IAA August 2014 by Eastern Trade Media

z August 2014 IndustrialAutomationAsia

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August 2014

MCI (P) 018/07/2014 | ISSN 0219/5615 | PPS 1561/06/2013 (022960)

Motion, Drives, Control | Fibre Optics | Machine Vision | Building Automation | Data Centres

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Advances In Fibre Cabling PG 36 Machine Vision: Faster Production PG 40 Data Centre: The IoT Era PG 48 COVER Aug 2014.indd 1

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ENQUIRY NO. 748

Jens Lehmann, German goalkeeper legend, brand ambassador of SCHUNK, the family-owned company, since 2012

... in your lathe

I push myself to my limits and often find that I achieve more than expected. The same can apply to your machine tool.”

“ In order to achieve 100% performance

... for your automated machine loading

... for your modular assembly automation

Discover new potentials now: www.sg.schunk.com/machine-potential

... in your machining center

... in your automated handling system

With superior components, we find potentials where you would never expect to find them. In your machine.

Superior Clamping and Gripping – It’s time to use your machine’s full potential!

04.07.14 08:53

... with mobile gripping systems

ADVERTORIAL SCHUNK Intec Singapore

Superior Clamping and Gripping respective application. That is exactly where we support our customers.

SCHUNK End-of-Arm Competence: The standardized gripping systems program from SCHUNK is the largest in the world. It includes grippers, rotary modules, quick change systems, as well as linear modules and modules for high performance assembly.

SCHUNK recently opened its own subsidiary in Singapore. What goal is the company pursuing with this investment? In addition to the subsidiaries in China, India, Japan, and Korea, SCHUNK Intec Singapore is already the fifth subsidiary of our innovative family-owned company in Asia. Our task is to actively support the SCHUNK sales partners in Southeast Asia. We have partners in Singapore, Thailand, Malaysia, Indonesia, Philippines and Vietnam. SCHUNK Intec Singapore will now be their direct contact to our headquarters in Germany. We enable direct coordination with our product and industry specialists as well as direct communication with the responsible design engineers. Another focus is the ongoing qualification and training of the sales employees and users in the individual countries. In addition, we see ourselves as a link to the universities and research institutes. What is SCHUNK’s position on the market? SCHUNK is considered worldwide to be the market and competence leader for both clamping technology and gripping

systems. Our standardized modular products give us an extremely broad base. Our strongest sectors are automotive, precision engineering, and robotics. Moreover, we are experiencing strong growth in aerospace engineering, marine, and offshore engineering, as well as health care. In all of these sectors SCHUNK already offers numerous superior components and solutions. Which trends do you currently see in clamping technology and gripping systems? One of the biggest challenges for industrial production is the increasing number of variants. Product life cycles are becoming shorter, while the choice of product variants is constantly on the rise and the consumers’ desire for new products also continues to grow. All of this directly affects production: development times and batch sizes decrease. Production managers have to be more flexible in their planning and actions. This is only possible with clamping solutions and handling systems that optimally combine precision, cost effectiveness, and flexibility. A strong market presence requires finding the best solution for the

What are the company’s key strengths? We offer optimal prerequisites for customized and efficient solutions in clamping technology and gripping systems with our standardized module program, which is the most comprehensive in the world. No other company in the world can offer a more comprehensive synergy from these two areas. SCHUNK modules are the key to highly efficient, precise, and reliable solutions. Thus our slogan: Superior Clamping and Gripping. Which “blockbusters” does SCHUNK have in its program? There are the SCHUNK grippers, with which our company has been setting standards for more than 30 years. From the world’s first standardized industrial gripper in 1983 to today’s intelligent mechatronic grippers, and mobile gripping systems we have succeeded in taking a giant leap in development. To this day the multitooth guided PGN-plus universal grippers are considered the benchmark in gripping technology. Other long-running successes are our precision toolholders, especially TENDO, the powerful and high-precision hydraulic expansion holder and the ROTA power chuck including the corresponding jaws. In addition, many other SCHUNK modules are established on the market, such as the exceptionally high-power VERO-S quick-change pallet system, the TRIBOS polygonal clamping technology for micromachining or the fast pick & place units for high-performance assembly. Every year we add about 40 new benchmark products. What is the secret of SCHUNK’s success? It is the combination of German engineering, pioneering spirit, and perfec-

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ADVERTORIAL

tion that has led SCHUNK to success. Maintaining our position on the market as technology leader has always required substantial effort. That is why SCHUNK invests about 8% of the turnover in R&D every year. Not to mention high sums for the qualification and continuous further training of the employees. Recruiting of new specialists is another important investment for SCHUNK: with a training ratio of about 12% SCHUNK has held a leading position in German industry for many years. Our customers around the world benefit from this high level of competence. How has SCHUNK grown? Established in 1945 by Friedrich Schunk as a machine shop, the company developed under Heinz-Dieter Schunk to become the competence leader for clamping technology and gripping systems. The starting signal for the SCHUNK standard clamping jaw products in 1966 was a milestone in the history of our company. Heinz-Dieter Schunk can proudly look back on this pioneering accomplishment. With more than 1,200 different jaw types today it is the largest portfolio of standard clamping jaws in the world. But that is not all: With

the expansion of the product area of hydraulic expansion toolholders in 1978 and the startup of the product area of gripping systems in 1982 Heinz-Dieter Schunk has shaped the success of our company to this day. The high quality, the consistent standardization and the unique synergy of clamping technology and gripping systems have earned SCHUNK an international reputation. Today Henrik A. Schunk and his sister Kristina I. Schunk manage the company side by side with their father in the third generation. More than 2,000 dedicated employees and a network of affiliated companies and sales partners in more than 50 countries around the world ensure an intensive market presence that is highly valued especially by our demanding customers.

Keng Lim Koh, SCHUNK Regional Sales Manager Southeast Asia SCHUNK Intec Pte. Ltd. 25 International Business Park #03-51/52 German Centre Singapore 609916 SINGAPORE Tel. +65 6240 6851 Fax +65 6240 6852 info@sg.schunk.com www.sg.schunk.com

SCHUNK Clamping Technology: The innovative toolholder systems, clamping vises, quick-change pallet systems, and lathe chucks are the key to highly efficient, precise and process-reliable solutions.

August 2014 | industrial automation asiaâ&#x20AC;&#x192; 3

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ISSUES & INSIGHTS

Building Intelligence

An effective building automation system requires the right mix of technology to ensure optimum performance and lower energy costs. By Philip Tang, Mitsubishi Electric Asia

PROCESS CONTROL

Motion Control: Safe Drive Monitoring With Added Value

The New Era Of Motion Control

Motion control offers both a safe and economic solution to many applications. By Mathias Ams, Sick

Motion control has come a long way from programmable logic controllers to PC-Based control. This transition and its continuing evolution will be discussed. By Chua Siang Poh and See Ya-Pei, Beckhoff Automation (Singapore)

SOFTWARE & NETWORKS

Advances In Fibre Cabling Systems

Current 100Mb/s applications with EtherNet/IP devices are addressed as well as the need for easy to deploy higher-bandwidth links requiring 1Gb/s transmission. By Robert A Reid and Daniel T McGrath, Panduit; and Michael Hines, OFS Specialty Photonics Division

INSTRUMENTATION & MEASUREMENT

Machine Vision: A Faster Way

Machine vision technology helps streamline and increase production, in the face of greater competitive pressures and increasing consumer sophistication. By Didier Lacroix, Cognex

ENERGY

Energy Change In China

IAA interviewed Terence Siau, director, strategy and planning, Building Efficiency Asia, Johnson Controls on his company’s Asia strategy and the opening of their manufacturing and research and development centre in Wuxi, China. By Mark Johnston

SECTOR SPOTLIGHT

Data Centres: Size Matters

Rethinking Data Centre Design

Larger data centre types are triggering a change in the distribution system of power solutions. By Amit Singh, Frost & Sullivan

An increasing variety of sensors are connecting many objects in a new era of connected ‘things’. This ultimately leads to an exponential increase of data, leading to a rethink in data centre design and operation. By Pankaj Sharma, Schneider Electric

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© 2014 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. All other logos, trademarks or service marks used herein are the property of their respective owners.

Attend our Industrial Machinery Webinar for Process Management at https://www.plm.automation.siemens.com/en_sg/ campaigns/single_topic. cfm?Component=217933&ComponentTemplate=186312

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Advanced Machine Engineering from Siemens PLM Software helps manufacturers develop more profitable industrial machinery, with faster product delivery and reduced lifecycle costs.

ENQUIRY NO. 732

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FEATURES

Industrial Machinery In Southeast Asia To Take A Digital Manufacturing Path

Manufacturers in this region should know that digital manufacturing is an important component within PLM and it is a tool to help them stay relevant and competitive. By Rajiv Ghatikar, Siemens PLM Software

Engineering For Extreme Environments

Advantages Of Data Logging Systems

Keeping Change In Sight

Environmental conditions need to be taken into account during the design process of engineering projects, especially those in vital sectors, such as energy. By Jeremy Lee, Moog

The data logger has many advantages over a recorder or data acquistion system. These advantages will be discussed. By Omega Engineering

IAA interviewed Lawrence Liu, GM, Agilent Technologies on the rebranding of Agilent Technologies’ electronic measurement group into Keysight Technologies. By Mark Johnston

Cover: Sick

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Reliable and Flexible Panel Designs Panduit provides high quality product systems that connect, manage, and protect today’s industrial systems throughout the physical infrastructure – from on machine control panels to facility electrical panels. Key product features include: • Space Optimization: Increase space savings and design flexibility in control panel layouts with innovative wiring duct • High Quality Connections: Improve system reliability with ferrules and tooling that provide superior performance • Safe and Secure Access: Maintain and monitor industrial networks using data access ports

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Comprehensive Systems To Meet Your Needs • Wiring Duct • Ferrules, Disconnects, and Terminals • Outlets • Installation Tools • Cable Ties and Wiring Accessories

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Visit www.panduit.com today for free control panel reference documents that can help to lower your panel costs.

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EDITOR’S PAGE

A CONNECTED

Published By:

EASTERN TRADE MEDIA PTE LTD (A fully owned subsidiary of Eastern Holdings Ltd)

FUTURE

SENIOR EDITOR

Joson Ng

josonng@epl.com.sg ASSISTANT EDITOR

Mark Johnston

markjohnston@epl.com.sg EDITORIAL ASSISTANT

Sharifah Zainon

The Internet of Things (IoT) is a term that many industries

sharifah@epl.com.sg

are talking increasingly about; many with great excitement for the

GRAPHIC DESIGNER

Peh Loon Chin

transformative effect of this technology, others with a sense of

pehloonchin@epl.com.sg

trepidation about what may happen and being left behind or the

SENIOR SALES MANAGER

Derick Chia

derickchia@epl.com.sg

disruptive effect of this technology.

ASSISTANT SALES MANAGER

There are many definitions being discussed about what IoT is and

Joey Peh

joeypeh@epl.com.sg

what it can do for people and how big the potential market is. As a ASSISTANT CIRCULATION MANAGER

Chiang Hui

technology, IoT is enabling consumers, buildings, industrial facilities,

chianghui@epl.com.sg

and entire companies to become connected. A current challenge for

CIRCULATION EXECUTIVE

Nurulhuda Binte Suhaimi

IoT is it creates an exponential amount of data, much more than what we can find use for. This feeds into another often discussed trend, ‘Big Data’, whereby uses for such huge amounts of data are found by making sense of this data.

nurulhuda@epl.com.sg CONTRIBUTORS

Philip Tang, Mathias Ams, Chua Siang Poh, See Ya-Pei, Robert A Reid, Daniel T McGrath, Michael Hines, Didier Lacroix, Amit Singh, Pankaj Sharma, Rajiv Ghatikar, Jeremy Lee, Augustine Quek EDITORIAL CONSULTANTS

Jim Pinto

Intelligent technologies in the Building Automation sector are

Industry Analyst

expected to reach US$74.8 billion by 2019. IoT will play an increasingly

Alastair Ross Director, Codexx Associates Ltd

important role in this business, increasing the efficiency and connectivity of buildings in the future. Energy management will be a major market for IoT technologies and the industry will welcome

SUPPORTED BY:

its benefits. The major driving factors for the Intelligent Building Automation Technologies market are efforts to reduce CO2 emissions, enhanced safety and security in intelligent buildings, sizeable reduction in

EASTERN HOLDINGS LTD EXECUTIVE BOARD CHAIRMAN

operating costs, and incentives provided by government. We will discuss intelligent building technologies in this issue of IAA, together with machine vision, data centres, fibre optic solutions, and motion, drives and control technologies.

Kenneth Tan EXECUTIVE DIRECTOR

Lum Kum Kuen

etm

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Mark Johnston Assistant Editor

MCI (P) 018/07/2014 ISSN 0219/5615 PPS 1561/06/2013 (022960) Co Reg No. 199908196C Printer: Fabulous Printers Pte Ltd

industrial automation asia | August 2014

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Philippines 1800 1888 3834 Vietnam 1800 585 837 Indonesia (62) 21 2924 191

Other ASEAN Countries (65) 6226 5886

ENQUIRY NO. 735

29/7/14 12:54 pm

INDUSTRY NEWS Emerson’s Singapore Service Centre Achieves Accreditation For Flow Calibration Singapore: Emerson Process Management announces its Singapore Flow Service Centre calibration and facilities have been certified as meeting the requirements of ISO/IEC 17025. The accreditation, by the Singapore Accreditation Council (SAC), confirms the company’s ability to perform testing and calibration of Coriolis flowmeters at the centre. In Singapore, ISO/IEC 17025 calibrations are mandatory for custody transfer applications to comply with legal metrology regulatory requirements. Previously, devices had to be shipped to other facilities for calibration, which increased lead time due to transit. The accredited Singapore calibration laboratory allows customers quick access to the company’s services within Singapore and Southeast Asia to meet their needs. Confidence in the technical competency of a calibration laboratory with ISO/IEC 17025 accreditation improves acceptance of goods exported internationally and customers can avoid expensive retesting when products reach their final destination. This accreditation expands customer

The company’s Singapore Flow Service Centre calibration and facilities have been certified as meeting the requirements of ISO/IEC 17025.

access to high-level calibration services and broadens the company’s calibration capabilities for Asia Pacific customers, including Singapore, Malaysia, Indonesia, Thailand, and other Southeast Asian countries. ISO/IEC 17025:2005 specifies the general requirements for the competence to carry out tests and/ or calibrations, including sampling. It covers testing and calibration performed using standard methods, non-standard methods, and laboratorydeveloped methods.

To meet the requirements of ISO 17025, the measurement uncertainty (accuracy and repeatability) of the calibration rig must be defined and documented. Calibrations are available for device line sizes of 0.25” to 4”, suited for devices used in oil and gas, chemical, life sciences, and terminal applications. In addition to ISO/IEC 17025 calibration, the centre also offers product analysis, repair, and training. The intention is to expand the calibration accreditation to other flow measurement technologies in the near future.

RS Components And Allied Electronics Expand Semiconductor Offering Singapore: RS Components (RS) and Allied Electronics (Allied) have signed an agreement with Rohm Semiconductor that positions RS and Allied as an authorised global distribution partner of the electronic component vendor. Both companies hold a sizeable inventory of several hundred

Rohm components, which includes discrete semiconductors, power management ICs, LEDs, display drivers, optical switches, video and audio processor circuits, and sensor devices. These devices are extensively deployed in a wide array of automotive, telecommunication, computer and

consumer applications. The new authorised distributor status bolsters the company’s alliance with Rohm, and provides a platform from which to substantially broaden the selection of its parts available direct from stock at the distributor’s global warehouses.

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Industry News

Rockwell Automation Focuses On Myanmar As Its Next Strategic Market Singapore: Rockwell Automation has announced that it will now focus on Myanmar as its next strategic market in Southeast Asia to drive further growth in its already strong revenue stream. The company has appointed Mins Control Systems Solution (MCSS) as its first recognised System Integrator for Myanmar to meet industrial automation demand by machine builders and Original Equipment Manufacturers (OEMs), as well as end users, seeking smart, safe and sustainable solutions for improved productivity and profitability. “We have been eyeing Myanmar to add to Rockwell Automation’s other Southeast Asia markets of Indonesia, Malaysia, Philippines, Singapore, Thailand and Vietnam. We are pleased that the time is now right for us to move in and capitalise on its robust economic growth and investment-friendly environment. Since

Staff and representatives from Rockwell Automation Southeast Asia and Mins Control Systems Solution (MCSS).

manufacturing constitutes about 20 percent of the country’s GDP, with oil and gas, construction, infrastructure and consumer packaged goods being important sectors, Myanmar is a natural expansion market for us. By leveraging

MCSS’ capabilities and experience, Rockwell Automation can now establish a foothold in Myanmar for our industrial automation technologies,” added Chris Marshall, market access director, Southeast Asia, Rockwell Automation.

Annual Internet Traffic To Grow More Than 20 Percent By 2018 Singapore: According to the Cisco Visual Networking Index Global Forecast and Service Adoption for 2013 to 2018, global Internet Protocol (IP) traffic will increase nearly threefold over the next five years due to more Internet users and devices, faster broadband speeds and more video viewing. Global IP traffic for fixed and mobile connections is expected to reach an annual run rate of 1.6 zettabytes — more than one and a half trillion gigabytes per year by 2018. The projected annual IP traffic for 2018 will be greater than all IP traffic that has been generated globally from 1984 to 2013 (1.3 zettabytes). The composition of IP traffic will shift dramatically in the coming few years. During the forecast period, the majority of traffic will

originate from devices other than personal computers for the first time in the history of the Internet. Correspondingly in Singapore, mobile data usage has increased by approximately 30 times from 0.25 petabytes in 2008 to 7.66 petabytes in 2013. Wi-Fi traffic will also exceed wired traffic for the first time. Today, Wireless@SG provides Singapore with free Internet access at 7,300 hotspots at speeds of up to 2 Mbps. IDA have also announced a regulatory framework that will free up TV White Space (TVWS) spectrum for wireless broadband communications and it can provide Wi-Fi capabilities with lower power consumption and cost as well as longer coverage range. Singapore is one of the first few countries in the

world to implement such a framework and the regulations will take effect from November 2014. In addition, Singaporeans are downloading and streaming more video content on the Internet, with consumers spending an average of 12.9 hours per week to access mediarelated websites. High-definition (HD) video will eventually constitute the bulk of the video content accessed as HD video will generate more traffic than Standard Definition (SD) video in the next few years. The Internet of Everything is also gaining momentum and by 2018 there will be nearly as many Machineto-Machine (M2M) connections as there are people on earth. Smart cars will have nearly four M2M modules per car.

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Reduce energy costs and gain competitive advantages with Energy Management Systems Building managers need Building Energy Management Systems to understand and improve their buildings’ energy usage. At TÜV SÜD, our Energy Management System (EnMS) consultancy services stands ready to help you set up your EnMS. With an effective EnMS, building owners and operators can integrate best energy management practices into their operations. For enquiries, please contact us at +65 6778 7777 or email enquiries@tuv-sud-psb.sg.

ENQUIRY NO. 738

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Industry News

Grundfos Supports The Green Growth Of Smart Nations Singapore: The Singapore and Danish Environment Ministries signed a bilateral agreement on June 3, 2014 during Singapore International Water Week to deepen environmental and water relations between the two countries. This will set the stage for more public-private sector collaboration on environmental and water sustainability, such as the MOU between global pump manufacturer Grundfos and Singapore’s national water agency PUB, to co-develop water technologies and solutions to meet current and future water challenges. Speaking on the importance of collaboration and the role of water technology in the evolution of smart nations at the signing ceremony for

both MOUs was Poul Due Jensen, Grundfos’ Group senior VP and regional MD for the Asia Pacific. “Grundfos recognises Singapore as the world-leading water hub for water technology and we are very impressed by the country’s leadership and focus on this area. Singapore uniquely has managed to closely tie together excellent academic institutes, a public utility organisation that is on the forefront in the world; and likewise, the right conditions for entrepreneurship and R&D activities,” he remarked. “The MOU with PUB marks the next step in our activities in Singapore. It will accelerate and open the doors to more research that is focused on the current and future needs of Singapore.

Poul Due Jensen, Group senior VP and regional MD for the Asia Pacific, Grundfos

We share the drive to develop responsible and sustainable solutions to the world’s most demanding water challenges, and are committed to create a platform for discussion and exchange of ideas on areas such as water and energy efficiency, water and wastewater treatment and likewise water quality.”

ABB Opens Regional Robotics Hub To Drive Productivity In Southeast Asia Singapore: ABB has officially opened its Regional Robotics Packaging Application Hub in Singapore. The centre reinforces the company’s position in robotics in Southeast Asia, providing value-added engineering solutions in industrial manufacturing processes tailored for the Asia market. A s p a r t o f t h e c o m p a n y ’s commitment and Singapore’s impetus to drive innovation and productivity, the hub will be a platform to develop novel robotics manufacturing solutions in hardware and software to benefit growing industries such as food and beverage, pharmaceutical, consumer electronics, and solar photovoltaics. The hub will also serve as a live learning and collaborative environment through research and problemsolving from real industrial cases. Through training industry partners and educational institutions, the company will help to develop highly competent engineering talents to serve the region,

The hub will be a platform to develop novel robotics manufacturing solutions in hardware and software to benefit growing industries such as food and beverage, pharmaceutical, consumer electronics, and solar photovoltaics.

accelerating the growth of technical competencies locally and regionally. An extension of its Robotics Application Centre that was set up in 2010, the new 600 sq m workshop features demo units for picking, packing

and palletising processes. The facility will allow end customers, channel partners and ABB to run trials with actual products, assemble robotics systems and conduct factory acceptance tests before delivery.

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Industry News

SDV Deploys Manhattan Supply Chain Commerce Platform Malaysia and Singapore: Supply Chain Commerce Solutions provider Manhattan Associates has announced that SDV, a supply chain management services company and a subsidiary of Bolloré, has successfully deployed Manhattan Associates’ Warehouse Management solution (WMS) to orchestrate the regional supply chain operations of Clarins and Sephora in South East Asia. French company Clarins is an international manufacturer and distributor of cosmetics, skincare and perfume brands. With the support of Manhattan’s solutions, SDV operates Clarins’ Regional Distribution Centre (RDC) in Singapore which, in turn, replenishes the cosmetics group’s country level Distribution Centres (DCs) throughout Asia Pacific. The RDC also distributes the company’s products directly to the local Singapore market, handles returns from local stores and manages inventory flows within Asia, between France and Asia and from the Singapore hub to global destinations. The company’s WMS has helped SDV: drive operational improvements within the RDC — including the optimisation of warehouse space and picking productivity; streamline batch decoding to better manage manufacturing and expiry dates; and improve service levels to stores and franchisees across the region.

Omega Engineering Launches New Websites In SEA And Taiwan Singapore: Omega Engineering has launched new dedicated websites for Malaysia, Philippines, Taiwan, and Thailand; to select your country, visit www.sea.omega.com. The addition of these websites will enable customers to generate quotations and buy the company’s products online in their respective currencies. The company offers more than 100,000 products for measurement and control of

temperature, humidity, pressure, strain, force, flow, level, pH and conductivity as well as a complete line of data acquisition, electric heating, and custom engineered products. The organisation’s Singapore website will continue to support Singapore and other Southeast Asian countries, such as Brunei, Cambodia, Indonesia, Laos, Myanmar, and Vietnam.

Four Awards For Tata Communications Singapore: Tata Communications has won three awards in the Enterprise Telecom Services category and one award in the Enterprise Infrastructure category at the 2014 Frost & Sullivan India ICT Awards. The Awards ceremony, attended by the telecom industry’s leading players, saw the company take centre stage to receive three ‘Service Provider of the Year’ awards for: 1) Audio Conferencing 2) Enterprise Data, and 3) Third-Party Data Centre, along with the award for Enterprise Ethernet Provider of the Year.

Anand Jethalia, Abhishek Mishra and Prabakaran Sivaguru, Conferencing and Collaboration Team, Tata Communications, receiving the ‘Audio Conferencing Service Provider of the Year’ Award from Dinesh Kumar, CIO, Bajaj Group & Wave Infratech, in the presence of Benoy CS, director, ICT Practice, Frost & Sullivan

Three Polytechnic Student Teams Lauded For Engineering Ingenuity Singapore: Daring to challenge conventions and passionate about serving the community, three teams from local polytechnics won the coveted IES Design Awards 2014 for their ingenious engineering innovations. Heng Swee Keat, Minister for Education presented the Gold Award to Temasek Polytechnic, the Silver Award to Ngee Ann Polytechnic and the Bronze Award to Nanyang Polytechnic at the National Engineers Day (NED) 2014 opening

ceremony at NUS University Town. The 2014 Gold Award went to Yang ShuangHe and Jia YiXin from Temasek Polytechnic for the ‘Mobile Body Balance Coaching Application’; the Silver Award to Tang Boon Ting, Siow Shu Yi, Wong Jin Wei and Cheong Yi Jie Louis from Ngee Ann Polytechnic for the ‘Adjustable Walking Frame’; and the Bronze Award to Glenn Chee Jun Yuan from Nanyang Polytechnic for the ‘NFC+ Elderly Medical Assistant System’.

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Industry News

Vodafone Report Shows Global Market For M2M Surging Ahead Singapore: Vodafone has published its second annual ‘M2M Adoption Barometer’, a global survey of the Machine-to-Machine (M2M) market, which finds that M2M adoption has increased by more than 80 percent, with over a fifth of companies now actively using the technology. M2M, which connects previously isolated machines or devices to the internet to make the ‘Internet of Things’ possible, is set to grow from 4.4 billion connected devices this year to 10.3 billion by 2018. The survey, carried out by Circle Research, captured the views of more than 600 executives involved in setting M2M strategy in seven key industries across 14 countries, making it one of the leading global surveys of M2M implementation. Three sectors have emerged as front runners in M2M with nearly 30 percent adoption rates: automotive, consumer electronics, and energy and utilities. Automotive is the most mature of the

sectors where M2M is now seen as an enabler for additional services such as remote maintenance and infotainment. M2M adoption in energy and utilities is also growing rapidly as ‘smart’ home and office services such as intelligent heating and connected security gain popularity. The report shows that the consumer electronics sector is at the forefront of a shift from the warehouse to the living room. This uptake is being fuelled by the use of M2M in connected devices such as smart televisions and games consoles. The research shows that nearly three quarters of consumer electronics companies will have adopted some form of M2M by 2016, whether for new products, logistics or production. Similarly, the report anticipates that 57 percent of healthcare and life sciences companies will have adopted M2M technologies by 2016. Take-up in the transport and logistics sector will be driven by fleet management benefits,

M2M is set to grow from 4.4 billion connected devices in 2014 to 10.3 billion by 2018.

as M2M-led routing, job allocation and maintenance schedules become even more evident. While more firms are seeing a return on investment from M2M than last year — 46 percent of respondents cited a ‘significant increase’ compared with 36 percent in 2013 — there are still some barriers to adoption, including managing security concerns and the challenges of global deployment. As predicted in last year’s report, the US has been overtaken by the Asia Pacific region as the geography with the widest adoption of M2M. This year’s report suggests that by 2016 the gap will be negligible with all regions close to a 55 percent average for adoption.

Honeywell To Automate Oil Sands Project In Canada Houston, US: Honeywell Process Solutions has been selected by Suncor Energy to provide automation systems for a new multi-billion dollar Fort Hills Oil Sands project in Alberta, Canada. The company will supply technology to integrate the site’s control and safety systems, manage alarms, and provide advanced simulation software that enables critical operations planning and operator training. As the Main Automation Contractor (MAC), the company will play a key role in helping the facility achieve its future

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productivity and operational efficiency goals. The facility is expected to be operational in late 2017. The Canadian Association of Petroleum Producers forecasts production from the Canadian oil sands to exceed five million barrels a day by 2030, up from 1.8 million barrels a day in 2012. “As energy demand continues to grow, the Canadian oil sands have become an important resource,” said Frank Whitsura, VP, Honeywell Process Solutions.

The company will supply technology to integrate the Fort Hills Oil Sands project site’s control and safety systems, manage alarms, and provide advanced simulation software that enables critical operations planning and operator training.

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Industry News

Basler Celebrates Opening Of Camera Assembly Facilities In Singapore Ahrensburg, Germany: With the Asia Pacific market for digital industrial cameras growing faster than any other worldwide, Basler is expanding production of its ace series cameras to meet this demand. A new facility, located in Singapore, will serve as the final assembly and distribution point for the most popular ace camera models. The locally assembled cameras will be

sold to the Asia Pacific market. The new production line was conceived and built in Germany and employees at the plant were trained at the company’s headquarters before the line was shipped to Singapore. The quality assurance protocols that originated in the company’s German facility will be duplicated in the Singapore location. As in Germany, every

camera will mechanically, optically and electronically be tested before it leaves the Singapore factory. The line also incorporates fully automated sensor positioning in order to guarantee consistency among all ace units sold and the highest quality standards at each production site. The company’s ace cameras will start rolling off the Singapore facility’s line in August 2014.

Bosch Heads Up Industry 4.0 Research Project IT Infrastructure For Smart Factories Stuttgart, Germany: In the future, Cyber-Physical Production Systems (CPPS) will allow industry to manufacture more flexibly and efficiently. Made up of intelligent machines, storage systems, and operating resources, these systems can autonomously exchange information, trigger processes, and control each other. An important foundation still missing for CPPS, however, is an integrated information and communication infrastructure that connects the entire system and other CPPS to each other, even between companies. A research team has set itself the task of developing this infrastructure. Supported by the German Federal Ministry for Economic Affairs and Energy, the Context-Aware Connectivity and Service Infrastructure for Cyber-Physical Production Systems (CoCoS) project kicked off at the beginning of this year and is set to run through the end of 2016. A consortium of industrial companies and academic partners are working on the CoCoS project. Heading up the project is Robert Bosch in Stuttgart. Additional partners are the German Research Centre for Artificial Intelligence (DFKI) in Kaiserslautern, DMG Electronics in Pfronten, Technische Universität Berlin, trustsec IT-Solutions in Stuttgart, and XETICS in Stuttgart. To document

Industry will be able to use the structures and functions of the Internet of Things to create smart, flexible production systems, making them a vanguard of Industry 4.0.

the performance capacity of the new platform philosophy, three of the partners — Bosch, DFKI, and DMG — are each building a demonstrator. These individual demonstrators will then be coupled together and evaluated. The CoCoS findings will lend themselves to application wherever production is split into several steps, such as the delivery of raw materials, the manufacture of components, or finished products — even when the production steps take place in different companies or at different locations belonging to a single company. CoCoS is as such helping to establish CPPS, which in turn will form the core of smart factories.

Industry will be able to use the structures and functions of the Internet of Things (IoT) to create smart, flexible production systems, making them a vanguard of the so-called fourth industrial revolution (Industry 4.0). This could give Germany a distinct competitive advantage both as a manufacturing location and as a leading global provider of plant equipment. Part of the ‘Autonomics for Industry 4.0’ technology program, CoCoS is receiving some �2.4 million (US$3.21 million) of funding from the German Federal Ministry of Economic Affairs and Energy (BMWi), following a decision in the German Bundestag. August 2014 | industrial automation asia 17

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Industry News

Harting Opens Quality And Technology Centre Espelkamp, Germany: Following a one-year construction period, the Harting Quality and Technology Centre (HQT) has officially opened its doors. At the HQT, the company will be researching new technologies, as well as developing quality products and solutions for the ‘world of tomorrow.’ “According to our vision, we want to shape the future with technologies for people. In opening our new Harting Quality and Technology Centre we have taken a decisive step forward in pursuing our course“, as Margrit Harting, senior VP and Partner, was pleased to inform some 180 attending guests. In his speech, Dietmar Harting, chairman of the board and personally liable partner, highlighted quality and technology as key drivers of innovation and growth. Dr Frank Brode, board member Quality and New Technologies, also addressed

The company will be researching new technologies, as well as developing quality products and solutions for the ‘world of tomorrow’.

the positive future aspects. “In establishing the HQT we made a conscious decision in favour of a transparent architectural concept fostering an open exchange of

ideas. The open campus structure enables the addition of further areas, thereby driving future growth“.

Applied Materials And Tokyo Electron Unveil New Company Name

Gary Dickerson, CEO, Applied Materials (left), and Tetsuro (Terry) Higashi, chairman and CEO, Tokyo Electron (right), unveil ‘Eteris,’ the new name and logo of their combined company once the merger is approved.

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San Francisco, US and Tokyo, Japan: Applied Materials and Tokyo Electron have unveiled the name and logo of their combined company which will be used once the merger closes. Derived from the concept of eternal innovation for society, Eteris [pronounced: eh-TAIRiss] embodies the spirit of what will drive the new company and speaks to what makes the combination unique. The unveiling of the company’s name and logo are the latest milestones in the merger’s progress. In June 2014 the stockholders of the two companies declared strong support for the combination. Approximately

99 percent of the shares voting at the Applied Materials stockholder meeting and 95 percent of the shares voting at the Tokyo Electron stockholder meeting voted to adopt the proposed business combination. These results underscore the value the combination brings to stockholders. The closing of the business combination remains subject to customary conditions set forth in the parties’ Business Combination Agreement, including review by regulators in various countries. Both companies expect the transaction to close in the second half of 2014.

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Apacer IAA AD-May2014-205x275mm-Revised-2.pdf Apacer Apacer Apacer IAA IAA IAA AD-Aug2014.pdf AD-Aug2014.pdf AD-Aug2014.pdf 2014/7/14 2014/7/14 2014/7/14 下午下午下午 02:44:55 02:44:55 02:44:552014/4/16 上午 11:51:35

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June 3-7,2014 BoothJ0818 ENQUIRY NO. 739

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INDUSTRY UPDATES

Diagnostic Mechanisms For Reduced Downtime PROFINET is based on Industrial Ethernet. In some cases this network structure can be quite complex due to the flexibility of Profinet. Profinet Technology offers m a n y s t a n d a rd d i a g n o s t i c mechanisms. Besides the diagnostics, Profinet offers related Ethernet standards such as Simple Network Management Protocol (SNMP) or Link Layer Discovery Protocol (LLDP). These mechanisms are standards which are built-in in a lot of Profinet devices available on the market. Sometimes it is not easy to keep an eye on the often complex and ﬂexible network architecture of a production plant. But a clever industrial network management tool or engineering software which automatically creates

Meaningful Device Name for easier identification of the failure.

pictures of the current network topology helps maintenance personnel with error analysis.

The Addressing Of A Proﬁnet Device Ever ything star ts with the addressing of a Profinet IO device; the big advantage is that the connection between a ProfinetIO controller and the remote IO device will be established over a ‘Device-Name’.

The device can already be equipped with a logical name, ie: location, panel number, and so on. In this case all diagnostic messages and events will include this device name and the maintenance personnel will already know where the failure occurred. A faster reaction to failures is possible. The diagnostic messages for the engineering tool will be compiled; device specific

Topological overview of a Profinet IO network.

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diagnostic is a par t of the imported GSD or GSDML file.

Topology Knowledge Is The Key To Success Such pictures graphically depict the structure of the network with the physical connections between the devices as well as their arrangement. Errors can be easily localised with the help of these pictures, for example, in plants that are networked with Profinet. The importance of knowing the topology increases with the number and variety of devices and network structures. Modern engineering tools are able to read back the topological information from the Profinet IO system and create a topological map of the network.

Working Concept Of Topology Detection A reliable method was introduced with the LLDP standard (Link Layer Discovery Protocol; IEEE 802.1AB) — also for Profinet — to find out more about the neighbourhood. LLDP helps devices discover information about their immediate neighbours

Web diagnostic to read back status of the controller and the connected fieldbus systems.

in the network at regular intervals and save this information for each device in the special Management Information Base (MIB) — RFC 2922; Physical Topology MIB. Mutual recognition using LLDP requires this function to be used throughout the system. However, a large network can always include devices that do not support this standard. What is more, there are also m a n u f a c t u re r - s p e c i f i c a n d model-specific differences in the data offered by SNMP. This means topology tools must use a

Working concept of Link Layer Discovery Protocol (LLDP).

variety of sources and be able to compensate any gaps in the data by employing special algorithms. If these gaps are too large or the results too inconclusive, the user can still correct them. But automatic topology re c o g n i t i o n a l w a y s w o r k s when standardised network components with SNMP and Profinet support are used.

Web Based Diagnostic For Remote Services In the past it was required to have an engineering tool and an engineering license just to read back some basic diagnostic data from the controller. Today it is already almost a standard the Profinet-Controller have a web diagnostic implemented to display the status of the central station as well as the connected fieldbus systems such as Profinet or Profibus. With every web browser it is possible to connect to the PLC and read back different information. This can also be possible with a smart-phone or tablet PC. ENQUIRY NO. 5101 August 2014 | industrial automation asia 21

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Newsdesk Newsdesk

CiA 402:

The Dominating Profile In Motion Control MOST of the motion control and drive manufacturers have implemented the CiA 402 communication profile. It is internationally standardised in the IEC 61800-7 series. Sub-part 201 specifies all the process data and the configuration parameters including the addresses in the CANopen dictionary. The CANopen dictionar y is the standardised deviceinternal list of parameters. This sub-part also specifies the different operation modes (eg: the profile velocity and the profile position mode for servo motors as well as the velocity mode for frequency inverters). The sub-part 301 standardises the mapping to different communication protocols. For CANopen, especially the PDO mapping is specified. Other mappings are for the Ethernet-

based protocols CC-Link IE, EPA, Ethercat, and Powerlink. Motion Controller Design CiA 402 communication is sometimes invisible, because it is used in local communication networks for multi-axis applications. Several vendors use CANopen networks just locally and provide any interface as connection to the host controller. There is also one supplier, who offers the CiA 402 interface just for configuration services, even when the devices are linked to the host controller by other network technologies. This shows and indicates that CiA 402 is one of the best-designed motion controllers and drive profiles. Recently, the CiA users and manufacturers group released an additional PDO mapping (CiA 402-5) for devices, which are able to control servo motors as well as frequency inverters. The generic and the typespecific PDO mappings are standardised in IEC 61800-7-301. This standard is under review and

The STAC6-C series of servo drives by Applied Motion products is just one example of the many products featuring CiA 301 (CANopen) and CiA 402 (motion control profile) functionality.

Measuring just 13 mm, the Gold Twitter by Elmo is one of the smallest CANopen servo drives suitable even for very space-limited applications such as service robots and medical devices.

has already passed the committee draft status. Before publication, it was again updated and again voted as a draft international standard. CiA 402 Applications The CiA 402 profile is mainly used in servo and stepper motor controllers. In particular, compact motion controllers implement CANopen interfaces with CiA 402. They are used in a wide variety of applications including packaging, textile, and plastic processing machines. In the future, such motion controllers will also be used in service robots. Some of these robots are batter y-powered. Other typical applications include laboratory equipment and medical devices. CiA 402 functions are also referenced in the CiA 417 CANopen profile for lift control systems for the car drive unit. ENQUIRY NO. 5102

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admeijer, Netherlands

Enhancements To Foundation Technical Specifications Foundation for ROM integrates remote Input/Output (I/O), ISA 100.11a, WirelessHART, wired HART, and Foundation fieldbus H1 protocols into a single, open-standard data management environment. THE Fieldbus Foundation has announced the latest updates to its open, non-proprietary Foundation fieldbus technical specifications. The specification updates (Version 2014.1) will further enhance Foundation for Remote Operations Management (ROM) and the usability of Foundation technology. The Foundation for ROM specification-related updates, along with an update to the Common File Format (CFF) specification, have improved coverage of ROM communication profiles under existing specifications in preparation for the first official ROM device registrations. Additionally, there is expanded specifications support for complex, mixed conventional I/O points. Foundation For ROM The first development of its kind, Foundation for ROM integrates remote Input/Output (I/O), ISA 100.11a, WirelessHART, wired HART, and Foundation fieldbus H1 protocols into a single, open-standard data management environment. With Modbus incorporation under development, Foundation for ROM allows full integration of field connected assets into the Foundation fieldbus infrastructure. These enhancements further extend the capabilities of Foundation fieldbus to wired and wireless devices installed in some of the world’s harshest and most remote locations. This open, non-proprietary solution provides a unified digital infrastructure for asset management in applications ranging from tank farms and terminals

Usability is an important element of this specification. The ultimate goal of this usability initiative is to make the end users’ experience with Foundation technology easier than with conventional analogue control systems.

to pipelines, offshore platforms, and even Original Equipment Manufacturer (OEM) skids. Usability Initiative As part of this new technical specifications release, a fixed set of Device Description (DD) Symbol IDs was added to technical note 16 in order to improve interoperability between backwards-compatible devices and host systems. This provides a more reliable way for a host to properly take advantage of the backwards compatibility of a device. In 2013, the foundation created a continuous improvement process initiative with the ultimate goal of making the end users’ experience with Foundation technology easier than with conventional analogue control systems. Since then, the Usability Initiative has resulted in four immediate objectives toward this common goal: backwards compatibility, pre-defined device templates, automated device replacement, and process value interchangeability. Backwards compatibility simplifies device replacement. ENQUIRY NO. 5103

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European EtherCAT

Plug Fest Highlights Master Controller Variety

With 52 participants from 12 different countries and a total of 41 EtherCAT devices, the 2014 European EtherCAT Plug Fest at the facilities of Renesas Electronics in Düsseldorf, Germany, was a success.

RECENTLY, the EtherCAT Technology Group (ETG) invited numerous manufacturers and developers of EtherCAT devices to the 2014 Spring European EtherCAT Plug Fest. A total of 52 participants from 12 countries came together at the facilities of Renesas Electronics in Düsseldorf, Germany, to test their EtherCAT master and slave devices for interoperability and to discuss technology with colleagues and EtherCAT experts on-site. The 17th EtherCAT Plug Fest in Europe proved that these events are still of great interest to manufacturers and developers of EtherCAT products. Testing Opportunities During the event the attendees had the opportunity to test their EtherCAT products for interoperability and to network with colleagues and EtherCAT experts who also joined the event. Thomas Rettig, who was on-site representing 24

the ETG, explained: “During the two day event, 10 EtherCAT masters provided by 10 different manufacturers were tested with 41 different EtherCAT slave devices — numbers that clearly illustrate the continued success of EtherCAT Plug Fests.” On-Site Experts These events take place annually in Europe, Asia and North America, where manufacturers and developers of EtherCAT devices have the opportunity to test their products for interoperability under real network conditions before their marketing and sales efforts begin. Therefore, the official EtherCAT Conformance Test Tool is used at the events, too. The on-site EtherCAT experts answer technical questions and help participating companies avoid possible design flaws during product development. ENQUIRY NO. 5104

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ISSUES & INSIGHTS

connect multiple buildings to the Internet through gateways, by converting information through an IP. A web-based automation system can provide significant facility improvements with a wide range of benefits over previous types of building automation, including:

Building Intelligence

Michiru Maeda, Singapore

An effective building automation system requires the right mix of technology to ensure optimum performance and lower energy costs. By Philip Tang, business development manager, Mitsubishi Electric Asia

t is all about growth. From the mere individual to the mighty corporation, growth is a popular indicator that signifies progress and success. In Building Management Systems (BMS), Navigant Research has predicted that global revenue for networked building automation control devices will rise from US$20.1 billion in 2013 to US$34.7 billion by 2021. As the various systems in a building often have their own proprietar y communications protocols, connecting them can be a challenging task. Therefore, the market is trending towards

the adoption of open protocols — which allow for more manufacturers to service the market. Navigant also mentions that Internet Protocol (IP)enabled devices play a role in this transition.

Offsite Access/Web-Based HMI Web-based BMS offers control and monitoring through any common web browser. Conventional building automation systems feature a central computer that is linked to controllers embedded into each function of a building. Web-based building automation systems allow operators to

• Reduced staffing needs — Web-based building automation allows a single building operator to easily access and manage system information, even while away from the building. As such, they can monitor multiple locations simultaneously. The immediate benefit is a massive reduction in expenses as staffing costs can be cut by 50 percent or more. • Enhanced security — Security personnel can monitor alarms and Heating, Ventilation and Air Conditioning (HVAC) conditions at all times, even off-site. • Data accessibility at all times — Specialists can pull up and analyse facility data from anywhere and at anytime, to work on projects or resolve problems. Decisions can be made remotely from real data and not based on assumptions. • Occupant options — Building occupants have the flexibility of requesting temperature points, temperature readings, HVAC operation, and air quality information. • Customer service — Customer ser vice processes can be expedited and enhanced. WebHMI uses a Web browser, such as Microsoft Internet Explorer, to provide an interface with MC-Works Super visor y Control And Data Acquisition (SCADA) graphics, trending and alarming applications (applications found within the HMI/SCADA suites). It delivers all the necessary components August 2014 | industrial automation asia 25

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ISSUES & INSIGHTS

Features

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Web Access to Business and Factory Information

Connect to ‘live’ plant, facility or corporate data over the Internet.

Thin-Client Architecture Requires No Installation

Delivers thin client visualisation, trending, alarming and reporting.

Firewall and Corporate IT-Friendly

Works with firewalls and routers over Local Area Networks (LANs), Wide Area Networks (WANs) and the Internet.

Data-Mine Historical Data from Standard Databases

View historical data from Microsoft SQL Server 2008, SQL Server Express, Microsoft Access, Plant Historians and more.

Comprehensive Security

Integrate with Windows security for ease of use.

Scalable Web Server Architecture

WebHMI scales seamlessly as applications and connections grow.

from a centralised Web server, for automatic installation to any PC that is running any browser. It is neither necessary to install any additional software onto the remote clients nor to export or convert displays, as it is equipped to handle all the required work processes. Managers, supervisors and operators can simply direct their browsers to the Web pages containing production reports, HMI graphics, historical trends and alarms. As the client PC loads the requested Hypertext Mark-up Language (HTML) page from the designated Web server (running WebHMI Server software), the necessar y components are automatically loaded onto the client PC in the background.

Overseeing Assets/ Predictive Software For Facilities Management/ Assets Management To d a y, c o r p o r a t i o n s a n d government entities demand that their facility portfolios are managed with ever-tightening goals — for both cost efficiency and to minimise environmental impact. In order to achieve operational

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goals, it is necessary for them to possess the ability to: integrate information from all building e q u i p m e n t , e n v i ro n m e n t a l sensors, occupancy tracking and energy metering. The information then has to be presented in a way that is meaningful and useful for decision-making. Facility AnalytiX is a complete, continuous commissioning software solution that is based on advanced Fault Detection and Diagnostics (FDD) technology. It is used to detect and diagnose faults for various types of building and manufacturing equipment. It uses the FDD algorithms to determine probable causes when abnormal conditions are detected on monitored equipment. The software solution also incorporates user customisable fault rules to calculate the probability of equipment failure. Personnel are then advised of immediate preventative actions that they can perform before faults occur, thereby improving safety and achieving energy savings. In the event that equipment failures do occur, the software analyses current and historical information, along with symptom/

cause relationships that the system has been taught. It executes probability algorithms and provides the user guidance with a list of probable causes — all sor ted according to descending order of probability. This immediate guidance reduces the time needed for diagnosis and repairs to be carried out. At the same time, equipment downtime is minimised while overall maintenance costs are reduced.

Keeping Track of Energy Consumption In today’s competitive global economy — with soaring energy prices and increasing environmental regulations — the ability to quickly analyse and closely control operating costs is critical. Managers and asset owners are searching for ways to lower energy costs, reduce consumption and minimise their carbon and environmental footprint. Energy AnalytiX is an EMS used for monitoring, analysing and managing energy use. It delivers rich platform and browser-independent real-time visualisation. The system is flexible and can be applied to applications ranging from a single building to an entire campus or multi-site enterprise. In addition, it is firewall-friendly, and provides secure custom energy dashboards and kiosks from which to view energy reports. This allows users to analyse energy consumption patterns, resource usage and to monitor progress on achieving sustainability goals. Site managers, building engineers or maintenance personnel can quickly and intuitively navigate and discover opportunities for continuous improvement.

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Claudio Jule, US

Managers and asset owners are searching for ways to lower energy costs, reduce consumption and minimise their carbon and environmental footprint.

The EMS acquires energy meter data from electric, gas, fuel oil, steam, chilled water or other meters through any available networking method. Via web services and International Electrotechnical Commission (IEC) protocols it is able to interface with the smart grid to collect rate and other supply information. It aggregates and records consumption data for long term archiving, continuous analysis and comparison.

The rate model configuration tools enable users to use virtually any rate model that their utility contract defines. This is so that costs can be automatically derived and recorded for comparison to budgets and past performance; and for the validation of actual utility bills.

Analysing Alarm History Alarm analytics enables plant personnel to visualise, analyse, and manage alarm information in accordance with industry best practices. The push for operational excellence in the manufacturing industry is driving the need for more effective alarm analytics. The proper analysis of alarms and events in a manufacturing plant can reveal significant opportunities for improving

current operations and mitigating abnormal situations. BizViz Alarm Analytics captures and analyses all alarm and event information to identify frequent a l a rm s , c h a t t e r i n g a l a rm s , cross-correlated alarms, and other alarm-related issues. This module also records, analyses, and displays operator-initiated process changes, and provides insight into the performance of the entire system. It is evident that technology plays a pivotal role in the management of building functions. By investing in the right tools, building owners and managers will be able to reduce costs, stay competitive and play their part in environmental conservation. ENQUIRY NO. 5201

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PROCESS CONTROL

Motion Control:

Safe Drive Monitoring With Added Value

Motion control offers both a safe and economic solution to many applications. By Mathias Ams, motion control product manager, Industrial Safety Systems Division, Sick

uring the setup, maintenance, and servicing of machines, staff members regularly find themselves in close proximity to hazardous points. Motion control technology therefore offers intelligent solutions for safe drive monitoring for use in these types of task. In addition to safety, it also offers increased machine and system productivity. In the operating environment of machines and systems, the safe monitoring of drives in various scenarios is of the utmost importance. Motion control technology offers both safe and economical solutions for performing multiple safe drive monitoring functions. It allows you to safely monitor the machineâ&#x20AC;&#x2122;s movement, providing safe interaction between machine and operator, and also offers

solutions for this task. The speed and position of hazardous movements are monitored safely. Interruption in the machine cycle no longer requires a system stop, increasing productivity of the machine.

Application Fields With Greater Safety And Efficiency Motion control solutions are suitable for access monitoring using standstill detection and reduced speed monitoring in maintenance mode. They can, for example, be used on grinding and polishing machines. Applications include complex multi-axis machines. The technology is used to monitor endof-line and wafer production handling machines for example. The function Safely Limited Speed (SLS)

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enables you to manually intervene in machines and processes without having to stop them. Production waste can be kept to a minimum. On automated guided systems, these solutions enable intelligent speed and direction monitoring as well as stop function monitoring. They are also used as superordinate logic controllers for protective fields covered by safety laser scanners. Moreover, the technology is also used in machines and transpor t systems to monitor movement direction and system stops by activating the function Safe Operating Stop (SOS). The ‘marriage’ of the car body and chassis in car factories is an example of this kind of application, with the car body and the bracket held in position while the connection is made.

An important area of applications is the safe drive monitoring of mobile machines, such as Automated Guided Vehicles (AGVs). The ideal solution for AGVs where people are able to stand in hazardous areas. Working in cooperation with safety laser scanners, it opens up new possibilities: Optimisation of the monitoring of protective fields and monitoring speed and brake ramp. Encoders are centrally connected to the motion control module and as such enable speed and brake ramp monitoring. This monitoring optimises protective fields, ensuring more effective use of the available space. With the aid of the Safe Speed Monitor (SSM) and SLS safety functions, the speed of an AGV can be monitored safely via an encoder on the wheels. Depending on this, the warning and protective fields of the safety laser scanners installed on the vehicle can be switched. If the warning fields are violated, the speed can be automatically and safely reduced. If a protective

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ENQUIRY NO. 683

Safe Monitoring Of ‘Mobile’ Applications

field is violated, the Safe Stop 2 (SS2) or Safe Stop 1 (SS1) and Safe Brake Control (SSC) drive monitoring functions intervene to monitor the vehicle safely and ensure that it comes to a safe stop. If the controller has actioned an emergency stop for an AGV, the Safe Direction (SDI) is activated. This means that the vehicle is only able to move in one direction, as such distancing itself safely from the obstruction. SDI therefore makes a valuable

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PROCESS CONTROL

fault and the machine’s drive is switched off. The major advantage of SLS reducing the speed safely is that processes do not necessarily have to be stopped. Setup processes can be completed more quickly, as the machine can be operated at reduced speed. This allows to improve the machine’s productivity.

Safety When Mechanical Guards Are Open Safe Speed Monitor (SSM) and SOS are implemented functions when mechanical guards such as covers or protective doors are installed to protect hazardous points, but when the operator is regularly required to reach into the process area. Typical examples of such machines include handling systems or machine tools. To allow the operator to reach in Motion control allows you to monitor the machine’s movement, providing safe interaction quickly and safely, for example between machine and opertator. to slide out pallets or to change a work-piece or tool, the technology contribution to structuring transport processes in a initially ensures that the drive comes to a safe stop more flexible and efficient way. and prevents a restart. Immediately afterwards, it releases the opening of the mechanical physical Safety Functions For Drives In guard to provide access to the hazardous point. This quick and safe operation improves the machine’s Stationary Machines Motion control is an intelligent solution for machines productivity and availability without delay. where physical measures are in place to keep the In the event of an emergency, it is crucial for a machine to be able to come to a standstill. In such operator away from the hazardous point, for example situations, the stop function is requested by pressing machine housing, a cover or a movable guard. The an emergency stop button, by opening a protective advantages are: Access protection with standstill door or hood, which has not been mechanically detection allows rapid intervention and maintenance interlocked, or by activating optical protective and service mode with reduced speed settings to equipment. The machine can consequently be shorten changeover and setup times. brought to a standstill in a safe and controlled The technology allows intervention once it has detected a machine’s standstill. Components and manner via the SS1 or SS2 functions. If the machine tools can be quickly replaced in machines secured fails to contact the controller or drive due to a fault, by monitoring the drive and avoiding untinted the mechanical brake can be activated via Safe Brake movement. That ensures safer and more efficient Control (SBC) as a final step. The Drive Monitor’s operation in maintenance mode. SS1, SS2, and SBC functions ensure safe shutdown When working on or in a machine, for example behaviour. The advantage of this is that the shutduring setup or maintenance work, SLS — safe down time and method are known. Shorter defined speed-monitoring function — reduces the risk of stopping distance of machines can be designed injury. It allows for the safe monitoring of a reduced optimally in terms of space and take up less room. machine speed, which is necessary during setup or maintenance of a press, a wood or metal processing Distinction Between Safety And Drive machine, or a gantry robot, for example, thereby Technologies Offers Greater Flexibility enabling the user to manually reach into the hazardous The safe monitoring of drives can be fully integrated area. If this speed is exceeded, it is detected as a into a safety controller — without separating or 30 industrial automation asia | August 2014

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distributing the safety functions at the controller or drive level. As the concept makes a clear distinction between automation and safety technologies, machine manufacturers and integrators can handle the requests of their end customers on an individual basis, for example, regarding the drive components and suppliers to be used. This enables them to optimise costs and use the advantages of market access on a regional level. Meaning that they do not need to rely on particular control and drive manufacturers — unlike in the case of safety integrated solutions — and allows a highly flexible response to the differing requirements of end customers.

Safe Drive Monitoring From A Single Source

ENQUIRY NO. 5301

ENQUIRY NO. 741

Motion control presents countless options for integrated and economical drive monitoring at the highest level of safety technology. What is more, there are also sensors that are not safetyoriented, such as encoders or motor feedback systems, and can therefore provide a complete safety application, including drive monitoring, from a single

manufacturer. For stationary applications, a variety of motors from different manufacturers can be used, where the motor feedback systems are already implemented. With these motor feedback systems, safe monitoring up to PL d/SIL2 with just one speed sensor — the motor feedback system — is possible, if Hiperface (safe) is used. For dual-channel structures, for example in the field of machine tools and processing machines, there are rotary encoders and linear measurement systems. In mobile applications with large pathways and measuring distances, as is common in crane systems, intralogistics, or material handling, systems consisting of encoders and distance-measuring. This all offers the ideal integration into the safety application, the independence from the drive system, means greater flexibility. It offers also a convenient engineering and convenient documentation as well as easy and fast diagnostic options. All together it is an all-inclusive safety application solution.

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The New Era Of Motion Control

Motion control has come a long way from programmable logic controllers to PC-Based control. This transition and its continuing evolution will be discussed. By Chua Siang Poh application engineer, and See Ya-Pei application engineer, Beckhoff Automation (Singapore)

ong before the invention of PC-based control, the Programmable Logic Controller (PLC) dominated the automation industry. PLCs are widely used in various control systems as they have dedicated processors for I/O controls which does not interfere with other devices. Software engineers also favour the simplicity of creating a PLC program based on the IEC61131-3 standard. In a typical PLC-based control system, visualisation, sequence and motion control are often implemented as individual hardware components or â&#x20AC;&#x2DC;black boxesâ&#x20AC;&#x2122;. This involves multiple vendors and takes much effort to integrate. For applications needing higher complexity and more disciplines like vision analysis, some engineers turn to using a PC as PLCs of that era are generally unable to meet this. In classical PC control, programing is done in higher-level languages like C/C++. However, with no definite standard to follow, program codes are highly individualised and difficult to manage. I/O and motion control are usually PCI cards installed in an IPC and wired externally to wiring boards and drives. As the number of I/O and motor axis increases, wire and cabling get unnecessarily complicated and the overall hardware and man-hour costs escalate. Both PLC and PC are still commonly used and have its own group of die-hard fans. However, with increased demands, these two control architectures are facing immense pressure to adapt.

Future Demands In Motion Control As technology progresses, so does our expectations. So what do we envision our machines will become in 10 years? We should be expecting intelligent and powerful machines that are fast in detecting changes, can switch its algorithm dynamically and accordingly, yet simple to build. Traditional methods of synchronisation are seldom flexible, and require complicated mechanical camming-disks. Numerical control offers an alternative motion control that is mathematically driven. By abstracting the motion path, we are able to alter the motion control with just a number of parameters. As such, motion control becomes simpler and dynamic in spite of the increased complexity of control, motion paths, and number of servo axes. To fully utilise this, the motion controller will need to process a large number of calculations and communicate with the drives within a short duration of time. Therefore, this would also imply that motion control architecture must have a very short cycle time. However, the machines are seldom seen as an isolated entity on the production floors. They are part of a smart and networked mesh of machines that shares information on its health, output, and energy consumption. Therefore, an intelligent machine co-operates with existing machines to maximise plant effectiveness. A fast motion control network is

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Merging Of IT And Automation

The eXtended Transport System (XTS) is a drive technology combining linear and rotary drive principles into one.

required, so that data accurately reflects the situation at its point of time. Furthermore, a faster network or fieldbus is required to avoid a network bottleneck due to the amount of data transferred. Despite this, the network topology should remain flexible and robust, yet simple to implement.

The move towards intelligent machines and plants is accompanied by increasingly complex automation architecture. Motion control, in this regard, is no less complicated. To meet the demand of flexible and fast motion control, we need to turn our attention to PCbased motion control. While the ultimate aim remains the same as traditional PLC-based architecture — that is automation — the approach and philosophy is different. By the merging of IT and automation, PC-based control opens up new potentials for the automation industry with the birth of Industry 4.0 and Internet of Things (IoT). Automation can now tap onto the advantages of IT to achieve faster performance with more functionality, but with lower cost. Control systems are no longer limited to industrial networks, but integrated into existing enterprise management networks.

Advantages Of PC-Based Motion Control In 1986, Beckhoff Automation introduced a design, combining the various software functionalities of

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ENQUIRY NO. 700

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PROCESS CONTROL

PLC, visualisation and motion into a single Industrial PC (IPC) platform based on a Windows/Intel architecture. This opened up greater possibility in the automation world for more complex applications. IPCs are designed to exploit the power of the latest computing processors and memory to tackle computational tasks. While the high end PLC may still achieve scan times down to 1ms, even a mid-low range IPC, that is handling even more axes, is capable of scan times in the microseconds. Despite this, the high-end PLC may still cost more than or similar to the mid-low range IPC. Essentially, this means that the cost-performance ratio scales much better for the IPC. Additionally, the IPCs’ functionality can be expanded through PCI cards, such as the integration of vision systems. With a wide variety of interfaces available to IPCs, users need not be locked in to a specific fieldbus, giving users the flexibility to tailor each machine according to the requirements of each plant and production. As a result, its vision, I/O and motion are seamlessly synchronised as one within a single architecture. Other third-party packages, such as SCADA and data-logging software only require a single platform. Certain functionalities traditionally taken care of by specialised hardware can be relegated to software libraries. This eventually leads to cost savings, and simpler mechanical and electrical designs. Beckhoff IPCs runs on Microsoft’s Windows operating system. It is robust and reliable and provides access to the wide variety of drivers and functions, such as printing and Internet Information Service, that are not readily available to PLCs. Furthermore, Windows also comes in embedded flavours for systems that do not require the full suite of Windows features. While most of these features may not be entirely critical in achieving a fully functioning and automated motion control, it is nevertheless there and waiting for us to find a creative use for them.

Traditionally when IPCs are used, the PLC applications are written as C++ applications and run within the operation system. As such, system resources allocation is dictated by the operating system’s original design.

Using numerical control, it is possible to create virtual master axis, which will synchronise the position and velocity of all the slave axes.

Motion Control With EtherCAT EtherCAT fully utilises the full-duplex features of 100BASE-TX to achieve data rates and bandwidths of up to 100Mbps. Hence, EtherCAT is suitable for real-time, high-speed-high-precision motion control. As more motion companies are already implementing or developing EtherCAT drives and motors for their customers, EtherCAT now commands a strong influence in the motion industry. Looking back, a conventional motion control system transmits analogue or a pulse signal from the IPC to the drive and motor through a variety of converters. With EtherCAT, positions and velocities are communicated directly to the drive via a Cat5e cable with a RJ45 connector. It simplifies the wiring of the entire architecture, yet allows a flexible topology to be implemented in a single system. EtherCAT also supports the integration of other fieldbuses onto the EtherCAT architecture. With such advantages of EtherCAT, the eXtended Transport System (XTS) was introduced — a drive technology which combined the linear and rotary drive principles into one. It consists of a modular linear motor, movers as moving parts and a mechanical guide rail. Each of the movers are configured as a single axis, which allows high precision control and are customisable according to the application. Materials can now be transported in a high-speed and continuous flow to meet the demand for higher productivity machines. Implementing EtherCAT motion control with an IPC allows you to control up to 255 axes on a single controller with minimal configuration. There are essentially no settings required in order for the system to work. It is definitely meant for the intelligent machine that is indeed simpler and faster. ENQUIRY NO. 5302

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ENQUIRY NO. 746

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U.S. Air Force photo/ Senior Airman Kenny Holston; Image: https://flic.kr/p/8zPTgw; License: https://creativecommons.org/licenses/by-nd/2.0/legalcode

SOFTWARE & NETWORKS

Current 100Mb/s applications with EtherNet/IP devices are addressed as well as the need for easy to deploy higherbandwidth links requiring 1Gb/s transmission. By Robert A Reid, product development manager; Daniel T McGrath, industrial automation solutions manager, Panduit; and Michael Hines, energy/ industry market manager, OFS Specialty Photonics Division

Advances In Fibre Cabling Systems T

raditional fibre cabling systems that support high bandwidth enterprise applications are being extended into industrial plant floor applications. At the machine control level, current needs for easy to deploy, robust fibre solutions that support 100Mb/s communications exist. For many EtherNet/IP applications requiring fibre, the use of currently available cabling systems presents unique challenges regarding robustness, support of realtime, low latency communication, and deployment ease by factory personnel. These challenges tend to inhibit the use of fibre and increase Total Cost of Ownership (TCO). Recently, fibre manufacturers have introduced Hard Clad Silica (HCS) fibres with improved bandwidth. These fibres are environmentally and mechanically robust and address difficult installation challenges. Through fundamental fibre design, these industrial fibres enable rapid and simple LC connector field termination with simple hand tools and a short learning curve. ODVA standards recognise the LC connector in both sealed and unsealed applications and high volume transceiver manufacturers have standardised the small form factor LC as the Media Device Interface of choice for 1,000Mb/s and beyond channels. Enterprise fibre structured cabling solutions are being deployed in Industrial Ethernet applications.

Ivan Soares Ferrer, Sao Paulo, SP, Brazil

Traditionally, these solutions fit at the top of the network, ie: Micro Data Centre and Zone solutions. Industrial Ethernet now propagates in the lower tiers of the network, such as control and device layers. In these areas the enterprise structured cabling model does not provide a strong value proposition. Additionally, the skill of typical personnel implementing control and device-level networks often excludes fibre installation best practices. A ‘fear of fibre’ mentality prevents widespread deployment and acceptance of fibre in such harsh environments. There exists a need for a rapid deployment, directattach cabling system that is ‘electrician friendly’. At the core of the proposed solution is a LC compatible crimp/cleave connector coupled with multimode Graded-Index Hard Clad Silica (GiHCS) fibre in industrialised cable form factors. These systems are compatible with mini switch and embedded switch solutions from vendors.

HCS Fibre Technology What Is HCS? Hard-Clad Silica (HCS, sometimes called Polymer Clad Fibre — PCF) are optical fibres with cores of pure silica glass (diameter: typically 200 μm) and a hard optical cladding made of special plastic (diameter: 230 μm typically). The hard cladding layer imparts unique properties on these fibres, serving

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to provide total internal reflection, enhancing the Silica, the glass used to make optical fibre, is fundamental strength of the fibre, and providing a a brittle material by itself. Brittle materials are crimp-worthy thin coating for simple and reliable characterised by the dependence of their mechanical connectorisation in the field. strength on the severity of surface flaws (Griffith HCS fibres have traditionally been ‘step-index’ flaws), rather than fundamental material strength. structures with large silica cores and medium When bent or under tensile load, these surface bandwidth, supporting transmission rates of less flaws act as stress concentrators and grow in size than 100 Mb/s. Traditional HCS fibres are suitable for and eventually result in catastrophic failure of the distances at such data rates of several tens of metres material or breakage when in the form of optical fibre. to several hundred metres and have commonly been used in applications such as ControlNet. By comparison, all-Plastic step-index Optical Fibres (POF) have lower bandwidth and only support transmission rates less than 40 Mb/s. They also have relatively high attenuation and are, therefore, power limited and supporting maximum distances of just several tens of metres. Graded Index glass fibres, like those used in enterprise structured cabling systems, have ver y high bandwidth with the ability to support Gb/s and multi-Gb/s data rates at significant reach. The attenuation in these fibres is low, therefore such fibres can extend application distance from several hundred metres Fluke 435 Series II Power Quality Fluke Ti400 Fluke Ti125 Fluke 810 to a few kilometres, covering and Energy Analyzer Thermal Imager Thermal Imager Vibration Tester the overwhelming majority of industrial networking Identify energy waste and save money applications encountered with with Fluke Energy Management Solutions now. Ethernet/IP. And from 1st July to 30 th September, when you purchase the selected Fluke tools, you can stand a chance to WIN an iPad mini with Retina display!* Purchase Any of the Selected Tools • Fluke 435 Series II Power Quality and Energy Analyzer • Fluke 434 Series II Power Quality and Energy Analyzer • Fluke 810 Vibration Tester • Fluke Ti400 9Hz Thermal Imager • Fluke Ti300 9Hz Thermal Imager • Fluke Ti200 9Hz Thermal Imager • Fluke Ti125/TiR125 9Hz Thermal Imager • Fluke Ti110/TiR110 9Hz Thermal Imager

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ENQUIRY NO. 744

HCS And High Strength Optical Fibre HCS fibres are designed for and used in applications that demand robust mechanical performance. These fibres are the best choice for industrial data links, factory automation, and utility applications, often found in harsh environments that require high mechanical integrity and reliability at the fibre level. The fibre’s HCS coating, while facilitating easy field connections, makes possible the vision of ‘electrician friendly’ field fibre terminations.

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The strength of silica optical fibre is timedependent and the degradation of fibre strength over time is known as static fatigue. In the presence of moisture crack propagation accelerates as water molecules act as catalysts to crack growth by reducing the surface energy of the glass. HCS coating technology, applied during the draw process on the pristine fibre surface, chemically bonds to the silica substrate. These chemical bonds significantly improve the mechanical properties of the silica fibre, making the coating virtually impermeable to moisture ingress. By isolating the silica surface from moisture in the environment fibre strength is greatly enhanced and static fatigue is significantly retarded. Managing static fatigue through HCS technology enables the optical fibre to withstand the tight, long-term bends, often found in the confined spaces of industrial installations.

Fibre Connector System The LC Connector In Fibre Management And Transceivers Small Form-Factor (SFF) transceivers (GBICs) on LAN equipment have been overshadowed by the Small Form-factor Pluggable (SFP) (‘pluggable’ versions of the SFF) transceiver in recent years. Industrial Automation equipment vendors are now offering SFP modular transceivers on their switch lines for Gb/s Ethernet Uplinks. Historically, in industrial automation, several lower density fibre interfaces have been deployed such as (Straight Tip (ST), Subminiature Assembly (SMA), Subscriber Connector (SC) and ‘propriety’ non-MSA (MultiSource Agreement) interfaces such as TosLink or Versatile Link. The optical receptacle on the SFP for Fibre Channel and Gb/s Ethernet is defined as an LC interface. Most major transceiver vendors, including early proponents of ‘MT-RJ-only’ transceivers, now sell SFPs with the LC interface only. The LC is the clear market leader in SFF connectors. The LC connector is the natural progression/ replacement for the SC, but is also displacing applications traditionally held by other connector systems such as the MT-RJ. The LC is popular as a 10 Gb/s Ethernet connector and is also the standard fibre interface for 1394B S800 (Firewire/iLink Home and Commercial Video) and for the InfiniBand Trade Association. To support the trend and seamless integration of readily available SFP transceivers in industrial networks, it is imperative that we provide a practical LC field-connection solution for harsh environments. The LC Connector is an industry standard

Vasant Dave, Baroda, Gujarat, India

SOFTWARE & NETWORKS

Fibre optical cable is an important component to a country’s infrastructure.

FOCIS-10 (TIA Fibre Optic Connector Intermateability Standard) compatible plug interface that provides a dependable, repeatable means of mating the precision ferrule used to align and secure the fibre. The LC connector, due to its reduced footprint, provides twice the interconnect density in cabling system patching bays. The LC also provides advantage on electronics (hubs, switches, and so on) through its reduced size. 10/100M & 1G Ethernet Physical Layer Considerations 1 IEEE 802.3u - 100BASE-FX The Fast Ethernet over Fibre-Optic at 100 Mb/s application (100BASE-FX — 12.5MB/s with autonegotiation) is a version of Fast Ethernet over optical fibre. It uses a 1,300 nm Near-Infrared (NIR) light wavelength transmitted via two strands of optical fibre, one for receive (RX) and the other for transmit (TX). The standard specifies a maximum distance capability of 2 kilometres (6,600 ft) for full-duplex over FDDI-grade (Fibre Distributed Data Interface) multimode optical fibre. The optical power budget for a channel built with these transceivers is several dB for OM1 fibre (1.5dB maximum of connector insertion loss allocation within this budget). 2 IEEE 802.3z - 1000BASE-SX Gb/s Ethernet over Fibre-Optic at 1 Gb/s (1000BASESX — 125 MB/s) is a fibre optic gigabit Ethernet standard for operation over multi-mode fibre. The standard calls for a NIR light operating wavelength between 770 and 860 nm but is typically referred to as 850 nm. The standard specifies a distance capability between 220 metres (62.5/125 μm fibre with low modal bandwidth) and 550 metres (50/125 μm fibre with high modal bandwidth).

Fibre Cable Styles Industrial networks operating at 1Gb/s max. require

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either a graded index OM1 or OM2-grade fibre. Several manufacturers produce a version of their HCS fibre with optional OM1 or OM2-compatible fibre in the core. We foresee the need for these fibres to be supplied in a duplex zip cord cable and a 2-fibre and 4-fibre breakout cable. Cabling systems are intended for open pathway and zone/control panel builds and are hence dual rated LSZH and Riser. These cables eliminate the aramid yarn that exists in standard 50/125µm zip and distribution cables. This system relies only on the optical fibre as a crimp substrate and strength member, significantly simplifying the termination process.

In Conclusion

ENQUIRY NO. 5401

ENQUIRY NO. 737

HCS fibre media has been proven reliable in many vertical applications spanning harsh environment (Military, Oil/Gas, utility, factory automation, Industrial Fieldbus and in-vivo Medical) applications. This GiHCS fibre variant presents a Multimode graded-index, high bandwidth, long reach fibre core in the same Hard Clad, large diameter footprint as the traditional HCS solutions.

The benefits of HCS LC connectivity and fibre media solutions have been shown in EtherNet/IP architectures for both Structured Cabling and Pointto-Point cable plant deployments. An examination of performance metrics (Bit Error Rate) for such channels and ultimate channel reach vs. cable plant design has shown the viability of using GiHCS fibre media and field deployable ‘Electrician Friendly’ HCS LC connector systems into 1000BASE-SX SCS-based cable plant (with limited restrictions). GiHCS fibre technology enables widespread field installation of fibre EtherNet/IP networks by providing a termination means similar to Plastic Optical fibre connectivity (with low TCO) while provisioning longer reach, high bandwidth channels (which POF does not). This easy to install fibre solution opens the door to new high bandwidth applications at all levels of the industrial network by building on ODVA recognised components. It also provides an immediate benefit for existing 100Mb/sec EtherNet/IP networks that are ‘direct attach’.

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INSTRUMENTATION & MEASUREMENT

Machine Vision:

A Faster Way Machine vision technology helps streamline and increase production, in the face of greater competitive pressures and increasing consumer sophistication. By Didier Lacroix, senior VP, International Sales & Services, Cognex

peed is everything. With increasing consumer demands today, there is greater pressure for manufacturers to deliver quality faster. At the same time, many products (such as mobile phones) experience shorter lifecycles and face more intense competition. This means that manufacturing processes need to be streamlined and sped up, to ensure that products can be quickly produced and delivered downstream. One way of shortening production cycles is to minimise errors and defects. To achieve this, manual-type inspections have to be replaced by machine vision. This is because machines can be programmed to check each product objectively, based on a specified set of standards and requirements. This effectively eliminates the fluctuations in Quality Control (QC) that are common with human-eye inspections, due to subjectivity of different individuals. On fastmoving production lines, the feasibility of employing human operators to perform inspections also declines sharply â&#x20AC;&#x201D; especially as line speeds increase.

Picking On Problems A company supplies coated steel products for a number of different uses, including cladding and roofing, general engineering, cabinets and shelving and domestic appliances. On its steel strip paint coating line, a wide range of surface defects have to be identified by an inspection system. There are approximately 300 colours and four emboss types, along with a wide variety of reflectance characteristics. One of the trends in the industr y is that the market is becoming increasingly sophisticated. Colourful products with distinctive decorative finishes are in demand where 40â&#x20AC;&#x192; industrial automation asia | August 2014

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many are also embossed. In the course of meeting this demand from a manufacturing point of view, an automated inspection process is necessary. This is to cope with a wide range of surface finishes, colours and reflectivity. Identifying a stain or a scratch when surface patterns are inherently part of the product, can be difficult. This is due to the nearly infinite variety of defect shapes and sizes, and also the randomness of occurrence. Ty p i c a l d e f e c t s i n c l u d e embosser pick off, furnace debris, paint misses, oven scrapes, blisters and water staining. About 15-20 primary defect types are expected, a l t h o u g h a l l a re i n f i n i t e l y variable. The traditional way of spotting surface defects in a

process line was to employ an operator to watch the strip as it passed a special inspection point under controlled lighting conditions. However, management has recognised that it is impossible for a human being to be consistently focused on such a task for more than a few minutes. Moreover, the product moves at a speed of 1.5 metres per second which makes it difficult to visually pick out mistakes. It was therefore necessary to select an inspection system that could be ‘trained’ over a period of time to recognise and classify each type of surface defect. This would allow operators to be alerted of genuine problems, so that corrective action can be taken quickly.

Integrated DSP-Based Soft Computing to Enable Intelligent Manufacturing

Enforcing Standards Besides, with increasing competition and the high standards being demanded by consumers, the company had been putting efforts into improving quality control. It realised that it had to turn to an automated vision inspection system to achieve the goal of 100 percent ‘defect-free’ product. Having already used surface inspection systems elsewhere in the company, the decision was made to implement a vision system to meet the challenges presented by the coated paint line application. The automated inspection system is made up of four highresolution cameras. The latter are mounted in pairs within housings above and below the strip, as

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Distributed Motion Slave Modules

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INSTRUMENTATION & MEASUREMENT

well as downstream along the line. Two high-powered lamps are floor-mounted on either side; and collimated unidirectional light is directed onto the strip to provide controlled lighting conditions for the cameras. Each individual camera checks half the width of the 1,600mm strip. The cameras and configuration chosen for this application exceed the requirements set by the facility. Its SmartView platform has thresholding algorithms that enable the system to decide if a particular surface anomaly is a defect. If it is, the system then proceeds to measure features such as width, length, density, and grayscale range. This feature ‘characterisation’ is then stored, along with a digital snapshot of the defect and its immediate surrounding material. Coil data can be sent from the company’s mainframe to the inspection system; and an inspection ‘recipe’ is selected for that particular product, based on colour, gloss level and emboss type. In this manner, the job of detecting and classifying defects is effectively carried out.

Complex Tasks Another company builds machines and systems that come equipped with solidstate lasers. These are used in the automotive and medical technology industries, among others. One particular application is found in the precision welding of small components that are made of different metals. Vision technology therefore needs to be integrated into the scanner optics for welding, on the company’s laser machines. This is known as Programmable Focusing Optics (PFO). The objective is to improve flexibility and accuracy, besides speeding up the production process for clients.

Machine vision makes it possible to automatically adapt the welding position to match the positioning and size each workpiece, without requiring operator intervention. The In-Sight vision system is able to determine coordinate transformation data and is user-friendly for staff who do not have experience with such technology. Any existing welding systems can be retrofitted without causing problems to the newly integrated vision system. The vision system comes in a compact design, allowing it to be mounted directly onto the PFO, thereby saving space. It also complies with the Ingress Protection (IP) 67 rating, and can withstand dust and water in harsh environments. By deploying vision technology in the machines, there is no longer a need for clamping and positioning devices. The precise fastening of parts relative to the laser is either no longer needed, or can be simplified — due largely to the ability of the vision sensors to locate small parts. This translates into greater flexibility during operation and a significant boost in production quality. Waste is therefore reduced and production costs lowered.

Adhering To Requirements An automated manufacturer of high-precision springs maintains high standards of production and requires online and real-time detection of product defects. This is to ensure that the number of defective products is as close to zero as possible. The manufacturer previously used a 2.5D projector to carry out measurements using manual observation. They also utilised random inspections as a method of QC. These mechanisms however, did not meet the demands of the production line. As the springs are tiny, there are significant challenges,

The precision required in electronics manufacture makes machine vision an ideal fit for this industry.

especially when coupled with the high speed of the production line. These factors make the defection detection process impossible for human vision to perform. In the light of these problems, the decision was made to install the In-Sight Micro 1100. This vision system performs measurements of spring length, diameter, and moulding angle of the centre circle for each object and identifies defects when they are present. The system is designed to detect defects on the basis of predetermined tolerances and at a rate that keeps up with the speed of the production line. When a quality problem is detected in an object, the system sends out a ‘defective’ signal for rapid classification and correction. Performing these tasks perfectly is critical during the entire manufacturing process, as well as during the production and delivery of the inspected objects. The vision system provides rapid defect detection — even with different product specifications — along with detailed records of the detection results and images. Machine vision can alter the production landscape in many facilities across different industry sectors. Clearly, it is far more reliable than human-

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eye QC processes that are prone to mistakes and operator subjectivity. In addition, it can reduce the number of operators that are required on each shift — very often to just one. With the proper alarms in place, the single operator can ensure a smooth production flow with minimal interruption. Furthermore, a record of inspections and problems can be stored in the database for further reference and as a reliable audit trail. The advantages offered by machine vision are therefore many. These range from effectively eliminating manual inspection inaccuracies and lowering labour costs to enhancing production efficiency.

The first step in a machine vision application — and the one that usually determines whether the application succeeds or fails — involves locating the object within the vision camera’s field of view. The process is known as pattern matching. This can be extremely challenging, since many variables may alter the way in which an object appears to the vision system. Traditional pattern matching technology relies on a pixel-grid analysis process — commonly known as normalised correlation. This method looks for statistical similarity between a gray-level model (or reference image) of an object and portions of the image to determine the object’s X/Y position. Although it is effective in certain situations, this approach is limited in: 1. The ability to find objects. 2. The accuracy with which they can be found, under conditions of varying appearance that are common to production lines (eg: such as changes in object angle, size, and shading). To overcome these limitations, PatMax — a Geometric Pattern Matching Technology, was developed. This technology learns an object’s geometry by using a set of boundary curves that are not tied to a pixel grid. It then looks for similar shapes in the image without relying on specific gray levels. The result is a revolutionary improvement in the ability to accurately find objects, despite changes in angle, size, and shading. ENQUIRY NO. 5502

ENQUIRY NO. 742

ENQUIRY NO. 5501

Technical Insight

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ENERGY

Energy

Change In China IAA interviewed Terence Siau, director, strategy and planning, Building Efficiency Asia, Johnson Controls on his company’s Asia strategy and the opening of their manufacturing and research and development centre in Wuxi, China. By Mark Johnston

hina is one of the most dynamic and rapidly developing economies in the world, and is a key market for many international organisations. With rising concerns around energy wastage and population, particularly in major urban areas, China is making major policy changes to combat the countries rising concern around pollution and climate change.

IAA: What part does China play in Johnson Controls overall strategy? Terence Siau (TS): In FY13, China accounted for 17 percent of Johnson Controls’ global revenues. Fuelled by large population growth, rapid urbanisation and rising demand for housing and infrastructure, China is expected to contribute a major share of growth in the global HVAC and building controls market. Besides being an important market, China also has a tremendous talent pool. The company collaborates with academic institutions in China and more recently partnered the Chinese Association of Refrigeration (CAR) and American Society of Heating Refrigerating and Air-conditioning Engineers (ASHRAE) to expand the scale of the CAR-ASHRAE Student Design Competition program. Being close to the customers is important to winning in China. The company has established a wide coverage in China from major mega cities to rural areas. Currently, there are almost 80 manufacturing plants as well as design and engineering centres in strategic locations in China in addition to many branches and partnerships. For our Building Efficiency business alone — one of the organisation’s four business units — there are more than 40 offices and service facilities in China, with two manufacturing sites located in Wuxi and Guangzhou. Plans are also underway to establish our second corporate headquarters in Shanghai by 2016.

IAA: Could you give me an overview of the manufacturing and research and development centre in Wuxi, China? TS: In May 2014, the company officially opened a US$35 million expansion of its manufacturing and research and development (R&D) centre in Wuxi, China. Spread across a total gross floor area of 138,500 sq m, the Wuxi facility is now one of the organisation’s largest research and development centres for building solutions in the world. It will focus on manufacturing and research and development for Heating, Ventilation and Air Conditioning (HVAC) systems, and industrial refrigeration solutions. The whole Wuxi facility’s R&D capability and manufacturing capacity is a strategic part of the organisation’s global Building Efficiency business. The new campus is equipped with the best facilities as well as automated and intelligent production lines for high productivity and superior quality. This will double our manufacturing capacity for HVAC, and triple capacity for industrial refrigeration. This campus is also dedicated to advancing research and development for large water-cooled centrifugal chillers and water/air-cooled screw chillers. This includes solutions like York Titan Centrifugal Chillers, York YSPA Air-Cooled Heat Pump Screw Chillers, and York YMC2 Water-Cooled Magnetic Centrifugal Chillers. A clear example of such innovation at work at the Wuxi campus is the development of heat recovery solutions that help district heating plants become up to 40 percent more efficient. The waste heat recovery solution recycles heat from industrial and power plants and turns it into cleaner heating for homes and businesses throughout China. This helps to utilise industrial waste heat more effectively and reduce the use of coal, and as such haze.

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more energy-efficient. Through innovative technologies such as the waste heat recovery solution, we are proud to help municipal facilities and communities in China to reduce their reliance on fossil fuels and use their resources more efficiently. In fact, we just won the Golden Bee Award, by WTO Tribune, a publication in China dedicated to corporate social responsibility research and promotion, for our waste heat The company’s manufacturing, research and development centre in Wuxi, China. recovery solution. Our established credentials in the market also enable companies to secure financing for projects At the centre of this innovation is the company’s that require huge capital outlay. York steam turbine-driven heat pumps, which converts the surplus heat into higher temperature IAA: Are you planning on expanding further hot water for use in a district heating system. We successfully implemented this heat recovery into China or Asia as a whole, if so, what is the solution at a large Chinese municipal heating facility extent of this expansion and where will you be in Northeast China, helping it save more than RMB7.4 expanding into? TS: Johnson Controls’ commitment to China and million annually (US$1.2 million). In environmental Asia is clear. We have aggressive growth plans for terms, the solution eliminated the need to burn China to set up new facilities, new branches and 9,200 tonnes of coal in the last heating season — the expand our channel network and talent pool. We are equivalent to removing 4,000 passenger vehicles from establishing a second corporate headquarters in the road for a year. Shanghai by 2016. The design and construction of the Wuxi’s favourable location and conditions make new campus will achieve China’s Three Star Green it a suitable place for setting up our manufacturing and LEED Platinum building certifications to become base. The company was one of the earliest foreign a landmark for China and the Asia region. companies to invest in Wuxi but now there are Building efficiency spearheaded a big push in over 90 Global 500 enterprises with operations and China with its 2005 acquisition of York International, projects there. which already had a leading market share for its heating and cooling equipment. Those products are IAA: China’s national legislature recently made now integrated with controls and other technologies some significant changes to the country’s developed by the company. In addition, we have just Environmental Protection Law, do you believe completed the recent acquisition of Air Distribution China is doing enough to tackle its pollution Technologies in June and are finalising the joint crisis and what further changes would you like venture with Hitachi. to see from Chinese policy makers? Besides building efficiency, other business TS: China’s Five-Year Plan on Energy Conservation units also have aggressive expansion plans. For and Emission Reductions has prompted a major example, in May, we announced the formation of commitment to reduce pollution from the burning of a global automotive interiors joint venture with fossil fuels, especially in using industrial surplus heat Yanfeng Automotive Trim Systems, a wholly owned as a major source of urban heating. subsidiary of Huayu Automotive Systems (HASCO), As an organisation that has been committed the component group of Shanghai Automotive to sustainable development and protecting the Industry Corporation (SAIC). environment for over a century, the company is ENQUIRY NO. 5601 heartened to see the Chinese government take such proactive steps towards tackling climate change. There is a real opportunity for the company to help customers in China address environmental VISIT US ON OUR WEBSITE AT challenges. From design to manufacturing to delivery, our products, services and solutions incorporate sustainability features that help our customers be

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SECTOR SPOTLIGHT

Andrew Brigmond, Kissimmee, Florida, US

Larger data centre types are triggering a change in the distribution system of power solutions. By Amit Singh, senior research analyst, energy & environment, Frost & Sullivan

Data Centres:

Size Matters W

ith the increasing number of large data centres in the ASEAN region, the UPS OEMs are engaging directly with the customers, bypassing the channel partners in the value chain. Operators in Equinix, Global Switch, and IBM, for example, prefer to rope in the power quality OEMs for their physical infrastructure solutions requirements. Schneider Electric struck a contract with Equinix to deliver energy management procurement and sustainability services, while Global Switch partnered with Eaton to supply power equipments. The Malaysian government estimates the market for data centres in Southeast Asia to be worth approximately US$10.9 billion (S$13.6 billion) in 2013. Malaysia intends to capitalise on this opportunity by taking the data centre space from 0.5 million (46,452 sq m) to 5 million sq ft (464,515 sq m) by 2020.

A Clear Trend The trend in the data centre construction market in ASEAN shows an uptake in third party data centres offering co-location and cloud computing services. In addition, US and Europe based multinational corporations prefer to set up consolidated large

data centre facilities in centralised locations, such as Singapore. Such a trend is going to impact the power and cooling industry structure to a great extent. It has triggered a polarising effect between the large scale data centres and small domestic data centres in the ASEAN region. The procurement trend is catching up fast in the large and extra-large data centre segments, while local small data centres are closing down or growing at a slower pace, as most of the enterprises are opting for cloud based services or associating with co-location service providers. Even though more than 80 percent of data centre facilities consist of small data centres, but large data centres make up more than 80 percent of construction/new build outs by value in the region. The OEMs are taking away all the opportunities from the channel partners, when it comes to serving the emerging large and extra-large data centre market space with facility sizes going beyond 100,000 sq f (9,290 sq m) of gross floor area. The UPS vendors usually serve small/medium data centres through authorised distributors and system integrators as the channel partners do business with them, while OEMs

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sell to the channel partners. In such a business model, the business is transactional in nature and solely depends upon the channel partners, and as such playing a bigger role in the data centre industry. In a changing scenario, where large/very large data centres demand for a more customised solution with stakes going very high, the OEMs not willing to take any chance, prefer to serve this market directly.

project management, and so on. Authorised distributors will not be playing any role in catering to this market, while system integrators in, for example, ST Electronics and Commverge Solutions will be occupying space as business partners to the OEMs in project execution as third party solution providers only. ENQUIRY NO. 5701

The Impact On Entry Barriers The UPS OEMs are trying to position themselves in the large data centre market as integrated solution providers. They mostly prefer to deal with them directly, participating in the bidding every year, while local SI/channel partners are being involved for part execution of the projects. This leaves little scope for them to be involved on a larger scale. This is unlike in the small data centre market, wherein they used to play a direct role in sales and execution of products and solutions. The requirement to innovate on both technology and process level will throw the biggest challenge for any new entrants in this market space.

The Effect On Profitability Though the profitability for the OEMs to large data centre segments is bound to increase, the major challenge lies in building the scale in order to cater to this market encompassing a wider spectrum of solutions including product and services. Channel partners stand to lose shine in the new scenario, while tier-II system integrators will play a bigger role by enabling the UPS and IT OEMs to execute the solutions on the ground level. The larger players, both power and IT OEMs are expected to develop strong competitive advantage by leveraging their capabilities in technology, brand name, manpower, execution,

ENQUIRY NO. 731

The Shift In Bargaining Power

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SECTOR SPOTLIGHT

Rethinking

Data Centre Design

n today’s Internet of Things (IoT) era where objects are gaining the ability to communicate, the ever growing volume and variety of digital data has become the critical success factor that businesses have come to rely on. Thanks to these new information networks and subsequent flow of Big Data, the IoT era holds the promise of more effective business models and improved processes. These opportunities are reaffirmed by research firm IDC who have forecasted that the global IoT market will hit US$7.1 trillion by 2020. However, for data facilities that are ill-prepared, the IoT and increase in data complexity can be an energy draining burden for a business’ data centre. For businesses to thrive in the IoT era, they first need to ensure that their data centres are capable of facilitating the transmission, processing, streaming and storage of the burgeoning information. Now more than ever, it is critical for data centre operators to strike the sweet spot between balancing cost-

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efficiencies in this energy intensive IoT-age, while still maintaining the optimal processing power. The following pointers outline how this IT harmony can be achieved to ensure data centre efficiency and effectiveness.

Data Centre Lifecycle Services (DCLS) In the IoT age, Big Data is driving the need for data centres to be more energy efficient and flexible. Factors affecting critical environments across all layers including the application, enterprise, IT, and infrastructure, need to be addressed. DCLS provides ongoing attention at each phase of the life cycle. Tailored to a wide range of data centres, the service helps to simplify processes, reduce costs and tackle technical business challenges in order to make data centres available, efficient and safe throughout their lifecycle. The steps follow a series of simple phases, broken down into: Assess, Plan, Design, Build and Monitor/ Operate/Optimise/Maintain.

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Assess — Identifying possible improvements on a current data centre build. Plan — Determining optimal costs, criticality, performance, timing, regulatory compliance and sustainability through methodology and automation tools. Design — Basic or detailed and constructible designs to assist with facility power, facility cooling, IT room infrastructure, security, DCIM, or an entire data centre. Build — Assembling and integrating all of the equipment on the site in a time and cost efficient, risk-free manner. Maintain, Operate, Monitor, Optimise a. Maintain — Maintain critical applications to operate at an optimal level. b. Operate — Operate utilising best in call methodologies with comprehensive policies and procedures. c. Monitor — Continuous monitoring to anticipate, identify and resolve issues faster and with greater accuracy, while retaining visibility and control. d. Optimise — Optimise and tune a data centre to its highest performance and safety levels.

1 2

By employing the holistic DCLS process, IT managers can ensure their facility’s optimal performance and greater efficiency at a more regulated cost.

Data Centre Infrastructure Management (DCIM) In this era which is driving up complexity of data, data centres need not only to be adequately serviced during their lifecycle, they also need to be equipped to process, analyse and crunch this information to make informed decisions to meet business and service-oriented goals. DCIM assists with this. A well-implemented DCIM system helps operators safely maximise the efficient use of power, cooling, and space capacities for current business needs and future ones. As we are propelled into this changing IT landscape, efficiency is key — particularly when addressing the demands brought on by Big Data. DCIM optimises the data centre’s performance, contributes to savings in energy, and reduces operating expenses by 20 percent so that it can more adequately handle the added data complexity. The crux of DCIM is that it works by collecting critical information from the IT facility — such as

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ENQUIRY NO. 743

ProducTVity Station

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SECTOR SPOTLIGHT

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spending. In fact, oversizing is the number one cause of inefficiency and therefore a higher than necessary total cost of ownership. Rightsizing has the potential to save you 13 percent on the total cost of ownership including IT, 30 percent of which is savings from your data centre’s physical infrastructure. It is these potential savings that are driving the industry toward modular and scalable solutions.

Data Centre Priorities In A Changing Environment With the IoT era upon us, there will be an increasing amount of data to interpret and analyse.

where the hot spots are, where there is available storage, when capacity has been reached — and allows the data centre manager to remotely configure the facility according to this information. With IoT driving up the complexity of data, DCIM enables facility managers to understand their data centre’s challenges and opportunities so that they can accommodate the added information and support their core business operations more effectively and efficiently.

Prefabricated Data Centres Another consideration businesses should take into account during this changing IT landscape, are modular, plug-and-play data centres. Prefabricated data centres are pre-engineered and pretested to work together. They enable new, established and growing companies to adapt and align their infrastructure to the speed of business growth in order to meet their ever-changing business needs now and in the future, which is essential in the IoT era with the ever growing volume and variety of digital data. Research firm, Gartner, reaffirms this, highlighting that legacy data centres are no longer appropriate for businesses. The report likened the data centre to an agile, living organism that evolves, and should therefore include flexible, modular, virtualised design principles. These flexible builds also make financial sense, enabling businesses to right-size their facility so that it is more efficient and cost effective. In an age where data is only becoming more complex, it is easy for companies to get bullish and base their IT facility on anticipated needs rather than current ones. However, what is generally not considered, are the costs associated with this. Inefficient data centres cost more than a lot of enterprises have the luxury of

In addition to the solutions discussed, underpinning all of these is the critical need for organisations to move towards a more energy efficient data centre model. This will not only reduce the costs of its operation, but also lower its environmental footprint. By adopting energy efficiency implementations including DCLS, DCIM and pre-fabricated models, businesses can hedge against increasing energy costs and consumption and even save up to 90 percent of their electrical bills. This becomes more relevant after understanding that carbon dioxide (CO 2) emissions from global data centres sum up to 116 million metric tonnes, roughly equal to the amount of CO2 emitted by the entire Czech Republic. We are living in a dynamic environment, and IT is leading the charge. However, it is the data centre manager’s responsibility to ensure they are leading their business’ IT responsibly. New approaches and services are needed to ensure that the market has data centres which are large enough, flexible enough, scalable, and energy efficient enough to cope with the IoT era’s demands. Relying on the same techniques as in the past and hitting merely average levels of energy efficiency is not an attractive option when the rapid growth in areas like Big Data are considered. While it is hard to pinpoint the size of the coming Big Data explosion, a recent IDC forecast predicts that Big Data technology and services will grow at a 27 percent compound annual growth rate through 2017, or about six times faster than the overall ICT market. If we do not do more to address data centre builds and IT energy efficiency, that sort of growth curve for Big Data is going to mean a hard hit for businesses and the environment. ENQUIRY NO. 5702

VISIT US ON OUR WEBSITE AT

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FEATURES

Industrial Machinery In Southeast Asia To Take A Digital Manufacturing Path

he highly fragmented global industrial machinery market is finally showing signs of improvement. The top four players, comprising of Mitsubishi Heavy Industries, IHI Corporation, Kawasaki Heavy Industries, and MAN hold about 14 percent of the overall global market value. In Southeast Asia across countries such as Vietnam, Indonesia, Thailand, Malaysia and Philippines, the industrial machinery industry (traditionally made up of the mould, tool and die sectors) is projected to capture a larger share of global trade over the next 10 years as their expansion outpaces that of developed nations. However, generating growth is simply not enough in todayâ&#x20AC;&#x2122;s highly competitive market. Increasing global competition and market demands from the aerospace and defence, mining, power generation and automobile industries, require these Southeast Asian manufacturers to continuously innovate and optimise their products, extending todayâ&#x20AC;&#x2122;s innovation process beyond its traditional boundaries. It is a necessity to look at continuous innovation which has become a core driver of growth, performance, and valuation, because if the global trend is anything to go by, manufacturers will find themselves facing an increasing number of new challenges and requirements leading to the decline in growth.

Meeting The Challenges One such requirement is the demand for more flexible machine tool designs that can be rapidly adapted to new products, as well as for machines that can be

easily integrated into existing plants. Another crucial challenge requires manufacturers to drastically reduce the time it takes to develop new industrial equipment, while ensuring that these machines can operate at close to 100 percent uptime. Equally important, major demographic changes over the next decade, such as ageing and retirement of the current workforce, will create large gaps in the workforce especially in Southeast Asia. Given these challenges, how can manufacturers ensure profitable growth and maintain margins in a globally competitive environment? How will manufacturers deal with the increasing pressure to improve operational performance while meeting escalating customer requirements and multiple configurations?

At The Forefront Of Technology Manufacturers in Southeast Asia must be at the forefront of adopting upcoming trend innovations and new technologies, as well as PLM solutions to enable them to flourish in this complex business environment. Success requires companies to facilitate open innovation, enable collaboration both inside and outside organisational borders, and instil discipline across their lifecycle processes. At present, Siemens PLM provides a PLM platform designed for industrial machinery manufacturers that unifies both the product and production lifecycles. This PLM solution for industrial machinery sets the pace for a future vision that delivers a new level of value to Southeast Asian manufacturers. August 2014 | industrial automation asiaâ&#x20AC;&#x192; 51

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FEATURES

Digital manufacturing strategy is adopted to improve quality and innovation.

By shifting the design and development of manufacturing processes upstream to interlock product design and development on an open PLM platform, manufacturers realise immediate productivity. The solution also improves efficiency, reduces ramp-up time in production through virtual design and better upfront validation, resulting in shorter commissioning times and a more efficient output.

Digital Manufacturing Path Siemens PLM solution for industrial machinery connects design, engineering, and manufacturing, so the product design and development process is globally unified and manufacturing becomes collaborative and strategic. The end result enables manufacturers in Southeast Asia to make smarter decisions and better products. However, above and beyond PLM solutions, Southeast Asian manufacturers have to be flexible in deploying new strategies led by innovative technology waves such as digital manufacturing to remain highly competitive across the region and the world. This technology is fast becoming a preferred choice for manufacturers all over the world as the quest to reduce capital expenditure, shorten lead times, and boost productivity is expected to spur investments in digital manufacturing. The heightened emphasis on product innovation will catalyse manufacturers to cultivate a digital manufacturing path to ensure consistent business profitability. Therefore, manufacturers in Southeast Asia must take notice and be vigilant about looking to the future.

Bolstering The Industrial Machinery Industry Digital manufacturing is the use of an integrated,

Today, there are PLM platforms designed specially for industrial machinery manufacturers that unify both the product and production lifecycles.

computer-based system comprised of simulation, 3D visualisation, analytics and various collaboration tools to create product and manufacturing process definitions simultaneously. Digital manufacturing evolved from manufacturing initiatives such as Design For Manufacturability (DFM), ComputerIntegrated Manufacturing (CIM), flexible manufacturing, lean manufacturing and others that highlight the need for more collaborative product and process design. The digital manufacturing industry has been identified as a strong growth segment for the total PLM market. According to CIMdata, digital manufacturing is forecast to grow at a rate of 7.5 percent over the next five years to reach US$754 million in 2017. Realising the potential of this strategy, many manufacturers were fast to be early adopters of digital manufacturing. One such company is Hitachi Construction Machinery. To preserve its industry reputation, Hitachi implemented a digital manufacturing strategy to improve quality and innovation. The company was looking to manage data throughout the product development process within a synchronised managed development environment as they maintain a close-knit collaboration with locations outside Japan while initiating global design operations. Additionally, the company wanted to establish a secure information sharing infrastructure that will support global expansion and collaboration. Deploying a digital manufacturing strategy to achieve synchronised management of product data and process knowledge, the company achieved shorter lead times for handling higher design volumes, real-time design made possible by effective data sharing, elimination of errors common with

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manual data transfer, increased product quality and more importantly higher levels of innovation in overall product development. For many companies, digital manufacturing improves design quality and product manufacturing speed throughout the lifetime of a product. With the help of this software, manufacturing processes can be improved at any given stage (conceptual, production, maintenance or service). Additionally, the software helps in cost saving, increasing business and market value. It improves collaboration between research and development units, manufacturers, distribution channels and customer communities, which increases effectiveness of feedback loops (distribution channels and customers). However, many of the long-term benefits from PLM cannot be achieved without a comprehensive digital manufacturing strategy. Digital manufacturing is a key point of integration between PLM and various shop floor applications and equipment, enabling the exchange of product-related information between design and manufacturing groups. This

alignment allows manufacturing companies to achieve their time-to-market and volume goals, as well as realise cost savings by reducing expensive downstream changes.

Going Digital Currently, the digital manufacturing pursuit is more aligned towards large enterprises. Small and medium businesses do not achieve adequate return-on-investments when they adopt digital manufacturing. Nevertheless, the trend towards product innovation across all end-user segments will boost market prospects and a well-planned digital manufacturing strategy has been shown to provide significant benefits. While digital manufacturing is an important component within PLM, all manufacturers should be aware of this strategy especially in the Southeast Asia region. Manufacturers must continously look to new innovations to stay relevant and competitive across the Asian and global market. ENQUIRY NO. 5801

The innovative soft starting solution for squirrel cage induction motors

RSGD Series: Monitoring, protection and self-learning features in a compact housing for fixed speed motors up to 45 Amp (22 kW)

The RSGD Series reduces the starting current down to 3 – 4 times the rated motor current, resulting in smoother starting and stopping of motors, increasing their lifetime and reducing the electrical disturbances.

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August 2014 | industrial automation asia

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FEATURES

he energy industry plays a vital role in the global economy and societies across the world. Oil and gas companies are moving into new and increasingly harsh and remote environments to meet the worldâ&#x20AC;&#x2122;s growing demand for energy. However, exploring new frontiers carries risks and underlines the importance of understanding, mitigating and managing these risks as effectively as possible. Even in the wake of the global economic crisis, worldwide energy consumption continues to surge, fuelled by growth in emerging markets. This ongoing demand for energy, together with diminishing supplies of traditional fossil fuels, especially in areas where they are easy to find and recover, is pushing oil and gas exploration out into new geographical and technological frontiers. This brings with it fresh new challenges and risks for oil and gas companies operating in these more extreme environments. Downhole drilling in the oil and gas industry is now using innovative electric motion controls. Sophisticated electric actuators can be combined with remote navigational control for drills located miles deep in the borehole to obtain real-time downhole sensory data. This rugged instrumentation and actuation must survive high temperatures and pressures, gases, fluids, and steam that all fall outside the normal range of industrial equipment. As anyone in the oil and gas industr y knows, reliability is critical to the economics of drilling. According to industry sources, the average cost of drilling is US$1 million per day offshore and about US$250,000 per day onshore. So engineers design systems to maximise production and performance. Many drilling operators still employ hydraulic steering

Engineering For Extreme Environments Environmental conditions need to be taken into account during the design process of engineering projects, especially those in vital sectors, such as energy. By Jeremy Lee, regional manager (Southeast Asia & Taiwan), Moog

systems, but some have begun exploiting intelligent electric actuators for directional drilling. The most advanced downhole directional steering systems are integrated electromechanical assemblies that employ custom-engineered brushless servo motors and electronic subassemblies housed in sealed enclosures.

Maintaining Contact Communications between the

downhole drill bit and the control systems at the rigâ&#x20AC;&#x2122;s surface involve pulses in the mud inside the drill string pipe, which includes the drill pipe, drill collars, and drill bit. Mud-driven alternators and turbines supply power for the electrically actuated rotary steerable drill heads. Some drill operators use miles of wire for power and communication for actuation tools. Electrical current passed over miles of wire with a relatively

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extreme temperatures. For example, the permanent magnet brushless motor design is a significant challenge, since the magnetic proper ties of the stator windings and rotor magnets cannot be modelled using textbook analysis. Brushless servo motors, using insulation materials on the stator windings, are specifically designed for these applications. Motor design, proper material selection, and manufacturing processes combine to create a highly robust motor with the appropriate form factor and reliability for demanding upstream oil and gas applications.

Innovations Needed The ability to put electric systems downhole, whether in Arctic temperatures or the sweltering

heat of the Middle East, has changed the economics of drilling and production. Producers have become dependent on instrumentation and downhole intelligence. As the search for resources ventures into ever more hostile environments in which electronics and mechanical devices often do not perform well or survive for very long, intelligent actuator systems will be at the forefront. Manufacturers must fund research into high-temperature, high-pressure electronics with wide thermal characteristics, advanced sensorless algorithms, and alternator active conditioning electronics. The goal is to minimise the size of the packaged solution. ENQUIRY NO. 5802

ENQUIRY NO. 750

large electrical resistance results in voltage drops that the electronics cannot tolerate. Downhole exploration and production requires electronics that operate reliably from -40 deg C to 240 deg C and are packaged to keep contaminants away from sensitive electronics and mechanics. Electronic devices, magnetic materials, and mechanical systems exhibit behaviours such as nonlinearities and unmodelled dynamics at high temperatures. Magnet and semiconductor makers do not often publish the device or material specifications in these temperature ranges, requiring engineers to develop empirical knowledge on site and in labs. Experimental testing gives designers a better understanding of how these materials behave at

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FEATURES

Advantages Of Data Logging Systems The data logger has many advantages over a recorder or data acquistion system. These advantages will be discussed. By Omega Engineering

data logger is an attractive alternative to either a recorder or data acquisition system in many applications. When compared to a recorder, data loggers have the ability to accept a greater number of input channels, with better resolution and accuracy. Also, data loggers usually have some form of on-board intelligence, which provides the user with diverse capabilities. For example, raw data can be analysed to give flow rates, differential temperatures, and other interpreted data that otherwise would require manual analysis by the operator. The major difference between a data logger and a recorder, however, is the way the data itself is stored, analysed and recorded. A data logger is an attractive alternative to either a recorder or data acquisition system in many applications. A common recorder accepts an input, and compares it to a full scale value. The pen arm is then deflected across the recording width, to produce the appropriate ratio of the actual input to

A data logger can record at very long intervals, saving paper, and can note when an alarm condition is occurring.

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the full scale input. For example, using a recorder with a 1 Volt full scale, an input of 0.5 Volts would move the pen 0.5/1 or 50 percent of the distance across the recording width. In comparison, a data logger accepts an input which is fed into an analogue-to-digital converter prior to analysis and storage. This method has advantages in accuracy and resolution, while only a recorder can provide a truly continuous trend recording. Data loggers can also offer advantages over dedicated computer interface systems. A data logger is a self-contained unit that does not require a host to operate. It can be installed in almost any location, and left to operate. It can be installed in almost any location, and left to operate unattended. Data loggers have a distinct advantage over conventional interface devices, in that they operate in this stand-alone mode, and yet have the capability to â&#x20AC;&#x2DC;dumpâ&#x20AC;&#x2122; or transfer the data to a host system, if required. Most data loggers have the ability to work similarly to standard recorders, in that they provide the user with a hard copy printout of the data recorded. This data can be immediately analysed for trends, or stored for historical archive purposes.

recording on paper, 2, no other external or peripheral equipment is required for operation, and 3, many data loggers of this type also have the ability to record data trends, in addition to simple digital data recording. In comparison, units with internal data storage tend to be more compact, due to the fact that no paper and recording equipment are required, and because they are much simpler electronically and mechanically. Data storage units are usually more economical. These units can also be operated in a stand-alone mode, with the ability to feed or download data to a host computer system. Raw data can be analysed to give flow rates, differential temperatures, and other interpreted data that otherwise would require manual analysis by the operator.

When compared to a recorder, data loggers have the ability to accept a greater number of input channels, with better resolution and accuracy. Data loggers can also monitor for alarm conditions, while recording a minimum number of samples, for economy. If the recording is of a steady-state nature, without rapid changes, the user may go through rolls of paper, without seeing a single change in the input. A data logger can record at very long intervals, saving paper, and can note when an alarm condition is occurring. When this happens, the event will be recorded and any outputs will be activated, even if the event occurs in between sample times. A record of all significant conditions and events is then generated.

Networking Used For Acquisition Requirements For users who must acquire data over many locations, and wish to have a single collection/recording point, networking is a truly viable solution. With a network, one central location is responsible for data storage and recording; data is collected by remote units in various locations, and then fed to this ‘master’ unit for storage/recording. This is a great convenience, in that an operator can retrieve the data from one location, rather than having to go to each individual site for collection. ENQUIRY NO. 5803 SG-984-e-spool 83x110_SG-984-e-spool 83x110 29.05.14 23:41 Seite 1

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ENQUIRY NO. 752

The differences between various data loggers is based on the way that data is recorded and stored. The basic difference between the two data logger types is that one type allows the data to be stored in a memory, to be retrieved at a later time, while the other type automatically records the data on paper, for immediate viewing and analysis. Many data loggers combine these two functions, usually unequally, with the emphasis on either the ability to transfer the data or to provide a printout of it. The advantages of the local hard copy data loggers are that 1, the operator has a permanent

FEATURES

Lawrence Liu speaking at the company’s measurement forum in Singapore.

Keeping Change In Sight

IAA interviewed Lawrence Liu, GM, Agilent Technologies on the rebranding of Agilent Technologies’ electronic measurement group into Keysight Technologies. By Mark Johnston

n times of uncertainty, agility and adaptability matters. Come November 2014 Agilent Technologies will be spinning off its electronic measurement business, forming a standalone company, called Keysight Technologies. The company will employ approximately 9,500 employees in 30 countries. The new company’s tagline, ‘unlocking measurement insights for 75 years’, commemorates the birth of the original measurement business in 1939. This measurement business became the Hewlett-Packard Company, from which Keysight and Agilent Technologies originated. The primary focus of this new company will continue to be the wireless eco-system, the aerospace and defense segments as well as the industrial, computers and semiconductors eco-system.

Looking Ahead Agilent Technologies comprises many different businesses; the electronics measurement group being one of them. When Keysight seperates from Agilent, the portfolio difference, technology leadership and overall customers will be very distinctive. In terms of revenue distribution, Lawrence Liu, GM, Agilent Technologies commented:“When we move on to become Keysight, all the revenue generated from what was the electronic measurement group will go straight to Keysight. With full control and a very focused business model, this in turn will create more innovations, fund new products, and drive new solutions to address existing and new 58

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Guests at the company’s measurement forum in Singapore learning more about EEsof EDA software.

markets.” Mr Liu also remarked that the move to Keysight will give them additional flexibility. However, he also admits that the work on branding will be important to ensure that the name gains familiarity. “The challenge of brand familiarity is to ensure that our customers, especially new customers, are familiar with our brand and our pedigree. However, we have done it before when we moved from HP to Agilent and so we know what needs to be done. Weighing on our side is that our products, customers, and focused markets remain the same.” In terms of market challenges, he explained: “As we are focusing on the same markets, we do not foresee a big issue. We have the same team, same people, same products and our current current customers.” Mr Liu also stated that by November 1, 2014 Keysight will be completely independent, having their own symbols and new branding. “From August 1 Keysight will be a subsidiary of Agilent, and on November 1 we will be publicly traded on the New York Stock Exchange.”

Asian Expansion In Asia, the company is currently surveying offices and realigning existing ones. “In Singapore we are in the process of splitting the two companies. We will continue to be present in most if not all of the countries that we currently operate in after the split,” stated Mr Liu. In terms of the physical location of Agilent and Keysight, Mr Liu stated: “most or rather all of the offices that we have currently would be in the same place as Agilent. As such, what we are doing now is we are just splitting physically (adding separating walls and new entrances). The new company will continue to develop new

Oscilloscopes are a major product line for the company.

products and also continue to produce existing ones, “While in Agilent we have thousands of products and also inventory parts, it will take time to move totally to the new Keysight brand. There will be a period of mixed branding when we roll out on August 1. Customers may still see some instruments that have Agilent’s and Keysights logo after this date. As time goes by, we will deplete the parts and eventually it will just be Keysight’s logo,” commented Mr Liu. On Southeast Asia: “Southeast Asia is very diverse. The region is made up of four or five very active countries; though small individually, as a whole it is actually pretty substantial. One of our major markets in this region is manufacturing.” Giving an example of the region’s importance as a manufacturing hub, Mr Liu explained: “An example of this is that you can see a lot of manufacturing operations from the US and even China and Japan moving out of those regions and into Southeast Asia. One classic example would be Samsung. A visit to their Vietnam facility recently, you would know they have a huge facility would be a clear example of the size of the operations and we are seeing a lot of Japanese operations there as well. Other segments that are strong in Southeast Asia would be automotive, components and semiconductor plus an emerging aerospace and defence segment.” ENQUIRY NO. 5804

VISIT US ON OUR WEBSITE AT

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EVENT REVIEW

Singapore International Water Week 2014 THE future of urban living will be fraught with challenges. By 2030, the United Nations predicts that of the more than 500 cities in the world with more than one million each, more than half will be in Asia. The World Economic Forum listed water crises as one of the top 10 global risks of highest concern in 2014 likely to cause significant negative impact to countries and industries for up to 10 years. According to the World Bank, the 2.9 billion urban residents who generated about 0.64 kg of Municipal Solid Waste (MSW) per person per day more than a decade ago would increase to 4.3 billion urban residents generating 1.42 kg/capita/day of

MSW, making up an estimated total of 2.2 billion tonnes per year by 2025. In view of these complex a n d h i g h l y i n t e rc o n n e c t e d urbanisation problems, there is greater realisation today than ever before that cities need to address these challenges in a more integrated manner. Singapore took an integrated a p p ro a c h b y c o n c u r re n t l y hosting the World Cities Summit (WCS), Singapore International Wa t e r We e k ( S I W W ) , a n d CleanEnviro Summit Singapore (CESS) at Sands Expo and Convention Centre from May 30 to June 4, 2014. The co-located events of WCS,

Lee Hsien Loong, PM, Singapore gave the opening address for WCS, SIWW, and CESS.

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SIWW, and CESS brought together more than 20,000 participants from 118 countries/regions from government, industry and academia to co-create integrated and sustainable solutions to the world’s urban development challenges. A key theme that was discussed and debated during the week was the issue of a ‘smart city’. There was broad agreement that a smart city is a green city and should be sustainable and liveable. Nearly 1,000 companies exhibited their solutions covering three main themes: city administration, resource utilisation and waste management.

City Administration Cities in the future will be ecosystems of efficiency, working in tandem with sensors, smart machines and applications distributed throughout the city.

The constant flow of data is analysed and decoded for faster collaboration and better decisionmaking on a city-wide scale. Like plant automation, cities will have unified and secure command and control centres that receives city-wide intelligence, event sensing and detection through multiple system integration and live data feeds. Imminent crisis can be averted by immediate responses from operational staff, which can react through alarm triggers, rule violations rather than continuous monitoring. One application could be pre-emptive flash flood avoidance. Alerts on heavy rains and high water level or even prewarning. With a single interface, staff can monitor real-time events, generate reports, track activity and view live and recorded information. Multiple users can also view data from multiple locations

s i m u l t a n e o u s l y, a l l o w i n g for greater multi-agency collaboration, through multiple systems. Rule-based engines, or advanced complex event processing triggers can then be used to alert relevant agencies so they can respond and intervene before a situation exacerbates. Social media analytic engines can be integrated into these systems to collect information and notifications from social media platforms. Such information provides additional source of data that can be used to predict threats that are not predictable with surveillance data alone. For example, NCS collaborative project with Airbus Defence and Space is currently testing an integrated surveillance and security system in the district of Little India, Singapore. According to Airbus, the system collects data primarily from three sources: fixed sensors (cameras with August 2014 | industrial automation asia 61

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EVENT REVIEW

Siemens held a press conference at the World Cities Summit to release a new study: ‘The Mobility Opportunity — Improving urban transport to drive economic growth’.

microphones) distributed within the district, cameras on mobile police units, and online media from the internet. The data then feeds into a data centre where advanced analytics, sentiment analysis, trend detection and predictive modelling provide real-time insights and predictive foresights. It also provides triggers to relevant agencies so that they can respond and intervene quickly. This system allows agencies to detect anomalies in crowds, such as flash mobs, presence of fights and aggressive behaviours, and optimise existing manpower resources while maintaining dayto-day city management activities. According to NCS, this system has actually detected a fire in March this year and enabled firefighters to respond within six minutes. Intelligent transport systems are another area for future automated city administration. Commuter travel intelligence allows real-time traffic situations to be captured through crowdsourcing. Advanced road pricing systems such as distancebased charging can be deployed to regulate flow and speed of traffic. Video and audio content analytics improve automated information extraction and analysis of events such as unattended vehicles, recognise vehicle license plate, detect illegal parking or even traffic rule violation.

On-board devices allow drivers to make real-time communications with other vehicles or the transport infrastructure. Integrated GPS systems, predictive modelling and event processing provides realtime road situation tracking and traffic updates. Mobile devices can track sentiment analytics of various travel routes and help plan best door-to-door journeys.

Resource Utilisation Major resources for urban use are water and energy. Automation solutions that efficiently deploys water and energy use are likely to be integrated into cities in the future. Energy data management can now be done city-wide, as smart street and public areas lighting run on configurable schedules, fault detection for street lamps, sensors and other energy-consuming devices. For residents, cloud-based utilities dashboard provides analysis of energy and water consumption with usage profiles. According to IBM, some cities lose as much as 50 percent of their water supply to leaky infrastructure. The automation and control of water resources would as such make the difference between smart use of water and wastage. Valve control through a pneumatic control circuit, where electrical signals from the sensor box are read and processed by the control module and controls

the pneumatic actuators via five or three-way valves. One example was Festo’s DFPI series of actuators integrated with closed-loop control functions. The cylinder, displacement encoder, valve block and positioner are safely accommodated in the housing, and do not require positioners and are not susceptible to external environmental factors. Pan Asian Holdings provide water and wastewater treatment from renewable energy sources such as windmills and solar photovoltaic. The offerings also include an Airwater machine which produces clean water by cooling air below its dew point. A green city also produces significant quantities of biomass and timber that can be utilised effectively. Examples include local pallet manufacturer LHT, which uses automation to convert wood wastes to materials for furniture, building material and heavyduty industrial; France-based Zeta pellets, which compresses solid biomass into pellets for energy production. According to Alexander Papenberg, commercial relations for Zeta pellets, the fuel is completely carbon-free and 50 percent less expensive than any fossil fuel.

Waste Management However not all wastes can be utilised and smart waste management systems is a necessary part of the urban ecosystem. This includes smart bins with ultrasonic sensors and collection trucks with RFID and GPRS systems. According to Armando Savares, senior business development manager, at Mindwave Solution, RFID/GPS Track and Trace System integrates vehicles, Machine-to-Machine (M2M) communications, sensors and analytics in real time. Unique RFID tags on each bin get read by a reader antenna on

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the truck, which is synched to a GPS-enabled Vehicle Mount Controller in the drivers cab. The information is transmitted back to the main server via 3G. This allows for monitoring and generation of reports from a central management system, or from an external located connected to the server.

Future Singapore F o r S i n g a p o re , t h e u r b a n challenges are no different from other developed cities with increasingly more complex problems, requiring innovative solutions to address them. Several projects and studies were announced to provide solutions for future urban problems. One such project was the development and operation of a metal recovery facility to salvage ferrous and non-ferrous metals from incineration bottom ash. The S$15 million (US$12 million) project is part of the

Government’s long-term strategy to manage solid waste in Singapore and move towards a resource efficient society. Singapore’s EZ-Link and Taipei’s EasyCard Corporation inked a Memorandum of Understanding (MOU) for the use of a single card to facilitate seamless travel and retail transactions in both countries, easing travel between and within both cities for tourists and business travelers. M O U s w e re a l s o s i g n e d between PUB and companies including Evoqua, Anaergia and Grundfos to explore R&D projects in water treatment. PUB and Evoqua will further develop electrochemical desalination technology to improve energy and cost efficiencies in seawater desalination, while collaboration with Anaergia focuses on potential waste-to-energy research projects. PUB and Grundfos will work on efficient pump solutions and R&D in wastewater treatment solutions.

The Housing and Development Board of Singapore signed a MOU with the Energy Market Authority, Singapore and Panasonic to study the feasibility of establishing a Smart Home Energy pilot to provide households with the possibility of implementing timeof-use electricity rate packages and integrating features such as the home energy management system. In his closing remarks, Dr Liu Thai Ker, chairman of the Centre for Liveable Cities (CLC), told the audience that the city was, in a sense, the largest piece of industrial design made by man and would be judged by whether it was user friendly, functioned well and looked good. He said: “In urban planning, we must have a humanist’s heart, a scientist’s head and an artist’s eyes. The ultimate achievement for a city is to earn unconditional respect from people all over the world, for our people, our city and our country.” The week saw S$14.5 billion in total value for the announcements on projects awarded, tenders, investments and MOUs. Returning exhibitors have committed more than half of the Water Expo space ahead of SIWW 2016. To be held from July 10 - 14, 2016, the 7th Singapore International Water Week will continue to be co-located with the World Cities Summit and the CleanEnviro Summit Singapore. May 30 - June 4, 2014 Sands Expo and Convention Centre Singapore

ENQUIRY NO. 5901

The Mitsubishi Electric Asia booth. One of the founding sponsors of SIWW.

Visit us on our website at

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EVENT REVIEW

ABB World Control Tour Singapore 2014 IAA attended ABB’s World Control Tour at Marina Bay Sands, Singapore, where the next generation of the company’s flagship Distributed Control System (DCS) was introduced. This and other topics were discussed with Tobias Becker, head of Control Technologies, ABB. By Mark Johnston

THE World Control Tour is a series of events held in different countries and regions, to discuss and learn about the latest automation trends and how organisations can take control of productivity, optimisation, energy efficiency, and security in a plant or data centre. Held on May 27 - 28, 2014, at Sands Expo and Convention Centre, Singapore, the event was attended by over 200 participants, with end customers, EPC, system integrators and OEMs attending. Almost thirty nationalities were also in attendance. In terms of industry verticals leveraged by the company, Tobias Becker, head of Control Technologies, ABB, explains: “We have pulp & paper, metals, and oil & gas. We are also involved in data centre operations, heavy industry, and the pharmaceutical industry.” T h e c o m p a n y ’s f l a g s h i p Distributed Control System (DCS), the 800xA is at the centre of this

tour, and is celebrating its 10 year anniversary in 2014. “The World Control Tour is focused on the DCS, which we consider as the core of our control technologies business. Specifically the 800xA or the extended automation portfolio we have. Of course there are other parts that are tightly connected to this product, which we always showcase together with our DCS,” commented Mr Becker. While the first day featured keynote speakers from ABB, guest of honour from EDB and its partner from Intel, the second day involved breakout sessions where guests were invited to delve deeper into their area of interest. The breakout sessions featured three tracks, namely a general track, data centre track, and an industry track, covering areas such as 800xA V6 introduction, cyber security, alarm management, big data in automation, the power of integration, asset management, and case studies from industry.

On celebrating its 10th a n n i v e r s a r y, M r B e c k e r commented: “We have fulfilled this products original vision. Over time we have taken feedback and added features that our customers have been asking for. As such, we feel it is a good time to celebrate our achievements and review our progress, so we are making this tour around the world, with Singapore being our 7th stop.” Other locations the company will be touring include North and South America, Europe, China, and the Middle East, with Singapore and Guangzhou, China being the only two locations in Asia.

World Control Tour Agenda When developing the Version 6 of 800xA, “we took into consideration feedback from our customers and focused on what is above and beyond what was already available in version 5.1 feature pack 4 of 800xA. From this feedback we learned our customers wanted

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Tobias Becker, head of Control Technologies, ABB, presided over the event, giving a keynote speech on day one.

to see three things, namely, ease of installation and upgrading, security, and future proofing,” stated Mr Becker. One of the main features that customers had been requesting is a means of installing and upgrading the systems operating system with ease, as many systems, more than 50 percent, are still running Windows XP. “As Microsoft was continuing its support for Windows XP there was no urgency to change operating systems. However that changed on April 8, 2014 with Microsoft pulling the plug on Windows XP. Of course this created a sense of urgency not least because of security concerns but also because it becomes inconvenient to support the system and supply hardware,” remarked Mr Becker. “ As such, a lot of customers wanted to move to a newer operating system and ultimately we accommodate that request,” he explained.

The second aspect focused on was security, with Mr Becker explaining that security had been a theme from the industry for some time and that it is something that the company has looked at addressing in this version. The last and third aspect that set the agenda was the future proofing of the product so that “it has the foundations to take our customers into the 2020’s,” remarked Mr Becker.

Evolving The Market Asia is seen as a dynamic region to work and do business with a broad exposure to industry verticals. In terms of the company’s approach, Mr Becker explained: “We use an approach called Develop Once, Deploy Often (DODO), which means that once we develop technologies we try and bring those technologies into as many applications as possible and adjust them accordingly to make them relevant. Due to that broad

exposure of verticals, Southeast Asia (SEA), in particular, is a great place for us.” Asia has many natural resources, as such, businesses like hydrocarbon or mining are plentiful, depending on country. Oil & gas to customer chemicals, pharmaceutical, and biotech organisations are located in the region, together with metals and cement industries, all of which the company is involved in. As such, Mr Becker explained: “You really have the full range of industries available in Asia. This creates a dynamic market for us to be involved in.” Expanding on this, he explained: “Singapore, in particular, has a huge need for building automation and data centre automation. This is something we do not see everywhere, and with huge cities there is a high need for HVAC and energy efficient infrastructure and related product offerings.”

Unresolved Challenges The development time for version 6 took 18 months but as Mr Becker explained: “In many aspects it took much longer, considering how things came about over the course of time.” In terms of unresolved challenges he explained: “I believe one of the big challenges over the course of the coming years is going to be making sense of Big Data. More raw data is being generated at an increasing rate; a direct result of the availability of new devices and an increasing number of sensors. This will ultimately generate more data that needs to be processed and analysed.” Five to ten years ago operators were starving for data, now the opposite is true and operators are essentially drowning in data. Managing all this data is, as Mr Becker remarked, going to be a challenge, however he also declared it represents an opportunity. August 2014 | industrial automation asia 65

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EVENT REVIEW

The event was attended by over 200 participants, with end customers, EPC, system integrators and OEMs attending.

“Our answer to this is to provide our Data Centre Infrastructure Management (DCIM) software suite, Decathlon, with tools that allow you to pull up data, historise, visualise, and connect it to various systems and generate reports,” he remarked, before adding that: “Our real vision is that our own domain experts as well as third party domain experts will be able to plug their own apps into the Decathlon service to complete the picture and make sense of that data.” Another challenge the company sees ahead lies partially in the demographic change but also in the available talent on the operator side. “A lot of our customers are building a lot of plants that require many operators, and with not enough operators to work for our customers the challenge becomes designing a control room environment where less people are able to control more,” concluded Mr Becker.

The Features In terms of features that have been added to System 800xA version 6, Mr Becker stated: “We have been asking our customers what they want to see from a DCS, and over the past 10 years they have requested features, such as, wanting to have simulation and training running on a real system and not on a separate simulator. However, recently they have requested a means by which they can easily upgrade the system to mitigate the risk from Windows XP, and provide better security for

A new way to visualise data was introduced by using a ‘Collaboration Table’ providing a 3D view of plant KPIs.

their system.” Tools and services have been added to make it as easy as possible to switch over from an old system. This includes an installation and upgrade tool for establishing node profiles, which enables an easier, centralised installation and faster restoration of the nodes while the system is being used. In addition, a ‘Customer Lab’ is available, which a service customer may use during system migration. This provides an initial check in a secure, virtual environment and in turn reduces the costs. O t h e r f e a t u re s t h a t t h e company added enabled a productivity increase in the system, by way of a better control room environment, but also a more lean deployment. “This is why we introduced virtualisation and multicore processing,” stated Mr Becker. In addition to ease of upgrading, version 6 will come with Windows MS 8.1/server 2012 R2. Digital code signing will also be included to ensure that the permitted code has been installed and used, in addition to the inclusion of network switches to reduce cost of commissioning and to increase plant safety. When asked what he considered the most important feature of version 6, Mr Becker responded: “I believe the most important thing that we have achieved with version 6 is to have a system in place that makes it much more easier to migrate from a 3rd party system or upgrade from one of our older systems to

our newest system. Why is this important? It is important because many customers will try and tackle upgrade issues all at once, and so the more convenient we make this process the more they will trust our system knowing that upgrading is a smooth process.” In addition, other products were showcased at the event that are compatible with 800xA version 6. These include wireless mesh routers that are designed to enable safe and secure deployment of mobile operator clients, maintenance workplaces, and even process controllers. A new information management p l a t f o r m p ro v i d i n g s e c u re connectivity to 800xA so that data can be safely collected, viewed, historised and reported above the control system layer. An embedded Public Address System is also available that allows text to speech announcements to be broadcasted in multiple languages from 800xA. Also introduced was a new way to visualise data by using a ‘Collaboration Table’ providing a 3D view of plant Key Performance Indicators (KPIs).

In Conclusion Overall the event was wellattended, with a general overview given by keynote speakers on the first day with a more in-depth look on the second day provided by three separate tracks. Themes revolved around major industry trends, aligning the organisation well going forward. These trends included Big Data, the Internet of Things (IoT), Process Safety, Electrical Integration, and Collaboration. Cyber Security was also a big theme, in addition to discussions on future proofing. May 27 - 28, 2014 Sands Expo and Convention Centre Singapore ENQUIRY NO. 5902

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PRODUCTS & SERVICES ABB: Uninterrupted Power Supply

Baumer: Edge Sensor

ABB has launched its medium voltage uninterrupted power supply series called the PCS100 MV UPS. This series is designed to provide large critical process industries and data centres centralised UPS protection with multi-megawatt ratings and typical efficiency of 99.5 percent. This product will initially be launched in China, where the country’s high technology industries rely on massive levels of power. Although this series is industrially rated it is also targeted towards mega-size data centres, which are increasingly being developed to satisfy expansive growth in cloud computing and co-location services.

The optical edge sensor PosCon 3D by Baumer is designed to reliably master tasks that used to be up to complex laser measuring systems. In parallel, this product provides convenience in both operation and installation. Multiple capabilities make the sensor a versatile solution to reliably detect edge positions and object or gap width. There is no need for a separate reflector. Object movements towards and away from the sensor within the measuring field will not impair the measuring result. It will reliably identify any object — independent of its colour and surface.

ENQUIRY NO. 5903

Apacer: Micro SD/Micro SDHC

Beckhoff Automation:

Apacer has launched the industrial Micro SD/Micro SDHC memory cards which conform to SD 2.0 specifications. Although the size is only one-tenth of a general SD card, the Micro SD/ Micro SDHC memory cards have a complete range of product types, providing SLC and MLC chips for choice. The SLC chips have capacities ranging from 256 MB to 4 GB. The more economic MLC chips’ capacities range from 4 GB to 32 GB. Designed with rigorous industrial specification demands, these products can also be applied to embedded devices for military use, communication and surveillance as well as vehiclemounted devices.

The EP9224 smart power box, from Beckhoff Automation, offers internal current and voltage measurement in addition to the possibility to connect four EtherCAT Box power supply branches. The values are available to the controller via EtherCAT and support the preventive maintenance of machines and plants as well as error diagnostics, especially in conjunction with the data logging function. The power consumption for the control and peripheral voltage is monitored, limited and if necessary also switched off in each 24 V supply branch of the smart power box. The input voltage and current values as well as all output currents can be transferred by EtherCAT to the controller as process data and evaluated.

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Smart Power Box

ENQUIRY NO. 5906

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PRODUCTS & SERVICES

Carlo Gavazzi Automation:

Fuji Electric: Variable Speed Drives

Carlo Gavazzi Automation has released the 4th generation Tripleshield capacitive sensor series, CA30CAN/CAF. The enhanced EMC performance allows these sensors to withstand higher electrostatic disturbances, while the Ecolab certification, rated to IP69K, makes this series suited for reliable detection in harsh environments subject to high temperature, chemical agents, steam and high-pressure cleaning. Designed by the companyâ&#x20AC;&#x2122;s competence centre in Denmark, this capacitive sensor series is mainly directed at Industrial markets such as plastic and rubber, agriculture, materials handling, packaging, food and beverage, HVAC, glass and ceramics and automotive.

Fuji Electric is now ready to supply its high-performance, standard-type series of variable speed drives, the Frenic-Ace in the APAC region. These drives are designed to maximise engineering flexibility and performance. The four in one rating variable speed drive comes with improved cost reduction and efficiency in its class. With good expandability communications and customisation logic functions design that will keep a project competitive in cost and technology. This product is suitable for air conditioning equipment, conveyors, food-related machinery, machine tools, textile and spinning machinery.

Capacitive Sensor

ENQUIRY NO. 5907

ENQUIRY NO. 5909

Contec: Industrial PC

Honeywell Process Solutions:

The EPC-2020 series, from Contec, is a customisable industrial PC which features a compact and attractive chassis with high performance and reliability. It can be used not only as an embedded PC which is used in semiconductor equipment or inspection equipment, but also as a desktop PC, especially in the healthcare field. The second generation Intel Core processor has also been adopted to achieve a controller which is power-saving and compact, but powerful. The series supports mirroring function (RAID1). It reduces the risk of missing data. In addition, this series is equipped with a writable DVD drive, so data can be backed up on DVD.

Honeywell Process Solutions has launched a range of SmartLine industrial temperature transmitters, which improve overall plant and employee efficiency even in harsh and noisy process environments. This product line is part of the companyâ&#x20AC;&#x2122;s SmartLine field instrument product family. In industrial plants, field instruments that measure temperature are used throughout the manufacturing process to enable operational safety and product quality. Large industrial complexes, such as those for refining crude oil or producing chemical products, can employ thousands of these devices within their manufacturing processes.

ENQUIRY NO. 5908

Temperature Transmitters

ENQUIRY NO. 5910

August 2014 | industrial automation asia

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PRODUCTS & SERVICES

Omega Engineering: Ultrasonic

Mobil Industrial Lubricants: Signum

The FDT-21 ultrasonic flowmeters, from Omega Engineering, is designed to be easy to use and easy to install. It is also designed to measure the fluid velocity of liquid in a full/closed pipe, with an accuracy of 1 percent and repeatability of 0.2 percent. Featuring a positive, negative and net totaliser and also a 4-Line LCD display designed to make reading the measurements easy. This product is suited for monitoring liquid flow in manufacturing, chemical treatment, automotive and biological applications.

Signum’s accurate in-service oil analysis has built a reputation for advancing productivity through safety, environmental care and productivity. Signum’s skilled professionals deliver detailed, actionable recommendations using proprietary test control limits set specifically for your equipment, and complex algorithms help pinpoint deviations and supply further insights to your business. With the launch of the Signum Laboratory in Shanghai Technology Centre, the Signum Oil Analysis program now delivers professional oil analysis services to customers across the Asia-Pacific region.

Flowmeter

ENQUIRY NO. 5911

Yokogawa: Single Loop Controllers

The Panduit Industrial UPS uses Ultra-capacitors instead of batteries, eliminating the number one cause of UPS failures which, in turn, lowers the risk of downtime. It is designed specifically to back-up industrial managed switches, HMIs and other low power devices. The no battery design is maintenancefree, the return-on-investment is up to two times better and the cost of ownership is 50 to 70 percent lower than an ordinary UPS. Easy remote device management uses standard web browsers and FactoryTalk interoperability, saving time and money on proprietary software. The compact, single unit (80mm wide) saves DIN rail space compared to typical battery UPS which is two pieces (120mm – 240mm wide combined).

Yokogawa Electric Corporation has announced that it has enhanced its YS1000 series single loop controllers. These controllers feature a Thin Film Transistor (TFT) LCD with improved display characteristics and a design that facilitates easy maintenance. This product now uses a TFT LCD screen that has a 1.5 times wider viewing angle. The display contrast and brightness are also notably improved, making the screen much easier to read. In addition, the TFT LCD has a longer lifespan and does not need to be replaced as frequently. This product can be used in operation, monitoring, and control of production facilities.

ENQUIRY NO. 5912

P&S.indd 70

ENQUIRY NO. 5913

Panduit: Uninterruptible Power

Supply

Oil Analysis

ENQUIRY NO. 5914

industrial automation asia | August 2014

1/8/14 9:04 am

Calendar Of Events 2014 aug 27 – 29 Taipei International Automation Exhibition 2014 TWTC Nangang Exhibition Hall Taipei, Taiwan Chan Chao International Email: automation@chanchao.com.tw Web: http://www.autotaiwan.com.tw/

27 – 30 MTT Malaysia Putra World Trade Centre (PWTC) Kuala Lumpur, Malaysia ECMI Email: overseas@ecmi.asia Web: http://mtt-kl.com

sep

10 – 12 Power-Gen Asia 2014 KLCC Kuala Lumpur, Malaysia Pennwell Email: mathildes@pennwell.com Web: http://www.powergenasia.com/

17 – 19 Electric & Power Vietnam 2014 Saigon Exhibition & Convention Centre (SECC) Ho Chi Minh City, Vietnam Hong Kong Exhibition Services Email: exhibit@hkesallworld.com Web: http://electricvietnam.com

17 – 19 Industrial Automation Vietnam 2014 Saigon Exhibition & Convention Centre (SECC) Ho Chi Minh City, Vietnam Hong Kong Exhibition Services Email: exhibit@hkesallworld.com Web: http://electricvietnam.com

17 – 19 Green Build Asia 2014

3 – 5 Semicon Taiwan 2014 TWTC Nangang Exhibition Hall Taipei, Taiwan SEMI Email: staiwan2@semi.org Web: http://www.semicontaiwan.org/

9 – 11 Medical Manufacturing Asia Suntec Convention & Exhibition Centre Singapore Messe Duesseldorf Asia Email: shirley@mda.com.sg Web: http://www.medmanufacturing-asia.com

Indoor Sports Complex Vung Tau City, Vietnam Fireworks Vietnam Email: viet@asiafireworks.com Web: http://www.oilgasvietnam.com/

27 – 31 Singapore International Energy Week Sands Expo & Convention Centre Singapore Energy Market Authority Email: ema_siew@ema.gov.sg Web: http://www.siew.sg/

nov 4 – 6 China International Industry Fair 2014

Putra World Trade Centre (PWTC) Kuala Lumpur, Malaysia UBM Email: norman.zainal@ubm.com Web: http://www.ecobuildsea.com/

Shanghai New International Expo Centre Shanghai, China Shanghai Eastbest International (Group) Email: office@shanghaiexpogroup.com Web: http://www.ciif-expo.com/

17 – 19 Thailand Lab 2014

4 – 8 Industrial Automation Show 2014

BITEC Thailand, Bangkok VNU Exhibitions Email: thailandlab@vnuexhibitionsap.com Web: http://www.thailandlab.com/

oct

2 – 4 Oil & Gas Thailand BITEC Bangkok, Thailand Fireworks Email: sg@asiafireworks.com Web: http://oilgasthai.com/

22 – 24 Oil & Gas Vietnam 2014

9 – 11 Metalex Vietnam 2014 Saigon Exhibition & Convention Centre (SECC) Ho Chi Minh City, Vietnam Reed Tradex Email: nutcharee.rata@reedtradex.co.th Web: http://www.metalexvietnam.com/

Shanghai New International Expo Centre Shanghai, China Hannover Milano Fairs Shanghai Email: ias@hmf-china.com Web: http://www.industrial-automation-show.com/

dec 3 – 5 Semicon Japan Tokyo Big Sight Tokyo, Japan SEMI Email: jeventinfo@semi.org Web: http://www.semiconjapan.org/

22 – 24 Electrical Power Automation & Smart Grid 2014 China International Exhibition Centre Beijing, China China Electrical Council, Adsale Exhibition Services Email: power@adsale.com.hk Web: http://www.epchinashow.com/epa

22 – 24 EP China & Electrical China 2014 China International Exhibition Centre Beijing, China China Electrical Council, Adsale Exhibition Services Email: power@adsale.com.hk Web: http://www.epchinashow.com/

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