IAA April 2012

April 2012 IndustrialAutomationAsia

www.iaasiaonline.com

April 2012

MICA(P) 011/07/2011 | ISSN 0219/5615 | PPS 1561/06/2012 (022743)

Logistics Insight | Chemical Process Control | Industrial Ethernet | Precision Engineering

Logistics Solutions:

Automating ToSuccess

www.iaasiaonline.com

Industrial PCs:

Increased Flexibility

Industrial Ethernet:

Network Design

SolidWorks World 2012

Every change, every recipe, every challenge.

Every. Thing. Controlled.

The days when consumers regarded sugar as a commodity are long gone. Changes in consumer tastes, and the demand for new product varieties require flexibility in production planning. Ever-changing food safety standards emphasise the need for better raw material traceability, laboratory sampling, and product control. ABB’s tireless commitment to process innovation can offer major performance improvements. Whether you choose to talk directly to us, or to one of our ABB Authorized value providers, you can rest assured that everything is controlled. Every change, every process, every recipe, every test, every product, every challenge. www.abb.com/sugar

ENQUIRY NO. 391

ENQUIRY NO. 393

contents april 2012

ISSUES & INSIGHTS

26

Industrial Automation: Warehousing, Process Control And Beyond

Industrial PCs are seeing increased use with the industrial automation community as flexibility and efficiency in industrial environments increase in importance. By Thorsten Kraus, director strategic product management/marketing, Advantech-DLoG

Process CONTROL

30

Chemical Process Control

The chemical process industry is as diverse as it has technical challenges, but with an expanding portfolio of specialised products catering to the industry's needs, a lot of these challenges are being faced head-on. By Augustine Quek

SOFTWARE & NETWORKS

34

Industrial Ethernet: More Than Industrial + Ethernet

Good design and management of industrial Ethernet networks are important for robust communication channels and secure data transfer. By Justin Nga, business development manager, Belden Industrial Solutions

38

Case Study: 728 Axes In 400 µs

Brückner Maschinenbau are making use of drives from B&R’s Acopos series synchronised via Powerlink. The transition helped the company in reducing costs of the drive equipment, shorten cycle time and simplify maintenance of the hardware and software. By Stefan Schönegger, GM, Ethernet Powerlink Standardisation Group, B&R Industrial Automation

Instrumentation & Measurement

42

Proper Employment Of Guided Wave Radar In Steam Loops

The application of guided wave radar to measure level in steam loops is addressed, including discussions of how this technology functions and differs from more traditional forms of level indication. By Keith Riley, product business manager, and Ravi Jethra, power & energy industry manager, Endress+Hauser 2 industrial automation asia | April 2012

Industry Service and Support Hotline

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Call to find out more.

Answers for Industry.

Create sustainable value Food and Beverage Industries

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Your manufacturing processes represent one way of counteracting these trends because they offer numerous approaches for shaping a more successful future for your company.

ENQUIRY NO. 396

Our fully integrated solutions will help you set new benchmarks for efficiency and productivity, whether you produce beverages, dairy products, sugar, bread, cakes and pastries, oils and fats, or tobacco. The Siemens Food and Beverage Industry Suite represents a comprehensive range of products, systems and services for the food and beverage industry.

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contents april 2012

ENERGY

48

The Types Of UPS Systems

Uninterruptible Power Supply (UPS) systems are an important element where reliable power supply is critical, for example, in data centres. Five of the most common UPS systems will be discussed here. By Sim Liang Kee, head of solutions engineer, Schneider Electric Singapore

56

Case Study: Transforming Safety, Quality & Productivity

An integrated robotic layer picking solution has transformed workplace safety and significantly improved the quality and productivity of mixed pallet assembly at Nestlé Australia’s national Distribution Centre (DC). By Michael Bradshaw, regional director, Integrated Systems, Dematic (Southeast Asia)

EVENTS

SECTOR SPOTLIGHT

52

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SolidWorks World 2012 CIA 2011

Automation: A Plus For Distribution

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The business case for an automated system should consider not only the 'hard' numbers such as labour and building cost savings, but also the second order benefits of a safer, more ergonomic environment with improved delivery flexibility and response times. By Brad Welsman, executive GM Automation APAC, Schaefer Systems International

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As years go by the world is seeing increased connectivity and flow of information and resources. This is spearheaded by networks such as the Internet, and transport channels such as by plane, road, or sea.

In an ever connected world efficiency is key, this is especially true for transport channels where the route taken or fuel consumption play a big part in overall cost of delivery. Depending on cost, companies may choose to operate locally and manufacture their products in the markets they serve.

In regards to the internet and non-physical means of gathering and transferring information, stability is important. Transferring physical goods requires both physical transport but also electronic tracking of those goods, done through the world’s communication platform — the internet.

To work in harmony, several elements need to function together, be it the RFID tags used to track cargo, or the scanner, which is used to read the tracking data relaying a cargo’s contents, to the servers and software used to store that information, analysis and/or arrange it, and then the cables which relay that information back to the sender to inform them of the cargo’s safe delivery.

Over the past 10 years, the Internet, in particular, has flourished, opening up new avenues for commercialisation. In recent years the Internet is transforming again, becoming more social and ultimately reaching more people with the advent of wireless technologies such as High Speed Packet Access (HSPA), Evolved High Speed Packet Access (HSPA+), and Long Term Evolution (LTE). This, together with more cables being laid across the world, will benefit all, and open up new ventures and new possibilities, not yet realised.

In the current issue of IAA, we examine the increased use of Industrial PCs in the logistics space, as well as the chemical process industry, and the importance of good design and management for Industrial Ethernet.

We have a discussion of the five most common Uninterruptible Power Supply (UPS) systems. In this issue we also have a review of SolidWorks World 2012, in San Diego, which IAA attended.

Mark Johnston Assistant Editor

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Irene Tow irenetow@epl.com.sg Contributors

Thorsten Kraus, Augustine Quek, Justin Nga, Stefan Schönegger, Keith Riley, Ravi Jethra, Sim Liang Kee, Brad Welsman, Michael Bradshaw Editorial Consultants

Jim Pinto Industry Analyst

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6 industrial automation asia | April 2012

ENQUIRY NO. 312

Industry News Grundfos Unveils Sustainable Facility In Singapore

(L-R) Soren Sorensen, group executive VP; Ole Lisborg, Danish Ambassador in Singapore ; Yeoh Keat Chuan, assistant MD, Singapore Economic Development Board; Niels Due Jensen, chairman of the Poul Due Jensen Foundation; Carsten Bjerg, CEO and group president; Poul Due Jensen, APREG regional MD.

Singapore: Grundfos has officially launched its new facility at the Tukang Innovation Park. The S$40 million (US$32 million) Green Mark Platinum facility, which houses Grundfos’ latest assembly line as well as its regional corporate offices, is a model of green manufacturing in Singapore.

Nearly 200 guests joined the celebration at the inauguration of the new facility. The event was attended

by Yeoh Keat Chuan, assistant MD at the Singapore Economic Development Board, and Ole Lisborg, Danish Ambassador to Singapore.

Working closely with partners Bovis Lend Lease, COWI and Cofely SEA the facility features a host of green technologies and smart engineering, as well as the company’s own high efficiency pumps, aimed at improving the building’s energy efficiency and reducing its carbon footprint. The result is a projected energy savings of more than 40 percent and a water savings of around 1.8 million litres each year.

Over the last 10 years, the company has seen a compound annual growth rate of over 10 percent, making it one of the fastest growing markets for high 8 industrial automation asia | April 2012

efficiency pumps and water management solutions. Today, over 60 percent of commercial buildings in Singapore feature the company’s solutions.

With the new assembly lines, which combine advanced technology, automation and best practices from other facilities, belonging to the company, worldwide, the company expects to increase output through its Singapore facility by 15 percent in the first year, scaling eventually to three times the current capacity by 2022 to serve the Asia Pacific market.

“We congratulate Grundfos on the opening of its Green Mark Platinum facility in Singapore. Grundfos’ latest investment further validates Singapore as an excellent location for sustainable development, where companies can grow their regional and global operations,” said Mr Yeoh.

Poul Due Jensen, APREG regional MD, Grundfos said: “Despite challenging global economic conditions, the Asia Pacific market is poised to be a key contributor for growth in the long term.

Grundfos Singapore provides a great base from which to expand our service to the region.”

Harting Awarded The ‘Hang Seng PRD Environmental Award’ Green Medal Hong Kong: Harting Hong Kong and Zhuhai Harting (factory) have been jointly awarded the Green Medal in the Hang Seng Pearl River Delta Environmental Award organised by the Hang Seng Bank. The Hang Seng PRD Environmental Award honours and encourages manufacturing companies in Hong Kong and the Pearl River Delta (PRD) region to continually enhance their environmental performance by recognising and rewarding their green achievements.

Angela Chau, de Bruijn Marcel and Eric Kwan presented the award at the ceremony (from left to right)

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ENQUIRY NO. 381

Industry News

Applied Materials And A*STAR’s Institute Of Microelectronics To Drive Advanced 3D Chip Packaging Singapore: Applied Materials and the Institute of Microelectronics (IME) have officially opened the Centre of Excellence in Advanced Packaging at Singapore’s Science Park II. Singapore’s Minister for Trade and Industry, Lim Hng Kiang, presided at the opening ceremony.

The Centre of Excellence in Advanced Packaging has been built with a combined investment of over US$100 million from Applied Materials and IME. The facility features a 14,000 square foot Class-10 cleanroom and is equipped with a fully-integrated line of 300 millimetre manufacturing systems to support the research and development of 3D chip packaging, a critical growth area for the semiconductor industry.

The Centre will be the most advanced lab of its kind dedicated to wafer level packaging and will combine Applied Materials’ equipment and process technology with IME’s research capability in 3D chip packaging.

The Centre positions Singapore as a global leader in semiconductor R&D and is expected to help accelerate the development and adoption of 3D packaging technology globally.

“Today, we are not only opening the most advanced wafer level packaging lab of its kind in the world, but we are also

(L-R) Prof Kwong Dim-Lee, IME; Leo Yip, EDB; Randhir Thakur, Applied Materials; Lim Hng Kiang, minister for trade and industry; Michael Splinter, Applied Materials; Lim Chuan Poh, A*STAR.

opening a new product development capability for Applied Materials in Asia,” said Mike Splinter, chairman and CEO, Applied Materials. “This Centre will strengthen our ability to advance new technologies and allow us to work more closely with our customers in Asia,” he added.

On the collaboration with Applied Materials, Lim Chuan Poh, chairman of A*STAR, said: “The combined efforts of Applied Materials and A*STAR’s Institute of Microelectronics are a continuing testimony to A*STAR’s spectrum of excellent and industry-relevant scientific capabilities. It reaffirms our strategy of leveraging a suite of capabilities to form meaningful and impactful public-private

research alliances which catalyse the growth of private sector R&D activities in Singapore. This will create many highvalue jobs locally and help to further anchor Singapore’s semiconductor manufacturing base.”

Professor Dim-Lee Kwong, executive director, IME, added: “The Centre of Excellence is a prime example of a strategic relationship fostered between two leading players in the global semiconductor value chain and will spur the development of innovative waferlevel packaging technologies to be implemented globally. This collaboration will enable the semiconductor industry to accelerate the adoption of 3D chip packaging.”

Dassault Systèmes Opens New Horizons With 3D Experience Singapore: Dassault Systèmes has announced the pursuit of a new strategy based on a 3D Experience platform that will change the way industry leaders and marketers create value for their end consumers. The 3D Experience platform transforms the way ‘innovators will innovate with consumers’ by connecting designers, engineers, marketing managers and even consumers, in a new ‘social enterprise’.

“We have evolved the V6 platform with our customers over the last few years. The addition of intelligent information search-based technologies, social innovation capabilities and realistic 3D virtual experiences made us ready to pioneer a new technological wave: a 3D Experience platform to serve the social enterprise of the 21st century,” said Bernard Charlès, president and CEO, Dassault Systèmes.

10 industrial automation asia | April 2012

“I am convinced that within this century, people will invent and innovate more than ever before. We must provide businesses and people with holistic 3D experiences to imagine sustainable innovations capable of harmonising products, nature and life,” he added.

“The way enterprises work internally and externally will change significantly in the next coming decades,” said Monica Menghini, executive VP, Industry, marketing and corporate communications, Dassault Systèmes.“ Therefore, our objective is to provide our clients with a powerful platform, which uses the universal language of 3D and the Web as the user interface, to help them to connect the dots for a game-changing increase in end-user value,” she added.

Industry News

TriQuint Semiconductor Opens International Headquarters In Singapore Singapore: TriQuint Semiconductor, a global RF solutions supplier, has officially opened its new International Headquarters in Singapore. The facility will be the focal point for most international customers, suppliers and manufacturing partners.

“Our business outside of the United States now contributes about 70 percent of the company’s annual revenue,” said Ralph Quinsey, president and CEO, TriQuint Semiconductor. “With Asia’s appetite for new technologies, particularly in mobile devices, and government support of the latest communications infrastructure, we believe Asia will continue to offer great opportunities for business growth. It is with that long term view that we further globalise our business, in order to strengthen our relationships with international customers and drive greater efficiencies across our supply chain,” he added.

The company’s headquarters is located at the Changi Business Park, close to Singapore’s Changi International Airport. This new office will offer dedicated resources in a wide variety of areas ranging from customer service to supply chain management.

“We are pleased that TriQuint Semiconductor is establishing its International Headquarters in Singapore. The headquarters is testimony to Singapore’s competitiveness as a preferred location for companies to gain supply chain efficiencies,” said Chong Joon Woon, director, Electronics, Singapore Economic Development Board.

(from left) Mr Chong Joon Woon, director, Electronics, Singapore Economic Development Board celebrates the official opening of TriQuint International Headquarters in Singapore with Glen Riley, VP and MD, TriQuint International.

TriQuint has just completed its sixth consecutive year of record revenue, largely driven by the proliferation of smartphones, tablets and the emergence of 3G/4G broadband wireless. Customers in Asia drove a big part of this growth and manufacturing partners in Asia assembled and tested almost all of the high volume TriQuint-designed products sold into these applications.

“We have solid plans to grow our share in the mobile device and network communications markets in Asia and Europe. Singapore is a great location to recruit and develop experienced talent, given the number of multi-national semiconductor companies already located here,” said Glen Riley, VP and MD, TriQuint International. “Over time we also plan to work on technology innovations and new product design out of Singapore, through close collaboration with international customers,” he added.

Environmental Biotechnologist Wins Lee Kuan Yew Water Prize 2012 Singapore: Singapore International Water Week has announced that Prof Mark van Loosdrecht has been awarded the Lee Kuan Yew Water Prize 2012 for his breakthrough contributions in creating sustainable solutions in the field of wastewater treatment. The highlight of the Singapore International Water Week, the Lee Kuan Yew Water Prize is an international water award that recognises outstanding contributions towards solving global water problems by either applying technologies or implementing policies and programmes, which benefit humanity.

As the fifth recipient of the Lee Kuan Yew Water Prize chosen from over 61 illustrious nominations received from

across 25 countries, Prof van Loosdrecht is recognised for pioneering an innovative biological process that provides a costeffective, robust and sustainable way to remove unwanted pollutants from used water. This was made possible by the discovery of a unique group of bacteria which removes pollutants in used water using less oxygen and no added organic carbon compared to conventional processes. The process called Anammox.

“I am truly humbled to receive one of the most prestigious awards recognised in the water industry and among our profession. With this award, I am further encouraged to ensure that my

technologies and research will continue to help create more sustainable solutions that are applicable to our modern world while protecting the quality of precious water,” said Prof van Loosdrecht.

The Lee Kuan Yew Prize award ceremony and banquet will be held at the Marina Bay Sands, on July 2, 2012 during the Singapore International Water Week 2012, the global platform for water solutions. As the winner of the Lee Kuan Yew Water Prize 2012, Prof van Loosdrecht will deliver the 5th Singapore Water Lecture prior to the award ceremony, where both the Water Prize and the World Cities Prize will be presented to the respective laureates.

April 2012 | industrial automation asia 11

Industry News

Nordson K K Names Elematec Corporation As Distributor For Japan

Midori Sakurai, Osaka, Japan

Tokyo, Japan: Haier Group officially announced its plans to establish its Asian headquarters in Osaka, Japan, and two R&D centres in Tokyo and Kyoto, a development that now establishes Japan an overseas market that combines all of the three key elements for business - R&D, manufacturing, and marketing.

The conference marked the official unveiling of the company's second brand in Japan, Aqua. In 2011 Haier purchased Sanyo’s washing machine and consumer refrigerator businesses in Japan, in addition to its washing machine, refrigerator and consumer home electric appliances businesses in Indonesia, Malaysia, the Philippines and Vietnam. Aqua, as part of Sanyo’s intangible assets, was transferred to Haier in 2011. Meanwhile, the company's owns two brands, Haier and Aqua, in the Japanese market as part of its dual brand strategy.

The company is expecting its sales in Japan to reach ¥50 billion (US$603 million) in 2012, including Aqua’s estimated ¥35 billion. However, the company emphasised that it is not only eying an increase in market share. "What is most important for us is to better understand Japanese consumers, and provide high-quality appliances to meet the demands of their lives through our localised operations, technology innovation, and resource consolidation," said Liang Haishan, executive VP, Haier.

Besides Japan, the company's is also launching its duel brand strategy in the Southeast Asian market where it will operate under the brand names of ‘Haier’ and ‘Sanyo’. The company's Asian headquarters in Japan will oversee the innovation-oriented R&D, manufacturing, and marketing across the two regional markets.

Du Jingguo, VP, Haier, commented: "Haier chose Japan as the home for its Asian headquarters because of the country's mature home appliances market and its global leadership position in terms of technological innovation and design.”

12 industrial automation asia | April 2012

Osaka, Japan

Fabel Nard, la ville du bois, France

Haier Establishes Asian Headquarters In Japan

View of Tokyo, Japan

Tokyo, Japan: Nordson K K has announced the selection of Elematec Corporation as the distributor of Nordson EFD precision fluid dispensing systems in Japan. The new partnership will add 21 sales and technical support offices to Nordson EFD’s existing network, greatly expanding the availability of their high-quality dispensing equipment Osaka, Japan to companies throughout Japan. Major markets for Nordson EFD equipment include the electronics, automotive and medical industries.

“Our new partnership with Elematec will significantly increase Nordson EFD’s ability to provide Japanese companies with innovative solutions for improving their R&D and production processes, and to support them with timely shipment of genuine EFD products from local warehouses,” commented Masaru Uchida, representative director of Nordson K K.

Industry News

Waterfall Security Solutions Joins McAfee Security Innovation Alliance Tel Aviv, Israel: Waterfall Security Solutions has announced that it has joined the McAfee Security Innovation Alliance (SIA) partner program. Under the auspices of the McAfee SIA program, Waterfall will integrate its widely-adopted Unidirectional Security Gateway solutions with McAfee products, including McAfee Application Control and McAfee ePolicy Orchestrator platform, to allow Waterfall solutions to report to enterprise-wide instances of McAfee products from secure, unidirectionally-isolated industrial networks. These integrations are in addition to the alreadyproven McAfee NitroView SIEM aggregation capabilities in the Waterfall for NitroView product.

"Utilities, chemical plants and other critical industrial infrastructure sites are not content to be islands of automation. These sites are demanding that enterprisewide deployments of security and monitoring systems extend into even the most secure industrial enclaves," says Andrew Ginter, director of Industrial Security, Waterfall.

"This partnership will enable critical infrastructures and industrial sites to communicate security events and information out of secure industrial networks and into enterprise-spanning McAfee systems, while mitigating network-connectivity risks to the safety and availability of industrial control systems," he added.

The company's Gateway products replicate industrial servers and information from industrial networks out to business networks, using hardware-enforced unidirectional communications. The hardware permits no communications or network attack back into the industrial network through the company's Unidirectional Gateways: no denial-of-

service attacks, no worms, no advanced threats with remote control tools, not even password errors or omissions are permitted. The gateway hardware has no physical data path that would permit any communications back into a protected network.

The company's existing NitroView SIEM replication solution permits plant-wide NitroView SIEM instances to report into enterprise-wide SIEM installations. The instance of the SIEM in the plant collects, reports, and manages information from plant systems, and makes that information available to plant personnel. The enterprise NitroView SIEM instance receives the unidirectionally-transmitted plant SIEM information, and provides enterprise-wide visibility, analysis and correlation capabilities.

"McAfee is committed to securing critical infrastructures, including industrial networks and safety-critical networks," said Ed Barry, VP, Security Innovation Alliance, McAfee.

"We're excited to partner with Waterfall to bring the benefits of integrated security solutions to critical industries relying on unidirectionally-isolated networks," he added.

Lior Frenkell, CEO and co-founder, Waterfall Security Solutions, adds: "Waterfall is pleased to partner with McAfee, and to join the McAfee Security Innovation Alliance. McAfee has demonstrated real leadership in working to improve the security of industrial systems and networks. Our decision to work with McAfee reflects the growing demand for McAfee solutions on the industrial networks that Waterfall equipment protects."

Fastway Ushers In Cable Digitisation With Next-Generation Cisco Set-Top Boxes New Delhi, India: Cisco has announced that it has been chosen by Fastway Transmissions (Fastway) to usher in cable digitisation across its customer base in the key states of Punjab, Haryana and Himachal Pradesh. As part of this initiative, Fastway is expected to deploy more than two million next-generation digital set-top boxes from Cisco, over the next two years. In addition to being one of the largest cable digitisation projects in the country, Cisco’s set top box comes at an affordable price point with an optimum feature set to suit Indian preferences.

By enabling services like residential TV, HDTV, gaming, digital video recording, video on demand and future ‘connected home' services, to retail consumers, Fastway can now evolve from a cable distribution company to a lifestyle-experience provider. The company plans to provide broadband services and is currently working with universities and institutes in Punjab and Himachal Pradesh to offer educational services. Cisco's cable digitisation solutions provide the massive scaling and operational cost optimisation benefits that cable operators need to transition

to a digital platform, apart from being able to take advantage of Cisco’s Capital leasing and finance options.

Peeush Mahajan, CEO, Fastway, said, "By utilising Cisco's next generation digital set top box, we can enhance the quality of our services, curb piracy and increase our subscription revenue by offering a plethora of innovative and interactive services giving us the competitive edge over direct-to-home players. Cisco's technology leadership and their understanding of the complexities of the cable distribution business helped them cement this deal."

April 2012 | industrial automation asia 13

Industry News

Agilent Technologies Completes Acquisition Of Accelicon Technologies’ Solutions California, US: Agilent Technologies has announced that Accelicon Technologies’ software solutions and technology for device-level modelling and validation in the electronics industry are now part of Agilent. The two companies had announced an acquisition agreement on December 1, 2011. Financial details were not disclosed.

The acquisition, led by the company's EEsof EDA organisation, further enhances its leadership in semiconductor device modelling.

Accurate, verified device models are

critical to reduce R&D design cycles as higher frequencies, smaller technology nodes, new materials and device layouts call for more accurate process design kits. As part of the Software and Modular Solutions Division, Agilent EEsof continues to integrate its design simulation with real measurements to improve design efficiency for engineers who develop communications systems.

These improved tools and processes solve the increasing complexities they face when designing communications systems for aerospace/defense and

commercial wireless applications.

The company's newly acquired solutions from Accelicon include MBP for device-level extraction and model generation, MQA for device-level model validation and AMA for advanced model analysis, including layout effects.

Accelicon was founded in 2002 by Dr Xisheng Zhang, who has now joined Agilent along with former Accelicon CEO Tim Smith. The majority of the former Accelicon employees are located in Beijing; they are also now part of Agilent.

MWH Contributes US$50,000 To Help Bring Solar Lighting To Rural India Colorado, US: MWH Global, a sustainable engineering company, has announced a US$50,000 donation to The Energy and Resources Institute (TERI), an India based, non-profit research organisation focused on finding solutions for critical energy, environmental and sustainable development issues. The funds will directly support TERI’s Lighting a Billion Lives program that aims to bring light into the lives of rural communities through solar lighting.

In India alone, 61 million rural households use kerosene and wicker lamps for lighting. Inadequate lighting has a direct impact on the livelihood, health, environment and safety of these rural residents. Lighting a Billion Lives, a program that launched in 2008, sets up a solar charging station in energy poor villages and offers certified, bright and quality solar lanterns for rent to the local community. Each village charging station is managed and operated by a local entrepreneur who leases the lanterns to village residents for an affordable fee, creating opportunities for renewable energy education and entrepreneurship in the villages.

The donation supports the multi14 industrial automation asia | April 2012

faceted climate change commitment program MWH developed through its partnership with the Clinton Global Initiative (CGI) in 2007 to advocate for sustainable practices, reduce energy use and greenhouse gas emissions and educate young people in our communities on the water cycle, energy use and climate change.

It is estimated that the MWH donation will help create renewable energy infrastructure for 13 villages in rural India, giving non-polluting and reliable solar lighting to about 2,500 villagers and reducing CO 2 emissions by 750 tonnes over the solar lantern’s useful life of 10 years, further expanding the firm’s commitment to sustainability and renewable energy projects. TERI has also committed to CGI to implement innovative solutions to some of the world’s most pressing challenges, including climate change.

The contribution to the Lighting a Billion Lives program was made through the MWH Caring Foundation. The foundation was established in 2002 to fund charitable and educational causes that align with the MWH purpose of Building a Better World.

Robert Gaskins, principal engineer (MWH); Dr Anjali Parasnis, Fellow and Coordinator (TERI); Rashmi Waddan, Environmental Champion (CCC Coordinator -MWH)

“Our purpose of Building a Better World is inherent in the way we do business and help the communities where our employees work and live,” said Alan Krause, president and CEO of MWH. “MWH and our MWH Caring Foundation are proud to support and partner with organisations like TERI that leave a lasting impact on people and the planet,” he added.

To date, the MWH Caring Foundation has donated US$800,000 to charitable organisations. Previous donations include the Queensland Premier’s Flood Relief Appeal in Australia the Armed Forces Foundation, Water for People, and President's Relief Fund for Earthquake Victims in Pakistan, among others.

ENQUIRY NO. 350

Industry News

New Application Improves Human Reliability

By Identifying Safe Operating Limits Texas, US: PAS, a supplier of human reliability software and services to the power and processing industries worldwide, has announced the release of inBound, an application that makes plant operators continually aware of safe operating limits.

Safe operating limit information is maintained by various groups within the plant and is not readily available to operators. As such, operators are generally unaware of the design and safety limitations of the processes they operate. The company has addressed this shortcoming with inBound, a layered application for The company’s PlantState Suite alarm management software.

InBound aggregates, validates, and displays physical constraints such as a vessel’s Maximum Allowable Working Pressure (MAWP), design constraints such as relief valve settings, and safe operating limits. These constraints may be manually entered, calculated, or imported into the software from engineering applications and databases.

The application enables engineers to develop a boundary hierarchy and automatically detects and reports deviations from that hierarchy, such as an alarm setting that is higher than a pressure-relief valve setting. This capability provides assurance that configuration parameter changes such

Young African Professionals Expand Opportunities With A US$250,000 Grant From The ExxonMobil Foundation Washington, US: The ExxonMobil Foundation has announced a US$250,000 grant to the Global Health Corps allowing the program to expand opportunities for young African professionals and to create the ExxonMobil Fellowships in Global Health. The grant will support eight fellows from Africa — each of whom is paired with a young professional from the US — committed to making a difference in global health. The Global Health Corps will give preference to applicants interested in the fight against malaria.

The Global Health Corps provides opportunities for young professionals from diverse backgrounds to work on the frontlines of global health issues in skillsbased, year-long fellowships. Fellows are drawn from various occupations, including medicine, supply chain and procurement management, engineering and education.

Assigned to a non-governmental organisation in a developing country, the fellows apply their expertise to disease management and simultaneously gain first-hand experience with pressing global 16 industrial automation asia | April 2012

health issues.

"We know that by mobilising young leaders to commit their passion and skills to global health equity, we will not only see better solutions, but also stronger leadership and great benefit to the overall health care infrastructure in these countries,” said Barbara Bush, CEO and co-founder, Global Health Corps.

Malaria is a major hindrance to economic development. The disease is estimated to cost Africa about US$12 billion annually in lost Gross Domestic Product (GDP), slowing GDP growth by as much as 1.3 percent per year.

“Programs like this are invaluable in building health care capacity in countries struggling to deal with numerous challenges, including the plight of malaria," said Suzanne McCarron, president, ExxonMobil Foundation.

“We are committed to doing our part to fight malaria and empower young professionals to make a difference in global health today and in the years to come,” she added.

as alarm limits and instrument ranges remain within the safe operating envelope of the plant.

By displaying safe operating limits in real time and in context within the plant’s existing control system graphics, inBound enables operators to proactively monitor measurements and take action as needed to prevent violation of limits.

“A compelling use for inBound is the monitoring of environmental limits,” said Eddie Habibi, founder and CEO, PAS. “Exposing these limits in context enables operators to visualise the processes proximity to boundaries in real time, and take action before an excursion occurs,” he added.

Company Notice Sick Optic-Electronic Pte Ltd is now known as Sick Pte Ltd, with effect from February 15, 2012.

Sick Pte Ltd 31, Admiralty Road, #04-01 to #04-08 Fook Tong Nam Building Singapore 739984 Tel : + 65 6744 3732 Fax : + 65 6841 7747

Relocation Notice X-Tech Precision Co Ltd has changed address, effective from November 1, 2011. New details follow: X-Tech Precision Co. Ltd 48/2 Sukhumvit Soi 11 Sukhumvit City Resort Klongtoey Nue, Wattana Bangkok 10110 Thailand Tel : +66 2168 4097 Fax : +66 2168 4098

There’s no way I can get all the I/O change orders done before start-up.

But we can’t start-up until the change orders are done.

YOU CAN DO THAT

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2012 Emerson Electric Co.

ENQUIRY NO. 386

Get the flexibility you need–where and when you need it–with Electronic Marshalling.

Tight project schedules and changing requirements are the norm, not the exception, so Emerson makes handling them easy by eliminating re-wiring altogether. Only with DeltaV Electronic Marshalling can you land field cabling wherever and whenever you want, regardless of signal type or control strategies. It’s the flexibility to add I/O today, tomorrow or ten years from now. See how DeltaV Electronic Marshalling makes it easy, scan the code below or visit: IOonDemandCalculator.com

Industry Updates

An integrated communication system such as Profinet is essential to enable the complete integration of centralised p ro c e s s - re l a t e d o p e r a t i o n s of a plant, with downstream applications involving mostly discrete processes, such as filling and packaging.

For this reason, Profibus & Profinet International (PI) established a working group of manufacturing companies (ABB, E m e r s o n , E n d re s s + H a u s e r, Pepperl+Fuchs, Siemens, Softing, Stahl, and Yokogawa), whose initial task was to define the particular characteristics of process industries.

Additional consideration was given to the requirements of NAMUR (an international user association of automation technology in process industries).

Besides the extended cycle times, continuous plant operation, and complex actuators and sensors, another major challenge was the sheer quantity of devices (up to 100,000 I/O signals).

Moreover, life cycles in the process industry are often very long. It is not unusual to find 20-year old control systems, with many plants are even older than that.

These specific characteristics have always been an impediment to the introduction of new technologies in the past. In spite of this, Profinet holds interesting prospects for process-related applications and the process industry sector, based in large parts on its flexibility.

In order to establish Profinet on a widespread basis, however, the specific requirements of this sector had to be implemented.

This effort focused on four main areas: 18 industrial automation asia | April 2012

Expanding Horizons For Profinet In The

Process Industry With over four million installed nodes, Profinet has long since become a familiar feature of production automation and drive engineering applications. But what about the process automation sector? By Dr Peter Wenzel, Profibus & Profinet International Support Centre Investment Protection In order to protect investments, seamless integration into existing fieldbuses must be possible. Many process industry plants have been in operation for several decades and have a large installed base of field devices, controllers, and communication systems.

Continued use of this installed base is the aim. How can this be ensured? By means of a proxy concept, the three communication systems encountered in process industries — Profibus PA, Hart, and Foundation Fieldbus — can be integrated into the higherlevel Profinet network. The proxy assumes responsibility for implementing the physics and protocol, and ensures the exchange of all I/O, diagnostic, and parameter assignment data as well as alarms with the field devices.

1

Configuration In Run The chemical industry, whose plants operate continuously 2

in most cases, places top priority on plant availability. It is inconceivable that a column would have to be shut down before making a parameter change or replacing a device. It must be possible to reconfigure devices and networks and to add, remove, or replace devices or individual modules during operation. Thanks to the auto-sense and topology detection features, devices are identified automatically and their locations pinpointed. This enables convenient, reliable solutions to be developed for device/spare part replacement scenarios, in which the replacement device parameters are assigned automatically by the control system.

All of these ‘Configuration in Run’ (CiR) measures are carried out in Profinet without any interruption and without adversely affecting network communication.

This ensures that plant repairs, modifications, or expansions can be performed without a

plant shutdown in continuous production processes as well.

Time Synchronisation And Time Stamping In power plant automation, an especially high value is placed on time-correct tracking of individual process signals. This is especially critical when it comes to malfunctions in individual automation areas. Afterwards, the plant operator wants accurate information on the order in which signals were sent and at what time. He is then able to perform a detailed ‘root cause’ analysis.

An accuracy of 1 ms is critical for this purpose.

This requires a time stamp for digital and analogue measured values and alarms that are accurate to the millisecond.

A precondition for this is an exact time synchronisation of the components involved: By means of a central system master clock (eg: based on GPS or DCF77), a master selected specifically for this purpose transmits a cyclic equidistant clock signal to all bus nodes, thereby synchronising 3

them. This ensures that I/O devices can provide real-time information about alarms and other important events with a time stamp that is based on a network-wide standardised time of day.

Scalable Redundancy To avoid automation failures caused by conditions such as wire breaks or short circuits, redundancy concepts were developed for Profinet, which can be structured differently depending on the application (‘scalable redundancy’).

The basis for these concepts is the automatic switchover of communication paths to intact paths in the event of a fault, along with communication of status information regarding the cause of the communication interruption.

The user can decide whether he wants to use controller redundancy, network redundancy, device redundancy, or device interface re d u n d a n c y. M o re o v e r, t h e recovery time of a communication system must be fast enough to prevent process disturbances. All redundant elements must have 4

a diagnostic capability so that faults can be detected and faulty elements replaced.

Uniform Concept Many users express the desire for an integrated communication system down to the field level.

Profinet enables a direct path to Manufacturing Execution System (MES) and Enterprise Resource Planning (ERP) systems, while at the same time facilitating the use of Internet services for things like remote maintenance, integration of wireless communication, or intelligent network management.

New architectures can be realised with Profinet. The flexible signal allocation allows signals to be assigned to controllers in the Profinet network without any rewiring. This aids in future plant expansions, even when continuous processes are involved. Over the long-term, this could also make planning of automation systems easier since individual lines can still be expanded even during the commissioning phase.

Outlook With completion of the ‘Profinet for Process Automation’ application profile, PI has taken an important step towards a uniform communication concept for process and production industries.

The preconditions for this have been put in place with the implementation of process-specific requirements. What remains now are a few housekeeping tasks, such as the review of security concepts, coordination with FDI, development of test specifications for devices, and certification of devices that meet the Profinet requirements.

ENQUIRY NO. 2101

April 2012 | industrial automation asia 19

Newsdesk

Reflection On

CiA’s Development From

Holger Zeltwanger, CEO, CiA

It was in 1991, at the Systems exhibition in Munich, Germany, when several companies had introduced board-level products with CAN interfaces. In those days, I was the editor of the German VMEbus magazine. By discussing compatibility issues with the CAN module manufacturers, I understood that even the physical layer was different. Most of them 20 industrial automation asia | April May 2009 2012

Holger Zeltwanger

had implemented a modified EIA 485 circuitry. Back in my office, I studied the CAN protocol in more detail and was fascinated by this robust and reliable communication protocol. I decided to invite some companies for a meeting to discuss the compatibility issues, and I rented a meeting room in a hotel close to my home.

Although I had invited just a few companies for the meeting held in January 1992, 23 parties showed up. Of course, the rented room was too small. Nevertheless, we discussed, in this meeting, not only the physical layer compatibility problem, but also the need for a standardised application layer.

All participants were German, which might have been the reason why we decided to legally form a nonprofit association. The participants asked me to organise a follow-up meeting and to prepare the foundation of a nonprofit association in accordance with German laws.

In March 1992, we established the CAN in Automation (CiA) users’ and manufacturers’ group as a non-profit association. I was elected as a member of the board of directors and charged to operate the CiA office. In fact, it was a home office. As an editor, I had the idea to publish a newsletter about CAN technology. Already in June, just three month after establishing the CiA, the first issue of the CAN Newsletter was released. It was a copied newsletter with just a few pages. Today it is a wellestablished printed magazine, and the CAN Newsletter Online has recently been introduced.

The CiA organisation grew slowly, but it was not so for the work: The members decided to exhibit jointly on the Interkama 1992 fair in Dusseldorf, Germany.

Furthermore, they decided to demonstrate interoperability of their CAN products.

Additionally, the inquiries to the CiA international headquarters

increased quickly. In 1994, I organised the first international CAN Conference with about 200 participants. In 1995, I rented an office in the neighbouring village and hired a half-time secretary on a freelancer basis. The CiA association grew constantly. I tried to avoid any involvement in the so-called ‘fieldbus war’. As an editor, I knew most of the German editors in the field of electronics and automation. This might be a reason, why CiA has bypassed the ‘war’. Another reason was that CiA had not tried to standardise its CAN Application Layer (CAL).

The increasing number of CiA members put more burden on the CiA office, so CiA hired more staff.

Today we have 14 employees in the CiA office.

In our 20 years of history, CiA has operated offices in the US, India, and China. The Chinese representation office established last year is still in operation, although the others have been closed. To be serious, I am in favour

of decentralised organisations with highly responsible individuals.

But this requires a lot of daily co-ordination and discussions; otherwise efficiency decreases dramatically.

The CAN users surprise me even today. There are so many new applications, which I never thought would use CAN technology: coffee machines, Pedelecs, subsea instruments, and so on. Last year, I was surprised by the membership increase of about 50 companies. Perhaps this year, I will be surprised by the success of the CAN-FD protocol and its impact on the CANopen technology. I also hope that the success of the CAN Newsletter Online will surprise me. It is up to you, to surprise me furthermore.

If you would ask me, whether I would do it again — to initiate the CiA and to manage this organisation — my answer would be a definite, yes.

ENQUIRY NO. 2102

CiA Milestones 1992: CAN Newsletter 1992: Joint stand at Interkama 1992: CiA 102 (physical layer) 1993: CiA 200 series (CAL) 1994: Joint stand at Hanover Fair 1994: 1st international CAN Conference (iCC) 1994: CiA 301 (CANopen) 1995: Office in Erlangen, Germany 1995: 100 members 1995: CiA 401 (I/O profile) 1997: CiA 402 (drive profile) 1997: 200 members 1998: CANopen product guide 1998: CANopen product certification 1999: 300 members 2001: CiA 304 (CANopen-Safety) 2003: 400 members 2003: Office in US 2003: CiA 417 (CANopen-Lift) 2008: Office in Nuremberg, Germany 2008: 500 members 2009: Office in India 2011: Office in China 2012: CAN Newsletter Online ENQUIRY NO. 2103

The CANopen-Lift demonstrator at the Interlift 2011 exhibition in Augsburg, Germany.

April May 2009 2012 | industrial automation asia 21

New ARC Study Indicates Foundation Fieldbus Maintains Market Leadership ARC Advisory Group, the wellknown manufacturing research and advisor y firm based in Dedham, Massachusetts, US, has released a new study entitled ‘Fieldbus Solutions in the Process Industries: Worldwide Outlook,’ which indicates Foundation fieldbus continues to lead the market in digital fieldbus communications for the process industries.

According to the new ARC repor t, Foundation fieldbus accounted for nearly threequarters of the total digital process fieldbus marketplace in 2011. ARC also predicts ongoing expansion of the market for process fieldbus products and solutions, with continued double-digit growth over the next five years.

Foundation fieldbus provides an all-digital communication i n f r a s t r u c t u re f o r p ro c e s s automation, with powerful m u l t i v a r i a b l e m e a s u re m e n t capabilities, powerful device diagnostics, and the ability to integrate wireless devices across multiple networks.

T h e b l o c k s t r u c t u re o f Foundation fieldbus is unique, and provides true distributed functionality for implementing control in the field, improved data management, and alarm and alert management.

Foundation technology is well prepared to take advantage of the growth opportunities in fieldbus technology over the next decade.

ARC Analyst Kevin Crisafulli 22 industrial automation asia | April 2012

said: “Fieldbus technology has made further inroads into the culture of process automation, despite the negative impact that the global recession had on the market. Manufacturers are beginning to understand that the real value of fieldbus savings and increasing efficiency are more closely related to operating expenditures, which will drive growth going forward.”

The Fieldbus Foundation’s global marketing manager, Larry O’Brien, commented: “Thanks to the efforts of our supplier partners and the stringent testing & registration process at the Fieldbus Foundation, there is a wide range of products, systems, and components to choose from. With Foundation fieldbus expanding into more and more application segments such as Foundation for remote operations management and Foundation for safety instrumented functions, we are easily looking at a market opportunity in the billions of dollars on an annual basis for the foreseeable future.”

Mr O’Brien added: “Foundation fieldbus remains the popular choice among end-users as an all-digital process automation solution that brings very positive returns to the bottomline. The technology allows you to see your process in high definition; manage information in real time; and optimise people, processes and technology.”

ENQUIRY NO. 2104

General Assembly Held In Sao Paulo, Brazil The Fieldbus Foundation held its 2012 General Assembly meeting from March 6 to 8, 2012, in São Paulo, Brazil, at the Sheraton São Paulo WTC Hotel. This key automation industry event attracted the leading suppliers and end users of Foundation fieldbus.

The 2012 General Assembly, themed, ‘In a World of Choices, Foundation Brings it all Together,’ included a comprehensive, end user-oriented agenda consisting of fieldbus project case studies and tabletop exhibitions from leading automation vendors across the globe, as well as a demonstration of the new Foundation for remote operations management technology.

According to Fieldbus Foundation president and CEO Rich Timoney, São Paulo was selected as the site of this year’s General Assembly due to its status as one of the world’s fastest growing industrial regions, and the overwhelming demand for Foundation technology within the area.

Mr Timoney said: “Brazil has been experiencing rapid growth in automation projects utilising Foundation technology and is arguably the central hub of the process automation industry in all of Latin America. Petrobras, Brazil’s largest oil producer, has been integrating Foundation fieldbus into their plants for some time, and is in the midst of a large expansion project utilising the technology.”

ENQUIRY NO. 2105

ENQUIRY NO. 382

Climate change and the disaster in Japan have pushed energy efficiency to the top of the agenda.

But what is EtherCAT’s role in energy efficiency?

Energy efficiency can be achieved with the help of communication networks in five main ways:

EtherCAT

And

Energy Efficiency 2

Novel EtherCAT enabled Linear Transport System saves Energy with smart magnetic movers instead of continuous conveyor belts.

1

More Efficient Manufacturing Is Also More Energy Efficient

Almost all machines and plants become more efficient if ultrafast control systems and corresponding high performance networks are utilised. First of all, the many short waiting times at so called transitions 24 industrial automation asia | April 2012

are shortened, and this improves the throughput of the machine. In addition, short control cycles lead to optimised, and as such, more efficient motion solutions. While improving machinery or a plant’s efficiency does not lead to a one-toone increase in energy efficiency, the energy consumption per manufactured unit is decreased.

Energy Optimisation Requires Detailed Process Information

Detailed process information requires communication bandwidth — often more bandwidth than classical fieldbuses can provide.

EtherCAT is so fast and provides so much bandwidth that it is, for example, possible to monitor vibration values continuously without the need to apply special measurement systems with a separate bus.

Condition monitoring based on these vibration values helps to detect mechanical wear before it becomes a significant problem that stops the machine — and early detection of mechanical wear also reduces the machine’s energy consumption.

3

Reduced Material Thanks To Faster Control Cycles

A leading plastics machinery manufacturer repor ted that introducing EtherCAT enabled very fast control cycles that could reduce the wall thickness of the plastic cups the machine makes.

Without compromising product quality, this saved over 100 tonnes of granulate material per machine per year. And of course, this also saves the corresponding amount of energy.

4

builder, where smart magnetic movers replace several continuous conveyor belts.

5

Switch Off Via Network What Is Not Needed Right Now

Last but not least, networks, such as EtherCAT, simplify the

switching off of machine and plant parts that are not producing right now — and restart them in time for the next production phase.

The conclusion: EtherCAT alone does not ensure an energy efficient application — but due to its outstanding performance, it helps in many ways to achieve that goal.

ENQUIRY NO. 2106

Ultrafast Control Technology Makes New Machine Concepts Possible

We are seeing an increasing number of novel, more efficient machine concepts, enabled by ultrafast control technology with EtherCAT. One example is the new linear transport system of the world’s largest packaging machine

Ultrafast Controls with EtherCAT save over 100 tonnes of granulate material per machine per year.

EtherCAT Now A Korean National Standard

Key Yoo, manager, ETG Office (Korea), shows the Confirmation from the Korean Ministry of Knowledge Economy that EtherCAT is accepted as a Korean Industry Standard.

The South Korean Ministry of Knowledge Economy (MKE) has announced that EtherCAT was accepted as a Korean Industrial Standard (KS) by the Korean Agency for Technology and Standards. This marks the successful completion of a two year effort driven by the Korean ETG office. Office manager Key Yoo led this vital initiative and also translated most of the 500 page EtherCAT specification.

“We are glad that EtherCAT now has been promoted to a Korean National Standard.

This is a major achievement for the local ETG team — particularly for Mr Key Yoo. He has gone above and beyond and devoted a considerable amount of his own time to accomplish this, which speaks volumes about his passion for the technology and its acceptance in Korea,” says Martin Rostan, executive director of the EtherCAT Technology Group. Mr Rostan continued: “Besides being a Korean Standard, having the EtherCAT specification in Korean will further boost the acceptance of the technology in this important manufacturing and engineering country.”

Mr Key Yoo, manager of the ETG Office Korea, adds: “EtherCAT is no longer only a system bus of the largest Korean controls suppliers, but has made an inroad in the many important industries in our country, such as semiconductor and flat panel manufacturing, ship building, and robotics. Now that EtherCAT is a national standard, this makes it even easier for other Korean vendors and users to adopt the technology.”

ENQUIRY NO. 2107

April 2012 | industrial automation asia 25

issues & insights

Industrial PCs are seeing increased use with the industrial automation community as flexibility and efficiency in industrial environments increase in importance.

By Thorsten Kraus, director strategic product management/marketing, Advantech-DLoG

Case Study

Industrial Automation:

Warehousing, Process Control And Beyond A

dvantech-DLoG terminals constitute the interface between modern manufacturing/warehouse computer processing and optimised logistics processes through the whole supply chain.

Networked IT with automated production lines that have multiple gated warehouses, handling points, robots for heavy goods, and ‘just-in-time’ deliveries throughout the world — managing logistics centres and manufacturing process flow is one of the most complex subjects in modern IT. Picking vehicles and spaces are equipped with industrial PCs, through which all logistics processes are consistently recorded and checked.

26 industrial automation asia | April 2012

Combining modern Vehicle Mount Terminal (VMT) equipment with highly sensitive industries, such as the food industries or mining sites, increases efficiency, safety and traceability. This guarantees rapid, flexible and faultless manufacturing process flow and order picking by employees and operators.

Modern trading houses or food industries which provide professional solutions to the international market places as a manufacturer, distributor, retailer and logistics provider are the ultimate challenge in automation for industrial PCs. The requirements are very high when it comes to hardware for manufacturing process flow control,

Consistent Computer Integration Accelerates Faultless Order Picking In addition to more time and error minimisation through the elimination of manual data inputs, the level of automation in the warehouse increases permanently as well. Instructions are transmitted directly to the warehouse employee via the terminal at the forklift, and by using the terminal, finished orders are noted in the warehouse management system without delay. This saves a lot of time — and eliminates the possibility of errors such as those arising from incorrectly sorted or labelled goods.

For additional matching of picklist specifications and removed items, the length, width, height and specific weight of items are also stored in the warehouse management system. Scales integrated

into the pick points determine the weight of the goods removed and compare the measured data directly with the information stored in the warehouse management system. Even if incorrect, labels are attached to goods of the same size; inconsistencies are directly recognised this way.

The Industrial PC/VMT As A Rugged Tool In The Warehouse It became obvious that the originally installed computers with VGA touch screens were not practical tools for use in a warehouse application. The TFT touch screens, with a resolution of 640 x 480 pixels, were too dark and too small — the displayed information was difficult to read in an easy and quick manner.

In addition, there was very little space left over for the user interface displayed on the screen, making it difficult to easily press the soft keys using fingers, and much more difficult for fingers with gloves. This increased the pressure on the screen, in the truest sense of the word — when a warehouse employee is forced to try over and over to correctly activate the input elements on the screen. A high failure rate of the devices resulted. Therefore, a lot of manufacturing and warehouses are switching to terminals that had a proven good reputation in the industry.

Industrial PCs or VMT’s of Advantech-DLoG are of

Low noise Low cost Long life up to 3.8 Billion life cycle igus® Singapore Pte Ltd 15 Shaw Road, #03-02 Singapore 367953

TEL: +65 6487 1411 FAX: +65 6487 1511 Email: asia-sales@igus.com.sg ENQUIRY NO. 389

storage, order picking and distribution purposes under extreme environmental conditions, such as dust, heat, and freezer conditions. Specifically, units operating in the food-industry underlies industrial hygiene regulatory, so moisture from washing down the units with high pressure water canons after each shift is loaded stress to the material.

In parallel, customers have high requirements on the availability of the products, so 24x7 operation is not unusual. Any down-time of a system would result in a shut down of the industry’s manufacturing or process line, since traceability, for example, in meat manufacturing, is a must by official authorities.

So from a warehouses assortment of, sometimes more than, 37,000 items that are permanently managed in storage, goods that can be combined with assortments of different manufacturers down to the full manufacturing process control under extreme environmental conditions, IT processing has special requirements to the hardware. However, IT-suppliers who want to prove value in these specific markets, do not just have to deliver efficient and ultra-ruggedised hardware, but also, they have to deliver seamless service coverage.

Consequently, the requirements on the storage and system technology are high. The customer-oriented and flexible logistics process uses computer-control for the manufacturing process, goods receipt, goods delivery, order picking and material flow control processes 100 percent of the time. This is because in order to maximise reaction time and quality of order picking, the system requires consistent IT-supported logistic processes. Previously, packers rushed through the warehouse with delivery receipts and dollies in order to return the completed list back to central management via tubular mail after picking up the order. Today, orders are transmitted via industrial terminals and wireless LAN technologies.

April 2012 | industrial automation asia 27

issues & insights

protection type IP65/66/67— this type of industrial PC/VMT provides the insensitivity to rough logistics activities required in every day operations.

The wireless devices connected to the warehouse management software were now able to reliably transmit instructions to the employees in the warehouse.

Weight Measurement Reduces Error Probability To A Minimum Employees at the logistics centre were satisfied with the new equipment, with daily use proceeding flawlessly. This is because the rugged technology does what it promises to do. So many customers decided to use terminals at their pick points as well, which are mostly automated: goods are delivered to these points, from storage, using conveying vehicles and automated conveyor belts; the pickers receive the amounts to be removed for an order via the terminals.

In the process, the weights of the individual goods containers are automatically determined by the built-n scales at the pick points and compared with the values prescribed by the warehouse management system.

Wireless Communication Is The Challenging Factor Indeed, roll-outs frequently come with challenges when it comes to the wireless connection of the industrial PC’s or VMT’s to the extensive WLAN infrastructure of a warehouse or production line.

While moving through the building in the suspended cars, or forklift trucks, the industrial PC’s and VMT’s have to switch between different WLAN sections without interruption (roaming). This does not always work from the start, since many factors are playing into that.

Some like infrastructure relevant items such as access point density, co-channel interference and mixed mode of b and g clients. Other factors such as seamless roaming, alternation between indoor/ outdoor, multi-path emission side effects, can be avoided by accurate design and adjustments of antennas, wireless radios and drivers and their perfect integration into existing Wi-Fi structures.

This is mandatory to guarantee seamless datatransmission and 24x7 operation.

Mobile Process Automation And Beyond Meanwhile, industrial automation has reached levels nobody could imagine a couple of years ago. Many mobile application segments such as industrial in-vehicle-computing are embedded into complex infrastructures. Industrial automation means real time data capture to reduce maintenance shutdowns 28 industrial automation asia | April 2012

to increase efficiency and productivity, as well as safety on construction and mine sites.

They key factor is always efficiency: to avoid truck queuing, shovel hang times, misdirected loads or mining sequence delays and to support real-time weight load transmission to the mining dispatch system, solution providers need reliable, powerful and ultra-ruggedised industrial PCs being installed in the mining equipment, and building the interface between control centre and truck/shovel system.

The requirement to this hardware is even harsher than what was experienced on logistics/manufacturing automation equipment. Operating temperature ranges of -30 deg C, permanent vibrations with accelerations up to 22 g-force, high-TX Wi-Fi communications and zero-failure tolerance are just some of the key requirements. The reason for that becomes more obvious by understanding what industrial process automation means in a mining environment.

Next to a productivity increase, the industrial PCs are responsible for a seamless communication between the central dispatch and each individual vehicle operating on a mine site. Positioning and safety tracking systems inside the PC are combined with external radar/sonar mechanisms to support collision avoiding mechanisms, by visual and voice alarms, and continuous speed monitoring of the vehicle.

As such, even the operators’ behaviour surveillance is supported by real-time asset health monitoring, to reduce maintenance cost and to have an effective tool for root-cause analysis in case of down-time.

But, operators also benefit from process automation. By integrated GPS supporting dynamic on board mine maps, travel times can improve and miscommunication is avoided. Machine guidance is another item industrial in-vehicle-computing is supporting by topographical support on positioning and optimising drills for blast designs.

Conclusion In conclusion, next to the efficiency and safety aspects, industrial PC’s and VMT’s support production recording and performance reporting.

So future applications will require even more automation support — independently if stationary or mobile, or as on mine sites, both.

ENQUIRY NO. 2201

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ENQUIRY NO. 383

NI TestStand, the Industry Standard in Test Management Software

process control

T

he chemical process industry has perhaps the most diverse product range compared to other industries, with products ranging from fuels to fertilisers to fibres. These chemical processes can be found in various industries, from food processing to production of inorganic chemicals. However, chemical processes all share many of the same challenges — a need to minimise uncertainty, increase productivity and reduce wastage.

To meet these challenges, automation processes have been developed to provide information about production assets availability, reliability, production throughput, quality, and energy efficiency. But just as no two chemical operations are alike, there is no standard solution for meeting these challenges.

A multitude of automation components currently exist as part of the overall control solutions for chemical processes. These include measurement devices such as analysers, wireless networks for relaying measurements, orders, actions and other information, and central controls that integrate all the various components.

Chemical Process Control

Kostya Kisleyko, Moscow, Russia

The chemical process industry is diverse as it has technical challenges, but with an expanding portfollio of specilised products catering to the industry’s needs, a lot of these challenges are being faced head-on.

By Augustine Quek

30 industrial automation asia | April 2012

Measurement For Control For all chemical processes, measurements must be made in order to control it. Measurement instruments include, weighing balances, pressure transducers, temperature sensors, vision optics, and so on.

One example is the Rosemount thermocouple and temperature transmitter for critical control and safety applications. It features a gas-tight sapphire protective tube that is hermetically sealed to the supporting bushing, together with a redundant seal system that prevents toxic gases from damaging the thermocouple. All of the seals are pressure tested with nitrogen at 110 bar, while the connection housing is made from forged steel to resist leakage of hydrogen gases. The corrosion resistant and gas-impermeable design gives the thermocouple a lifespan of 6,000 to 18,000 hours. The predictive thermocouple degradation diagnostics contained within the transmitter can provide an alarm when the resistance of the thermocouple changes. This enables maintenance staff to plan the change out of the thermocouple prior to an unplanned shutdown, minimising cost and plant downtime.

Another device is ABB’s Fourier Transform Infrared Spectroscopy (FTIR) analyser, which uses infra-red radiation to conduct measurements by monitoring the physical and chemical properties of a process stream.

Based on patented technology from the company the analyser can monitor continuously almost any chemical in a wide range of concentrations in process streams. The company claims that this analyser can reduce chemical consumption by up to 30 percent

the entire OneWireless network. The diagnostic data is passed from the HART transmitter through the OneWireless network. FDM, AMS, or some similar application running on the user’s process control system is able to read the HART data from the transmitter wirelessly through the OneWireless network. The Honeywell OneWireless Network can transmit field information into Experion PKS or any other control system wirelessly via OPC client or Modbus-TCP.

ISA100.11a Network The OneWireless Network from Honeywell is an ISA100.11a-ready, industrial wireless network that forms a fully redundant and self-healing mesh network to support Wi-Fi devices and industrial I/O devices simultaneously. Part of this wireless network is the OneWireless Adapter which allows access to information locked in any wired HART devices and brings it into any ISA100.11a compliant control system. The OneWireless Adapter utilises the radio electronics of the XYR 6000 family of transmitters for getting the data wirelessly from any two- or fourwired HART device. Each OneWireless Adapter can scavenge power from the 4-20ma loop in addition to being battery powered by a long-life ‘D’ size lithium battery. The Adapter’s transmission range is 1,000 ft.

(305 m) Line-Of-Site (LOS) under ideal conditions.

The Adapter will transmit the HART PV’s and diagnostic data over the company’s OneWireless network. The four HART PVs can be viewed using a standard Internet browser through the Wireless Device Manager’s user interface. This interface is the same user interface used for configuring and viewing

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WirelessHART Network An example of a wireless network in operation can be seen at the Calgon Carbon Corporation plant in Blue Lake, California. The network uses the WirelessHART communications standard, and provides continuous temperature measurements from a rotating catalyst kiln where spent carbon particles are reactivated.

According to Calgon, WirelessHART was chosen because of the ability to communicate in spite of the constant rotation of the kiln. The wireless transmitters mounted on raised platforms on the surface of the kiln were simply connected to the existing thermocouples, and the WirelessHART self-organising mesh network was set up with a single Smart Wireless gateway from Emerson Process Management. The six transmitters monitor temperatures in five zones of

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Michael R, Albany, New York, US

in the semiconductor manufacturing process through monitoring of etching, cleaning and stripping fluids that are used in the wafer cleaning process. In the petrochemical industry, FTIR analysers can track g a s o l i n e p ro p e r t i e s precisely during blending Constant measurement of to within 0.02 to 0.05 of variables in important for the correct pump octane, the safety and efficiency of any process. significantly reducing the addition of excess octane. In the pharmaceuticals industry, the FTIR technology is claimed to be able to handle huge flows of data achieving the objective of consistent product quality, the solution increases availability by as much as 40 percent and reduces costs by up to 30 percent through integration with various process analytical devices.

The transmission of these data from devices to controllers can be done wirelessly, as wireless networks are an emerging component of chemical process automation. Wireless networks save plants the cost of cabling and the hassle of field wiring between devices. Wireless communication as such helps optimise plant productivity and reliability, improve safety and security, and ensure regulatory compliance.

April 2012 | industrial automation asia 31

Ariel da Silva Parreira, Patzcuaro, Michoacan, Mexico

process control

the kiln and at the outlet, communicating data reliably from the rotating kiln to the gateway, which then integrates the measurements in a host PLC.

Improving Automation Software In addition to hardware devices and information networks, automation software has also improved to not only handle process, discrete, and motion control, but also predictive modelling, and simulation.

For example, ROMeo, short for Rigorous Online Modelling and Equation Based Optimisation is an advanced online chemical process optimiser of SimSci-Esscor, a division of Invensys. It includes a chemical component library, thermodynamic property prediction methods, and unit operations such as distillation columns, heat exchangers, compressors, and reactors as found in the chemical processing industries. It can perform steady-state mass and energy balance calculations for modelling, simulating and optimising continuous processes.

Another example is the Connoisseur model predictive control, a comprehensive, Advanced Process Control (APC) software that improves process profitability by providing insight into process control strategies. A unique feature of the software is that it permits the application of predictive multivariable control to batch processes with multiple process models. The software is also compatible with all major computer suppliers and vendors of control systems equipment. Such software can play an important role in chemical processes by optimising manufacturing operations and making performance improvements, resulting in improved quality and increased profits.

Software plays a critical part in integrating and monitoring real-world automated processes.

System Integration With software, instrumentation and information, integration of these various components through a master control system is necessary.For example, the Proficy Process Systems 2.0 from GE Intelligent Platforms features Control Modules, single point of configuration, common notification service, alarm enhancements, function blocks, and productivity tools. Productivity tools for bulk configuration changes through spreadsheet imports and exports including control module and alarms objects creation and modification are now standard. Its flexible, open and expandable architecture allows users a choice 32  industrial automation asia | April 2012

of HMI visualisation technology controllers. Its Control Modules are specific User Defined Function Blocks (UDFB) that provides enhanced capabilities suitable for process applications, such as selecting parameters for tracking, storing and control. A single point of configuration allows users to perform all configuration tasks from only one point, including HMI properties, security configurations, and historian configurations.

Proficy Process Systems Version 2.0 also includes the ability for users to add their own function blocks and faceplates in addition to the list provided with the system. This allows system integrators, OEM, and end users to create standard blocks specific to their own business applications. Function blocks for split range control are also possible, where one Proportional–Integral–Derivative (PID) loop is used to manipulate two process devices.

Safety, Flexibility And Efficiency Would Be The Three Central Factors That Govern Future Development In The Automation Of The Chemical Process Industry.

Conclusion The globalisation of markets as well as increasing competitive pressure coupled with shorter product lifecycles and higher risks have lead the chemical industry to increasingly automate more and more of its processes. Safety, flexibility and efficiency would be the three central factors that govern future development in the automation of chemical process industry. Rapid response to market dynamics necessitates flexible production processes that are not only absolutely safe, but also operates at maximum efficiency. In addition, maximum process and system reliability, reduced production costs, assured reproducible product quality and efficient resource management represent basic requirements.

These requirements will become increasingly stringent due to global trends such as resource scarcity, climate change. Therefore, chemical process industries, from pharmaceuticals to petrochemicals, would require more reliable, fault-free, and safe process controls for sustainable success in the chemical industry.

ENQUIRY NO. 2301

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ENQUIRY NO. 400

software & Networks

Industrial Ethernet

More Than Industrial + Ethernet

Gary Scott, Elmira, Ontario, Canada

Good design and management of Industrial Ethernet networks are important for robust communication channels and secure data transfer. By Justin Nga, business development manager, Belden Industrial Solutions

T

he increasing use of digital equipment in industrial environments coupled with increased integration and data bandwidth requirements has led to growing adoption of Ethernet (IEEE 802.3) for communication in place of older serial-based communication systems.

However, simply selecting ruggedised versions of Ethernet equipment originally designed for conventional IT environments will not create a true Industrial Ethernet network.

Ruggedness is important, but it is only one part of a much larger picture. An excessive focus on particular physical characteristics such as temperature and vibration specifications leads to other critical factors being overlooked, and 34  industrial automation asia | April 2012

hence inappropriate purchasing decisions.

System-wide considerations have a bigger impact than the physical characteristics of an individual component. Fitting a race-tuned engine to an otherwise standard car will improve its performance, but it will not match a fully prepared racing car with the same engine.

Power and torque are only part of the story — suspension, brakes, tyres and so on, all contribute to how quickly the car can get round the track and whether it will last the distance.

A racing car also needs features for quick repairs or replacement (eg: the single nut securing a wheel to the hub instead of the four or five used on most road cars) and

remote monitoring and diagnostics to ensure success.

Similarly, Industrial Ethernet is about the entire network.

The physical network consists of cables, connectors and active components, such as, switches and routers, all of which affect end-to-end signal transmission. A deep understanding of how they work together allows the design of a network that will operate effectively under the challenges of an industrial environment.

The physical design must also be complemented by an equally well thought out logical design including addressing and segregation. Other critical factors that must be considered include ease of configuration and diagnostics, network and cyber

mean time to repair is crucial, especially as Murphy’s Law dictates that any failure however unlikely will occur at the most inconvenient time and location.

Where IT equipment is usually replaced on a three to four year cycle, the components of an industrial network can easily be in operation for 10 years or more. If

you need to replace a faulty device after several years, will the backup of its configuration be easily retrievable? Will the replacement have the same firmware to ensure site-wide compatibility? Can the old firmware and configuration be saved and restored from removable media without involving a computer? How long will expansion

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ENQUIRY NO. 385

security, network management tools, redundancy protocols, automation integration, and remote access.

It is important to consider the total lifecycle of a project from initial design through engineering, commissioning, operation, maintenance, and any later upgrades or expansion. Physical specifications are important to the initial design process, but other factors will arise later in the total lifecycle, especially during operation, maintenance, expansions and upgrades.

Proven reliability and maintainability are also more important than bandwidth alone for automation and control s y s t e m s , w h e t h e r y o u a re coming from the perspective of occupational health and safety or the need to avoid production downtime.

Many industrial environments recognise that the personnel who will operate and maintain the network may not be IT specialists, and are then tempted to install basic unmanaged network switches in the name of simplicity.

With advancements in Industrial Ethernet today, a case can readily be made for products that come with web-based, graphical, easy to use software configuration and diagnostic interfaces, and with options that can be set via DIP switches, which are familiar to the electricians likely to be charged with installation and modifications.

Although it may be acceptable to shutdown part of an IT network for a period of time, for example, to install additional network equipment, that luxury is rarely open to the person in charge of a factory or process control network where 24x7 operation is the norm. This also impacts on maintenance: while mean time to failure is an important statistic,

27/08/2010 15:56

April 2012 | industrial automation asia 35

software & Networks

modules (eg: additional ports) be available for the base unit you purchase today? How long will the supplier provide a repair or replacement service in the event of hardware failure? Some vendors have a total lifecycle perspective of the Industrial Ethernet network solution intended for industrial environments, while others plainly stop at physical ruggedisation.

Network Security And Network Management Cross disciplines of Industrial Ethernet that require focus now and into the future are network security and network management.

Automation control systems are no longer impervious to cyber security threats now that open system platforms like Windows and Ethernet are being widely deployed and integrated. Cyber security trends indicate that threat vectors on how viruses propagate continue to evolve and their payloads directly impact on Industrial Ethernet

Zeusmedia, Weilmünster, Germany

Good Industrial Ethernet Design A sensible approach to Industrial Ethernet design and implementation is to start by understanding the application and site-specific issues.

Begin by considering the physical environment and some b a s i c a rc h i t e c t u r a l i s s u e s .

Will the network hardware be installed in 19in racks, DIN rails or a combination? What are the available power supplies at that location? What is the temperature range? Are there any airborne contaminants (such as the hydrogen sulphide present in water treatment plants) that may be conductive or corrosive?

How much bandwidth will be required? Where and how will the physical cabling be run? Is fibre or copper cabling more appropriate due to distances or electromagnetic interference?

Then consider an appropriate network topology (eg: ring, star or a combination). Complement the physical topology with the appropriate logical network design for addressing and segregation.

Cabling Design And Installation Even something seemingly as basic as cabling deserves careful consideration. Proper physical cabling design and installation has largely been ignored as most industrial networks typically carry smaller packets of data and operate well below capacity.

However, once a network begins to grow and the utilisation increases, poor physical cabling will eventually result in per formance issues and lack of scalability. Industrial environments are often subject to vibration, dust, oil, moisture, UV exposure, and vermin, which are not usually significant issues in the typical office or data centre. A correctly specified cabling solution should include jacket materials suitable for the environment, and factory-tested patch leads with moulded boots and suitable connectors.

36 industrial automation asia | April 2012

communications and automation control systems.

As these threats will continue to evolve, a comprehensive Industrial Ethernet network design must consider using defense in depth methodologies which focus not only on the technology, but also the organisational aspects of procedures, policies and awareness training for employees.

This will provide a high level of protection, and in worst case scenarios, isolate any potential threats from spreading and creating further damage.

Network Management Software Network Management Software is an essential part of any Industrial Ethernet network and allows for centralised management and monitoring of the Ethernet infrastructure.

Users will see benefits throughout the entire system lifecycle, making the engineering, installation, testing and commissioning process more efficient and thorough.

Conclusion Network security and network management are not ‘set and forget’ disciplines and must be considered as ‘living’ disciplines.

Information obtained from the systems and tools will require regular monitoring, reviews and actions to ensure that the Industrial Ethernet network is secure and operating according to the specifications.

Only a minority of people currently consider the c o m p re h e n s i v e d e s i g n a n d implementation approach described above, but a structured and total lifecycle approach to Industrial Ethernet will improve the performance, reliability, scalability and longevity of your network.

ENQUIRY NO. 2401

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Marcell Marra, SJ Campos

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software & Networks

Brückner Maschinenbau are making use of drives from B&R’s Acopos series synchronised via Powerlink. The transition helped the company in reducing costs of the drive equipment, shorten cycle time and simplify maintenance of the hardware and software. By Stefan Schönegger, GM, Ethernet Powerlink Standardisation Group, B&R Industrial Automation

Case Study

728 Axes In 400 µs O

n the Linear Motor Simultaneous Stretching Te c h n o l o g y ( L I S I M ) lines produced by Brückner Maschinenbau, over 700 clips pull the plastic film through the machine and simultaneously stretch the material in the machine and cross-machine directions. The clips are pulled by a magnetic field like the railway cars on a magnetic levitation train. Linear motors with windings numbering 728, generate the moving magnetic field that makes this possible. Since recently, motion control is handled by drives from B&R’s Acopos series, which are synchronised via Powerlink, 38 industrial automation asia | April 2012

a real-time protocol for standard Ethernet.

With the transition to the c o m p a n y ’s t e c h n o l o g y, t h e Chiemgau-based machine manufacturer was able to reduce the cost of the drive equipment, significantly shorten the cycle time, simplify maintenance of the hardware and software and replace proprietary drive and bus technology with an off-the-shelf solution.

At up to 6.6 m/s, hundreds of clips speed through the LISIM system on two opposing ring-shaped rail lines. They grip the plastic film, which has been produced using

an extruder and a casting roller, along its left and right edges, and pull it through the system at increasing speed, stretching the film in the machine direction. The rails are not parallel,instead, the distance between them increases along the length of the line. This simultaneously stretches the film perpendicular to the machine direction with absolutely no scratches. During this stretching process the film is also passed through an oven. The high temperature binds the molecular structure and permanently defines the film’s physical properties, such as shrink, which were affected by

the stretching.

After completion of the stretching process, the clips release the film and travel empty back to the beginning of the system. A rack transports the film from the system where it is wound up after trimming off the unusable edges.

Only a certain number of clips are actually driven; hundreds of non-driven clips improve force distribution and prevent the film from sagging as it is stretched.

The driven clips are designed as a secondary side (rotor) of the linear motor and are therefore equipped with permanent magnets on the traction surfaces. The linear motor is split to improve force distribution, with the primary elements (stators with windings) positioned symmetrically above and below the permanent magnets on the traction surfaces. The

On the LISIM lines, over 700 clips pull the plastic film through the machine and simultaneously stretch the material in the machine and crossmachine directions.

windings are distributed along the rail in zones of different lengths so that no more than one powered clip is present in each zone.

728 Individually Controlled Windings Each of the zones is controlled separately using an inverter. This new LISIM system from BrĂźckner relies on B&R drive technology:

The current for the 728 zones along the approximately 65 m long machine is supplied by 384 single and dual-axis inverter modules in conjunction with 14 power supply modules from the company’s Acopos device series that are synchronised via Powerlink. The electrical power must be higher in longer zones, so drive types ranging from 2.6 A to 22 A with

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April 2012 | industrial automation asia  39

software & Networks

398 Acopos modules control the clips through precise synchronisation with Powerlink.

a power rating of 5 kW must be used.

Through the use of Acopos modules in combination with Powerlink, the machine manufacturing company was able to replace the proprietary products with cost-effective standard solutions. The further development of these standard solutions is of course required and funded by all users.

Precise Synchronisation With Powerlink “This was possible because Powerlink allows precise synchronisation of hundreds of network nodes and simultaneously provides high data throughput.

On one hand, we were able to reduce the cycle time significantly — it is now only 400 µs. On the other hand, we were able to move large chunks of software from the drives to a central drive controller,” explains Günter Oedl, electrical engineering manager for automation and development at Brückner Maschinenbau. “This significantly simplifies servicing and maintaining the software,” he added.

All of the 398 Acopos modules (power supply modules and inverters) in the system are synchronised by 12 industrial 40 industrial automation asia | April 2012

There are a total of 398 Acopos modules in the LISIM line control cabinet. They are synchronised using 12 industrial computers from the AOC810 series. To make this possible, they are each equipped with three Powerlink cards that drive up to 13 modules. A further Powerlink card allows the industry computers to communicate with each other or with a higher-level APC810 that runs Brückner’s motion control software.

computers from the APC810 series.

They are each equipped with three Powerlink cards that control up to 13 modules. Using another Powerlink card, the industry computers communicate with each other or with a higher-level APC810 that is running Brückner’s motion control software. The plant control system, which for example is responsible for controlling the oven, is connected to this B&R industrial computer using a Profibus interface.

Advantageous for machine manufacturers is also that Powerlink is not a proprietary bus system; instead, it is an open source solution and is therefore supported by many producers.

As such, the number of solutions available is ver y large, and t h e y i n c l u d e p ro f e s s i o n a l diagnostic tools.

Closed Loop Control Without Sensors For Greater Efficiency And Robustness The planned switch from open loop to closed loop control of the windings will result in a significant increase in energy savings. For this purpose, Brückner must rely on a sensor-free method because sensors cannot be mounted near the oven.

“Thanks to sensor-free control, we are able to reduce the power used by each system by 100 to 150 kW,” states Mr Oedl. Another plus point of this control method is much higher damping compared to a weakly damped magnetic shaft mass system. Machines with sensorfree control are therefore more resistant to disturbances such as process variations or film rips.

“The advantages of the sensorfree closed loop control are clear.

We therefore welcome the fact that we will be able to obtain ideal solutions from B&R in the future,” concluded Mr Oedl.

ENQUIRY NO. 2402

1 – 5 July 2012 Sands Expo & Convention Center, Marina Bay Sands Themed ‘Water Solutions for Liveable and Sustainable Cities’, the Singapore International Water Week 2012 is one of the mustattend water events in the global water events calendar. The event comprises the Water Leaders Summit, Water Convention, Water Expo and Business Forums. It culminates in the presentation of the Lee Kuan Yew Water Prize, a prestigious international award to honour outstanding contributions in solving water issues.

Water Expo (2 – 4 July) Water Expo is one of the world’s most comprehensive water trade shows on innovation, products and services, drawing strong participation from leading industry players and international pavilions.

In 2012, Water Expo’s exhibit portfolio expands to include Trenchless Asia 2012; adding innovations and products on trenchless technologies to the already comprehensive mix of water-focused solutions.

Moya Asia Ltd MWH PWN Technologies BV Sembcorp Industries Ltd Siemens Water Technologies Suez Environnement Toray Industries Inc. United Engineers Ltd Veolia Water Solutions & Technologies (SEA) Pte Ltd Xylem Inc.

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Industrial Water Solutions Forum (3 July) NEW! ‘Towards Water Sustainability in the Industrial Sectors’ The inaugural Industrial Water Solutions Forum examines challenges faced by industrial sectors, such as energy and manufacturing, in water management and how innovative solutions could address such challenges. Leaders from the global industry water-users can network and exchange views on the risks and challenges for large industrial water users and opportunities for current water solutions providers in industrial water management.

Business Forums (3 – 4 July) The Business Forums offer industry leaders extensive business networking, partnership information and lucrative deal-making opportunities across key markets covering the Americas, Australia, China, Europe, India, Japan, Middle-East & North Africa and Southeast Asia.

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ENQUIRY NO. 401

A PREMIER WATER EVENT LIKE NO OTHER

instrumentation & Measurement

Proper Employment Of Guided

The application of guided wave radar to measure level in steam loops is addressed, including discussions of how this technology functions and differs from more traditional forms of level indication. By Keith Riley, product business manager, and Ravi Jethra, power & energy industry manager, Endress+Hauser

M

ost radar devices utilised for level detection employ electromagnetic pulses (microwaves) to measure the liquid level in tanks. Like the speed of sound, the speed of light (electromagnetic radiation) is well known — 186,000 miles per second. The level of liquid is determined by identifying the time it takes for the microwave pulse to travel from the measuring device to the liquid and back.

Equation 1: D = C x T/2 D = distance from measuring device to liquid C = speed of light T = amount of time for microwaves to travel from device to liquid and back 42 industrial automation asia | April 2012

Why do radar level devices u s e m i c ro w a v e s c o m p a re d to other types of energy in the e l e c t ro m a g n e t i c s p e c t r u m ?

Process conditions such as vapours, temperature, pressure, buildup and condensate have little effect on radar devices. However, the ability for the process medium

Kai Gieseler, Burgwedel, Niedersachsen, Germany

Wave Radar in Steam Loops

to reflect or not reflect microwaves needs to be taken into account.

One can determine the medium’s ability to reflect microwaves by looking at the dielectric number of the media. The dielectric number is a measure of the polarisation power of an insulating material or how much charge can be stored in a type of material verses air. Water has a dielectric number of 80 and is considered a great reflector of microwaves. Air has a dielectric number of one and is considered a poor reflector of microwaves.

A Guided Wave Radar (GWR) device uses the same principle as non-contact radar devices — it has the ability to transmit and receive reflected microwave energy. The primary difference between the two devices is the typical operating frequency (1.5 GHz for GWR) and the presence of a wave guide. The wave guide is a metal rod or cable which guides the energy to the

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instrumentation & Measurement

process media. The transmitter directs the pulse down the guide with approximately 80 percent of the available energy staying within an 8 inch radius.

Why would getting more energy directed on the process media be of help? It is all about the signal to noise ratio. Even with interference from nozzles or point level devices, more energy can be reflected back to the transmitter.

More energy also means the ability to work better with lower dielectric liquids or other factors that can attenuate signal strength such as agitation or foam. Just like non-contact radar, GWR devices are very accurate (±0.4 inches) and the accuracy is independent of the liquid’s conductivity, density and dielectric number. This means no re-configuration of the instrument is needed if changes in the process liquid occur.

Steam Loop Applications What sets steam loop applications apart and makes them unique?

The propagation speed of the microwave pulse generated by a radar device is well defined and stable. Typical process conditions such as pressure (vacuum or high pressure) or temperature have minimal if any effect on this speed. The same is true of vapour blankets. Normally they are not 44 industrial automation asia | April 2012

a significant concern. However, there are specific circumstances when this statement will not be true.

If the vapour in question is considered a polar gas, (a vapour whose dielectric constant can change due to pressure/ temperature) the propagation speed of the microwave pulse can be affected. Hydrocarbons display very little change in their dielectric constant even at very high pressures/temperatures.

Steam on the other hand is greatly influenced by the pressure/ temperature of the application.

Why does this phenomenon affect the performance of a GWR? A radar pulse travels at the speed of light, but that fact is predicated on the pulse moving through vapour with a dielectric constant < 1.0. If the dielectric constant of the vapour space in a vessel starts to become greater than 1.0, that propagation speed will be reduced. This means it is going to take more time for the pulse to reach the liquid surface and return to the transmitter.

What effect can this actually have on my measurement? At lower pressures for saturated steam, the measured error experienced is relatively small and probably

not noticeable. However, once an operating temperature of 400 deg F (204 deg C) is required that is not necessarily true. The measured error could be 3.5 to 4 percent. At 600 deg F (316 deg C) that error can increase to 19 or 20 percent.

How can this impact on my level indication be accounted for?

Historically the only way to offset the physical effect of a steam phase was to implement a correction factor in the electronics of the transmitter. While this works, it has one large deficiency. The correction factor is only valid for a given pressure/temperature setting.

During startup or if the operating parameters for the application change, this adjustment will not be valid. In fact, it could actually make the measured error worse than if you had no correction factor at all.

The other method is to program a compensation table into the DCS or PLC so it is responsible for correcting the raw signal from the GWR. A dynamic form of compensation is a much better solution and ensures your level measurement is accurate regardless of changes in the process. The best method for achieving this is by implementing a reference section on your wave guide.

To flue gas cleaning

Steam loop

Boiler 450°F 2785 psi

Preheater 662°F 130 psi Intermediate heater

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Superheater

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Boiler feed pump

338°F 2465 psi High pressure preheater

Condensate pump 100°F 160 psi

Feedwater container Low pressure preheater

Additional condensate from full desalination

impact the performance of the unit, especially if water quality is not tightly controlled. Even if none of this happens the setup for a displacer is based upon a specific water density. Should the pressure/temperature of the water vary, the level indication will be off.

• Water Columns w/ Conductivity Probes These devices have long been used in conjunction with direct reading glass gauges to provide a remote reading option to the control room.

While not technically a continuous signal, when fully functional they do provide good control without

Comparison To Other Level Technologies How does the accuracy and performance of a GWR with dynamic compensation compare to other more conventional technologies employed in steam loops?

• Direct Reading Glass Gauges For boiler drum level this is still the only true direct level indication per PG-60 of the ASME Boiler and Pressure Vessel Code. A Direct Reading Glass Gauge can be used in conjunction with other nondirect reading devices, but cannot be eliminated. Consequently, at least one operational glass gauge must be present.

• Displacer Transmitters This is a semi-submerged float or weight connected to a spring balance. The complete assembly is typically enclosed in a chamber attached to the boiler drum.

As the float weight changes in conjunction with the drum water level the varying tension on the spring balance is converted to a level signal.

Issues encountered with these systems stem from wear and maintenance. Over time metal fatigue will result in measurement drift and error in your level indication. Corrosion can also

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A Guided Wave Radar Supplied With Dynamic Gas Phase Compensation will provide a highly accurate level measurement. Properly designed, the unit will operate in saturated steam conditions up to 2,900 psig @ 690 deg F (366 deg C) with no fear of damage to the electronics.

It will also eliminate the concern of having a measured error of up to 20 percent or more that must be accounted for. Instead you receive a level indication directly from your GWR you can depend upon.

April 2012 | industrial automation asia 45

instrumentation & Measurement

Example steam: Resulting errors in the gas phase

the need to have a technician physically at the boiler drum.

A signal from the conductivity probes is typically received at a control panel. In turn this will illuminate a series of lights providing remote level indication.

The control panel can also provide high/low relays as well as a 4-20 mA output.

Maintenance is the issue most commonly faced with these instruments. The conductivity probes are subject to corrosion due to contact with the process w a t e r a n d re q u i re re g u l a r replacement. Considering most systems have between 10 – 20 probes per column, this is not an inexpensive process.

• Magnetic Level Gauges A Magnetic Level Gauge is probably the most common replacement for most of the more traditional level gauges in a steam loop, including boiler drum level.

However, even though a magnetic gauge has local visual level indication, it is not considered a direct reading level gauge. The level indication is dependent upon the magnetic attraction between the internal float and exterior indication device.

Like other displacer type devices, a magnetic gauge is designed for a specific liquid 46 industrial automation asia | April 2012

density. If the float is not properly manufacture or the density of the process changes, measured error will occur.

• Differential Pressure Transmitter As its name implies, this level indication device is measuring the difference in pressure between the vapour space in a vessel or chamber and the liquid height. The net result is the pressure exerted on the lower sensor independent of the pressure in the vessel. By comparing this value to a known density, the liquid height can be determined.

Initially this is an accurate and dependable method of level indication. However, over time the diaphragm or sensing component is subject to metal fatigue as it responds to changes in pressure.

This results in drift and the need for recalibration.

As with the displacer type instruments a differential pressure transmitter is calibrated based upon a specific liquid density. If that density changes measured error in the level indication will ensue.

• Guided Wave Radar The strength of guided wave radar is based upon the fact that it has no moving parts, has digital

electronics, and a linear output.

This means it is not subject to drift or calibration issues unless the unit is physically damaged. GWR is also impervious to changes in pressure or temperature. It is simply reacting to the change of impedance that occurs as the generated pulse contacts the liquid surface. By employing a dynamic form of Gas Phase Compensation any ef fect a h i g h p re s s u re / t e m p e r a t u re polar media might have on the units’ signal propagation is also largely eliminated.

Conclusion There is no shortage of technology choices for continuous level measurement in your steam loop.

All have unique features and benefits that need to be carefully evaluated prior to selection for your individual application.

In the case of GWR, one of the first considerations is what the operating temperature and pressure will be. For saturated steam conditions < 204 deg C a standard GWR will provide excellent service. At saturated steam conditions > 204 deg C the impact on measured error due to the effects of steam vapours will be more pronounced. This is when dynamic Gas Phase Compensation needs to be employed for maximum accuracy along with a more temperature resilient design to protect the electronics.

A p p l i c a t i o n f l e x i b i l i t y, resistance to effects from process conditions, low maintenance re q u i re m e n t s a n d d y n a m i c compensation all combine to make GWR an accurate and reliable choice for steam loop applications. These features also result in low cost of ownership and tighter control over system operation.

ENQUIRY NO. 2501

ENQUIRY NO. 380

energy

Whrelf Siemens, Dordrecht, Netherlands

Uninterruptible Power Supply (UPS) systems are an important element where reliable power supply is critical, for example, in data centres.

Five of the most common UPS systems will be discussed here. By Sim Liang Kee, head of solutions engineer, Schneider Electric Singapore

The Types Of

UPS Systems T

here is much confusion in the marketplace about the different types of Uninterruptible Power Supply (UPS) systems and their characteristics.

For example, it is widely believed that there are only two types of UPS systems, namely standby UPS and on-line UPS. However, they do not correctly describe many of the UPS systems available. There are five common types of UPS systems available, today, including standby, line interactive, standby-ferro, double conversion on-line and delta conversion online. Each of these UPS systems has their respective advantages, disadvantages and practical applications as below.

The Standby UPS The standby UPS is the most common type used for desktop computers. In the block diagram illustrated in Figure 1, the transfer switch is set to choose the filtered AC input as the primary power source (solid line path) and switches to the battery/inverter as the backup source, should the primary source fail. When that happens, the transfer switch must operate to switch the load over to the battery/inverter backup power source (dashed path). The inverter only starts when the power fails, hence the name ‘standby.’

48 industrial automation asia | April 2012

Benefits And Limitations: High efficiency, small size and low cost are the main benefits of this design. With proper filter and surge circuitry, these systems can also provide adequate noise filtration and surge suppression.

Limitations include the need for battery usage during brownouts. The design, too, gets impractical beyond a volume of 2kVA and, as such, makes this design best value for personal workstations.

The Line Interactive UPS The line interactive UPS, illustrated in Figure 2, is the most common design used for small business, SURGE SUPPRESSOR

FILTER

TRANSFER SWITCH

BATTERY CHARGER

Figure 1: The Standby UPS

BATTERY

INVERTER

TRANSFER SWITCH

TRANSFER SWITCH

TRANSFORMER

INVERTER BATTERY CHARGER

INVERTER

BATTERY < CHARGING (NORMAL)

DISCHARGING (POWER FAIL) >

Figure 2: Line interactive UPS

Web and departmental servers. In this design, the battery-to-AC power converter (inverter) is always connected to the output of the UPS. Operating the inverter in reverse during times when the input AC power is normal, provides battery charging.

When the input power fails, the transfer switch opens and power flows from the battery to the UPS output. With the inverter always on and connected to the output, this design provides additional filtering and yields reduced switching transients when compared with the standby UPS topology.

Figure 3: Standby-ferro UPS

Benefits And Limitations: High efficiency, small size, low cost and high reliability coupled with the ability to correct low or high line voltage conditions make this the dominant type of UPS in the 0.5-5 kVA power range.

The Standby-Ferro UPS The standby-ferro UPS was once the dominant form of UPS in the 3-15 kVA range. This design depends on a special saturating transformer that has three windings (power connections). The primary power

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energy

STATIC BYPASS SWITCH

STATIC BYPASS SWITCH

DELTA TRANSFORMER

RECTIFIER

INVERTER

DELTA CONVERTER

MAIN INVERTER

BATTERY

Figure 4: Double conversion on-line UPS

path is from AC input, through a transfer switch and transformer and then to the output. In the case of a power failure, the transfer switch is opened and the inverter picks up the output load.

Benefits And Limitations: In the standby-ferro design, the inverter is in the standby mode, and is energised when the input power fails and the transfer switch is opened. The transformer has a special ‘ferroresonant’ capability, which provides limited voltage regulation and output waveform ‘shaping’. The isolation from AC power transients provided by the ferro transformer is as good as, or better than, any filter available.

However, the ferro transformer itself creates severe output voltage distortion and transients, which can be worse than a poor AC connection.

Standby-ferro UPS systems are frequently represented as on-line units, even though they have a transfer switch, the inverter operates in the standby mode, and they exhibit a transfer characteristic during an AC power failure. Figure 3 illustrates this standby-ferro topology.

High reliability and excellent line filtering are this design’s strengths. However, the design has very low efficiency combined with instability when used with some generators and newer power-factor corrected computers, causing the popularity of this design to decrease significantly.

The Double Conversion On-Line UPS This is the most common type of UPS above 10 kVA. The block diagram of the double conversion on-line UPS, illustrated in Figure 4, is the same as the standby, except that the primary power path is the inverter instead of the AC main.

In the double conversion on-line design, failure of the input AC does not cause activation of the transfer switch because the input AC is charging the backup battery source that provides power to the output inverter. Therefore, during an input AC power failure, on-line operation results in no transfer time. Both the battery charger and the 50 industrial automation asia | April 2012

Figure 5: Delta conversion on-line UPS

inverter convert the entire load power flow in this design.

Benefits And Limitations: This UPS provides nearly ideal electrical output performance. However, the constant wear on the power components reduces reliability over other designs. In addition, the input power drawn by the large battery charger may be non-linear which can interfere with building power wiring or cause problems with standby generators.

Delta Conversion On-Line This UPS design, illustrated in Figure 5, is a newer, 10 year old technology introduced to eliminate the drawbacks of the double conversion on-line design.

The delta conversion on-line UPS always has the inverter supplying the load voltage. However, the additional delta converter also contributes power to the inverter output. Under conditions of AC failure or disturbances, this design exhibits behaviour identical to the double conversion on-line.

Benefits And Limitations: The most important benefit of this UPS system is a significant reduction in energy losses. The input power control also makes the UPS compatible with all generator sets and reduces the need for wiring and generator oversizing. During steady state conditions, the delta converter allows the UPS to deliver power to the load with much greater efficiency than the double conversion design and, as such, makes it highly suitable for large installations.

In Conclusion As demonstrated above, significant differences in the respective UPS systems offer theoretical and practical advantages and no single UPS type is ideal for all applications. Nevertheless, the basic quality of design implementation and manufactured quality are often dominant in determining the ultimate performance achieved in the customer application.

ENQUIRY NO. 2601

ENQUIRY NO. 375

sector spotlight

Automation:

Plus For Distribution A

The business case for an automated system should consider not only the ‘hard’ numbers such as labour and building cost savings, but also the ‘second order’ benefits of a safer, more ergonomic environment with improved delivery flexibility and response times. By Brad Welsman, executive GM Automation APAC, Schaefer Systems International

E

xperience has shown that automated storage and order picking systems can deliver substantial operating savings in Distribution Centres (DC), while at the same time improving the quality of order fulfilment.

What benefits exactly can be expected from automated systems within the distribution c e n t re a n d h o w a re s u c h systems justified?

Reduced Labour Costs Automated storage and order picking systems reduce the need for labour and wheeled machinery in the DC. In automated goodsto-person order picking systems for example, the right goods are brought automatically to the person at the right time. Walking is virtually eliminated and productivity when picking slower moving SKUs, in particular, can be 10 times higher than with traditional zone picking or walk pick-to-pallet approaches.

52 industrial automation asia | April 2012

High productivity ergonomic goods-to-person pick stations minimise twisting and bending.

Reduced Dependency On Labour Availability A n i n c re a s i n g p ro b l e m i n distribution today is finding enough people to carry out the often laborious task of picking and packing. Moreover, where labour resources are scarce, operations often have to contend with a high turnover of staff, which in turn leads to soaring training and administration costs and undermines quality.

Higher productivity automated systems reduce the number of

operators required for storage, picking and packing, and provide a much higher degree of ergonomics which helps retain staff and maintain quality.

Improved Space Efficiency By making maximum use of headroom and minimising aisle widths, automated storage systems for pallets, tote bins and cartons reduce footprint requirements for stock storage and with it land and building costs.

A d d i t i o n a l l y, a u t o m a t e d

goods-to-person picking systems do not have a traditional pick face, but rather draw Stock Keeping Units (SKUs) directly f ro m a n a u t o m a t e d b u f f e r system which is significantly more space efficient.

Improved Ergonomics & Safety With an increasing focus on occupational safety & health, and an ageing workforce, operations are coming under more pressure to provide a safe and ergonomic environment for operators.

Safety and ergonomics are becoming increasingly important drivers for automation. Automated storage systems reduce the need for forklift trucks and eliminate the need to have pallet move-ments interleaved with other tasks, such as order picking.

Automated goods to person

Automated storage reduces space requirements and increases safety.

palletising stations provide for sliding rather than lifting of cases and eliminate walking. Additionally, ergonomic pick from tote stations for small and split case items minimise bending and twisting, reducing injuries, complaints and lost time.

More Resilient To Changing Order Profiles A general trend towards more SKUs, combined with increasing

pressure to reduce store stock and optimise store shelf space, has dictated the need for more frequent smaller deliveries.

In manual picking systems, more SKUs and smaller orders mean greater walking distances that reduce productivity. In contrast, automated goods-toperson pick stations are equally productive for small orders as they are for large orders and the productivity is independent of the number of SKUs. Extended Facility Life Automated systems deliver increased productivity and therefore a higher capacity for m e e t i n g f u t u re t h ro u g h p u t requirements. Automated storage allows for better use of existing space and automated picking systems do not have a pick face

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April 2012 | industrial automation asia 53

sector spotlight

Goods to person pick station productivity is independent of the number of SKUs.

whose length increases with the number of SKUs. These things, combined with an increased resilience to changing order profiles, all contribute to extending the life of a facility. The opportunity to ‘sweat the existing assets’ and delay a move to a new or different facility can often translate into significant savings.

Benefits Of Automated Storage & Order Picking Systems • Reduced labour costs • Reduced dependency on labour availability • Improved space efficiency • Improved ergonomics and safety • More resilient to changing order profiles • Extended facility life • Higher quality fulfilment

Higher Quality Fulfilment In automated picking systems, there is a greater degree of flexibility with respect to how and when an order is assembled.

So, for example, the ability of goods-to-person picking systems to build pallets in accordance with differing store requirements with equal productivity can translate into significant savings.

54 industrial automation asia | April 2012

Moreover, automated goods-toperson picking systems typically allow for any order to be picked at any time, improving response times and increasing fulfilment consistency and quality, all of which leads to higher customer satisfaction and ultimately increased sales.

Automation For You In general, the justification or business case for an automated system will be based on comparing the automated option to one or more alternatives.

The alternative may be to just continue as is, however, where an operation has outgrown its current facility, the comparison may be between moving now to a new manual site versus automating the existing site to prolong its life. Where an operation has to move to a new site in any case, the comparison may be between building a new manual site versus building a new automated site.

An automated system will require significantly more initial investment than a manual system, however, potential associated savings in building and land costs need to be taken into account.

Automated systems also require much higher maintenance costs including preventative maintenance, spare parts and b re a k d o w n s u p p o r t , w h i c h

together can run to five to 10 percent of the initial investment per annum.

T h e h i g h e r p ro d u c t i v i t y associated with automated system leads to lower labour costs and this is a key driver in determining the feasibility of the higher investment. The savings in labour costs are very much dependent on the labour rate and the throughput of the system.

The case for automation is much stronger for operations that run three shifts in a high labour cost area. In considering a labour rate for the business case evaluation, all associated costs including overtime payments and management, recruitment and training costs should be included.

These can be substantial for large manual sites, especially where there is a scarcity of labour and/or a high turnover of staff.

In most cases, automated systems require a much smaller footprint than manual systems.

This may translate into direct cost savings from an immediate reduction in space usage or alternatively, it may allow a building expansion or a transfer to a new facility to be deferred.

These savings should also be calculated and factored into the business case.

Finally, the business case for an automated system should consider not only the ‘hard’ numbers such as labour and building cost savings, but also the ‘second order’ benefits of a safer, more ergonomic environment with improved delivery flexibility and response times.

Although sometimes difficult to quantify, these benefits include less lost time through injury, increased staff retention rates and higher customer satisfaction, which leads to increased sales.

ENQUIRY NO. 2701

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ENQUIRY NO. 399

．VIP Dinner - Build and extend your network and forge new friendships and partnerships

sector spotlight

An integrated robotic layer picking solution has transformed workplace safety and significantly improved the quality and productivity of mixed pallet assembly at Nestlé Australia’s national Distribution Centre (DC). By Michael Bradshaw, regional director, Integrated Systems, Dematic (Southeast Asia).

Case Study

Transforming

Safety, Quality & Productivity T

he high demand for Nestlé’s leading household brands means most of its DC’s orders — around 80 percent — are distributed as full pallets. Picking the remaining 20 percent of orders — which are distributed in pallet layer and full case quantities — has involved the manual handling of around five million cases per year, creating a significant and ongoing Occupational Health and Safety (OH&S) challenge.

Nestlé’s layer picking solution eliminates the need to manually handle around four million of those cases.

The layer picking system achieves very high throughput rates thanks to logistics systems supplier Dematic’s FreePick Maximiser patented software.

By cross-matching orders and pairing those with compatible order profiles, FreePick Maximiser enables around 20 percent — in some instances up to 50 percent — of goods for orders to be distributed without them being physically picked.

56 industrial automation asia | April 2012

A Safer, Smarter Solution To Picking And Building Layers Orders from Nestlé’s SAP warehouse management system are downloaded i n t o D e m a t i c ’s P i c k D i r e c t o r warehouse control system to initiate picking. Interfacing with FreePick Maximiser, PickDirector orders the stock required for layer picking in the sequence required to fulfil the next wave of orders.

This is retrieved from the adjacent bays of reserve storage by an RF directed forklift and loaded onto the induction conveyor spur. As pallets are fed into the layer picker, they are scanned, and the control system directs the operator to remove the required amount of stretch wrapping from the pallet.

The pallet is then conveyed into the layer picker where it will go directly to one of four pick and put locations, or, if it is not immediately required, into one of eight buffer storage locations serviced by an automated pallet cart.

Completed orders are conveyed through the integrated layer picking system being check weighed, stretch wrapped and labelled on the way, until they exit ready for collection, and are transported to dispatch by forklift. Orders that require further case picks to be added to the layers exit the system, where a barcode label is attached prior to their retrieval by forklift. After the required case picks have been completed using the DC’s new voice picking system, the pallet is reinducted onto the system, check weighed, stretch wrapped and labelled for dispatch.

Superior pallet build quality improves transport utilisation, with less handling damage and fewer returns.

While the software requests pallets to arrive at the layer picker in a particular sequence to suit order assembly, the reality is that pallets occasionally turn up out of sequence. The buffer storage locations enable such pallets to be temporarily stored online, within the layer picker, until required.

As new pallets of stock are fed into the system, the layer picker selects the required layers and transfers the stock to one of four customer order pallets. Any stock remaining on a pallet either forms the basis for another order via the system’s FreePick Maximiser software, or is returned to the adjacent reserve storage bays for use at a later stage.

Building Stable Rainbow And Sandwich Pallets To Order With the supply chain running leaner, there is a general trend towards ordering smaller quantities of goods such as layers, rather than full pallets, or cases rather than layers. Many customers also require pallets to be built in a certain way to suit further processing.

To maximise pallet building flexibility, the layer picking system has four order picking positions, which enables up to four orders to be picked concurrently. An empty pallet station accommodates the production of multiple layer sandwich pallets.

The 4-axis robotic layer picker is equipped with a dual bellows and vacuum-gripping head capable of handling up to 80 percent of Nestlé product range, covering a broad range of packaging types from cartons to bags and bottled beverages.

When the robot is directed to pick up a layer, the bellows inflate and close around the product, creating a seal. The vacuum exerts just enough pressure to pick up the layer, minimising the potential for product damage during handling. The vacuum gripper head offers the maximum versatility in product handling, making it suitable for picking layers from any pallet stacking pattern, even those that have a hole in the middle.

Voice Picking A Sound Solution For Case Picking The introduction of voice-directed computing has also improved the safety of Nestlé’s remaining manual case picking requirements. The company’s forklift operators now wear a small headset and a lightweight, voice computer attached to their waist. The workers simply listen and respond to clear, verbal commands instructing them where to go and what to pick.

A significant advantage of voice directed computing for order picking is that it leaves the user’s hands and eyes free at all times, making handling and picking cartons faster and safer.

ENQUIRY NO. 2702

ENQUIRY NO. 384

Robotic layer picking cell.

April 2012 | industrial automation asia 57

EVENT PREVIEW

Metaltech 2012 The 18th international manufacturing solutions event Metaltech would once again be held at the Putra World Trade Centre, Kuala Lumpur, Malaysia. This year’s event would take place on May 15 – 19, 2012.

Incorporating the Welding Technology Exhibition 2012 (WeldTek) and Automation Technology Exhibition & Conference (Automex), the event is expected to attract 25,000 trade visitors. They hail from many industries such as aerospace maintenance, parts manufacturing, automotive manufacturing and electronics production.

The total number of exhibiting companies is expected to hit 1,500 with seven national pavilions contributing to the numbers. The seven countries are Austria, China, Germany, South Korea, Singapore, Taiwan and United Kingdom. Together with the local exhibitors, they will take up a total exhibition area of 30,000 sq m (gross).

High Growth The machinery and tools industry is a high performance industry sector, with companies ensuring their technological advancement through expertise and continued innovation.

Malaysia has a diverse and growing manufacturing sector that plays a huge role in the economy, plus initiatives to promote manufacturing related activities 58 industrial automation asia | April 2012

granted by the Malaysian government makes the country a suitable place for proper business development and investments.

May 15 – 19, 2012 PWTC Kuala Lumpur, Malaysia

ENQUIRY NO. 2801

Other Highlights To emphasise on the diverse nature of the manufacturing sector, the two sub-events at Metaltech are expected to provide a comprehensive coverage for visitors who might have interests other than metalworking.

• WeldTek is the 12th Malaysian International Exhibition on welding equipment and technology, welding services and welding competition • Automex is the Malaysia International Exhibition and Conference on process automation, factory automation, industrial automation, instrumentation and control, bus and wireless technology, hydraulics and pneumatics and robotics ENQUIRY NO. 2802

Exhibitors Profile

Products At Metaltech

Sheetmetal Technology • Bending • Drawing • Forging • Laser Cutting • Notching • Punching • Wire and Tube Forming • Riveting • Roll Forming • Shearing, Stamping, Water-Jet Cutting • Sheetmetal Processing / Metal Forming Machine Tools • Boring • Broaching • CNC Wire Cut • Cutting Tools / Inserts • Deburring • Drilling • EDM/ECM • Filling • FMC/FMS • Gear Cutting • Grinding • Honing • Lathes • Metal Cutting Machine Tools • Milling • Planing • Threading • Sawing • Screw Cutting • Shaping • Slotting • Special Purpose Machine and Unit Heads • Tapping • Turning Software and Prototyping Systems • CAD/CAM/CAE and Prototyping Machine • Computer Hardware • Fused Deposition • Software • Laminated Object Manufacturing • Selective Laser Sintering • Stereo Lithography Measurement Technology • Metrology Equipment • Sensors • Testing Machines • Precision Measuring Machines and Instruments • Optical Measuring Instruments for Machine Tool Industry Mould And Die • Die Sets • Die Cast Moulds • Graphite • Mould Bases • Mould Repairs • Moulds and Dies • Pins • Special Steels / Tool Steels Surface and Heat Treatment • Accessories for Casting • Forging and Casting Equipments • Chemicals • Chroming and Other Surface Finishing Technology • Furnace • Foundry Engineering • Lapping • Super Finishing • Polishing • Spray Painting Systems • Surface Treatment and Finishing • Vibrator Deburring Machines and Consumables Shot / Sand Blasting Equipment Material Handling and Storage • Material Handling • Factory • Storage and Warehousing • Industrial Robots Welding Technology • AC/DC Power Sources • Fume Extraction System • Software • ARC-Welding MIG / TIG / SA Equipment • Plasma Cutting Equipment • Manual ARC-Welding Equipment • Spot / Stud Welding Equipment • Welding and Fastening Equipment • Training • Welding Flux and Other Consumables Tools & Toolings • Power Tools • Hand Tools • Cutting Tools • Workholding Devices • Hydraulic & Pneumatic Tools • Air Tools

Tesa: Precision In Motion The two Tesa-Hite 400 and 700 height gauges are fitted with the opto-electronic measuring system with incremental glass scale. Due to their construction, they are suited for dimensional inspection on the shop floor.

Full autonomy is ensured through battery power. Each model allows height or step dimensions, diameters, centre-to-centre distances, groove width and the likes to be accurately measured. They feature a wide application range with two sizes available, with measuring spans of 415 mm or 715 mm respectively. In addition, their electronics are totally protected against oil and water splashing and dust particles (IP65).

ENQUIRY NO. 2804

Autodesk:

Simulation Software Autodesk Inventor software takes engineers beyond 3D to digital prototyping by giving them a set of tools for 3D mechanical design, simulation, tooling, visualisation and documentation that enables them to design, visualise, and simulate products before they are ever built.

The software produces an accurate digital model, which is a virtual representation of the final product that can be used to validate the form, fit, and function of the product prior to production.

ENQUIRY NO. 2805

ENQUIRY NO. 2803

April 2012 | industrial automation asia 59

EVENT PREVIEW

RFID World Asia 2012 The 2012 edition of RFID World Asia, currently in its 9th year, will be held from April 25 - 27, 2012, at the Suntec Singapore International Convention and Exhibition Centre, Singapore.

The three-day event is expected to draw more than 8,000 attendees including over 200 international solution providers from Asia and beyond, such as Bartronics, Daifuku, Dematic, Fujitsu, Giga TMS, Golden Spring Internet of Things Inc, Greenclay International, Hong Kong RFID, LHT Holdings, SAG, Shenzhen SyncoTech, Silicon Craft Technologies, SISS Technology, SMARTRAC, STAR RFID, Tatwah Smartech, TCM RFiD, Teslin

by PPG Industries, and Wavex Technologies, to name a few.

RFID World Asia aims to attract regional and international industr y professionals in healthcare, pharmaceutical, government, CPG, retail, construction, aerospace, defence, energy, logistics, warehousing, supply chain, manufacturing, and mining companies with RFID deployments.

60 industrial automation asia | April 2012

Event Highlights include: • Eight co-located events over three days at one venue: Cards & Payments Asia 2012, Prepaid Cards Asia, Near Field Communication (NFC) World Asia, Digital ID World Asia, RFID World Asia, Retail World Asia, Online Retail World Asia, and Digital Signage World Asia.

• New co-located events: – Online Retail World Asia – Digital Signage World Asia • Three Group Pavilions: China (first time) by the China Council or the Promotion of International Trade (CCPIT), France by the French Trade Commission (UBIFRANCE) and Singapore by the Singapore Manufacturers’ Federation (SMa).

• Over 60 free on-floor seminars in three functional theatres.

• Smart Card Awards Asia: In its inaugural year, the awards will have 10 categories including two for RFID. The awards will be held on April 25, 2012 at Marina Mandarin Hotel, Singapore.

The show will focus on seven key themes, namely: trends & opportunities, excellence in operational efficiency, authenticity & identity management, RFID in Asia, enhancing visibility & traceability, inventory & asset management, and the future of RFID. Speakers at the 2012 edition of the show include representatives from Abercrombie & Fitch, Australia Post, CHEP, Eurotyre, GAP, Goodpack, GS1 Japan, GS1 Singapore, J Crew, RFID International Business Association, Secure Information Disposal Services, Thai Tank Terminal, Voluntary Interindustry Commerce Solutions (VICS), Vopak, and many more.

A post-conference masterclass entitled ‘Unleash Your Business Potential with RFID and Other Emerging Technologies’ will be available on April 27, 2012 for delegates to learn from Frank Dorrian, president of RFIDba Asia Pacific, and other experts in RFID. April 25 - 27, 2012 Suntec Singapore Singapore

ENQUIRY NO. 2806

ENQUIRY NO. 398

EVENT PREVIEW

Renewable Entech Energy Pollutec Boilex Pumps & Valves

Asia 2012

The renewables energy/entech pollutec/boilex/pumps and valves Asia 2012 will be held at BITEC Exhibition Centre in Bangkok, Thailand, from June 6 - 9, 2012. The exhibition has expanded in 2012 to include four key areas, namely, renewable energy, environmental protection, boilers, and pumps & valves.

Show Highlights Include: International Conference On Renewable Energy Asia 2012

An international presentation on energy security and independence covering trends, technology & markets for renewable energy.

The conference is co-organised by the Joint Graduate School of Energy & Environment (JGSEE), the Centre of Excellence for Energy & Environment, King Mongkut University of Technology, and UBM Asia (Thailand).

Plenary Session on Renewable Energy — four parallel sessions covering solar energy options: smar t grids/renewable and 62 industrial automation asia | April 2012

wind/green energy, building environment/biomass/biogas & waste-to-energy Energy Saving Seminar For Thai Industries & CEO Energy Talk

Features energy-saving technology from many areas. An open discussion will feature top CEOs sharing success stories that led to their commitment to energysaving policies.

Carbon Credit Opportunities For Local Communities

T h i s s e m i n a r i s o rg a n i s e d by the Committee on Science, Technology, Information and Telecommunications and The Senate of Thailand. It provides important information on carbon credit. Also covered — possible strategies, and business practicality. Case studies for local communities plus details on how to transition successfully into the carbon business.

One-Stop Clinic

The clinic is divided into four

zones: The starter zone for information on policies and regulations. The support zone deals with applications, permits and government incentives. A technical zone handles consultancy matters, best locations for R/E projects, hardware systems and technology.

Finally, there is a financial zone where visitors learn how to get projects up and running.

Boilex Asia 2012

Displays the latest boilers, instrumentation and technology for trouble-free, money saving operation. The global industrial b oi l e r ma r k et i s p ro je c te d to be 620,000 tonnes per hour by 2015, driven by emerging Asian economies.

Thai Water 2012

The first international exhibition that provides working solutions for water and waste-water control.

June 6 - 9, 2012 BITEC Bangkok, Thailand

ENQUIRY NO. 2807

Manufacturing Surabaya 2012

East Indonesia’s trade exhibition, Manufacturing Surabaya 2012, will return June 6 – 9, 2012 at the Grand City Exhibition & Convention Centre. This year’s event will be the biggest in its history attracting over 450 participating companies.

Maysia Stephanie, project manager for the organisers PT Pamerindo Indonesia said: “We have been overwhelmed by the demand for space. This is the first time that the entire exhibition will be full and we are looking at options to try and meet the demand from more companies who still want to participate.”

N a t i o n a l p a v i l i o n s f ro m S i n g a p o re ( h e a d e d b y t h e Singapore Manufacturers Association) and Taiwan (headed by the Taipei Machinery Traders Association) will exhibit alongside Akyapak, Autonics, Dine, Endress and Hauser, First Machinery, Fu Sheng, Guhring, Haas Indonesia, Kawan Lama, Mori Seiki, Multi Mayaka, Somagede and Trumpf.

The exhibition is fully supported by the Ministry of Industr y, Indonesian Mold & Die Association, the Indonesian M a c h i n e To o l I n d u s t r i e s Association and the Indonesian Packaging Federation.

A h i g h l e v e l c o n f e re n c e organised by the Indonesian Mold & Die Association will be held in conjunction with the exhibition.

Exhibits on display range from machine tools and metalworking technologies to automation a n d c o n t ro l s o l u t i o n s , g a s engines, marine equipment and services, oil and gas processing equipment, cutting and welding gear, test and measurement equipment and tooling.

June 6 - 9, 2012 Grand City Exhibition & Convention Centre Surabaya, Indonesia ENQUIRY NO. 2808 April 2012 | industrial automation asia 63

EVENT REVIEW

IAA was in attendance at SolidWorks World 2012 and met up with executives from DS SolidWorks to discuss the show and their business throughout Asia. We also spoke with Azhar Athly, the winner of this year’s student skills competition.

By Mark Johnston

The 2012 edition of SolidWorks World took place at the San Diego Convention Centre, San Diego, California, from February 12 to 15, 2012.

This year saw the highest number of attendees to date, with approximately 5,900 registrations in total, from over 50 countries.

2012 also saw the highest number of exhibitors, with 111 exhibitors occupying the partner pavilion; a 6,000 sq ft product showcase with an estimated US$1 million worth of products on display. 2012 also saw a large increase in downloads for the shows mobile application, a 151 percent increase from the 2011 show, 3,287 downloads, in 2012, to be exact.

The event had 250 technical training sessions that were well attended by the very people who use the software on a daily basis.

The show has changed a lot over the years, and it will continue to do so into the future. The reason for this is simple, how user’s design products, not just the creative process of designing, but the way that design happens, the experience the designer has, and the tools 64 industrial automation asia | April 2012

available to him are constantly evolving. This is particularly true when we follow the evolution of the computing platform in general, and our interaction with that process continues to evolve at an accelating pace.

Pleased with how the 2012 edition of SolidWorks World went, Bertrand Sicot, CEO, SolidWorks, stated: “SolidWorks World, as an event, has matured a lot over the past 14 years. It has grown to become many things together — a worldwide press event, a user conference, a solution partner exhibition, a reseller meeting and a company kick off. This year was the biggest event across each area.”

The Speakers There were many speakers during the course of the event, while users, SolidWorks staff, and the press looked on.

One of the speakers was Dr Maia Hoeberechts, a scientist with the Neptune Canada project, a regional cabled ocean network, located in the Northeast Pacific. Part of the Ocean Networks Canada (ONC)

Observatory, they gather live data and video from instruments on the seafloor, making them freely available to the world, 24/7. Other speakers included Tony Fadell, founder and CEO, Nest Labs, Mike Rowe, the mikeroweWorks Foundation & Dirty Jobs (TV series), Ben Kaufman, CEO and founder, Quirky, Ben Maisonnier, CEO, Aldebaran (NAO Robot), and many others. All with one thing in common, SolidWorks helped their organisation.

SolidWorks Training Certification Dassault Systèmes (DS) SolidWorks also announced that they had awarded their 50,000 certifications for the company’s SolidWorks training certification program. The program was created more than a decade ago, and is to recognise a user’s competence in using the tools and capabilities of the SolidWorks software platform.

February 12 - 15, 2012 San Diego Convention Centre San Diego, US ENQUIRY NO. 2809

SolidWorks Partners

On ASEAN Sharon Toh, GM, AP South, SolidWorks IAA: What are the biggest industries SolidWorks supplies to, in Southeast Asia?

Sharon Toh (ST): I believe the biggest industries we supply to are industrial equipment, automation, and customer products. We are also doing increasingly well in medical.

IAA: What feedback have you gotten about SolidWorks World 2012, so far?

ST: The feedback has been very positive, and everyone has been talking fondly about the key notes, in terms of innovation. I personally love the collaborative engineering aspect of the show.

Every year the show is getting better, we have a big team of people working on improving the show every year. Also, when you come to the show you do not feel like you are an outsider, people just talk to you.

ENQUIRY NO. 2810

On Sustainability Asheen Phansey, product manager, sustainability, SolidWorks IAA: What is your role at SolidWorks?

Asheen Phansey (AP): To understanding our market for sustainability. What do our customers want? How do they want to do environmental assessment, and sustainable design?

Evangelising the product, in regards to the sustainability module in SolidWorks.

IAA: How does DS SolidWorks define sustainability?

AP: A sustainable product, or a green product, does not exist. It would be one that is never manufactured or sold. How we define it is that sustainability is relative, it is taking as measure of where we are, and improving.

There are two sides to that, one is measure. We have had to decide what are the key metrics to measure environmental impact. For this we use carbon footprint, total energy, air impact, and water impact. We feel this is a good sample of what is possible to measure.

The second is redesign, so once we measure, we then figure out the way forward. SolidWorks has tools for this, we help our customers.

ENQUIRY NO. 2811

“As a third time participant to SolidWorks World it is getting better every year, from almost all aspects: organisation, logistics, content and campaigns.”

Sam Golan, president & CEO, PAS Technology “SolidWorks World 2012 in San Diego was a tremendous success for SpaceControl.”

Marc Weigand, marketing director, Space Control “We generated ten times more direct customer leads than we planned, and are in multiple discussions with resellers around the world. Given all of this, we doubled our space for SolidWorks World 2013.”

Steven McLendon, executive VP, ExactFlat

Top 10 most requested features for SolidWorks 2013 1. More CPU cores.

2. Mass properties should include the option to automatically put a point at the centre of gravity.

3. Do not delete your children, dangle them instead.

4. Address shaded with edges bleed thru issue.

5. Reduce the bounding box of drawing views to visible components only.

6. Ability to control a plane’s front and back side orientation.

7. Dimensions should stay where you place them.

8. Escape key should immediately return control of the interface.

9. Add ‘Lock Rotation’ option to cylindrical mates.

10. Add a ‘Thread Creation Wizard’.

April 2012 | industrial automation asia 65

EVENT REVIEW

Student Skills Competition In 2011, the SolidWorks skills competition marked its inaugural year with the aim of promoting and encouraging students to develop skills in engineering design.

Students from Australia, India, Malaysia, New Zealand, Singapore, South Korea and Thailand, all competed to be crowned winner, and ultimately win a chance to attend SolidWorks World 2012, in San Diego, California.

The skills competition started with country level heats, the top three winners of which would go on to compete regionally against the winners in each respective country.

The country level heats took place from October 1, 2011, to November 5, 2011, with the winners of the respective countries converging in

Singapore on November 28, 2011, for the regional finals.

In the regional finals the students were tasked with the redesign of a wall-mounted TV bracket, of which they were tested on qualities such as, design features, load bearing capabilities, manufacturing techniques, material choice, sustainable design considerations, and presentation skills.

A panel of judges from industry and the educational sectors ultimately judged between them and decided on the winners. The students then presented their designs and made their case, with the hope of impressing the judging panel.

Azhar Athley (Singapore) ultimately won the regional competition. Azhar is a student

from NUS and a participant in NUS’s University Scholars’ Programme (USP). The runners up were Kam Sen Hao (Singapore) from NUS, and Aaron Boo (Singapore) from SP, in second and third place, respectively.

IAA had the oppor tunity to interview Mr Athly on his experience competing in the competition and his thoughts on SolidWorks and his experience at SolidWorks World 2012.

SolidWorks World 2013 SolidWorks World 2013, its 15th year, will take place at the Swan and Dolphin Hotel, Walt Disney World Resort, Orlando, Florida, US, from January 20 to 23, 2013.

ENQUIRY NO. 2812

Interview With Azhar Athly The winner of the SolidWorks Student Skills Competition was Azhar Athly (Singapore), an NUS student. Coming in third and fourth place, Azhar Athly also from Singapore, were Kam Sen Hao and Aaron Boo. IAA interviewed Mr Athly on Singapore’s success story, and his thoughts on SolidWorks World, and his plans for the future.

extreme-performance machines that even drew the interest of the US Army. I greatly benefited from the various breakout sessions led by experienced speakers, learning new features and picking up useful tips and tricks that help to boost my productivity. All in all, the experience has truly deepened my knowledge and appreciation of the functionality of SolidWorks.

After graduation, it would be nice to secure a job in the aerospace or automotive industry as a design engineer, but my dream job would definitely be to work for a Formula 1 team as an aerodynamicist.

IAA: In your opinion, why has Singapore been so successful in this competition, considering the top three awards were for Singapore?

Azhar Athly (AA): I think the tertiary institutions in Singapore deliver a very strong grounding in the fundamentals of engineering, which perhaps gave us that extra edge when tackling the design problem in the competition. It also helped that we are familiar with 3D CAD software in general, having used them for various projects as part of our coursework.

IAA: What is your favourite feature of SolidWorks, and why?

AA: I think that SolidWorks has the best solver compared to its competitors when dealing with assemblies. In my opinion, it has the greatest versatility in terms of mates and constraints: there is a large selection of mate types to choose from, which are also easy to specify. I find SolidWorks especially robust when handling dynamic assemblies and subassemblies with multiple degrees of freedom. This comes in very handy when validating the range of motion and checking for interference at the top-level assembly. Based on my experience, large assemblies with over a thousand parts run more smoothly in SolidWorks than in any of its competitors, which really saves me a lot of time.

IAA: How was the SolidWorks World experience for you, and what are your plans for the future?

AA: It was really inspiring for me to see for myself how SolidWorks is used in the industry to design practically anything, from consumer products to

66 industrial automation asia | April 2012

ENQUIRY NO. 2813

AnaLabAsia2011, CIA 2011 and EnviroAsia2011 Controls, Instrumentation and Automation 2011 (CIA 2011), AnaLabAsia 2011, and EnviroAsia 2011, were held along side each other at their 2011 edition, located within Suntec Singapore, from November 22-25, 2011.

The three events are squarely a i m e d a t A s i a ’s s c i e n t i f i c , environmental, and process technology industries. Business a n d i n d u s t r y p ro f e s s i o n a l s got together over the four exhibition days, deriving value from possible sourcing and networking opportunities.

The event recorded 4,052 business attendees, including visitors, industr y speakers and delegates and members of the media from more than 46 countries.

At the CIA 2011 exhibition the HART Communication Foundation displayed live demonstrations of WirelessHART, also known by its international standards name: IEC 62591. Several manufacturers of WirelessHART devices and software had their products working together in the booth.

One of the live demos included WirelessHART products from ABB, Emerson, Endress+Hauser, Mactek, Pepperl+Fuchs, and Siemens.

Others included Phoenix Contact, Rohrback Cosasco Systems (RCS), and Stahl. Interoperability between transmitters, gateways, and wireless adapters from these vendors is made possible by the common standard.

Exhibitors Award Positive Testimonials Exhibitors were able to meet up with prospective new business partners and were able to keep in touch with existing associates.

“The crowd is good, and we have gotten some new sales leads,” confirms Takashi Kumamoto, manager of debut exhibitor Yoshimura, Japan.

Many exhibitors are already looking forward to 2013. “The event is well-organised and attracts the right audience, which can be seen when we were approached by many visitors after the launch of our customised gas alarm system during the show. We will definitely

come back in 2013 together with our distributor - Johnson Scientific Equipment Co,” says Koji Yoshino, subsection chief of Marketing and Sales from Komyo Rikagaku Kogyo K K, Japan.

A Thought Leadership Platform The Plant Processes and Safety Conference 2011 and Sustainable Development through Energy Management Conference 2011 drew delegates into intense discussions on current industry trends and topical issues.

“This is what the industry needs. The knowledge and expertise sharing was great, the experience was very enriching and the conference definitely elevated the learning curve for the industry,” says Devender Singh, regional marketing manager, GE Energy, and speaker for the ‘Strategies for OPEX savings to ensure ROI’ session.

November 22 - 25, 2011 Suntec Singapore Singapore ENQUIRY NO. 2814 April 2012 | industrial automation asia 67

products & Services ABB:

Cognex:

ABB has developed the MB-Rx in-situ Reaction Monitor for research laboratories and pilot plants in the chemical, petrochemical, pharmaceutical and biopharmaceutical industries.

The equipment features a Hastelloy ATR probe and a software interface that also allows for rapid set-up of experiment templates.

The analyserâ&#x20AC;&#x2122;s compact footprint allows it to fit inside crowded fume hoods, providing convenient access to reactors. Permanently aligned optics and a light source with an average lifespan of 10 years make the equipment virtually maintenance-free.

Cognex has introduced the In-Sight 500. The product is a fixed-mount vision system packaged in a IP65-rated housing.

It is powered by a proprietary vision chip technology, Cognex Vision System on a Chip (VSoC), which enables the system to process images at up to 500 frames per second (fps) with windowed acquisition.

The product can achieve speeds of 100fps at the full 1024 x 768 pixels of resolution and 200fps at 640 x 480. Also, it provides the ability to further window an acquired image which can accelerate the acquisition to as high as 500fps.

In-Situ Reaction Monitoring

Enquiry no. 2901

Industrial Vision System

Enquiry no. 2903

Agilent:

Cummins Power Generation:

The Agilent Wireless Remote Connectivity solution for Handheld Digital Multimeters (HH DMMs) enables monitoring of multiple measurements simultaneously and wirelessly, via Bluetooth technology. This is made possible by simply attaching the U1177A Infrared(IR)-to-Bluetooth adapter to any of Agilent HH DMMs and installing the free Android-based applications, the Mobile Meter and Mobile Logger.

The Mobile Meter allows data monitoring and data can be saved as a text/picture to be shared via email. The Mobile Logger enables real-time data trending for up to three HH DMMs. Once installed, an Android smartphone/tablet can be used as a remote measurement/control and reporting device.

Cummins Power Generation has launched the diesel engine C17D5T generator set. The genset features an integrated automatic transfer switch, a large, pilferage-protected fuel tank, a weather-protected enclosure and longer intervals between servicing times.

The generator set meets both prime and standby requirements of telecommunications operators. Ranging from 8 kVA to 3,500 kVA for both the 50 Hz and 60 Hz markets, the genset is suited to a wide range of applications.

Wireless Remote Connectivity Solution

Enquiry no. 2902 68â&#x20AC;&#x192; industrial automation asia | April 2012

Diesel Engine Generator Set

Enquiry no. 2904

products & Services

Dematic:

Harting:

Dematic has developed RapidStore, a modular Automated Storage and Retrieval System (ASRS) for heavy unit loads. Designed and engineered in Germany and manufactured in their regional product centre, RapidStore Storage and Retrieval Machines (SRMs) are available in a range of sizes and speeds to precisely match storage and handling requirements.

Requiring aisles from just 250mm wider than the load and up to 30m high, the system ensures higher storage density and immediate access to each and every pallet.

The company’s RapidStore SRMs have a mast design that allows them to operate at travel speeds up to 240 m/min, with hoisting speeds up to 85 m/min, enabling higher throughputs to be achieved.

Soanar offers Harting’s Ha-VIS Fast Track Switches series, which is an alternative switch for flexible topologies especially for Profinet applications and it is an ideal switch for interconnecting non-automation (IT), communication and automation applications on a single network.

Fast Track Switching operates by using the Ethernet headers to detect those automation frames that are important for the application in order to forward them with top priority by way of the cut-through process.

Soanar offers a range of Industrial Ethernet Switches, from low cost 8-port unmanaged switches to Rack-Mount Gigabit POE managed switches.

Modular Automated Storage And Retrieval System

Industrial Ethernet Switches

Enquiry no. 2905

Enquiry no. 2907

Fluke:

Intense:

Fluke corporation has introduced five new thermal imagers to the market.

They include the Ti110 and Ti125 for plant technicians, HVAC/R professionals and electricians who need to maintain and inspect electrical and mechanical equipment and components.

Also, the TiR110 and TiR125 for building inspection and energy audit professionals evaluating and reporting insulation problems, air leakage, moisture issues, or construction defects.

Ti110, Ti125, TiR110, and TiR125 include IR-OptiFlex focus system, IRPhotoNotes annotation system, and focus-free video, IR-Fusion technology, and SmartView.

And, lastly the Ti100 for general applications has been introduced, representing the value conscious choice for professionals.

Intense has announced the production release of a 300 mW version of the Series 6030 and Series 6130 ultra high power, high brightness single mode laser diodes.

Designed for defence, medical, and print/imaging applications such as spectroscopy and industrial coding, the diodes are available in 980, 830, 808, 785, and 780nm wavelengths. Custom packaging and wavelengths are available on request.

Part of the company’s Series 6000 family of single mode lasers, the Series 6030 and Series 6130 are based on the company's patented Quantum Well Intermixing (QWI) technology, which increases the brightness and reliability of laser diodes while avoiding the usual problems associated with catastrophic optical mirror damage.

Ultra High Power Single Mode Laser Diodes

Thermal Imagers

Ti125

Enquiry no. 2906

Enquiry no. 2908 April 2012 | industrial automation asia 69

products & Services

Mitsubishi Electric:

Red Lion Controls: Digital

Mitsubishi Electric has introduced an improved range of servo amplifiers – the Melservo-J4 series. MR-J4 features an increased speed loop frequency of 2.5kHz. Faster response and shorter cycle time can be expected.

Optimisation of machine performance can be achieved via the one-touch tuning function. With the one touch tuning function, servo gain, machine resonance suppression filter, and vibration suppression filters are automatically adjusted.

The new servo motors are equipped with a 22 bit absolute encoder (4,194,304 pulses/rev). And, SSCNetIII/H communication speed has been increased to 150 Mbps full duplex.

Red Lion Controls has announced the addition to their PAX2 Series of dual line display meters. The PAX2D Digital Panel Meter is a single package featuring a dual counter and dual rate meter, with a third counter and rate display that allows the user to perform math functions. With universal features and versatile programming capabilities, this single meter can suit virtually any digital pulse applications.

The meter accepts inputs from proximity sensors, magnetic sensors, photo eyes, length sensors, rotary pulse generators, transistors and simple switches. A universal power supply accommodates both AC and DC inputs.

Servo Amplifiers

Panel Meter

Enquiry no. 2909

Enquiry no. 2911

Netherlocks:

Sick:

Dutch interlock specialist Netherlocks has now launched an Interlock System Information (ISI) Touch Screen key management device. As a standalone unit or integrated into either a key cabinet or control panel, the ISI Touch Screen stores all relevant information about an interlock system in a digitised, centralised, userfriendly format that is accessible by any operator without a need for specialised training.

All relevant interlock keys are shown on screen, and touching them will display detailed information about the key itself and the related system: system name, operating sequence logic, P&ID and Location. Additional buttons are present for on-screen instructions, general interlocking information and the company’s contact details.

Sick have introduced the ML20, a markless sensor.

The markless sensor is suitable for applications in the packaging industry.

User-friendly configuration is offered via the sensor’s control panel or by using the company’s SOPAS software via Ethernet.

The markless sensor provides benefits particularly in the field of roll-fed label machines. It is typically used for controlling the cutting process in order to separate labels without the use of print marks, which take up a lot of space and are unaesthetic. Furthermore, the machine process is made more stable, and waste caused by incorrect cuts is minimised.

Touchscreen Interlock Management System

Enquiry no. 2910 70 industrial automation asia | April 2012

Markless Sensor

Enquiry no. 2912

Calendar Of Events 2012 april

3 – 6 Automation World 2012

Coex Convention and Exhibition Center, Seoul Korea Coex Email: automationworld@coex.co.kr Web: http://automationworld.co.kr/index. html?TPL=en_main.tpl

23 – 27 Hannover Messe 2012

Deutsche Messe Hannover Germany Deutsche Messe AG Hannover Email: info@messe.de Web: http://www.hannovermesse.de/home

24 - 26 Semicon Singapore 2012

Marina Bay Sand Singapore Email: lchan@semi.org Web: http://www.semiconsingapore.org/

25 – 27 RFID World Asia 2012

Suntec Singapore International Convention and Exhibition Centre Singapore Terrapinn Email: audrey.leong@terrapinn.com Web: www.rfidworldasia.com.sg

May 9 - 11 China Epower 2012

Shanghai New International Expo Centre Shanghai, China MP International Private Limited Email: info@zhongmao.com.cn Web: http://www.epower-china.cn

15 - 19 Automex

PutraWorld Trade Centre Kuala Lumpur, Malaysia Email: info@tradelink.com.my Web: www.tradelink.com.my

17 – 20 IA Robotics 2012

Bangkok International Trade & Exhibiton Centre Bangkok, Thailand UBM Asia (Thailand) Co Ltd Email: info@cmpthailand.com Web: http://www.intermachshow.com/

22 - 24 Industrial Automation Kuala Lumpur

Kuala Lumpur Convention Center (KLCC) Facon Exhibitions Sdn Bhd Email: sales@faconex.com Web: http://www.tradeshowz.net/trade-eventdetail/industrial-automation-kuala-lumpur.html

18 – 20 Propak China 2012

June

06 – 09 Renewable Energy Thailand 2012

Bangkok International Trade & Exhibiton Centre Singapore Bangkok, Thailand UBM Asia (Thailand) Co Ltd Email: info@cmpthailand.com Web: http://www.renewableenergy-asia.com/

12 – 14 Green Energy Asia 2012

Kuala Lumpur Convention Center (KLCC) AMB Exhibitions Sdn Bhd Email: support@ambexpo.com Web: http://www.biztradeshows.com/tradeevents/green-energy-asia.html

13 – 16 Propak Asia 2012

Bangkok International Trade & Exhibiton Centre Singapore Bangkok, Thailand Bangkok Exhibition Services Ltd Email: info@besmontnet.com Web: http://www.propakasia.com/

Shanghai New International Expo Centre Shanghai, China China International Exhibitions Email: vicky@chinaallworld.com Web: http://www.propakchina.com/en/index.asp

10 – 12 Robotics Asia 2012

Putra World Trade Centre Kuala Lumpur,Malaysia Protemp Exhibition Sdn Bhd Email: kelly@protempgroup.com Web: http://www.roboticsasia.org/2012/

August 29 – 1 Sep Taipei International Industrial Automation Exhibition 2012

Taipei World Trade Center Nangang Exhibition Hall Taiwan Chan Chao International CO., LTD. Email: show@chanchao.com.tw Web: http://www.chanchao.com.tw/automation/en/ index.asp

July 1 – 5 Singapore International Water Week

Marina Bay Sands Singapore Singapore International Water Week Pte Ltd Email: info@siww.com.sg Web: http://www.siww.com.sg/

3 – 6 MTA Vietnam

Saigon Exhibition & Convention Centre Ho Chi Minh City Singapore Exhibiton Services Pte Ltd Email: mta@sesallworld.com Web: http://www.mtavietnam.com/

10 - 12 July 2012 Robotics Asia 2012 Putra World Trade Centre Kuala Lumpur, Malaysia Email: kelly@protempgroup.com Web: www.roboticsasia.org

11 – 13 Indo Renergy 2012

Grand City Convex Surabaya Surabaya, Indonesia PT. Napindo Media Ashatama Email: agung@napindo.com Web: http://www.indorenergy.merebo.com/ English/

September 5 – 7 Semicon Taiwan 2012

Taipei World Trade Center Nangang Exhibition Hall Taiwan Taiwan External Trade Development Council,TAITRA Email: ehuang@semi.org Web: http://www.semicontaiwan.org/en/

26 – 28 Thailand Lab 2012

BITEC Bangkok, Thailand N.C.C. Exhibition Organizer Co., Ltd Email: www.thailandlab.com Web: thailandlab@qsncc.com

October 3 – 5 Power Gen Asia 2012

Impact Exhibition and Convention Centre Bangkok, Thailand PennWell Conferences & Exhibitions Email: exhibitpga@pennwell.com Web: http://www.powergenasia.com/index.html

4 - 6 Metalex Vietnam 2012

Saigon Exhibiton and Convention Center Ho Chi Minh City, Vietnam Reed Tradex Web: http://www.metalexvietnam.com/

To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Editor IAA Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building, #02-05, Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 • Email: iaa@epl.com.sg

Advertising Index

64

|

IndustrialAutomationAsia

ADVERTISING I N D E X

ADVERTISER

PAGE NO ENQ NO

ABB Pte Ltd

IFC

391

Adder Technology (Asia Pacific) Pte Ltd

49

394

Advantech Co. Singapore Pte Ltd

39

392

Carlo Gavazzi Automation Singapore Pte Ltd

53

388

Cognex Singapore Inc

35

385

Dematic S.E.A. Pte Ltd

IBC

387

HEAD OFFICE SINGAPORE Eastern TRADE MEDIA PTE LTD 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/6379 2806 SINGAPORE: salesIAA@epl.com.sg

Emerson Process Management Asia Pacific Pte Ltd

17

386

EPSON Singapore Pte Ltd

43

402

Flir Systems Co., Ltd

9

381

Fuji Electric Asia Pacific Pte Ltd

7

312

IFM Electronics Pte Ltd

45

395

Igus Singapore Pte Ltd

27/31

389/390

JJ Lapp Cable (S) Pte Ltd

57

384

OBC

397

National Instruments

29

383

Premier Exhibition Services Sdn Bhd

47

380 398

Mitsubishi Electric Asia Pte Ltd

PROTEMP Exhibitions Sdn Bhd

61

Rockwell Automation South East Asia Ltd

1

393

Schneider Electric IT Singapore Pte Ltd

33

400

Semicon Singapore

55

399

SICK PTE LTD

23

382

Siemens Pte Ltd

3

396

Singapore International Water Week

41

401

Soanar Pte Ltd

15

350

UBM Asia (Thailand) Co., Ltd

51

375

ADVERTISING SALES OFFICES

MEDIA REPRESENTATIVES JAPAN:

Ted Asoshina Echo Japan Corporation Tel: 81-3-32635065 Fax: 81-3-32342064 aso@echo-japan.co.jp

KOREA:

Young-Seoh Chinn Jes Media International Tel: 82-2-481 3411/3 Fax: 82-2-481 3414 jesmedia@unitel.co.kr

TAIWAN:

Robert Yu Worldwide Services Co Ltd Tel: 886-4-23251784 Fax: 886-4-23252967 sales@wwstaiwan.com The closing date for placing advertisements is not less than FOUR WEEKS before the date of publication.

Please contact our nearest advertising office for more details.

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.

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1,400 picks per person per hour 400% productivity increase A world-first picking solution

Grant McClean of Coca-Cola Amatil (right) with David Rubie

Another logistics result.

When Coca-Cola Amatil wanted to build a new distribution centre to service their route trade, they asked Dematic if they had any bright ideas. It was a big task: 14,000 customers, regional and metropolitan deliveries from Bega to Coffs, 700 SKUs, and a demand for shorter lead times. Big tasks call for big answers, and Dematic’s specialist food and beverage design team worked closely with CCA to develop a whole new distribution concept. After exhaustive simulation and the development of patented software, a world’s first picking solution was delivered that helped CCA exceed their distribution goals while achieving outstanding productivity, greater accuracy and lower overall distribution costs. That’s what we call a logistics result.

Ask us.

(65) 6398 3980 www.dematic.asia

Scan to view case study

Creating Logistics Results

Logistics Solutions | System Design & Integration | Software & IT | Voice Picking | AS/RS | Storage Solutions | Conveyors | Service & Support

ENQUIRY NO. 387

ENQUIRY NO. 397