Sensorless Cavitation Detection

Detecting Cavitation with CANplus™ Engine Control Panels

Cavitation can severely damage pump equipment and machinery. 

Cavitation is the formation of bubbles within a liquid due to a significant reduction in pressure. Different liquids have varying levels of resistance to cavitation based on factors such as gas concentration and foreign particles. When these bubbles enter an area of higher pressure, the bubbles implode, leading to high-impact forces on metal surfaces, resulting in fatigue and cavitation pits within the pump.

Cavitation can be detected audibly, with acoustic instrumentation, by machine vibration sensors, or by a decrease or change in performance. Cavitation can dramatically affect the performance and lifespan of machinery where liquid is present, making it vital to understand what this phenomenon entails and how best to combat it.

Machine learning detects cavitation on CANplus engine control panels.

Cattron’s CANplus™ engine control panels have built-in machine learning, enabling the panel to detect cavitation without additional sensors. Machine learning delivers unparalleled performance and reliability to the CP1000 and CP750-E engine control panels.

Incorporated into the CANplus control panels, machine learning is a powerful feature that allows the system to learn the unique normal operation patterns for your application, engine, or pump. Unlike traditional preset factory settings, this advanced edge computing adapts to the specific application of your equipment.

The CANplus panel uses engine data from its machine-learning algorithm to identify and notify operators of cavitation conditions before they cause damage. This proactive approach safeguards against unexpected downtime and maintenance costs and ensures that your engines and pumps are operating at their optimal capacity and efficiency.

Not only do our CANplus CP1000 and CP750-E engine control panels offer cavitation detection and machine learning, but they can be seamlessly integrated with our RemoteIQ™ cloud-based monitoring and control solution to provide an extra layer of oversight and management, giving you peace of mind.

Examples of Cavitation and Detection

In a scenario involving the movement of pond water by a pump, debris accumulation within the inlet strainer may impede flow, leading to a restriction in the pump’s intake. This restriction causes a decline in pressure on the suction side, approaching vacuum levels. Eventually, the pressure drops low enough to breach the water’s vapor barrier, resulting in bubbles forming within the centrifugal pump, typically originating near its center. As these water bubbles migrate towards higher-pressure zones, they undergo implosion. CANplus machine learning, trained to recognize the system’s normal behavior, can autonomously identify cavitation instances based solely on the data collected from the engine. This eliminates the need for additional suction and discharge pressure sensors. Integrating pressure transducers into the system further enhances the panel’s capability to detect deviations from the optimal system performance.

Although cavitation in deadheaded pumps is less common, it can still occur under certain conditions. When a pump is deadheaded, the pressure at its inlet diminishes as it attempts to draw in fluid despite the closed valve or system obstructing flow. Much like the situation with a clogged strainer, the vapor barrier is eventually breached, leading to the formation and implosion of bubbles within the pump. CANplus machine learning can also identify this type of cavitation using data from the engine, offering a comprehensive solution for cavitation detection across various scenarios.

Long Ranger Watering using Tyro M2M system

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Irrigation of Dutch tulips using M2M

A well-known supplier of irrigation systems and water pumps. In addition, they also maintain agricultural machinery for farmers from the region. We had the opportunity to take a look at a recently delivered system. What we did not know beforehand was that we ended up in beautiful surroundings with stunning, colourful tulip fields.

Cogem water pump and irrigation hose reel from AP

The mechanisation firm has already provided pumps from Cogem and irrigation drums from AP with our M2M system on a number of occasions. In their own workshop, they provide the pumps and reels with an Aquarius M2M transmitter.

Cogem is an Italian manufacturer that delivers generators and pumps on a global scale. Almost every pump has a remote control, which is brand-independent.

AP Mechanical Engineering specializes in the production of machines for the agricultural sector. The irrigation drums of AP are a well-known sight in the countryside. The M2M system, which is explained in more detail below, can also be applied to irrigation drums of other brands.

Operating the M2M system

The system works as follows: The irrigation reel is used to set the length of time the tulips are to be irrigated. As soon as no more irrigation is required, the system sends a signal to the receiver on the pump. The pump is then switched off.

Some systems also come with an additional hand transmitter. This allows you to manually adjust the number of speeds from the tulip field or switch off the system. The distance from the reel to the pump is, in many cases, several hundred meters. The farmer regularly has to move the sprinkler or switch it off. Nothing is more convenient than being able to do this remotely using a remote control.

Mobile Air Compressor Control
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Complete Control Solution for Compact Mobile Equipment

Mobile air compressors are compact, portable machines designed to generate compressed air for various applications across construction, mining, agriculture, and manufacturing industries. These compressors are typically mounted on trailers or skid frames, making them easily transported to job sites and offering efficiency and mobility for demanding environments. OEMs, distributors, and rental equipment operators rely on the air compressor’s ability to operate in remote locations and adapt to various tasks.

 

Fully Integrated and Comprehensive Solution

We offer an integrated engine and compressor control solution for mobile air compressors, including a robust engine controller, remote control, telemetry, and monitoring.

 

Engine Control 

A DynaGen™ engine controller provides an easy-to-use, integrated control panel for mobile air compressors. Its rugged design ensures it can safely and reliably operate in extreme environmental conditions often found in job sites where air compressors are used. Here are just a few of the things that a DynaGen controller can manage:

remoteiq, dynagen, tyro and messenger ble
  • Throttle control
  • Automatic load/unloading of the compressor
  • Display machine air pressure
  • Auto throttle speed to maintain air pressure
  • Control the engine warmup based on the engine coolant temperature
  • Monitor and protect the compressor oil temperature

 

Remote Control  

In addition to the DynaGen controller, air compressors can be equipped with a Tyro™ handheld radio remote control system. Integrating remote controls enables the operator to control functions such as engine start/stop, IDLE rate speed control, and light control from the convenience of a handheld transmitter. This allows workers to operate the machinery from a safe and efficient distance.

 

Remote Monitoring  

DynaGen controllers are also telemetry-ready, should you want to introduce remote monitoring capabilities. Our RemoteIQ™ cloud-based platform provides a secure and cost-effective way to optimize the management of a single machine or an entire fleet of air compressors with GPS location tracking, real-time equipment status, and alert notifications.

Remote monitoring allows operators to access real-time data at any time, from anywhere, on any laptop or mobile device. It alerts the operator to potential issues before they cause damage, ultimately prolonging the compressor’s lifespan and ensuring reliability in demanding conditions.

 

Ease of Integration and Added Value 

What sets us apart is our extensive knowledge of control products and the ability to integrate engine control, radio remote control, and telemetry into a combined solution that improves the air compressor’s performance and simplifies its operation. A single-control solution provides simplicity and increases operator safety while improving overall machine efficiency. For OEMs and distributors looking to enhance their brand, private labeling, incorporating a company’s brand identity, such as name, logo, and color palette, is available.

Eliminating Integration Barriers in Robotic Systems with XBMCU
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Robotic systems have revolutionized manufacturing across industries, yet a persistent challenge remains: optimizing integration processes and simplifying system maintenance. For system integrators, facility managers, OEMs, and maintenance teams, the complexity of connecting robotic systems with existing control architectures often creates costly delays and implementation challenges.

At Cattron™, we’ve addressed this challenge with the XBMCU Multi-Interface Machine Control Unit. This compact device fundamentally transforms how robotic systems integrate into industrial environments by supporting wireless control and monitoring through safe, encrypted RF communication combined with diverse serial protocol support.

The Integration Challenge in Robotics 

For control engineers and machine builders implementing robotic solutions, historical challenges include the time and expense of traditional cabling required to bring valuable data and critical controls to end users. These dated methods not only cost time and money upfront to set up but require much more maintenance long-term, resulting in system downtime and additional costs to sustain operation.

“Application requirements are dictated by the machinery in use, existing communication systems, and industrial standards,” explains Mark Densley, sales leader at Cattron. “The XBMCU’s flexibility allows it to support industrial automation no matter the technology in place, benefiting both OEMs and end users with a singular product solution.”

Advanced Wireless Technology for Robotics 

The XBMCU’s wireless functionality is provided by Cattron’s black channel, encrypted RF protocol. The unit serves as a gateway for machine data and control to safely travel over the air for a truly wireless solution with range support up to one kilometer.

This capability is particularly valuable for robotic applications, as the XBMCU takes data from the machine via traditional I/O or a customer PLC, converts it using a custom RF message structure with encryption, and broadcasts it to a variety of Cattron transmitters or another XBMCU in what is known as a machine-to-machine solution.

Cattron is a market leader in providing safe and reliable RF communication, and in combination with the advanced design of the XBMCU, represents the next era of wireless control for industrial automation integration. Specifically, the XBMCU’s machine-to-machine configuration acts as a bridge providing machine data and control in real-time, eliminating human response delays and taking the optimization of machine control and maintenance to an entirely different level.

Simplified Serial Integration

The XBMCU champions complex operations with a straightforward hardware interface. Setting up serial communication is as easy as connecting a PLC to the D-coded M12 connector. For safe protocols such as CANopen Safety, CIP Safety, and PROFIsafe, customers only need to add a power supply, and their machine is ready to go.

The unit supports a comprehensive range of protocols, including:

  • Ethernet IP with future CIP Safety support
  • PROFINET with PROFIsafe (currently under certification)
  • Dual CANbus interfaces supporting J1939, CAN FD, CANope,n and CANopen Safety

This protocol flexibility enables the XBMCU to serve as a universal bridge between different robotic components, reducing system complexity and integration time.

Facilitating Robotic Safety Applications

Safety is paramount in robotic applications, and the XBMCU also delivers here. The core of the XBMCU product is designed and certified PL-d per the ISO 13849 standards. Beyond the hardware, the XBMCU has achieved several certifications with lab-tested and approved PROFINET and Ethernet/IP, and is in the process of TUV certification for PROFIsafe and CIP Safety.

The XBMCU works seamlessly with Cattron’s Safe-D-Stop™ wireless emergency stop system, enabling operators to carry portable e-stops with them as they work alongside robotic systems. This capability transforms the traditional stationary e-stop approach into a mobile safety solution that follows the operator, addressing a critical need in dynamic robotic work environments.

Machine-to-Machine Communication for Robotics

The XBMCU facilitates data-rich, bi-directional machine-to-machine communication that enhances robotic system performance. This connectivity enables:

  • Seamless coordination between multiple robots
  • Integration with existing PLC systems via serial protocols
  • Real-time data exchange between robotic end-effectors and control systems
  • Remote monitoring and control capabilities

This machine-to-machine configuration acts as a bridge, providing machine data and control in real-time, eliminating human response delays and taking robotic system optimization to a new level. The result is robotic systems that operate as cohesive units rather than isolated machines, maximizing efficiency and throughput.

 

Technical Specifications for Robotics Applications

The XBMCU’s technical capabilities make it ideal for demanding robotic applications:

  • Eight digital inputs configurable for Category 3 PL-d
  • Six 3A digital outputs configurable for Category 3 PL-d
  • Wide range 9-36 VDC supply
  • IP66-rated aluminum enclosure for harsh environments
  • Lab-certified PROFINET communications with Class C Conformance
  • Black channel wireless interface for secure communications
  • Data logging capabilities for performance analysis

Practical Applications in Robotics

The XBMCU demonstrates significant value in several robotics applications:

AGV/AMR Control: The unit enables wireless control of autonomous vehicles through safe, encrypted RF communication with range support up to one kilometer, maintaining consistent connections even in challenging industrial environments.

Robotic Cell Automation: The XBMCU streamlines cell implementation and reduces maintenance requirements by facilitating communication between robotic arms and peripheral equipment with simplified connectivity.

Collaborative Robot Safety: The integration with Cattron’s Safe-D-Stop wireless e-stops enables enhanced safety protocols around collaborative robots, allowing operators to immediately halt operations from anywhere in the workspace.

Remote Operation: For hazardous environments or remote operations, the XBMCU enables operators to control robotic systems from safe distances using Cattron’s wireless transmitters.

Machine Tending: The unit simplifies the integration of robotic machine tending applications by reducing the complexity of connecting robots to the machines they service.

Transforming Robotics Implementation 

The XBMCU is the wireless solution customers can rely on to improve their system operation and efficiency without compromising safety. The plug-and-play approach with simple M12 connectivity allows systems to be operational within minutes, dramatically improving implementation timelines and reducing engineering overhead.

For robotics integrators and end-users alike, this represents a paradigm shift in how automation solutions are deployed, maintained, and scaled. The XBMCU’s ability to work as an independent PLC while supporting multiple communication protocols makes it a versatile solution for virtually any robotic application.

The XBMCU offers robotics implementers a reliable, secure, and efficient path to enhanced automation without the traditional integration complexity that can delay implementation. For more information about implementing the XBMCU in robotic applications, contact us at [email protected].

Highly Mechanized Manure-Mix Slurry Equipment

Due to the high degree of industrialization in the agricultural sector, practically in all branches, ultramodern machines are deployed. The same applies to the manure storage and usage branch. In large silos there are thousand cubic meters of manure/slurry which is stored until it is dispatched.

Manure-mix-pump remotely controlled

In the meantime, the manure must be mixed into a homogeneous mass for spreading purposes. A German machine manufacturer, specialized in manure technology, offers high-quality solutions for the processing of manure. An example of this is the manure-mix pump. A machine that is built on a standard tractor with a powerful pump and a mixer.

Hydraulic arms

The mixer and the pump hang on the hydraulic arms. Between these arms, there is a long pipe that pumps up the manure from the silo into the manure container.

Wireless control

All functions of the machine, about 24, can be wirelessly managed by using the wireless remote controls Pyxis / Aquarius and  Cetus / Norma, with 12 functions. By making use of a menu structure and a two-hand control, all 12 functions are managed by the 12-channel keypad of the Cetus transmitter.

Easy to use

The keyboard is very clear due to the symbols on it and can be operated intuitively. This wireless system provides the user with the necessary flexibility required to keep an eye on every part of the process. Besides that, you get an uncluttered cabin without all types of control cabinets with cables. It can be said that the use of radio remote controls has made manure management an easily manageable job.