination simplifies commissioning and start-up.
It automatically activates when the device coupler determines that it is the last fieldbus device coupler in the segment; if it is, it terminates the segment, since the downstream device coupler will assume that responsibility.
No action – such as setting DIP switches – is necessary by the installation person to terminate a segment properly.
If a device coupler is disconnected from the segment accidentally or for maintenance, the automatic segment termination detects the change, and terminates the segment at the proper device coupler.
This allows the remaining devices on the segment to continue operation.
* Fieldbus cable – one of the central themes of fieldbus for process control is that it should be as practical as possible.
Power and signal shall be available on the same cable, and that cable should not be fundamentally different from conventional instrument cable already in common use.
Some cable manufacturers take advantage of the uninitiated by offering ‘fieldbus’ cable in the same way as they make ‘intrinsically-safe cable’ (same as ordinary instrumentation cable but with an alternate colour sheath at significantly extra cost).
In general, if a cable is already in use for instrumentation and control, it is almost certainly fine for H1/PA use.
Typically, 0.8mm2 cable is used, with shield on individual spurs and with overall shield if used as part of a multi-core cable.
Conventional instrumentation cable may not have digital communications parameters included on its data sheet (effective impedance at 31.25kHz, attenuation rate in dB/km, etc) and so its performance in fieldbus applications cannot be guaranteed.
The Fieldbus Foundation’s test specification for cable allows manufacturers to test conformance to a proper performance specification.
Advice – if it is intended to use cable glands to seal the cable entry into a device coupler or junction box, check that the fieldbus cable used is properly ’round’ – many less-expensive two-wire cables have a distinct ‘lay’ evident in the outer sheath of the cable and this will not seal effectively in the cable gland.
* Fieldbus Wiring – fieldbus cable may be virtually indistinguishable from 4-20mA cable, but field wiring techniques and accessories are definitely different.
Fieldbus systems are simple to design because all of the device wire-pairs are connected in parallel but, in practice, any attempt to fill a box full of terminals and just ‘jump’ between all positives and all negatives will result in a ‘rats nest’ of cables within the enclosure.
This may be acceptable in some plants, but will lead to all sorts of maintenance problems once the installers have left the site.
* Device couplers – a better idea is to use device couplers – junction boxes specifically designed for fieldbus implementation.
These units automatically provide the necessary system interconnections without confusion and greatly speed up the process of device installation.
They should incorporate the required terminator with either manual or automatic activation.
* Short circuits – short circuits are a common problem in any fieldbus installation.
Maintenance technicians can jostle cables, corrosion can weaken connections, and vibration from pumps and motors can loosen cables and connectors.
Segment designers must be concerned about what might happen to an entire fieldbus segment if any single instrument shorts out.
It is highly recommended that the segment designer incorporates some form of spur short-circuit protection, which may be active or passive in design.
Passive protection is very simple and usually provided by fuses on each spur which ‘blow’ to disconnect any individual fault.
This is inexpensive and very reliable, but it does require manual intervention – someone has to replace the blown fuse (hopefully after repairing the fault).
Device couplers often provide active spur protection in two basic forms.
1 – ‘Current limiting’ 2 – ‘Fold-back’.
Current- limiting and fold-back types both auto-reset after fault removal and both normally incorporate LEDs to indicate spur status.
The current-limiting technique limits the amount of power the short circuit can draw to between 40 and 60mA (vendor dependent) but it also holds that fault on the segment continuously.
Although this design protects the segment from the initial short, the additional current draw from the short can deprive other instruments on the segment of power, overload the segment power supply, and possibly cause catastrophic failures on the segment.
If current-limiting designs are to be used, ensure that the segment power supply can cope with these additional loads.
For example, a segment may have 10 measuring devices plus two valves connected via 1000m of 50 Ohm nominal cable (say, 250mA total).
In this case, the trunk voltage drop equals 12.5V, which allows 12.5V at the farthest device.
However, if a short occurs at a spur and an additional 60mA load is ‘locked in’ to the segment, this takes away enough power so that devices receive less than 9V (8.5V for the farthest device), and some will drop off the segment.
If two shorts occur, all the devices could drop off, and an entire process unit might go down.
Therefore, if current limiting protection is used in a device coupler, one must provide a 60mAsafety margin.
That is, do not install as many instruments as the segment can theoretically power; instead, leave at least three spurs empty.
An alternative design is the ‘fold-back’ variety, where any faulty spur is switched off and that load is completely removed from the segment.
The fold-back technique disconnects the shorted spur from the segment, thus preventing loss of an entire segment.
The fold-back technique has a logic circuit on each spur that detects a short in an instrument or spur, disconnects that spur from the segment, and illuminates a red LED that can be seen by maintenance personnel.
With fold-back device couplers, one doesn’t have to worry about spur failures and can have confidence about placing more devices on fieldbus segments.
Since the cost of H1 cards (US$2,500) and other segment hardware can be cost-prohibitive, being able to place more devices on a segment can save a considerable amount.
A typical FOUNDATION fieldbus segment, consisting of an H1 card, power supply, device couplers and cables, can cost about US$5,000.
A large process plant may have hundreds if not thousands of devices.
If the ‘safety margin’ approach is used, where the entire capability of fieldbus is not used, the cost of all the extra fieldbus segments can become substantial.
For example, assuming that a typical fieldbus segment with modern fold-back protection can accommodate 16 20mA fieldbus devices, it requires 63 fieldbus segments to support 1,000 devices, at an approximate cost of US$312,500.
If a safety margin approach must be used because of current limiting protection, and each segment can now only accommodate ten instruments, then 100 segments are needed, at an approximate cost of US$500,000.
Simply by specifying fold-back short circuit protection, an end user can save US$188,000.
* Redundant Operations – fieldbus systems offer many advantages to process companies, not the least of which is the elimination of ‘home run’ wiring and the ‘snake’s nest’ of twisted-pair wiring in field-mounted marshalling cabinets.
Fieldbus eliminates all this because it allows up to 32 devices to be wired together over a single twisted-pair digital ‘network’ or segment.
However, fieldbus systems present a problem: what happens if the segment cable or the power conditioner driving the segment cable fails? Depending on where the failure occurs, the entire segment – with all 32 devices – could go down.
An entire process unit could then go off line.
One answer is to provide redundancy wherever possible, to ensure that any single failure cannot take down an entire process unit.
Redundancy can be employed in two basic ways.
1 – Redundant power conditioners.
2 – Redundant trunks.
A redundant power conditioner has two power conditioners, both powered by a load-sharing pair of 24V DC power supplies.
Such a system can survive the failure of either 24V DC power supply or either power conditioner.
If a failure occurs, the unit automatically and ‘bumplessly’ switches all load to the backup unit.
It also has an alarm output to indicate that a failure has occurred.
If any of the individual modules fail, replacements can be ‘hot swapped’ into place without shutting down the segment.
The power conditioner modules plug into a DIN carrier, which can accommodate four or eight modules, to provide redundant power for two or four fieldbus segments.
For a redundant configuration, each pair of power conditioner modules requires two power supply inputs and one connection to the fieldbus segment.
Installation is not difficult, because a redundant power conditioner requires no changes to be made to the fieldbus segment, device couplers or interface card.
However, in most cases (depending on the vendor), the DIN carrier can accommodate simplex (non-redundant) or duplex (redundant) power conditioners, but not both.
That is, you cannot mix redundant and non-redundant power conditioners in the same DIN carrier.
Therefore, when determining which critical fieldbus segments will have redundant power conditioners, take care to plan fieldbus wiring so that the critical segments are routed to the proper DIN carrier.
* Redundant trunks – in a critical process segment, it may be necessary to provide redundancy on the main segment cable or ‘trunk’.
This protects a process unit from going down if something happens to the main cable, such as a forklift running over the cable, water getting into the conduit, or any of a host of problems that can occur in a factory.
If the system can be switched to a backup or redundant segment, then the process can continue operating.
* Communications loss – it is important to note that fieldbus instruments can continue to operate by themselves if communication to the host DCS is lost.
In FOUNDATION fieldbus installations, the field devices can talk to each other, and continue monitoring and control operations according to the last setpoints provided by the DCS.
However, they cannot continue to operate if the trunk cable is broken, because the cable provides power to the instruments.
One way to provide redundancy is to duplicate the entire segment.
This requires a duplicate interface card (such as an H1 card for FOUNDATION fieldbus), a duplicate power conditioner, duplicate cable, duplicate device coupler, and duplicate field instruments.
When one segment fails, the DCS switches over to the backup segment.
While this is an extremely expensive hardware solution, it does provide redundancy for every device in the segment.
No matter what fails, a backup exists.
To install such a system, one has to determine the conditions that will cause the DCS to switch segments, and program the DCS accordingly.
Check with the DCS vendor to make sure the DCS can identify a segment failure.
Some can only determine that an interface card failed.
If this is the case, one must devise some way of determining that a segment failed.
It is possible to set up a software scheme that periodically polls the fieldbus devices, asking for device status.
If none of the devices respond, the software could conclude that the segment has failed, and call for the DCS to switch to the backup segment.
However, maintenance procedures then become very complex, with special overrides to cater for out-of-service devices, etc.
An alternative method is to use a fault-tolerant segment with parallel interface cards, parallel power conditioners, dual trunks and one field device coupler.
This eliminates the need to duplicate field instruments and avoids difficult maintenance issues, while still improving the segment MTTF by 7-10 times at virtually no cost.
The power conditioners determine when a cable break occurs, cut power to the failed trunk, and use the backup cable immediately.
This ‘fault-tolerant’ approach simplifies installation, because it does not require any special programming of the DCS.
When the fault-tolerant system detects a cable break, it deprives the H1 card of power, so the DCS knows that a failure occurred and can switch to the backup H1 card.
It also gets an alarm from the power supply, indicating that a failure occurred.
And, because the power conditioners have auto-termination capability, the proper segment termination is set automatically.
The fault-tolerant system does not require any other special hardware; the DIN-rail power conditioner modules can be installed in the same DIN rack as conventional modules.
No special installation wiring is necessary in the field.
It is probably advisable to route the two segment cables differently, so that the same physical incident – such as a wayward forklift – does not take out both cables at the same time.
If a certain type of field instrument is prone to failure, a redundant instrument can be installed, and wired into any spare spur on the device coupler.
The DCS has to be configured accordingly, so it recognises a device failure and knows to switch to the backup instrument.
* Working in Hazardous Areas Three methods are available for installing fieldbus in hazardous areas.
1 – Intrinsically-safe systems.
2 – Explosion-proof cabinets.
3 – Non-incendive equipment.
Intrinsically-safe (I S) circuit designs limit the electrical energy at the device to a level below the explosive limits of the environment and remain safe with a component failure.
An intrinsically-safe circuit, as defined by the NEC, is ‘a circuit in which any spark or any thermal effect is incapable of causing ignition of a mixture of flammable or combustible material in air under prescribed test conditions’.
An I S circuit uses a safety device such as a safety barrier to limit the power in the hazardous environment and, because I S is considered to be very safe, this type of system can be worked on while energised without gas clearance testing (commonly referred to as a ‘hot work permit’).
An explosion-proof design and installation (flameproof/ Exd in Europe) requires that if a fuel were ignited inside the device enclosure, the enclosure will contain the energy of ignition and disperse it into the classified area at a level low enough to prevent a secondary ignition from occurring outside the enclosure.
Explosion-proof designs require special installation methods, as well as requiring the electrical devices and enclosures to be rated explosion-proof (NEMA 7/9) for the proper area classification.
This type of system cannot be worked on while energised without a gas clearance certificate.
A non-incendive circuit, as defined by the NEC, is ‘a circuit, other than field wiring, in which any arc or thermal effect produced under intended operating conditions of the equipment is not capable, under specified test conditions, of igniting the flammable gas-air, vapor-air or dust-air mixture’.
Non-incendive circuit designs do not take component failure into consideration, thereby offering a reduced level of safety by comparison to the intrinsically-safe circuit design and are therefore only allowable in Division 2/Zone 2.
There are two fundamental types: non-arcing which cannot be worked on while energised without gas clearance testing; and energy-limited, which is more like a poor man’s I S and can be disconnected ‘live’.
While all three methods have been used for fieldbus installations, the most popular – especially in Europe – is intrinsic safety.
One might consider that this is an historical hangover: I S systems were great for analog electronic modules that needed frequent access in the field and for the adjustment of limit switches on valves.
Fieldbus devices have no physical adjustments accessible in the field or otherwise, and all changes are made through the segment communications, so putting yourself through the ‘pain’ of I S fieldbus (and it can be very painful indeed) is not necessary at all.
However, company specifications don’t always follow technology very fast so I will describe how to minimise that heartache.
* Installing intrinsically-safe systems – intrinsically-safe methods for fieldbus include the following.
1 – Entity.
2 – FISCO.
3 – Split Architecture Entity.
An Entity system requires ‘barriers’; that is, devices that limit the amount of current that can enter the hazardous area.
In general, intrinsically-safe fieldbus was originally based on the FOUNDATION fieldbus FF816 specification, Entity systems are highly reliable, especially when based on simple resistive current-limiting, which allowed Entity parameters for field devices to be at least 24V/250mA/1.2W.
These barriers allow about 80mA for Gas Groups ABCD (NEC) or IIC (IEC).
The major problem in installing an Entity system is the large number of barriers required, and the amount of cabinet space required in the ‘safe area’.
Because each barrier can work with only four fieldbus devices, this requires a large number of fieldbus segments.
For example, a conventional (non-hazardous) segment with 16x 20mA fieldbus devices would have to be separated into four segments in a hazardous area.
Each segment requires an H1 or PAinterface card, power supply/conditioner, barrier, trunk cable and a device coupler.
FISCO (Fieldbus Intrinsically Safe Concept) provides 115mA, instead of just 80mA, allowing an ISCO power supply to power about five conventional 20mA fieldbus devices.
Beware – some FISCO fieldbus instruments are designed to take lower current (12mA or 15mA).
Some less-scrupulous manufacturers use that value to claim that FISCO systems drive more devices; however, be aware that less current usually means less capability in the devices themselves.
FISCO also introduces a drawback: the complexity of the FISCO electronic current-limiting design itself and the requirement to have multiple such circuits in series (current-limiting must still be available even if a circuit fails in an unsafe way) means that the overall MTTF of these units is much lower than users might expect.
FISCO systems are also much more expensive because of the high cost of the FISCO power supplies and fieldbus devices.
Installation of FISCO is similar to an Entity system: the FISCO power supplies are mounted in the safe area.
The rules for using FISCO allow only 1000m (3250ft) of cable in total and only 60m (195ft) spurs, about half that of a ‘normal’ fieldbus.
This should not pose a problem in most installations, because of the limited number of devices on each segment.
A split-architecture system puts part of the barrier in an isolator and part of it in each of the spurs of a field-mounted device coupler.
By splitting the intrinsically-safe current-limiting method in this way, the system can put a full 350mA on the trunk that leads into hazardous areas with Gas Groups C and D, and still have intrinsically-safe spurs that match FF816 Group A and B approved devices.
This overcomes both the FISCO and conventional Entity restrictions on available current.
Up to 16 devices can be put on a segment, nearly four times as many as an Entity or FISCO system.
Installation is much simpler, because fewer devices and segments are required.
In general, a split-architecture system requires only 25% of the cabinet space of an Entity or FISCO system.
One problem you may encounter during installation is incompatibility of conventional and FISCO devices.
In previous implementations, the split-architecture design has been based on device Entity parameters of 24V, 250mAand 1.2W (values which the I S power supply must guarantee not to exceed and which are specified in IEC61158-2 and associated documents).
FISCO devices, on the other hand, are associated with Entity values of 17.5V, 380mA and 3.8W, so it has not been possible for Entity systems to easily demonstrate compatibility and safety with FISCO devices.
This had become an issue with some device manufacturers who have specified FISCO approvals for their devices but not Entity approvals, and with some older devices which have Entity approvals but not FISCO.
A recent enhancement in split-architecture systems is the incorporation of FISCO-compatibility at the field device coupler.
Having FISCO and Entity compatibility at the device coupler in a split-architecture design enables all users to implement intrinsically-safe fieldbus with any desired mix of approved devices without the limitations in cable lengths and reduction in MTBF that results from a pure FISCO system.
* Removing and replacing instruments – maintenance people want to be able to remove devices from fieldbus segments in hazardous areas without turning off the whole segment, and without going through complex disconnection procedures and mechanical interlocks, if they can be avoided.
In Zone 1 applications, simply specify a device coupler approved for Zone 1 that also has a magnetic interlock on each spur.
The technician puts the key in the slot, which isolates the spur, and makes it accessible for re-wiring without shutting down the segment.
This works particularly well if IEC/AEx standards are being followed, since that particular device coupler can fit inside a low- cost GRP enclosure (Exe/AExe approved) with spurs fully accessible in Zone 1.
Some device couplers are designed and approved for use in Zone 1 and Zone 2 with flameproof Exd devices.
For flameproof, Division 1 applications, live de-mateable plug/socket combinations are available from many manufacturers.
If an application demands live exposure in Division 1 or connection into Zone 0, then field barriers can be used which allow intrinsically-safe spurs to be attached to the non-intrinsically safe trunk.
Cost issues involve the amount of time a maintenance technician must spend removing and replacing instruments.
If the process is laborious, it might take hours to follow all the safety procedures.
If the process simply requires a key, then an instrument can be disconnected in a few seconds.
* Simplify the installation – many of the installation headaches discussed in this article can be minimised through careful selection of fieldbus equipment at the beginning of the project.
Few end users realise that fieldbus components, such as power supplies and device couplers, are not manufactured by the DCS vendor.
Instead, they are provided by associated suppliers, such as MooreHawke, and others.
Therefore, even if a user is buying an Emerson DeltaV or a Yokogawa Centrum or a DCS from any other supplier, it is possible to specify fieldbus components separately.
Note that the choice of physical layer product makes no difference to the DCS operation.
All fieldbus power conditioners and device couplers simply enable the fieldbus power and communications to work; they do not communicate with the DCS.
To simplify installation of your fieldbus system, evaluate the components carefully from the various suppliers.
Look for the following.
* Automatic Segment termination on device couplers to eliminate termination problems during installation, startup and regular maintenance.
* Foldback short circuit protection (which disconnects a shorted device from the spur) to eliminate the need to leave spurs empty.
* Power supplies with built-in power conditioning, redundancy, and surge protection.
Fieldbus is an exciting technology and there are many benefits, which will accrue to end users and early adopters.
Implementation of real fieldbus systems is still a new experience for many engineering companies, and many subcontractors are coming to wire up devices without any real understanding of the different requirements and problems presented by fieldbus systems.
Keep some of the guidelines described here in mind when ordering a fieldbus system and when dealing with an installation subcontractor.
* About the author – Mike O’Neill is a director of MooreHawke, a division of Moore Industries.
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More and more applications require the collection of data from sensors in high temperature environments….
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More and more applications require the collection of data from sensors in high temperature environments. In recent years, great progress has been made in the fields of semiconductors, passive devices, and interconnects, enabling high-precision data acquisition and processing. However, there is an unmet need for sensors that can operate at high temperatures up to 175°C, especially easy-to-use sensors provided by microelectromechanical systems (MEMS). Compared to equivalent discrete sensors, MEMS are generally smaller and consume less power and cost. In addition, they can integrate signal conditioning circuits in the same size semiconductor package.
The ADXL206 high-temperature MEMS accelerometer has been released, which provides high-precision tilt (tilt) measurements. However, more flexibility and freedom are also required to accurately measure system movement in harsh environmental applications where the final product may be subject to shock, vibration and violent movement. This type of abuse can lead to excessive wear and premature failure of the system, resulting in high maintenance or downtime costs.
To meet this need, ADI has developed a new high-temperature MEMS gyroscope with integrated signal conditioning, the ADXRS645. The sensor provides accurate angular rate (rotational speed) measurement even in shock and vibration environments and is rated for operation up to 175°C.
working principle
MEMS gyroscopes use Coriolis acceleration to measure angular rate. For the interpretation of the Coriolis effect, start with Figure 1. Picture yourself standing on a rotating platform, near the center. Your speed relative to the ground is shown by the length of the blue arrow. If you move closer to the outer edge of the platform, your speed relative to the ground increases, indicated by the longer blue arrow. The growth rate of the tangential velocity caused by the radial velocity is the Coriolis acceleration.
If Ω is the angular rate and r is the radius, the tangential velocity is Ωr. So, if r changes while the velocity is v, there will be a tangential acceleration Ωv. Its value is half of the Coriolis acceleration. The other half comes from the change in radial velocity direction, totaling 2Ωv. If you apply a mass (M), then the platform must exert a force—2MΩv—to produce this acceleration, and the mass also experiences a corresponding reaction force. The ADXRS645 exploits this effect by using resonant masses that correspond to when a person moves to the center and to the outer edge on a rotating platform. The mass is made of polysilicon, micromachined, and bonded to the polysilicon frame, so it can only resonate in one direction.
Figure 1. Example of Coriolis acceleration. As the person moves north to the outer edge of the rotating platform, the westward velocity component (blue arrow) must increase,
to keep the course moving north. The required acceleration is the Coriolis acceleration.
Figure 2. Demonstration of the Coriolis effect: responding to resonances of a silicon mass suspended within a frame.
The green arrows indicate the forces on the structure (based on the state of the resonating mass).
Figure 2 shows that as the resonant mass moves toward the outer edge of the rotating platform, it accelerates to the right and applies a reaction force to the frame to the left. As it moves toward the center of rotation, it applies a force to the right, as indicated by the green arrow.
To measure the Coriolis acceleration, we attach the frame containing the resonant mass to the substrate using a spring at 90° to the direction of resonant motion, as shown in Figure 3. This figure also shows the Coriolis detection pointer, which, via capacitive transduction, detects the displacement of the frame when subjected to a force applied to the mass.
Figure 3. Schematic diagram of the mechanical architecture of the gyroscope.
Figure 4 shows the complete structure, from which it can be seen that when the resonant mass moves and the mounting plane where the gyroscope is located rotates, the mass and its frame are affected by Coriolis acceleration and rotate 90° due to vibration. As the rotation speed increases, the position of the mass body and the signal obtained from the corresponding capacitor change. It should be noted that the gyroscope can be placed at any position of the rotating object at any angle, as long as its detection axis is parallel to the rotation axis.
Figure 4. The frame and resonant mass are affected by the Coriolis effect, resulting in lateral displacement.
Capacitance detection
The ADXRS645 measures the displacement of the resonant mass and frame due to the Coriolis effect through a capacitive sensing element attached to the resonator, as shown in Figure 4. These elements are silicon rods, interleaved with two sets of fixed silicon rods connected to the substrate, forming two nominally equal capacitances. Displacement due to angular rate creates differential capacitance in the system.
In practice, the Coriolis acceleration is an extremely small signal that causes beam deflections of fractions of an angstrom and capacitance changes on the order of Zefarads. Therefore, it is extremely important to minimize mutual interference from parasitic sources such as temperature, package stress, external acceleration and electrical noise. Part of this effect is achieved by placing electronics (including amplifiers and filters) and mechanical sensors on the same die. However, it is more important to implement differential measurements as far apart as possible in the signal chain and correlate the signal to the resonator velocity, especially when dealing with the effects of external acceleration.
Vibration suppression
Ideally, the gyroscope is only sensitive to RPM and nothing else. In practice, all gyroscopes have some sensitivity to acceleration due to their asymmetric mechanical design and/or insufficient micromachining accuracy. In fact, acceleration sensitivity can take many forms – the severity of which varies by design. The most severe are usually the sensitivity to linear acceleration (or g-sensitivity) and the sensitivity to vibrational rectification (or g2-sensitivity), severe enough to completely cancel the rated bias stability of the device. Some gyroscopes have rail-to-rail differences in output when the rate input exceeds the rated measurement range. Other gyroscopes tend to lock up when subjected to shocks as low as a few hundred g. These gyroscopes are not damaged by the shock, but also can no longer respond to the rate and require a restart.
The ADXRS645 employs a novel angular rate detection method that enables it to suppress shocks up to 1000 g. It uses four resonators for differential signal detection and rejection of common-mode external accelerations independent of angular movement. The resonators at the top and bottom of Figure 5 are independent of each other and operate out of phase. So, they measure the same amount of rotation, but output in opposite directions. Therefore, the angular rate is measured using the difference between the sensor signals. This eliminates the non-rotating signal that affects both sensors. The signals are combined internally hardwired in front of the preamp. As a result, extreme acceleration overloads are largely prevented from reaching the electronics, allowing signal conditioning to maintain angular rate output during large shocks.
Figure 5. Four-channel differential sensor design.
Sensor installation
Figure 6 shows a simplified schematic of the gyroscope, associated drive and detection circuitry.
Figure 6. Block diagram of an integrated gyroscope.
The resonator circuit senses the velocity of the resonating mass, amplifies it, and drives the resonator while maintaining a well-controlled phase (or delay) relative to the Coriolis signal path. Coriolis circuits are used to detect movement of the accelerometer frame, utilize downstream signal processing to extract the magnitude of the Coriolis acceleration, and generate an output signal consistent with the input rotational speed. In addition, the self-test function checks the integrity of the entire signal chain, including sensors.
Application example
For Electronic equipment, the most demanding environment is the oil and gas downhole drilling industry. These systems utilize a multitude of sensors to better understand how the drill string is operating below the surface to optimize operations and prevent damage. The rotational speed of a rig is measured in RPM and is a key metric that rig operators need to know at all times. Previously, this metric was calculated by a magnetometer. However, magnetometers are susceptible to ferrous materials in the rig casing and surrounding wellbore. They must also have a special non-magnetic drill collar (housing).
Beyond simple RPM measurements, there is a growing interest in understanding drill string movement (or drill string dynamics) to better manage parameters such as magnitude of applied force, rotational speed, and steering. Poorly managed drill string dynamics can result in high drill string vibration and extremely erratic movement, which can lead to extended drilling times in target areas, premature equipment failure, difficult bit steering, and damage to the well itself. In extreme cases, equipment can fracture and remain in the well, where it can be retrieved at a very high cost.
A particularly detrimental movement, stick-slip, can result from poor management of drill string parameters. Stick-slip is the phenomenon in which the drill bit gets stuck, but the top of the drill string continues to rotate. After the bit is jammed, the bottom of the drill string continues to rotate and tighten until enough torque is reached to cause fracture and loosening, which is usually very violent. When this happens, there are large spikes on the drill that spin at RPM. Stick-slip generally occurs periodically and can last for a long time. A typical RPM response to stick-slip is shown in Figure 7. As the drill string at the surface continues to function normally, rig operators are often unaware that this very destructive phenomenon is taking place downhole.
Figure 7. Example of a stick-slip cycle RPM profile.
A key measurement in this application is accurate and frequent measurement of rotational speed near the drill bit. A gyroscope, such as the ADXRS645 with vibration dampening, is ideal for this task because its measurements are not affected by the linear movement of the drill string. In the presence of high levels of vibration and unstable movement, the rotational speed calculated by the magnetometer is susceptible to noise and errors. A gyroscope-based solution can instantly measure rotational speed without the use of zero-crossing or other algorithms susceptible to shock and vibration.
Additionally, gyroscope-based circuits are smaller and require fewer components than flux magnetometer solutions, which require multiple magnetometer axes and additional drive circuitry. Signal conditioning is integrated into the ADXRS645. Housed in a low-power, low-pin-count package, this device enables a high-temperature IC to sample and digitize the gyroscope’s analog output. Using the simplified signal chain shown in Figure 8, a gyroscope circuit that provides a digital output and is rated at 175°C can be implemented. For a complete reference design of the data acquisition circuit, visit www.analog.com/cn0365.
Figure 8. Gyroscope digital output signal chain rated at 175°C.
Summarize
This article introduces the ADXRS645, the first MEMS gyroscope that can be used in a high temperature environment of 175°C. This sensor accurately measures angular rate in harsh environmental applications, preventing the effects of shock and vibration. This gyroscope is powered by a series of high temperature ICs to acquire the signal and process it. For more information on ADI’s high temperature products, visit www.analog.com/hightemp.
About the Author
Jeff Watson is a systems applications engineer in Analog Devices’ Instrumentation, Aerospace and Defense business unit, working on high temperature applications. Before joining ADI, he was a design engineer in the underground oil and gas instrumentation industry and the off-highway vehicle instrumentation/controls industry. He holds bachelor’s and master’s degrees in electrical engineering from Penn State University.
More and more applications require the collection of data from sensors in high temperature environments. In recent years, great progress has been made in the fields of semiconductors, passive devices, and interconnects, enabling high-precision data acquisition and processing. However, there is an unmet need for sensors that can operate at high temperatures up to 175°C, especially easy-to-use sensors provided by microelectromechanical systems (MEMS). Compared to equivalent discrete sensors, MEMS are generally smaller and consume less power and cost. In addition, they can integrate signal conditioning circuits in the same size semiconductor package.
The ADXL206 high-temperature MEMS accelerometer has been released, which provides high-precision tilt (tilt) measurements. However, more flexibility and freedom are also required to accurately measure system movement in harsh environmental applications where the final product may be subject to shock, vibration and violent movement. This type of abuse can lead to excessive wear and premature failure of the system, resulting in high maintenance or downtime costs.
To meet this need, ADI has developed a new high-temperature MEMS gyroscope with integrated signal conditioning, the ADXRS645. The sensor provides accurate angular rate (rotational speed) measurement even in shock and vibration environments and is rated for operation up to 175°C.
working principle
MEMS gyroscopes use Coriolis acceleration to measure angular rate. For the interpretation of the Coriolis effect, start with Figure 1. Picture yourself standing on a rotating platform, near the center. Your speed relative to the ground is shown by the length of the blue arrow. If you move closer to the outer edge of the platform, your speed relative to the ground increases, indicated by the longer blue arrow. The growth rate of the tangential velocity caused by the radial velocity is the Coriolis acceleration.
If Ω is the angular rate and r is the radius, the tangential velocity is Ωr. So, if r changes while the velocity is v, there will be a tangential acceleration Ωv. Its value is half of the Coriolis acceleration. The other half comes from the change in radial velocity direction, totaling 2Ωv. If you apply a mass (M), then the platform must exert a force—2MΩv—to produce this acceleration, and the mass also experiences a corresponding reaction force. The ADXRS645 exploits this effect by using resonant masses that correspond to when a person moves to the center and to the outer edge on a rotating platform. The mass is made of polysilicon, micromachined, and bonded to the polysilicon frame, so it can only resonate in one direction.
Figure 1. Example of Coriolis acceleration. As the person moves north to the outer edge of the rotating platform, the westward velocity component (blue arrow) must increase,
to keep the course moving north. The required acceleration is the Coriolis acceleration.
Figure 2. Demonstration of the Coriolis effect: responding to resonances of a silicon mass suspended within a frame.
The green arrows indicate the forces on the structure (based on the state of the resonating mass).
Figure 2 shows that as the resonant mass moves toward the outer edge of the rotating platform, it accelerates to the right and applies a reaction force to the frame to the left. As it moves toward the center of rotation, it applies a force to the right, as indicated by the green arrow.
To measure the Coriolis acceleration, we attach the frame containing the resonant mass to the substrate using a spring at 90° to the direction of resonant motion, as shown in Figure 3. This figure also shows the Coriolis detection pointer, which, via capacitive transduction, detects the displacement of the frame when subjected to a force applied to the mass.
Figure 3. Schematic diagram of the mechanical architecture of the gyroscope.
Figure 4 shows the complete structure, from which it can be seen that when the resonant mass moves and the mounting plane where the gyroscope is located rotates, the mass and its frame are affected by Coriolis acceleration and rotate 90° due to vibration. As the rotation speed increases, the position of the mass body and the signal obtained from the corresponding capacitor change. It should be noted that the gyroscope can be placed at any position of the rotating object at any angle, as long as its detection axis is parallel to the rotation axis.
Figure 4. The frame and resonant mass are affected by the Coriolis effect, resulting in lateral displacement.
Capacitance detection
The ADXRS645 measures the displacement of the resonant mass and frame due to the Coriolis effect through a capacitive sensing element attached to the resonator, as shown in Figure 4. These elements are silicon rods, interleaved with two sets of fixed silicon rods connected to the substrate, forming two nominally equal capacitances. Displacement due to angular rate creates differential capacitance in the system.
In practice, the Coriolis acceleration is an extremely small signal that causes beam deflections of fractions of an angstrom and capacitance changes on the order of Zefarads. Therefore, it is extremely important to minimize mutual interference from parasitic sources such as temperature, package stress, external acceleration and electrical noise. Part of this effect is achieved by placing electronics (including amplifiers and filters) and mechanical sensors on the same die. However, it is more important to implement differential measurements as far apart as possible in the signal chain and correlate the signal to the resonator velocity, especially when dealing with the effects of external acceleration.
Vibration suppression
Ideally, the gyroscope is only sensitive to RPM and nothing else. In practice, all gyroscopes have some sensitivity to acceleration due to their asymmetric mechanical design and/or insufficient micromachining accuracy. In fact, acceleration sensitivity can take many forms – the severity of which varies by design. The most severe are usually the sensitivity to linear acceleration (or g-sensitivity) and the sensitivity to vibrational rectification (or g2-sensitivity), severe enough to completely cancel the rated bias stability of the device. Some gyroscopes have rail-to-rail differences in output when the rate input exceeds the rated measurement range. Other gyroscopes tend to lock up when subjected to shocks as low as a few hundred g. These gyroscopes are not damaged by the shock, but also can no longer respond to the rate and require a restart.
The ADXRS645 employs a novel angular rate detection method that enables it to suppress shocks up to 1000 g. It uses four resonators for differential signal detection and rejection of common-mode external accelerations independent of angular movement. The resonators at the top and bottom of Figure 5 are independent of each other and operate out of phase. So, they measure the same amount of rotation, but output in opposite directions. Therefore, the angular rate is measured using the difference between the sensor signals. This eliminates the non-rotating signal that affects both sensors. The signals are combined internally hardwired in front of the preamp. As a result, extreme acceleration overloads are largely prevented from reaching the electronics, allowing signal conditioning to maintain angular rate output during large shocks.
Figure 5. Four-channel differential sensor design.
Sensor installation
Figure 6 shows a simplified schematic of the gyroscope, associated drive and detection circuitry.
Figure 6. Block diagram of an integrated gyroscope.
The resonator circuit senses the velocity of the resonating mass, amplifies it, and drives the resonator while maintaining a well-controlled phase (or delay) relative to the Coriolis signal path. Coriolis circuits are used to detect movement of the accelerometer frame, utilize downstream signal processing to extract the magnitude of the Coriolis acceleration, and generate an output signal consistent with the input rotational speed. In addition, the self-test function checks the integrity of the entire signal chain, including sensors.
Application example
For Electronic equipment, the most demanding environment is the oil and gas downhole drilling industry. These systems utilize a multitude of sensors to better understand how the drill string is operating below the surface to optimize operations and prevent damage. The rotational speed of a rig is measured in RPM and is a key metric that rig operators need to know at all times. Previously, this metric was calculated by a magnetometer. However, magnetometers are susceptible to ferrous materials in the rig casing and surrounding wellbore. They must also have a special non-magnetic drill collar (housing).
Beyond simple RPM measurements, there is a growing interest in understanding drill string movement (or drill string dynamics) to better manage parameters such as magnitude of applied force, rotational speed, and steering. Poorly managed drill string dynamics can result in high drill string vibration and extremely erratic movement, which can lead to extended drilling times in target areas, premature equipment failure, difficult bit steering, and damage to the well itself. In extreme cases, equipment can fracture and remain in the well, where it can be retrieved at a very high cost.
A particularly detrimental movement, stick-slip, can result from poor management of drill string parameters. Stick-slip is the phenomenon in which the drill bit gets stuck, but the top of the drill string continues to rotate. After the bit is jammed, the bottom of the drill string continues to rotate and tighten until enough torque is reached to cause fracture and loosening, which is usually very violent. When this happens, there are large spikes on the drill that spin at RPM. Stick-slip generally occurs periodically and can last for a long time. A typical RPM response to stick-slip is shown in Figure 7. As the drill string at the surface continues to function normally, rig operators are often unaware that this very destructive phenomenon is taking place downhole.
Figure 7. Example of a stick-slip cycle RPM profile.
A key measurement in this application is accurate and frequent measurement of rotational speed near the drill bit. A gyroscope, such as the ADXRS645 with vibration dampening, is ideal for this task because its measurements are not affected by the linear movement of the drill string. In the presence of high levels of vibration and unstable movement, the rotational speed calculated by the magnetometer is susceptible to noise and errors. A gyroscope-based solution can instantly measure rotational speed without the use of zero-crossing or other algorithms susceptible to shock and vibration.
Additionally, gyroscope-based circuits are smaller and require fewer components than flux magnetometer solutions, which require multiple magnetometer axes and additional drive circuitry. Signal conditioning is integrated into the ADXRS645. Housed in a low-power, low-pin-count package, this device enables a high-temperature IC to sample and digitize the gyroscope’s analog output. Using the simplified signal chain shown in Figure 8, a gyroscope circuit that provides a digital output and is rated at 175°C can be implemented. For a complete reference design of the data acquisition circuit, visit www.analog.com/cn0365.
Figure 8. Gyroscope digital output signal chain rated at 175°C.
Summarize
This article introduces the ADXRS645, the first MEMS gyroscope that can be used in a high temperature environment of 175°C. This sensor accurately measures angular rate in harsh environmental applications, preventing the effects of shock and vibration. This gyroscope is powered by a series of high temperature ICs to acquire the signal and process it. For more information on ADI’s high temperature products, visit www.analog.com/hightemp.
About the Author
Jeff Watson is a systems applications engineer in Analog Devices’ Instrumentation, Aerospace and Defense business unit, working on high temperature applications. Before joining ADI, he was a design engineer in the underground oil and gas instrumentation industry and the off-highway vehicle instrumentation/controls industry. He holds bachelor’s and master’s degrees in electrical engineering from Penn State University.
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Key Specifications/Special Features: Material: SS 304, 304L, 316, 316L, WCB Proportion: pump parts 35%, valves…
The post Non-standard investment casting machinery engine parts first appeared on Walker Machining.
Key Specifications/Special Features:
Material: SS 304, 304L, 316, 316L, WCB
Proportion: pump parts 35%, valves parts 35%, impellers 10%, other accessories 20%
Craft: water glass techniques
Process: mould developing-precision casting-machining-polishing
Advantages: dimensional accuracy can reach 5‰ of nominal size to the best extent, the roughness level is Ra0.8-3.2μm
All products are non-standard accessories, please share your full set of drawings to get latest quotation.
Primary Competitive Advantages:
Brand-name Parts
Country of Origin
Experienced Staff
Form A
Guarantee/Warranty
International Approvals
Military Specifications
Packaging
Price
Product Features
Product Performance
Prompt Delivery
Quality Approvals
Reputation
Service
Small Orders Accepted
Main Export Markets:
Asia
Australasia
Central/South America
Eastern Europe
Mid East/Africa
North America
Western Europe
Payment Details:
Minimum Order:50 Sets
Delivery Details:
FOB Port:Ningbo
FOB Range: US$ 1 – US$ 200 per unit (Sets)
Lead Time: 15 – 66 days
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PIM Plastic mold company is a qualified manufacturer of plastic. With over 14 years’ knowledge…
The post manufacturer of plastic,making molding first appeared on Walker Machining.
PIM Plastic mold company is a qualified manufacturer of plastic. With over 14 years’ knowledge of producing and exporting different kinds of china plastic injection molding, we have extremely distinctive and skilled know-how particularly in plastic molding and logo producing.
We offer the entire set of state-of-the-art machines and strong capability in mould designing and brand new products building which guarantee us to create the accurate custom-made products based on your unique demand. We have a great number of sizes and designs accessible to fulfill various needs.
We are positioned in Taizhou, close to Ningbo Port and Shanghai Port which allow us to make contact with consumers globally. Top quality, fast shipping and liable support help make us a dependable companion with consumers in European countries, The united states and other areas and locations.
We constantly make an effort to offer the very best plastic goods at the best price achievable within the soonest time. Using our specialist help, we just help make your promotional campaign a worry-free experience!
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In every historical development stage of China’s automobile industry, Lanzhou Refining and Chemical Company…
The post To further standardize and improve the production and supply of automotive lubricants in China first appeared on Walker Machining.
In every historical development stage of China’s automobile industry, Lanzhou Refining and Chemical Company Feitian Lubricant has given reliable guarantees. Up to now, China FAW Group Corporation has confirmed n types of “Feitian” lubricants as its supporting products; Dongfeng Motor Corporation has confirmed 7 types of “Feitian” lubricants for its factory loading oil and social service station oil; Many automobile production plants including Yuejin Group, China National Heavy Duty Truck, Chongqing Changan and Changhe have selected Feitian lubricants.
With the intensification of competition in the automobile market and the opening of the lubricant market, automobile manufacturers have decomposed the pressure to reduce costs to parts manufacturers, including the purchase of automobile lubricants, which invisibly buried the quality assurance of certain products. Potential crisis. Here are some misunderstandings in the selection of automotive lubricants and hope to be taken seriously. Brand-name cars cannot afford to use genuine lubricants, so they have to turn to local small blending plants to purchase. What must be emphasized here is that a few simple inspection qualification indicators cannot represent the intrinsic quality of the product. There are many examples like this. With China’s accession to the WTO, China National Petroleum Corporation established the China National Petroleum Corporation Lubricant Company to meet the challenge of major foreign lubricant companies to seize the Chinese lubricant market. The lubricant production and operation strategy of “Five Unifications, One Concentration” of the lubricant company’s “unified allocation of resources, unified product standards, unified network layout, unified price management, unified organization of scientific research, and concentration of power to highlight famous brands” will have a significant impact on the Chinese lubricant market. Play a strong role in promoting, which will undoubtedly further standardize and improve the production and supply of China’s automotive lubricants, so as to meet the requirements of the development of China’s automotive industry for lubricants.
The automotive parts and parts machining, PTJ Shop offers the highest degree of OEM service with a basis of 10+ years experience serving the automotive industry. Our automotive precision shop and experts deliver confidence. We have perfected the art of producing large component volumes with complete JIT reliability, backed by the quality and long-term reliability our customers expect.
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Recently, the National Development and Reform Commission announced the list of the first batch of…
The post The National Development and Reform Commission issued: List of National Engineering Research Centers in the New Sequence, see what non-ferrous industries are there? first appeared on Walker Machining.
Recently, the National Development and Reform Commission announced the list of the first batch of national engineering research centers included in the national new sequence managementAccording to reports, the National Engineering Research Center is a research and development entity established by the National Development and Reform Commission to serve the country’s major strategic tasks and implementation of key projects.In February this year, the National Development and Reform Commission organized the optimization and integration of the existing National Engineering Research Center (National Engineering Laboratory) in the fields of new materials, energy conservation and environmental protection.Up to now, a total of 38 national engineering research centers across the country have been included in the first batch of new sequence management lists.
Among them, the National Engineering Research Center for High-Performance Homogeneous Alloys established by the Institute of Metal Research of the Chinese Academy of Sciences, the National Engineering Research Center for Powder Metallurgy established by Central South University, the National Engineering Research Center for Rare Earths established by Youyan Rare Earth New Materials Co., Ltd., The National Engineering Research Center for Rare Metal Materials Processing established by the Non-Ferrous Metal Research Institute, the high-quality non-ferrous metal green special metallurgy national engineering laboratory established by the Institute of Technology Group Co., Ltd., and the key integrated circuit materials established by the Institute of Semiconductor Materials Co., Ltd. The National Engineering Research Center, the National Engineering Research Center of Silicon-based Materials Preparation Technology established by Luoyang Sinosilicon High-tech Co., Ltd., the National Engineering Research Center for Industrial Environmental Protection established by the China Metallurgical Construction Research Institute Co., Ltd., and the process engineering research of the Chinese Academy of Sciences Established National Engineering Research Center for Green Recycling of Strategic Metal Resources, National Engineering Research Center for Non-Pollution Non-Ferrous Metal Extraction and Energy Conservation Technology established by Beijing Mining and Metallurgical Technology Group Co., Ltd., National Engineering Research Center for Low-Carbon Non-ferrous Metallurgy established by Central South University WaitEleven non-ferrous industry national engineering research centers were shortlisted for the first batch of 11 new-sequence national engineering research centers.
Source: China Metallurgical Nonferrous Technology Platform
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Compact panel bridges, or bailey bridges, are a type of portable, pre-fabricated, truss bridge. They…
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Compact panel bridges, or bailey bridges, are a type of portable, pre-fabricated, truss bridge. They are known for their convienent transport, speedy erection, and easy disassembly. Because of this they are adopted extensively and one of the most popular bridges in the world. Compact panel bridges are light-weight and made of high tinsel strength steel. This gives them great stability in addition to a heavy load capacity. They are known for their long lasting fatigue life as well. Compact panel bridges are capable of altering their span in order work in a variety of settings. Compact panel bridges work well as temporary bridges, emergency bridges, and fixed bridges. Here at Shanghai Metal Corporation (SMC), we have the highest national qualifications to assure quality and safety in our compact panel bridges. Our compact panel bridge was co-developed in a lab in partnership with a university. We also have have 3,000 employings working to ensure an on time delivery and customer satisfaction.
Compact panel bridges are known for their easy trasportation and assembly. They are composed of a light weight main beam. This main beam is connected to the panels by connection pins. These are then assured by the 3m panel. Compact panel bridges can be launched in a couple of methods. They can be slid or rolled from the abutment or lifted piece by piece by craines or stand jacks. Sometime they do require a combination of erection methods. This is called a hybrid scheme. Most times their components and beams are small and light weight enough to be transported in the back of truck beds. They can be assembled quickly and can even be done overnight to minimize distruption.
The history of the compact panel bridge dates back to World War II. Donald Bailey, is accredited with the invention, hence the name “Bailey Bridge”. Bailey was a civil servent in the British war office who tinkered with bridges as a hobby. He presented his idea to the British Royal Army and they began making a prototype at the Military Engineering Experimental Establishment in 1941. However, the completed concept was not completed until 1942. By D-Day in 1944 several compact panel bridges were available and ready to use on that monumental day in history.
Guest contributors are welcome at the Alloy Wiki.It is a weekly wiki and guide on alloy information and processing technology, while also about the vast array of opportunities that are present in manufacturing. Our team of writers consists of a Machining Material Supplier / Machinist / Tool and Die Maker, a Biomedical Engineer / Product Development Engineer, a Job Development Coordinator / Adjunct Professor, and a President and CEO of a manufacturing facility.
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According to Taiwanese media reports, TSMC will mass-produce the 5-nanometer A14 processor for Apple’s next-generation…
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According to Taiwanese media reports, TSMC will mass-produce the 5-nanometer A14 processor for Apple’s next-generation smartphone iPhone 12 in April this year.
The production of A-series chips usually starts from April to May, so this means that TSMC’s mass production of the A14 processor is on schedule and has not been affected by other factors.
TSMC has been the exclusive supplier of Apple’s “A-series” processors since 2016. Among them, the iPhone 7 and iPhone 7 Plus are equipped with the A10 processor, which uses a 16-nanometer process. The A11 processor in the iPhone 8, iPhone 8 Plus, and iPhone X uses a 10-nanometer process.
The 2018 A12 processor uses a 7-nanometer process, while last year’s A13 processor uses a 7-nanometer process + extreme ultraviolet lithography process. This year, TSMC will use 5nm technology to produce the A14 processor.
Last year, TSMC announced a $25 billion investment in 5-nanometer manufacturing technology to remain the exclusive supplier of its “A-series” processors.
According to well-known Apple analyst Mingqi Guo, Apple will release four iPhone 12 models that support the 5G standard this fall, including a 5.4-inch iPhone, two 6.1-inch models, and a 6.7-inch model. model.
In addition, Apple is likely to release a new low-end model iPhone SE2 in the first half of this year, but this product is likely to use the A13 processor.
According to Taiwanese media reports, TSMC will mass-produce the 5-nanometer A14 processor for Apple’s next-generation smartphone iPhone 12 in April this year.
The production of A-series chips usually starts from April to May, so this means that TSMC’s mass production of the A14 processor is on schedule and has not been affected by other factors.
TSMC has been the exclusive supplier of Apple’s “A-series” processors since 2016. Among them, the iPhone 7 and iPhone 7 Plus are equipped with the A10 processor, which uses a 16-nanometer process. The A11 processor in the iPhone 8, iPhone 8 Plus, and iPhone X uses a 10-nanometer process.
The 2018 A12 processor uses a 7-nanometer process, while last year’s A13 processor uses a 7-nanometer process + extreme ultraviolet lithography process. This year, TSMC will use 5nm technology to produce the A14 processor.
Last year, TSMC announced a $25 billion investment in 5-nanometer manufacturing technology to remain the exclusive supplier of its “A-series” processors.
According to well-known Apple analyst Mingqi Guo, Apple will release four iPhone 12 models that support the 5G standard this fall, including a 5.4-inch iPhone, two 6.1-inch models, and a 6.7-inch model. model.
In addition, Apple is likely to release a new low-end model iPhone SE2 in the first half of this year, but this product is likely to use the A13 processor.