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MICA(P) 154/07/2009 | ISSN 0219/5615 | PPS 1561/06/2010 (028221)
RFID: The Small Wonder DCS Migrations:
Risk vs Return End Of Line Packaging:
Go Green! MES: Effective Execution Online Diagnostics:
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MITSUBISHI ELECTRIC
The Energy Saving is
MITSUBISHI FREQROL F700
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ENQUIRY NO. 099
Obvious
contents February / March 2010
ISSUES & INSIGHTS
20 RFID: Smooth Operator
The London Underground uses RFID technology to support their escalator maintenance operations. By John Williams, CoreRFID
24 Airport Luggage Identification System: Sort It Out!
The Airport Luggage Identification System makes quick time of luggage sorting. By Thomas Lim, Sick
CONTROL POINT
26 DCS Migrations: Risk vs Return
If executed correctly, a phased migration can offer increased productivity and a sharper competitive advantage. By Mike Vernak, Rockwell Automation and John Bryant, Arkema
SOFTWARE & NETWORKS
30
Online Diagnostics: Easy Access
Using operator interfaces to optimise performance of industrial wireless networks. By Jim Ralston, ProSoft Technology
Instrumentation & Measurement
34 All Calibrations Are Not Created Equal
Use an ISO/IEC 17025 accredited laboratory to be sure of the accuracy of calibration results. By Sheila Goodson, director of quality and organisational development, Quest Technologies
SECTOR SPOTLIGHT
ENERGY
Of Line Packaging: 36 End Go Green!
A comparison of the sustainability of ‘pad shrink’ packaging systems versus RSC cases. By Peter Fox, Delkor Systems
40
MES: Increased Execution Effectiveness
Effectiveness of processes have been known to increase by seven to 10 percent with the application of MES. By Ralf Schubert, Schubert
2 industrial automation asia | Feb/Mar 2010
Audits & 42 Energy Savings Opportunities
Energy audit kits and training help your staff identify and correct energy waste. By Mark Price, Fluke Corp
Saving In 44 Energy Your Hands
By selectively switching off any consumer loads that are not currently required, the demand for energy and the associated costs can be drastically reduced. By Norbert Brousek, Siemens
ENQUIRY NO. 092
Feb/Mar 2010
February / March 2010
Feb/Mar 2010 IndustrialAutomationAsia
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MICA(P) 154/07/2009 | ISSN 0219/5615 | PPS 1561/06/2010 (028221)
MICA(P) 154/07/2009
RFID: The Small Wonder Risk vs Return
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FEATURES
DCS Migrations:
ISSN 0219/5615
End Of Line Packaging:
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Go Green! MES: Effective Execution
PPS 1561/06/2010 (028221)
Sustainability: Take It, It’s Yours!
46
Online Diagnostics: www.iaasiaonline.com
SMC’s Dr Song Bin discusses his vision for the newly launched centre. By Joson Ng and Derek Rodriguez
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EDITOR’s PAGE
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Opportunities
In an effort to keep figures in the black in the labouring economy, many companies have made cost cutting measures top of their to-do list. One way companies are cutting costs is by shifting their manufacturing facilities to other areas to take advantage of lower production costs. However, deservedly or not, there is a perception amongst the general public that products manufactured in certain areas are of lower quality than those with a ‘Made In Japan’ or ‘Made In Germany’ sticker. The recent recall of Toyota cars with components made Most of the time, in a Czech plant and Peugeot companies Citroen’s similar campaign the for cars from the same plant further attempts to justify this inherent ability to country-biased impression. Of course, cost cutting save by need not be synonymous with in a compromised quality. They are other ways about it, as we . explore in this issue of IAA. Assessing energy usage in a facility and identifying areas where energy savings can be achieved is one. Another is by optimising energy usage by switching off unnecessary loads. We also found out more on the newly opened Sustainable Manufacturing Centre, which collaborates with companies small and large to find innovative new ways of minimising waste. Aiming to combine cost benefits with environmentally friendly performance, three key points have already been identified as focus areas for the centre. Most of the time, companies already possess the inherent ability to save by using their resources in a more efficient manner. The first step is simply quantifying usage and pinpointing zones where savings can be made. Once this information is available, the rest will surely fall into place.
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ENQUIRY NO. 078
Industry News Ziemann To Erect Brewery In Cambodia
Ms Okhna Pheap Heak, chairlady of the board of Chip Mong Group and Joachim Gunkel, MD, Ziemann Group
Phnom Penh, Cambodia: The Ziemann Group has received an order to build a turnkey brewery in Phnom Penh/Cambodia. The contract for the engineering and construction of a plant was signed at a formal ceremony on December 13, 2009. The order has been placed by the Chip Mong Group, a familyowned enterprise. The complete plant is designed for an initial annual output of 500,000 hl. Expansion plans will allow a further increase in the production to 1,000,000 hl and 2,000,000 hl per annum,
in line with Cambodia’s fast-growing beer market. The Chip Mong Group has decided in favour of a brewhouse with a Ziemann mash filter and an output of up to 14 brews/day. The cold block, process technology, automation and utilities will also be provided by Ziemann as well as the complete filling plant for bottles, cans and kegs. The green field plant will carry the name Khmer Brewery and will be built in Choueng Ek, a district of the capital city Phnom Penh. Construction work will begin in January 2010.
Shaw & Westinghouse Reach Milestone At Nuclear Site In China Louisiana, USA: The Shaw Group and Westinghouse Electric Company, along with China’s State Nuclear Power Technology Corporation (SNPTC), Sanmen Nuclear Power Company (SMNPC) and China Nuclear Industry Fifth Construction Corporation (CNF) successfully completed the lift and setting of the containment vessel bottom head (CVBH) of Unit 1 at the Sanmen AP1000 nuclear power plant project. The CVBH serves as the foundation for the containment vessel, a capsule-shaped steel structure that will house the nuclear reactor. The project team used a large-capacity crane to lift, position and install the CVBH. The lift of the CVBH and its supporting structures was more than 900 tonnes. The CVBH is the second massive nuclear plant structural module installed by the China Project AP1000 team members, following the Auxiliary Building Module CA-20 set at Sanmen Unit 1 earlier this year. 8 industrial automation asia | Feb/Mar 2010
Industry News
Gerard79, D¸sseldorf, Germany
Suzuki Starts Building Automobile Plant In Thailand
Japan: Suzuki Motor Corp is moving forward with its plans to take part in Thailand’s eco-car project. The company plans to invest 20 billion yen (US$217 million) in construction of an 650,000 sq m automobile plant that will have facilities for pressing, welding, painting, assembly, and engine production. It plans to start producing eco-cars at the plant in March 2012. The planned production volume is 10,000 units by end of
Specialty Chemicals Company In Shanghai Receives HART Award Texas, USA: The HART Communication Foundation has recognised the Evonik Degussa Specialty Chemicals Company in Shanghai, China, with the HART Innovative Achievement Award. This award is presented to recognise exceptional achievement, ingenuity and innovation in using the Power of HART Communication in real-time applications to improve operations and maintenance and to realise greater benefits from intelligent instrumentation and automation system investments. Following research on the use of HART in all phases of the plant life cycle, engineers at Evonik decided to utilise HART Communication throughout their new methacrylates production complex, including design, construction, device configuration, loop check, operations, maintenance and troubleshooting. The complex has more than 2,000 HARTenabled instruments and valves installed from multiple global manufacturers.
December of first year. Suzuki is also set to reorganise its Thai automobile sales operations. It currently markets automobiles in Thailand through its local sales subsidiary, Suzuki Automobile (Thailand), but plans to gradually shift sales operations to its local production company, Suzuki Automobile Manufacturing (Thailand).
Galen Building Wins Award Singapore: The Galen building at the Singapore Science Park has been accorded the ‘Trane Energy Efficiency Leader Award’. This is the first time that this award is given out in the Asia-Pacifc region. And for the building owner Ascendas, the award recognises their commitment to energy efficiency and environmental stewardship. Prior to the infrastruture upgrades, the Galen was challenged with high energy costs. An internal energy audit revealed that the six-story building’s air conditioning system and its high energy consumption was the cause. The building needed improvements to not only save operating costs, but also to be environmentally responsible. In August last year, the Galen completed infrastructure improvements which involved the replacement of the existing air-cooled chillers with water cooled systems. Energy management systems were installed to control and configure energy consumption to ensure optimal usage.
Power Supply System Business To Be Launched Tokyo, Japan: On January 1, 2010, Fuji Electric Systems (FES), a wholly-owned subsidiary of Fuji Electric Holdings, merged the uninterruptible power supply (UPS) business of FES and TDK-Lambda Corporation (TLJ), a wholly-owned subsidiary of TDK Corporation, with the internal power supply business (mainly comprised of custom power supplies) of Fuji Electric High-Tech Corporation (FH), in line with previous announcements. With a full lineup of products including internal power supplies and small-, mediumand large-capacity UPS, FES will develop its business with the aim of offering a power supply solution business that satisfies customers. Feb/Mar 2010 | industrial automation asia 9
Industry News
JJ-Lapp Supplies Roller Coaster Cables Singapore: The opening of Universal Studios Singapore at Resort World Sentosa, a movie-theme park featuring 24 rides and attractions, 18 of which are unique only to Singapore, will take place in early 2010. As part of the many attractions, funseekers will be able to enjoy the world’s highest dueling roller coaster (42.5 metres). But there’s no ride without cables. To make the ride work, JJ-Lapp Cable supplied 45 kilometres of cable, including the Olflex Classic 110 Black 0,6/1kV, a multi-conductor, flexible control cable designed for outdoor use in all electrical equipment in dry, damp and wet conditions.
Patrick Moore, Oklahoma, US
eSolar Partners With Penglai
Beijing, China: eSolar, a global provider of concentrating solar power (CSP) plants, and Penglai Electric, a privately-owned Chinese electrical power equipment manufacturer, have announced a master licensing agreement to build at least 2 gigawatts (GW) of solar thermal power plants in China over the next 10 years. Penglai Electric plans to develop 2 GW of power plants by 2021 using eSolar’s solar thermal technology. The solar thermal power plants will be co-located with biomass electricity generation facilities. Penglai Electric will leverage local manufacturing to source some of the equipment. In total, the plants will eliminate 15 million tonnes of carbon dioxide emissions annually. China is currently the market leader in the PV manufacturing industry. The deal represents the country’s first major move into concentrating solar thermal power. The Chinese government recently announced its aggressive plans to increase the country’s renewable power generation capacity to 15 percent by 2020. 10 industrial automation asia | Feb/Mar 2010
Mitsubishi Electric & Zhuzhou CSR Times Electronic Win Order Tokyo, Japan: Mitsubishi Electric and Zhuzhou CSR Times Electronic have received orders from Beijing MTR Construction Administration Corporation for electric railcar equipment to be used on the Beijing Subway Changping Line. The order, worth approximately 3.6 billion yen (US$40 million), comprises variable voltage variable frequency (VVVF) inverters, traction motors, auxiliary power supplies, regenerative braking systems and other electric equipment for 27 six-coach trains. Deliveries will begin this May. The Changping Line is one of five new subway lines scheduled to start operating in Beijing this year. The 32.7 kilometre line running through the Changping district of northwest Beijing will have nine stops between Xierqi and Ming Tombs Scenic Area stations. Mitsubishi Electric’s Itami Works will manufacture traction motors for the 162 coaches. Zhuzhou CSR Times Electronic will make the box frames and procure certain components. Zhuzhou Shiling Transportation Equipment, a joint-venture between the two companies, will assemble all components and execute final testing. Mitsubishi Electric already has received a large number of orders for electric railcar equipment around the world. In China alone, orders received from city metros include products for the Beijing Subway lines 2 and 8; Tianjin Metro lines 1, 2 and 3; Guangzhou Metro lines 4 and 5; and Shenyang Metro Line 1.
Industry News
Sakhalin-1 Project Continues Drilling
Texas, USA: ExxonMobil have announced the successful completion of the first two extended-reach wells at the Odoptu field offshore eastern Russia, employing one of the world’s most powerful landbased rigs. ExxonMobil subsidiary Exxon Neftegas Limited (ENL) is operator on behalf of the five-company international Sakhalin-1 Consortium. The Yastreb rig, which is located onshore Sakhalin, drilled horizontally under the Sea of Okhotsk to a target area in the Odoptu oil reservoir over nine kilometres offshore. The extended-reach wells are the first two of seven which will tap the reservoir at Odoptu. The field is anticipated to begin producing oil in the second half of 2010.
The continued application of ExxonMobil’s leading-edge Fast Drill technology has resulted in record performance at Odoptu, paving the way for lower development costs. Additional ongoing activities at Odoptu include the construction of a new onshore oil and gas treatment facility and flowline to the existing Chayvo onshore processing facility. The Sakhalin-1 Project includes the phased development of the Chayvo, Odoptu and Arkuntun-Dagi fields, with an estimated total resource of 2.3 billion barrels (307 million tonnes) of oil and 17 trillion cubic feet (485 billion cubic metres) of natural gas. The Chayvo field, which was the initial phase of the Sakhalin-1 Project,
began production in 2006. Since startup, the Sakhalin-1 Project has produced over 240 million barrels (32 million tonnes) of oil for export to world markets. It also has been a key supplier of nearly 180 billion cubic feet (over 5 billion cubic metres) of associated natural gas to customers in Khabarovsk Krai, in far eastern Russia, to heat homes and meet growing energy needs. The project will continue to help meet future natural gas demand in this region. Since the start of the Sakhalin-1 Project, the Russian State has received US$2.6 billion in royalties and its share of oil and gas, and the Sakhalin Oblast has received nearly US$650 million in production bonuses.
A*Star’s Aerospace Programme Expands Singapore: The Agency for Science, Technology and Research (A*Star) has announced the successful induction of four new members namely Bombardier, Bodycote, Rösler and a local SME, Addvalue Technologies, into its Aerospace Programme. Including the new members, there are now 18 companies in the consortium, of which seven are local companies. The programme, launched in 2007, is an ongoing and proactive industry engagement effort that enables members to partake in aerospace R&D by leveraging on A*Star’s scientific know-how and resources, and is helmed by industry giants. It employs over 50 full-time equivalent scientists and engineers and has invested a total of S$18 million (US$12.8 million) on 16 projects to date. Said Lim Chuan Poh, chairman, A*Star: “R&D is the cornerstone of innovation and progress, and will play an integral role in the continuing growth of the local aerospace industry. A consortium approach is an effective way to bring together the scientific and business communities to shape R&D agenda for the purpose of translating research into useful applications to achieve economic goals.” Feb/Mar 2010 | industrial automation asia 11
Industry News
Mary Gober, US
Degree In Events & Facilities Management To Train 6,000 In Green Building Management Careers
Singapore: The Building and Construction Authority (BCA), SIM University (UniSIM) and the Singapore Polytechnic (SP) ) are jointly offering the Bachelor of Science in Events and Sustainable Facilities Management programme, the first of its kind in Singapore that equips graduates with competencies in both facilities and events management. To achieve the Inter-Ministerial Committee for Sustainable Development’s (IMCSD) target for 80 percent of buildings to be Green Mark certified by 2030, Singapore needs about 6,000 facilities management professionals within the next 10 years. This new undergraduate degree would help in meeting this demand by producing practitioners with the requisite knowledge, skill and competency to manage buildings effectively and optimise the use of resources (such as energy and water) in the operation of buildings. “The proper maintenance and management of the growing number of green buildings and the ambitious plan for green retrofits of the existing building stock will require an adequate pool of knowledgeable and competent facilities management practitioners to be trained up. This new degree programme will form the cornerstone of BCA’s strategy to build a pipeline of facilities managers equipped with technical and managerial knowledge to improve building management and resource efficiency in our built environment” said Dr John Keung, CEO of the BCA. This degree will be conferred by UniSIM. It will oversee the overall development of the programme, offer its curriculum development expertise and develop the modules in management. As with all UniSIM programmes, classes will be conducted on a part-time basis where students have up to eight years to complete their studies, this programme would also appeal to working adults who are contemplating a career switch. Students will gain from a firm foundation in leadership, planning, design, financials, communication and management skills together with the essential specialised competencies in the areas of events and sustainable facilities management. The programme will be conducted at three campuses through a combination of face-to-face lectures, laboratory works and blended e-learning, and will also be delivered by academic staff from the three institutions. The first intake will commence in July 2010. 12 industrial automation asia | Feb/Mar 2010
Greenkote Coating Process Chosen By Daimler Ohio, USA: Greenkote, a global coating technology company, will provide corrosion protection for selected Daimler automotive parts beginning the first half of 2010. Initial orders include components for passenger safety related applications. Additionally, the automotive industry giant is finalising technical approval of Greenkote as one of its suppliers of zinc diffusion coatings, using the company’s patented Thermo-Diffusion coating process. The decision by Daimler to use Greenkote zinc thermal diffusion coating protection comes after nearly two years of testing zinc diffusion systems and topcoat on its products, especially those most sensitive to corrosion. The extensive testing involved mostly small screws, with more than 10 potential products identified to undergo the duplex coating process. Other small parts include fasteners, fixtures, screws, nuts and some critical wiper parts on several of Daimler’s automotive platforms including Limousine E-Class and S-Class vehicles.
Wonderware Names Longwatch As Certified Software Partner Massachusetts, USA: Longwatch, a supplier of video monitoring hardware and software products, was named by Wonderware as a Certified Software Partner. Wonderware Software Partner’s products are endorsed or certified by Wonderware to be applications with proven compatibility with their software. Certified software partners have access to Wonderware Beta programs, toolkits and senior technical support people so they can integrate and extend Wonderware software on an ongoing basis.
Industry News
ABB Wins Control System Order For Power Plant In China Zurich, Switzerland: ABB has won an order from the Guangdong Yudean Group to supply the complete process control system for units 3 and 4 of their Hui Lai thermal power plant located in the Guangdong province of China. Each of these units have generating capacity of 1,000 megawatts and are designed to set new efficiency standards in the country. ABB’s scope of supply comprises an integrated control system, including boiler protection, turbine control, flue gas desulfurisation, common auxiliary electrical systems and central control room. ABB is also responsible for engineering, installation and commissioning. The units are scheduled to start production in 2011. ABB previously supplied control systems for units 1 and 2 of the plant with of a similar scope. These 600-megawatt units have been in successful operation since 2007. ABB’s common control technology for the four units reduces the need for training and the cost of maintenance and spare parts, in addition to improving operator efficiency and plant safety.
Diamond Phoenix & System Logistics Merger Complete Maine, USA: The merger between Diamond Phoenix and System Logistics is complete and the company is now operating under the name System Logistics Corporation, a member of the Italian company, System Group SpA. The company joined System Logistics in September 2009. The merger between the two companies benefits customers with a wider mix of order fulfillment technology and service offerings, including a global system design team, dedicated research and development teams, enhanced concept simulations, and advanced testing and analysis of material handling data for intra-logistic solutions.
Green Light For Bombardier Trams With Energy Storage
Berlin, Germany: Rhein-Neckar-Verkehr (RNV) is set to commission the first six new Variobahn type Bombardier trams at its Heidelberg site in Germany. These trams are the first to feature the commercial application of the Bombardier MITRAC Energy Saver, the energy storage system. With this system, vehicles require up to 30 percent less energy and are capable of catenary-free operation. “We will save about 93,000 kWh of electrical energy per vehicle each year. That also benefits our region due to lower emissions when generating electricity at the power station”, said Martin in der Beek, CTO of Rhein-Neckar-Verkehr. The MITRAC Energy Saver is part of the ECO4 portfolio of Bombardier Transportation, enabling rail vehicles to be operated in a particularly economical and energy-saving way. The MITRAC Energy Saver saves up to 30 percent energy and utilises an energy recovery system: three roof-mounted energy storage units use their capacitors to store the energy generated during braking, ready to release it again when accelerating or during operation. The double-layer capacitors of the MITRAC Energy Saver store up to 3 kWh per vehicle. When starting up and accelerating, vehicles require a particularly large amount of electricity and put a significant burden on the power supply network. This is reduced by about 40 percent with the MITRAC Energy Saver, allowing the network to be utilised more cost effectively. Yet another advantage of the Bombardier energy storage is the catenary-free operation in sections. With the MITRAC Energy Saver, sections of the route without contact wires can be operated using the stored energy. This typically makes sense in areas of historical importance, where the unique scenery is to be preserved. The technology might also be used on two route sections planned at Neuenheimer Feld in Heidelberg where the electrical fields of the contact wire could possibly interfere with the highly-sensitive measuring instruments of the University’s Physical-Technical Institute and the German Cancer Research Centre. Thirteen more vehicles will be supplied in 2010 for Line 5 and sections in Mannheim. The RNV has ordered a total of 19 light rail vehicles with the MITRAC Energy Saver. They will enter service by the end of 2010. Feb/Mar 2010 | industrial automation asia 13
Industry News
Nik Frey, Switzerland
Innovations In Beverage Segment Address Cost, Environment, Markets
Virginia, USA: The beverage packaging industry is experiencing a period of increasing innovation in design, materials and efficiency intended to meet cost and environmental concerns while enticing splintering consumer groups, according to ‘Beverage Packaging Market Assessment — A Benchmark Study’, conducted by Proactive Worldwide, on behalf of PMMI. “Single-serve containers are particularly strong market drivers. Consumers are seeking ‘grab and go’ convenience at retail, and they’re increasingly looking to packaging for portion control – even with beverages,” notes Charles D Yuska, president & CEO of PMMI, which produces the Pack Expo trade shows. “Sustainability is also a market driver as consumers expect brands to play a role in helping the environment.” Top beverage packaging trends PMMI expects to impact the market include: • Eye-catching single serve packaging • Cost-effective ‘green’ packaging, driven by manufacturers’ cost and environmental concerns
• Plastics as ‘the material of choice’ because of rapid innovations likely leading to lighter, more eco-friendly packaging • New packaging machinery that is flexible and supports the latest container technologies • Rapid growth for pouch containers as manufacturing technologies bring costs and speeds of pouch beverage production in line with high-speed glass bottle production • Minimising secondary packaging to cut costs and reduce overall carbon footprints According to the report, the US$22 billion US beverage primary packaging market is dominated by plastics, with 40 percent of consumer goods companies (CPGs) using a variety of formats to attract consumers. Other materials used are aluminium (35 percent), glass (18 percent) and paper (5 percent), and today’s most popular primary packaging format for beverages is the bottle, which the report puts at 55 percent of the marketplace. Researchers predict market growth
will exceed US$28 billion by 2020, with plastics and bottles driving innovations and sales in that time. “In the beverage segment, plastics are the leading materials, and bottles the dominant packaging format to attract consumers,” says Mr Yuska. “The research we conducted clearly shows that plastic bottles will be the primary areas of focus for consumer goods companies looking to increase sales and gain brand awareness.” In addition to being the material of choice, beverage manufacturers expect plastics to drive a vast majority of incremental beverage container sales through 2020. Respondents to PMMI’s survey spoke of plastic as the medium in which green, eco-friendly/bio-degradable packaging technologies will flourish. Additionally, innovation efforts with plastics are expected to continue focusing on improved break resistance, light weighting and features that reduce spilling. Pouches are expected to show the greatest percentage growth between 2010 and 2020, increasing as much as 105.9 percent, from US$545 million to 1,378,000,000.
Energy Parametrics & Communications To Expand Into Asia California, USA: Energy Parametrics & Communications will be expanding its operations into the Asian energy and communications marketplace with the opening of Bangkok, Thailand offices, located in Bangkok City Tower, beginning in February 2010. Dr Chavalit Thisayakorn, director of Advanced Technologies, Energy Parametrics & Communications, will head the Thai operations. 14 industrial automation asia | Feb/Mar 2010
“In general, we have found the Asian market to be very progressive in relation to upgrading and advancing their communications and energy systems. Presently, Energy Parametrics & Communications is unfolding its broadband over power lines program to select companies and entities throughout the region,” said COO Gary Rayward.
Industry News
California, USA & Cheltenham, UK: Artisan Software Tools and Aonix have merged to create an independent force in the mission- and safety-critical systems and software development tools market. The merged company is named Atego and headquartered in San Diego CA, USA and Cheltenham, UK. The management, employees and existing shareholders continue to own the majority of the combined group, with backing from leading institutional investors ETV and Spark Ventures. James B Gambrell (former CEO of Artisan) has been appointed as executive chairman of Atego, and will focus on the company’s strategic direction and future M&A activities. Pierre Cesarini (former CEO of Aonix) now serves as the CEO of Atego and is responsible for the merged company’s worldwide operations. In addition to the appointment of the Chairman and CEO, the existing management teams will be merged into one.
GE Oil & Gas Signs Agreement With Shenyang Turbo Machinery Beijing, China: GE Oil & Gas has entered into an agreement to acquire a minority equity interest in Shenyang Turbo Machinery Corporation, a large-scale Chinese state-owned enterprise dedicated to the design and manufacture of turbomachinery equipment and the main operating subsidiary of Shenyang Blower Works Group Company (SBW Group). SBW Group’s domestic installed base includes over 1,850 large-scale centrifugal compressors, 1,059 large water pumps and 885 reciprocating compressors, and its customers include China Petrochemical Corporation, China National Petroleum Corporation, Linde, JSW Steel Limited, and China National Offshore Oil Corporation.
ST Aerospace Renews Contract With US Airways Alfredo Farid Chujachi, Mexico
Atego Launches As Foundation For Integrated Tool Chain Strategy
Singapore: ST Aerospace has renewed a maintenance contract with US Airways worth US$60m over three years. Commencing in January 2010, the renewed contract will primarily cover heavy maintenance visits for US Airways’ fleet of Airbus A330 as well as Boeing 737, 757 and 767 aircraft. Maintenance work for the aircraft will be performed at ST Aerospace’s Mobile facility at Alabama (US). ST Aerospace’s relationship with US Airways began in 2003 with maintenance on Airbus A319 and A320 aircraft. Since then, US Airways has extended it to the mentioned aircraft types. The company has redelivered a total of 206 aircraft to US Airways to date.
Opportunities In Automotive Market For Electric Motor Manufacturers Wellingborough, UK: The automobile market has crashed, and whilst this has affected component suppliers, there still remain areas where the electrical motor market is growing, according to a new report from IMS Research. With light vehicle sales having experienced the largest drop in living memory in most ‘western’ economies, one would expect a reduction in the number of electrical motors used in automotive applications. However, ‘The World Market for Electrical Motors in Automotive Applications’ report shows that the continued growth in vehicle sales in regions such as China and South America, the continued penetration of actuated systems into a greater number of vehicles and the innovation of new technologies requiring motors, has helped soften the drop in demand to some degree. Demand for some types of electrical motors is holding up better than for others. The brushless DC motor market, for example, is performing relatively well. To quantify this, worldwide sales of motors used in automotive applications are estimated to have dropped by almost 20 percent, from 2.3 billion units, over the period 2007 to 2009. In contrast, sales of brushless DC motors are estimated to decrease by only six percent over the same period. Nevertheless, the market for brushless DC motors in automotive is still small, accounting for only around five percent of motors used in automotive applications. Also many high volume applications, such as seat adjustment or window actuation, only require intermittent operation. So while brushless DC motors may be used in some top-end vehicles, primarily to benefit from the reduced noise levels of the motor, this is not true for the ‘mass market’. According to report co-author, Alex West: “In spite of the higher cost of these products, the greater reliability and energy efficiency as well as longer lifetimes of brushless DC motors, make them popular in applications with high duty cycles. Already many of the fuel pump applications have switched from brushed to brushless. This replacement trend is expected to continue in water pump applications, such as in cooling systems.” Other applications also using this technology include dual clutch and automated manual transmission, as well as HVAC and power steering systems. Also, as the market for electric and hybrid vehicles increases, this is expected to spur demand for the more efficient brushless DC motors. Feb/Mar 2010 | industrial automation asia 15
Newsdesk Conformance Test Plan For Subsea Profile
Device Profile For Inclinometer Released As Draft Standard
The CiA 410 CANopen device profile for inclinometer version 1.3 has been released as draft standard (DS). The device profile is intended for one- and two-axis inclinometers sensing the longitudinal and lateral slope values and providing them with a 16-bit or 32bit resolution. Beside of editorial clarifications the PDO (process data object) description was extended by the definition of the counter start value for synchronous process data transmission.
The SIIS group requested a conformance test plan for CiA 443, the CANopen profile for SIIS level-2 devices. The conformance test plan will include an EDS test as well as lower tester test cases. The corresponding CANopen SIG Subsea will also start the review process for CiA 443. The conformance test plan will cover the updated profile. In addition, it is planned to organise some plug-fests for CiA 443 devices. Plug-fests prove the interoperability of devices, while conformance testing proves the correct implementation of the profile. ENQUIRY NO. 1103
CANopen SIG Hydraulics Re-established
ENQUIRY NO. 1101
CANopen In PV Systems
ZVEI and CiA jointly organised an information day on communication technologies to be used for photovoltaic (PV) systems. The event attended by about 70 people was focused on external and internal networks. CiA proposed the CiA 437 CANopen application profile as the base for further developments. Companies such as Skytron use CANopen already in many projects. Juwi, Q-Cells, and other PV system makers require increasingly standardised embedded interfaces for PV devices such as inverters, sensors, meters, etc. ENQUIRY NO. 1102
The VDMA is reviewing its bus-independent profile for fluid power (hydraulics) devices. CiA members and other interested parties are commenting the reviewed profile. The association will update the corresponding CANopen CiA 408 profile. For that reason, CiA has re-established the CANopen SIG (Special Interest Group) Hydraulics. The group will send joint comments to the VDMA by end of February. In parallel, the CiA 408 profile specification will be restructured in order to improve the readability and to improve the mapping of the VDMA profile to CANopen. ENQUIRY NO. 1104
Device Profile For PLCopen Motion Control CiA has released version 1.0 of the CiA 452 CANopen device profile for PLCopen motion control as draft standard proposal (DSP). The device profile specifies the CANopen interface for drives controlled by programmable logic controllers (PLC) using PLCopen motion control. The drive uses some
operation modes and configuration parameters as defined in the CANopenrelated parts of the IEC 618007 (Adjustable speed electrical power drive systems). Parameters for such additional modes as gear, jog and camming are defined in the CiA 452 specification. The drive is controlled by
a drive command and 16-bit or 32-bit reference values, which depend on the chosen operation mode. The mode-dependent feedback from the drive is given via a status word and the current values. Thus the drive control is fulfilled using one TPDO (transmit process data) and one RPDO (receive process data). ENQUIRY NO. 1105
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Updated Foundation Fieldbus Host Test Kit The Fieldbus Foundation has released its updated Foundation fieldbus Host Test Kit (HTK) DD Application Module (Version 2.0.0). This test kit, driven by the foundation’s End User Advisory Council (EUAC), includes hardware and software for testing the functionality of a fieldbus host and its conformance with the Foundation host profile specifications. The Test kit is designed to validate host applications implementing DD services, files for persistent storage of functional parameter data, and grids for vector data visualisation and manipulation. Hosts successfully completing the Fieldbus Foundation’s test requirements are authorised to bear the official Foundation fieldbus product registration symbol. Field Diagnostics The HTK 2.0.0 has been updated with field diagnostics capabilities per the Foundation fieldbus Diagnostics Profile Specification (FF-912), which was defined to allow any Electronic Device Description (EDD)-based system to access and configure the diagnostics in fieldbus devices. The field diagnostics profile introduced a new field diagnostic alert type and supports more extensive integration capabilities (such as Wizards for
configuration), which will enhance diagnostics performance. Rather than introduce significant changes to the Foundation protocol, the diagnostic profile specification builds upon the existing diagnostic capabilities of fieldbus equipment, and at the same time, adds a greater degree of organisation so field instruments can represent their diagnostics in a more consistent way. This technology, per the NAMUR 107 recommendation, allows fieldbus end users to specify the diagnostics most important for a given operation or process area. They can also determine the priority of the diagnostic information and identify all appropriate recipients for particular data. In addition, the diagnostic profile specification allows for common tools and engineering procedures, which will reduce costs and deliver actionable intelligence from the field level to the end-user. Made To Fit In addition to field diagnostics, the revised test kit incorporates profiled custom function blocks enabling the manufacturer/end user to define custom blocks meeting the Foundation fieldbus specification requirements in their host system. This provides the user with flexibility to expand and tailor their systems for each specific application.
HTK 2.0.0 also includes a Compatibility_Rev parameter ensuring interoperability between an existing fieldbus instrument and a new replacement. The parameter is advantageous in situations where a sudden malfunction occurs and it is critical to install a replacement unit quickly that will support all features previously downloaded to the device. Thanks to the Host Test Kit DD Application Test Module, end users benefit from significantly improved host-to-device integration. Foundation fieldbus host suppliers benefit from standardised test requirements and test cases for all hosts within a profile tested to the same requirements; standardised DD and CF files assuring hosts can parse files; and standardised test devices for all basic I/O function blocks and specialised test transducer blocks. The module is designed to validate host applications implementing DD Services 4.2 or greater. This includes DD Services 5.0 constructs such as charts, graphs, images and waveforms for visualisation; files for persistent storage of functional parameter data; and grids for vector data visualisation and manipulation. The test kit, developed in cooperation with the Fieldbus Foundation’s EUAC and System Integration and Maintenance team, was driven by end users to bring about consistent interoperability between hosts and devices regardless of the host supplier. Specifications now include profiles for functionally different hosts and the appropriate features that apply to each profile. ENQUIRY NO. 1106 Feb/Mar 2010 | industrial automation asia 17
Asia Powered By EtherCAT: High Velocity & Precision
The EtherCAT equipped E-Star hot-glue labeling machine can label between 24,000 and 48,000 bottles per hour
The Chinese company E-Star Packaging Equipment specialises in packaging machinery for the food and beverage markets along with shrink wrapping machinery and fully automated car ton packaging and labeling. Thanks to EtherCAT combined with PCbased control and highly dynamic drive technology, the new hotglue labeler developed by E-Star achieves a throughput of 24,000 to 48,000 bottles per hour. The hot-glue labeling machine is a EtherCAT based development which is used mainly for labeling cylindrical-, elliptical- or rectangular-shaped PET bottles for treated drinking water, fruit juice and other beverages. 18
industrial automation asia | Feb/Mar 2010
High Precision The containers are lined up vertically on the single-lane conveyor belt and transferred to the central carousel via a worm feeder. Here they are fixed and clamped between a centring head and a rotary table. The centred containers are then rotated around their axis and forwarded to the labeling unit. The feeding roller supplies labels continuously to the cutting roller. It is driven by an EtherCAT controlled servomotor which adjusts its velocity to the length of the label and simultaneously checks the correct position of the cutting point. The label is cut to length on a special roller. It is
then picked up by the transfer roller and taken to the gluing roller which applies glue to either end of the label. The label is transferred to the rotating container at which point the glue strips and a special smoothing device guarantee precise application. Interaction Of All Control Components The main requirement of the controller is to detect the label length extremely quickly in real time and adjust the loading speed accordingly to ensure the correct position of the cutting point. The position of the print marking can be recorded precisely via Software NC. The positional data is forwarded via EtherCAT to the Embedded PC, which calculates the label length and adjusts the cam curve correspondingly. The loading velocity of the servomotor is adjusted in order to implement the loading process precisely. EtherCAT and the controller ensure ultimate loading accuracy with < 0.01 mm deviation to avoid the occurrence of a cumulative loading error. PC-Based Control The PC together with the Beckhoff TwinCAT Software enable the integration of functions such as PLC, Motion, HMI, and temperature control onto one powerful CPU platform. The peripheral components are networked and synchronised via EtherCAT for performance and reliability while maintaining the expandability of the system. Different label formats can be handled without needing to make any adjustments. ENQUIRY NO. 1107
Industry Updates Profile For Identification Systems Available
Certification For PA Profile V3.02 Available V3.00 V3.01 V3.02
PI is now making the ‘Identification Systems – Proxy Ident Function Block’ profile available for Profinet, as well. Product tracing and optimisation of logistics processes are playing a more and more important role in industry. For this reason RFID systems often have to be integrated into higher-level company networks. These tasks are well supported through application of the profile. The interoperability between the controller and identification systems is based on agreements regarding communication events, basic application services, and the programming language to be used. The ‘Proxy Ident Block (PIB)’ device block based on IEC 61131-3 has been specified for this purpose. In this process the communication interface has been encapsulated by function blocks, and a uniform
interface to the control program has been created. With the extension of the profile, both Profibus and Profinet modules can now be addressed via a uniform interface. Thus, the foundation is laid for enabling the device block for access to identification devices in the Profinet network, as well. As a result it is now possible to use the same PID block to integrate both Profibus and Profinet devices. The new profile version is backward compatible. Through use of the profile, users can make use of identification devices of different providers via a standardised interface. This can result in significant time savings during commissioning, which reduces costs for system integrators and ultimately also for operators. ENQUIRY NO. 1108
The development of Profibus PA Profile V3.02 by PI (Profibus & Profinet International) has been welcomed by users in the process industry. Effective immediately, certification is available for this profile version for ensuring product quality. PI views this quality measure as very important, since error-free communication between devices of different manufacturers is only ensured when products are certified. The test cases required for testing the new profile V3.02 features have been created and have already been implemented in the test systems of PI Test Laboratories. The PA Profile V3.02 meets user requests for suitable version management of devices, device files, and software platforms, in order to minimise maintenance expenses for device integration over the life cycle of production equipment, as well as user requests for device replacement during operation. Thus, it establishes the foundation for an easy device integration procedure and makes it easier for users of 4-20 mA technology to upgrade to the many possibilities of digital fieldbus technology. ENQUIRY NO. 1109
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issues & insights
Smooth RFID:
Operator The London Underground uses RFID technology to support their escalator maintenance operations. By John Williams, marketing director, CoreRFID
T
he escalators of the London Underground carry over three million passengers every day from the street to the platforms and back again. One part of London Underground is responsible for maintenance, upgrading and replacement works across two thirds of the London Underground system, and has almost 200 escalators to support. Maintaining escalators is a task with unique problems. Failure to carry out adequate preventative maintenance puts passenger safety at risk but taking escalators out-of-service during normal travelling hours is unpopular with passengers as well. To address this London Underground decided to use RFID technology to support their escalator maintenance operations and worked with CoreRFID to develop a solution for London Underground. The result, the Step Tracking System, combines readily available components in a way that promotes passenger safety and convenience for London Underground and saves costs in service engineering. CoreRFID developed a pilot version of the Step Tracking System as part of a joint project with London Underground and is now involved in its operational
20â&#x20AC;&#x192; industrial automation asia | Feb/Mar 2010
deployment across the Bakerloo, Central, Victoria, Waterloo and City, Metropolitan, District, Circle and Hammersmith and City lines. The Business Problem Millions of passengers use the escalators on the London Underground every day. The steps that make up these escalators are subject to constant wear from the feet of passengers and from the mechanical movement on the escalator track. A failure in an escalator step could cause serious injury. If an escalator step were to fail during the rush hour, lives could be put at risk and serious disruption to travelers would result. To prevent such an event, London Underground have an inspection and maintenance regime that ensures the structural integrity of every step is checked at least once during the course of every year. With almost 30,000 separate escalator steps needing to be checked this maintenance approach requires significant effort by London Undergroundâ&#x20AC;&#x2122;s engineering staff. The problem is complicated by the time required to carry out non-destructive tests on the structural
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Encoders Resolvers Speed switches Tachogenerators Counters Tachometers Process displays Spindle positioning systems Actuators and positioning drives Angle measuring systems Accelerations sensors Inclination sensors
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The Pilot & The Solution CoreRFID and London Underground worked together to come up with an effective solution design and to select and trial the most appropriate technology in a pilot application. The eventual solution was to attach UHF RFID tags to the underside of each escalator step. Whenever a check is needed of the specific steps present on an escalator, the tags can be read by a portable reader that is slotted into a cradle near the track of the escalator mechanism on a regular basis. As the escalator runs and each step passes the cradle, the reader detects the signals from the tag. In this way information about which steps are present in which escalator can be collected without interfering with the normal operation of the escalator. A decision had been taken longer term to mount the tags on the steps using rivets but for an initial trial mounting the tags by using acrylic adhesive
Photoelectric sensors Inductive sensors Capacitive sensors Ultrasonic sensors Magnetic sensors Vision sensors Precision switches My-Com
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Digital cameras Intelligent cameras Camera modules Smart vision sensors Optical inspection systems OCR- and code identification
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Baumer (Singapore) Pte. Ltd. Blk 21 Kallang Avenue · #04-173, Kallang Basin Industrial Estate, Singapore 339412 Phone +65 6396 4131 · Fax +65 6396 5091 sales.sg@baumer.com · www.baumer.com
ENQUIRY NO. 097
integrity of steps. Because of the effort involved, only a small number of steps can be removed from the escalator to be tested during an over night maintenance shift. These steps are exchanged for already tested ones. The removed steps are transferred to another site for testing before returning to the pool of steps available for re-installation. The issue of step control is complicated by the fact that there are many types of escalator, although almost 70 percent of all steps belong to one of the four main types. As a result any one escalator consists of an everchanging set of steps. Keeping track of when each step was tested and replaced is a major challenge. On some occasions steps are removed from escalators simply in order to identify them. In addition, although individual steps are identified by a plate on each it has proved difficult to link the identity of a step with its engineering history and that if a step should fail a test it is almost impossible to know whether there are other steps in the network that have the same usage and service history that might also be at risk of failure. Difficulties with the readability of plates (they become obscured by dust and grease) and the problem of having to stop escalators in order to read step data means that information can only be collected during the over night maintenance shift and even then information is rarely completely accurate. London Underground needed a system that would collect data automatically from individual steps, that could cope with the problems of dirt and grease and that would be robust enough to stand up to the constraints of one of the world’s most heavily used mass-transit systems. They turned to RFID as a technology to help them.
Feb/Mar 2010 | industrial automation asia 21
issues & insights
service shift. Data is being held on the date of the last nondestructive test (NDT). Because of this it will be possible to check that any given step has not exceeded the time allowed between NDT’s, helping to avoid the risk of failure. This will help to protect passengers and reduce disruption to escalator services. CoreRFID worked with London Underground to devise a way of packing the data to be recorded on the tag. UHF tags typically hold as little as 64 bytes of data. By minimising the amount of data to be read, London Underground and CoreRFID expected to be able to ensure that high read speeds would be possible. In practice this was found to be the case. With the reader mounted in its cradle, it was possible to retrieve data from the steps as the escalator ran at its normal speed. Trials indicated that it was possible to consistently and accurately read the data from the steps during one or at most two rotations of the escalator.
UHF RFID tags like this were attached to the underside of each elevator step
was tried. In practice the adhesive mounting for tags proved more robust than anticipated. In spite of the vibration, dirt and constant movement, not a single tag detached from its escalator step over a period of two months. Even so, riveting is being used for the eventual deployment to ensure that tags remain attached. The initial trial was conducted on an escalator at St Paul’s underground station on the Central Line. Tags were installed on the 92 steps of the escalator and data written to each tag indicating the step number, its year of manufacture and elements of its service history. The writing process was monitored carefully during the trial. It was recognised that initial data recording would need to be done while the escalator was out of service and that, as a result, the time taken for each step had to be kept to a minimum. Writing data to RFID tags is very much slower than reading and requires the writer to be significantly closer to the tag than does reading. For the Step Tracking System, the escalator is inched forward, a small number of steps at a time, as the data is recorded on each step. London Underground expect that, in time, they will be able to achieve a time of 45 minutes for a 90 step escalator, allowing the writing process to be accommodated during a normal out-of22 industrial automation asia | Feb/Mar 2010
Data Collection & Use The Step Tracking System uses a reader/writer integrated with a rugged handheld computer, suitable for use in the dusty and greasy environments found under escalators. The reader/writer can be operated with one hand and has a battery life of between four and fourteen hours of continuous use, allowing it to be used for an entire shift without re-charging. The application running on the hand-held computer has been designed to be simple to operate when used in the cramped conditions found in the escalator well. The same application is used by the manufactures of steps to encode manufacturing details on each step before new steps are delivered. Data stored on the tag and, as a result, available for collection includes the unique step identifier, manufacturer, date of manufacture, station, escalator number, step number on the escalator, and so forth. Reading the data provides the basic information needed to manage each individual escalator step. For the first time it will be possible to know exactly how long an individual step will have been installed on an operational escalator. It will become possible to make better decisions on when steps need to be exchanged for testing or replaced. Data collected in the Step Tracking Systems’ handheld computer can be extracted in a simple data exchange format such as XML or as comma separated value (CSV) file. It can then be integrated with an asset database system such as Mincom’s Ellipse. ENQUIRY NO. 1201
Get Positive Results From YourPositive SafetyResults Investment Get From INTEGRATED SAFETY Your Safety Investment INTEGRATED SAFETY
With over 100 years of industrial automation experience and an extensive knowledge of safety systems, Rockwell Automation understands the requirements of applying integrated safety to your plant floor. Integrating safety control to operate with the standard control system is one way to achieve flexible, effective safety solutions. Our full portfolio of safety products, from safety controllers and relays to individual safety components, integrate and communicate seamlessly to provide a complete safety solution for your application. • Presence Sensing Safety Devices • Safety Switches • Interlock Switches • Safety Relays & Contactors • Emergency Stop Devices
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Malaysia Tel: 603 8997 6688 Fax: 603 8997 6699 Rockwell Automation Southeast Asia Pte Ltd Philippines Tel: 632 323 0588 Fax: 632 323 0561 Singapore Tel: 65 6356 9077 Fax: 65 6356 9011 Thailand Tel: 662 936 1500 Fax: 662 936 1510 Indonesia Tel: 62 21 573 5680 Fax: 62 21 573 5679 Vietnam Tel: 848 255 6400 Fax: 848 255 6411 Malaysia Tel: 603 8996 1688 Fax: 603 8996 1699 www.rockwellautomation/sea.com Philippines Tel: 632 893 9712 Fax: 632 810 4397
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issues & insights
Airport Luggage Identification System:
Sort It Out! The Airport Luggage Identification System makes quick time of luggage sorting. By Thomas Lim, manager, Application Center Asia, Sick
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he dema nds of ba g ga ge handling are met by providing solutions of precision, reliability and quickness. The Airport Luggage Identification System is a full automatic reading gate including all framework, antennas, decoder, the local network controller and host communication interface to read the IATA-RFID-tags on belt conveyors, passing on the identification data to the baggage handling control system. The local network controller unit incorporates a controller for the local Controller Area Network (CAN) scanner network, opto-
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isolated digital I/O’s, flexible multiple host interfaces and an interface supplying diagnostic data for use with a remote diagnostic tool solution to monitor the operation and performance of the system. The host interface can be adapted to customer’s specific requirements in terms of the communication protocol and electrical interface with Ethernet, Profibus or serial. The complete system consists of four sets of antennas, an RFID interrogator, a control unit, an encoder and connecting cables between the devices. As an option, the system is also available in a redundant configuration.
Features & Benefits The heart of the system is made up of an industrial controller with opto isolated digital I/O interfaces. Access of the individual devices in the system during setup and commissioning is made via the controller. The system includes performance reporting capability which provides for single antenna read rate, total read rate and daily read rate statistics. Recording of the performance statistics can be made up to 365 days. In view that the system is in use in a mission critical environment, the system is available as a 100 percent redundant design according to BNP-Specification as an option. The reading performance of the system is at it’s highest due to the uniform coverage of the reading zones, thus ensuring extremely high availability of the system. Remote Diagnostic Tool A remote diagnostic tool is an option, but is needed for any kind of graphical visualisation of readingperformance. The visualisation can be done locally at each system or in a central control-room. The airport reading gates are designed to be maintenance free. There is no recalibration required. All the connections to the antennas, RFID-reader, and the controlling light beam switches are plug and socket. The parameters that are stored in each individual device (barcode scanner) are also stored on a separate nonvolatile memory which makes device replacement very easy and fast, which is critical in an airport baggage handling environment. The control cabinet is free standing and can be mounted in such a position as to allow easy access to logically arranged internal wiring connections. ENQUIRY NO. 1202
ENQUIRY NO. 088
control point
DCS Migrations:
Risk vsReturn If executed correctly, a phased migration can offer increased productivity and a sharper competitive advantage. By Mike Vernak, DCS program manager, Rockwell Automation and John Bryant, engineering and maintenance manager, Arkema
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he plant is running for now, but it’s taking longer and longer to find replacement parts. You often look for them on eBay because the parts houses you typically use no longer have what you need, and the parts that are in stock are getting more expensive. Finding service is getting tougher too. Your legacy system might be 20 or more years old, and the engineers and technicians who originally installed it are retiring. Even the incumbent vendors are not supporting these old systems anymore. It’s a lonely burden and because you’ve managed to keep the plant running, upper management doesn’t even feel the pressure. In fact, as long as the plant is running and there is no downtime, dollars are spent elsewhere. Things can’t last like this, but what can you do? It’s difficult to justify a system migration based only on what might happen. However, if you’re able to demonstrate the improvements that new technology can provide, your argument for migration strengthens.
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Arkema, an Axis, Ala-based industrial chemical producer, recently used a phased DCS legacy migration program to migrate their Square-D CRISP platform to an updated control system that is multidisciplined, informationenabled and scalable for future upgrades. ROI on risk mitigation alone isn’t enough. It is also important to show a competitive advantage in the marketplace. Beyond Risk Mitigation Migration decisions can be broken down into risk mitigation and performance improvements. Risk mitigation is about what keeps you up at night, and performance improvements are what provide a su s t a i n a ble , co mp e t it i ve advantage. As companies look to migrations with a stronger strategic eye, they want to know and understand their potential gains in both areas. However, it’s difficult to get excited about future productivity gains if it means crippling current production. Do I have to update my
system all at once? How long do we have to stop production? How can I budget a project of this type? These questions are universally voiced across industries when migrations are discussed. Companies today view migration decisions as a key part of a business strategy, offering a competitive advantage. Migrating to newer equipment can offer many benefits such as increased information flow through improved system integration, more production with greater throughput, less training and spares, and reduced energy costs through sustainable manufacturing systems. Most legacy systems were designed for a specific use. A distributed control system (DCS) once connected only to the process itself, whether for a chemical plant, steel mill or utility plant. Now, companies can replace DCS systems with a single, plant-wide, integrated system, connecting conveyor lines, discrete manufacturing, drive, batch and safety control systems, and the shipping department. Using a single platform also helps reduce maintenance and training costs, which is a huge fixed cost for most companies. The entire plant can see additional performance growth due to the increased availability of data and the corresponding improvement in information flow. A single, plant-wide system allows for an unlimited number of end-user enabled reports, which are easy enough for the company to create based on the increased informational data available. This means better control over quality, tighter process management and greater potential for a satisfied customer, all of which adds competitive advantage. In addition, ex per t data sharing helps produce higher qua lity products, increa sed operator knowledge, and provides corporate entities with improved
Plant Floor Migration Execution To execute a rip -and-replace migration, customers must be willing to shut down the process for a period of time, which can get expensive. Today’s 24/7 market often makes downtime not an option. When a plant isn’t running 100 percent of the time, it may not make its projected profit. Although there is a proper time and place for a rip-and-replace strategy, companies often look for ways to reduce the short-term complexity and expense, even when total system replacement is the goal. Phased migration approaches offer many advantages. By looking at one section of the system at a time, the customer reduces the risk of unseen complications halting the migration midstream. A migration in one area often provides you with more spares for another area, allowing more time to evaluate the next move. A phased migration approach demands a high level of system, industry and project management knowledge. The installation company must have a solid knowledge of the new and legacy systems as well as a full understanding of the specific industry’s requirements. Project management experience is also essential, since execution timing and budgeting only allows for a very small margin of error. Nonetheless, the person doing the project needs to have the right skill level to get the job done. The key stage in the migration strategy order is when the customer replaces the least supported systems first − typically the humanmachine interface (HMI) consoles.
Twenty years ago, before the influx of standardised protocols, these consoles were proprietary. Today, however, HMI systems are often no longer supported. Customers find it easier to spend money to replace operator consoles and engineering workstations with modern PC-based platforms. An additional benefit of this migration
is that console replacements do not require downtime. HMIs are a plug-and-replace item and can interoperate with the existing operator stations. New consoles can also be customised to have the same look and feel as the old system. Automation suppliers know it’s an emotional decision to
ENQUIRY NO. 101
production capabilities. When a single, information-enabled system is used, plant managers have much more data available to make faster and smarter decisions – and at a much lower cost.
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control point
implement a migration. After all, you understand the old system’s technology and have employed operators who are well versed on it. Even though a migration is often justified, risk can still be a factor. However, deploying new operator consoles side by side with the old ones – even before removing the legacy system consoles – helps ease the pain and the fear associated with migration. Another central element to any retrofit is making sure that operator stakeholders are included in the decision-making process, even when decisions are made purely based on feeling. Specifically when dealing with an existing system, emotional decisions do play a role. A supplier should meet with the operators, and the maintenance and production teams so there is a common understanding of how the processes are controlled, how the plant is maintained, and the type of production information that will be available. For example, if the operator feels as though new HMI screens look too different than the version that the operators were trained on, additional training is needed. Plus, it may cause operators to misinterpret data and therefore not run the process correctly. This risk needs to be mitigated upfront. Ultimately, a migration project is not successful until the operators agree it is successful. T h e s e co n d p h a s e o f a migration might include replacing the controllers. This step can take three months to three years depending on the customer’s interest, need and budget. It’s important to note that the new controllers can be installed before the HMI swap-out is complete, if the installation timeline is tight. This works with many customers, but is not the only approach for a particular migration. To a l low com mu n ic at ion from the new controllers, many 28 industrial automation asia | Feb/Mar 2010
automation suppliers continue to develop interface solutions to legacy I/O infrastructures needing to be replaced. Also, new controllers can be installed in parallel with legacy systems, using the same I/Os. It takes on a monitor mode only until the system is verified as working correctly. Once both systems are up, old systems can be used until everything is double-checked. Then, the tra nsfer from the legacy control to the new control platform can be completed. This allows manufacturers to build on past equipment investments, and also gives the supplier a more flexible migration strategy by which customers can revert back to their old system if issues occur or if the process is beyond the customer’s comfort level. Phase Three: Migration Enablers Migration enablers are tools to make upgrades and replacements more efficient and are particularly important with phased migrations. It’s also important to note that migration enablers are rarely valuable without a high level of system and technical knowledge. In the right hands, these tools will not only help reduce the risks associated with migration, but will also allow the manufacturer to benefit from the years of experience that were used to create such tools. Again, automation suppliers have seen this need and many have developed enablers to convert databa se s, config urations, graphics and field I/O connections in order to reduce risk, increase speed, and reduce engineering effor ts necessa r y for the migration. These enablers range from simpler, cross-referencing tools to elaborate ones that take extensive training to use and to verify proper outcomes. Enablers can provide tremendous value as long as the person using them
truly understands the technology and potential limitations. A phase three migration might include adding more controllers and I/O off of the new HMI infrastructure that was provided. A not her e x a mple m ig ht b e customers who need to build a new system onto the existing system. A utilitie s compa ny that generates power – with a DCS system controlling the whole plant – finds that the Environmental Protection Agency (EPA) requires their coal-fired system to add flue gas scrubbers on all stacks. The company suddenly needs to build off its HMI infrastructure and add new control systems to operate the scrubbers. They can start to deploy new control systems on these scrubbers and be completely interactive with the rest of the system already in place. Phase three is also where the legacy I/O infrastructure is replaced. Certain automation suppliers have developed special cables to help retain the existing field terminations that bring instrumentation signals up to an I/O module. By incorporating the
field wires into this termination unit and cabling the signals from that unit up to the I/O module, the supplier has essentially eliminated the need to touch the field wiring – a huge cost in any migration, as well as a prominent place for errors to be made. For e x a mple , Ro c k wel l Automation replace s t he customer’s cable, takes out the I/O, keeps the termination units in place, and then plugs new Allen-Bradley cables into new I/O modules. This allows the customer to cut over multiple I/O quicker and without errors. Whenever a step can be eliminated, such as an electrician not having to touch field wiring, you are mitigating risk. In addition, a lot of unnecessary labor is reduced, including timely operations like ringing out new wires and connections. Justifying Funding For A Migration Often people seeking to justify equipment migrations are not from the finance department. Instead, they are middle managers who are ultimately concerned with manufacturing a quality product on time and at a cost point that provides a competitive advantage. It’s important for managers to realise that many of the formal financial tools used to evaluate migration decisions like return on investment (ROI) and net present value (NPV) are critical to force the collection and comparison
of numbers and to consider alternatives. However, without applying experience and wisdom to these numerical outcomes, it’s hard to imagine consistently achieving good migration project decisions. Both sides must work together in order for a migration to be justified. ROI and NPV are some of the many financial tools used in project justification. However, these concepts are relatively simple to apply depending on the number and type of variables to be used in the evaluation. After a little thought, one can gain a rough idea of some of the investment component s appropr iate to include in these models: acquiring hardware and software, support, maintenance, training, spare parts, inventory costs, carrying costs, and the list goes on. To make your modeling and data collection more manageable, it is often helpful to make projects more specific by looking at HMIs as one aspect of the project, then creating financial evaluations on that portion alone. You will have to offset these investment costs with performance gains and risk mitigation. The performance gains will depend on the manufacturing and competitive advantages one gains from new technology, such as improved system integration, increased information flow, throughput to increase production, energy reduction, and reduced training and spares.
This evaluation is sometimes more difficult when doing a phased migration over time, because some of the benefits may not be realised in the first phase of the project, and must be amortised over time. In some cases, most of the benefits will not be realised until phase two or three is complete. NPV models can help you understand what value the project offers today. Risk mitigation comes from reduced breakdown, easier access to parts, and other service and support. R isk mitigation ca n a lso result in executing the migration. Carrying out migrations in phases, using well-developed enablers that build efficiencies, and working with a migration team that has the system, industry, and project management knowledge to help you evaluate, plan and execute your project successfully are keys to reducing risk. Additionally, understanding the areas that offer the greatest ROI upfront and working on those areas first can offer greater shortterm returns. These short-term benefits may offset having to wait to receive the performance advantages of a completely new system. This way, customers will get the competitive advantage and performance advances right away. Plus, parts of the migration can be covered through budgets that have already been in place, without any distribution of capital funds. Instituting a phased migration is a major step for any manufacturing system. Although replacing an old DCS system with a single, plantwide system poses some risks, it is important to help your production team realise the potential benefits. Always bear in mind that if executed correctly, a phased migration can offer increased productivity, a sharper competitive advantage and, ultimately, more satisfied customers. ENQUIRY NO. 1301 Feb/Mar 2010 | industrial automation asia 29
software & Networks
Easy Online Diagnostics:
Access Using operator interfaces to optimise performance of industrial wireless networks. By Jim Ralston, wireless sales engineer, ProSoft Technology
U
sing a n OPC ser ver for wireless diagnostics opens up many possibilities for mo n itor i n g a nd opt i m i z i n g the wireless network. To fully understand the possibilities, it is first useful to examine the key diagnostic metrics that are often monitored. In RF systems, links are established between wireless devices (sometimes known as wireless access points, bridges and clients) using pre-determined RF channels and authentication routines. Each wireless device both transmits and receives (but not at the same time). W hen a n R F signal is transmitted, it has certain amount of energy (measured in dBm, or decibels below one milliwatt). Loss occurs through the air based upon distance and if obstructions are in the way. When the signal is received at the remote antenna, the signal must be strong enough for successful data transmission. The strength of the received signal is known as RSSI (Received Signal Strength Indicator). 30â&#x20AC;&#x192; industrial automation asia | Feb/Mar 2010
A no t he r ve r y i mp or t a nt measurement is the noise within the channel. The received signal must be higher than the noise in the band to decode the information. Noise is also measured in dBm. A not her com mon me t r ic is signal-to-noise ratio which is calculated using measured signal strength (RSSI) and noise. The higher the ratio, the more reliable the system will operate. As data packets are exchanged, most industrial wireless devices will include an error correction algorithm to ensure that packets are received successfully and ret ra nsmitte d if ne ce ssa r y. Diagnostic tools can report the number of packets successfully transmitted and the number of bad packets received. This provides a way to calculate RF error rates, which is another key metric. Diagnostics can also monitor the number of attached nodes (clients). This metric is interesting because it can quickly report (alarm) if a link goes down and also report if the number of attached
clients is higher than expected thus representing a possible security threat. It is also possible to monitor the identity (MAC address) of the attached wireless clients, adding additional security. Finally the number of bytes transmitted is a useful measurement because it shows actual utilisation of the wireless link. By calculating bytes transmitted per second and comparing it to the capacity of wireless technology, bandwidth utilization is monitored. Wirele ss dia g nostics ca n include many other attributes, but these are considered the essential ones. Other metrics that may be monitored include environmental conditions (temperature, supply voltage), VSWR (Voltage Standing Wave Ratio) useful for detecting antenna or coax problems and channel frequency drift. Operating An OPC-Based Diagnostic System Now that we have an understanding of the metrics available for monitoring, we can explore how
a wireless link fails, the critical OPC clients have access to the server. Fig 1 illustrates how one centrally located OPC server can collect wireless diagnostic information and make it available to all HMI clients on the local and remote networks. For more complex networks, it may make sense to install more than one OPC server thus proving diagnostic information directly to more clients. Once the server is installed, it will routinely poll the designated diagnostic data from each wireless device. The frequency of the poll is usually configurable and could be as quick as every 100 ms or as slow as every 60 seconds. This setting is dependent upon how vital the current information is to the application and how congested the wireless network is. The quicker the update time, the
more wireless bandwidth is being used for diagnostics, and the less available for the application. The server will usually organise the diagnostic data by device name (or other user designation) and each metric will become a unique tag for the OPC client. Most HMI and SCADA software packages are OPC compliant and provide a way to browse for available OPC tags. Once the tags are detected by the client, they can be used in virtually any way that the control engineer requires. Before developing the project, consider the overall communication architecture of the system. Where are the vital links? What would happen if a link fails? How can I prevent a problem before it occurs? Once the network architecture is understood, consider the needs
ENQUIRY NO. 055
to implement and operate an OPC based wireless diagnostic system. First it is important to note that only one server is required to collect the diagnostic information. For Ethernet systems, wireless diagnostic OPC servers can be present anywhere on the network. They are configured to collect the designated diagnostic data for each selected wireless device. Because the server is located at one particular leg of the wireless network, the server is collecting some of the diagnostic data over the hard-wired Ethernet network and others over the wireless network. T herefore if a link fa ils, diagnostics are obviously lost for that particular device. It is generally good practice to locate the server where it will have the fewest number of wireless connections for the diagnostic data to transverse so if
Feb/Mar 2010 | industrial automation asiaâ&#x20AC;&#x192; 31
software & Networks
of each user. A production worker probably has no idea what RSSI means, but could convey to the supervisor if the HMI is stating that a wireless link has failed. If the operator is alone, the HMI could advise who to contact (eg SI responsible for the wireless link, or engineer on call if a PLC problem). The operator also has a way to know that the wireless link is functioning, so if a system problem occurs, the fault is not in communications. Conversely, the engineering ma nager may wa nt to v iew all relevant data on a screen monitoring the entire wireless network. The more detail, the better because the engineer could decipher the meaning of each. It is important to tailor the HMI display for the skill sets and knowledge of the user. Most H M I a nd S CA DA software packages also support alarming and trending functions. Alarms can notify the operator, ma intena nce ma na ger or engineering manager of a fault condition (like a wireless link failure) or if communications are degrading so that preventative action can be scheduled. Alarms can also be sent remotely (like an email over the Internet, or cell phone text message) so that
Fig 1: The Wireless OPC Server collects diagnostic data from two separate RF networks. Any HMI client on the logical network has access to the diagnostic information
notification is immediate. Trending functions are useful for reviewing performance history and analysing correlation. For example, the number of bytes transmitted can be trended over time to see if throughput demands are increasing. It is a lso possible for automation equipment (such as PLCs) to access OPC data within their internal program. This opens up the possibility of not only notifying operators/managers when a problem occurs, but having the PLC program act on
it. For example, if a wireless link fails then the PLC could activate a back-up communication link (such as a redundant wireless connection). In this case, the system would recover without any human intervention. As you can see, there are many ways to use RF diagnostic data when made available in an OPC server. The best use is dependent on the process type, how wireless is being used in the system and user needs. ENQUIRY NO. 1302
Application 1: Wastewater Pump Stations A wastewater facility uses a wireless SCADA network to connect several remote pump stations. The water treatment plant PLC remotely turns on and off the pumps based on flow measurements. Each RF link is several miles, so travel to a pump station takes time. The system integrator has decided to use OPCbased wireless diagnostics in the following ways: · Operator interface notification of link failure · Alarm notification sent to plant superintendent · Trending of RSSI to monitor change in line-of-sight (e.g. tree growth) The operator interface displays RF Links Status between the Pump Station and Water Treatment Plant. If a pump station is not starting (for example), the operator could quickly tell if the link is at fault. If not, then there is another problem and the operator can contact the appropriate person or travel to the site to repair the problem.
32 industrial automation asia | Feb/Mar 2010
Application 2: Oil Pipeline An oil distribution system uses a wireless SCADA network for pipeline flow measurement, leak detection and valve actuation. The pipeline is many miles long using wireless Ethernet repeaters to span the entire length. The SCADA network provides automatic process control via a PLC system. Operators may monitor alarms and manually control valves, while the system collects oil flow data. Because the SCADA network is critical for the pipeline operation, the system uses redundant repeaters using mesh network architecture. That way if a repeater fails due to a hardware failure or damage from an electrical storm, communications are not lost. Using OPC tags, the HMI displays and monitors the RF conditions between each repeater site. The system quickly detects if a repeater site has failed or is close to failing. If a failure occurs, the RF system automatically heals itself, and the operator is notified that a site has failed so that repairs may be made to reestablish the RF network redundancy. The control system may be made aware that the RF redundancy has been temporarily lost to prepare for a safe shutdown in case communications are lost.
Packaging, Food and Beverage Carlo Gavazzi offers a broad range of Sensors, such as Inductive, Capacitive, Conductive, Ultrasonic and Photoelectric for packaging, food & beverage machinery. The sensing program of Photoelectric consists of various sensing principles: diffuse, background suppression, retro-reflective with or without polarization, throughbeam, contrast, color sensors and clear object detection.
CARLO GAVAZZI AUTOMATION SINGAPORE PTE LTD (Asia Pacific RHQ) 61 Tai Seng Avenue #05-06 UE Print Media Hub, Singapore 534167 Tel: (65) 6746 6990 • Fax: (65) 6746 1980 Website: www.gavazzi-automation.com • Email: info@carlogavazzi.com.sg
ENQUIRY NO. 100
Also available are Capacitive Sensor; Ultrasonic and Conductive Probes use for detection of granular & liquids for application such as water purification, drainage, waste water treatment and production lines of food & beverage etc.
Feb/Mar 2010 | industrial automation asia 33
instrumentation & Measurement
All Calibrations Are
Not
Created Equal Use an ISO/IEC 17025 accredited laboratory to be sure of the accuracy of calibration results. By Sheila Goodson, director of quality and organisational development, Quest Technologies
M
ost people would probably agree that regular maintenance and calibration of equipment and instrumentation is the best way to ensure the accuracy of the device and further the value of the original investment. ISO 9001 and similar standards also require the calibration of devices that affect quality and/or the quality of inspection and test results. But, how do you know that the calibration laboratory you use is providing you with accurate results? And, by what criteria do you determine whether you are using a reliable and credible laboratory? The only way to be sure of the accuracy of the calibration results and the technical credibility of the laboratory is to use an ISO/ IEC 17025 accredited laboratory as your calibration source. What It Means To Be ‘Accredited’ ISO 17025 shares many of the same quality management system (QMS) requirements as ISO 9001
34 industrial automation asia | Feb/Mar 2010
and similar standards; but with a greater technical focus. Like ISO 9001, the ISO 17025 standard includes requirements for document control, contract review, internal audits, documentation of customer complaints, management review, etc; however the standard adds another set of technical requirements. The lab must not only show evidence of compliance with the standard, but also demonstrate an acceptable level of proficiency. Depending upon the accrediting body and the additional policies and requirements placed upon them by the associations that provide their recognition, there are likely to be additional requirements that the lab must adhere to in order to achieve accreditation. Requirements above and beyond ISO 17025 for mea surement traceability, proficiency testing, calibration programs and others are not uncommon. The accreditation assessment to ISO 17025 is an assessment of the technical operations of the laboratory. Assessors are assigned
by the accrediting body based upon their technical expertise in the type of calibrations being performed by the laboratory and their experience in the respective industry. Listed are critical areas of importance that are assessed in detail: • Laboratory personnel are required to understand how to operate the equipment they use and how it affects t he ca libration re sults. Additionally, they must show that they can competently perform calibrations and evaluate the results. To be authorised to perform accredited ca librations, they need to understand the measurements they are taking, why they are taking them and evaluate the results to determine the correct operation of the instrument. Super v ision, inter na l audits and external audits verify through interview and observation that laboratory personnel are competent in these areas. • The laboratory’s environment mu st b e mo n itore d to ensure that conditions do not invalidate the results of
• In order to a ssure the qua lity of ca libration results, laboratories are required to participate in proficiency testing and/or interlaboratory comparison programs where they exist. T he se pro g ra m s ve r i f y t he lab orator y ’s ac tua l performance and the results are an indication of the lab’s competence.
• • All equipment used to calibrate items must be traceable through an unbroken chain of calibrations or comparisons to relevant national standards, eg NIST. According to the ISO 17025 standard, a calibration cer tificate prov ided by an accredited laboratory is sufficient evidence of PCA2010 traceability. MagAd(IndAuto)p.fh 9/28/09 2:50 PM Page 1
Periodic internal checks of pr i m a r y a nd re fe re nce standards are conducted to verify that the standards are working correctly and providing accurate results. P r i m a r y a nd re fe re nce standards are the devices used to take measurements and perform calibrations.
• All measurements have some degree of error. That amount of error is the measurement uncer ta int y. Accredited laboratories are required to calculate measurement uncertainty for each calibration parameter. The measurement uncertainty is listed on the calibration certificate and on the laboratory’s scope of accreditation. The scope identifies the types of calibrations the lab is accredited to perform along w it h t he me a su re me nt uncertainty. The accrediting body analyses the claimed measurement uncertainty for completeness and accuracy. ENQUIRY NO. 1401
ENQUIRY NO. 075
the calibrations or adversely affect the required quality of any measurement. Conditions that may be monitored include te mp e rat u re , hu m id it y, barometric pressure, sound and vibration levels, etc. Records show ev idence that the monitoring activity occurred as well as any actions that were taken if acceptable conditions were exceeded.
Feb/Mar 2010 | industrial automation asia 35
sector spotlight
GoGreen! End Of Line Packaging:
A comparison of the sustainability of ‘pad shrink’ packaging systems versus RSC cases. By Peter Fox, director of sales, Delkor Systems
T
he te r m ‘su st a i n a b i l it y ’ is he a rd in boa rdrooms e v e r y w h e r e t h e s e d ay s because it is a concept that embraces both environmental a nd b ot tom - line bu sine ss concerns. Fo r p r o d u c t p a c k a g e r s , sustainability means reconciling what can be conflicting goals: minimising whatever negative impacts their packaging may have on the environment, while adequately protecting products during shipping and handling. Packagers today are fac i n g i nc re a si n g de ma nd s for ‘sustainability’ from every direction – consumers, retailers and non-profit watchdog groups – with few of these groups offering specific guidelines on how to measure it. What’s more, packagers are encouraged to achieve these dual goals while also controlling the costs of packaging to their customers.
36 industrial automation asia | Feb/Mar 2010
Standards For Sustainable Packaging One organisation that has tried to define sustainability is the Sustainable Packaging Coalition, an industry-working group dedicated to transforming packaging into a system that encourages a sustainable flow of materials. This group lists these ideal attributes of sustainable packaging: • Beneficial, safe and healthy for individuals and
communities throughout its life cycle • Meets market criteria for performance and cost • Sourced, manufactured, transported and recycled using renewable energy • Ma x i m i se s t he u se of renewable s or recycled source materials
Raw Material Weight Comparison Raw Material Type Weight (lbs) Pad and overwrap
Figure 1
Raw Material Type Weight (lbs) RSC Container
Corrugated Pad 0.016
Corrugated Case 0.218
Shrink Film 0.019
BOPP Tape 0.002
Adhesive 0.004 Total RM Weight (lbs) 0.039
Total RM Weight (lbs) 0.220
0.039 Total RM Weight (lbs)
0.220 Total RM Weight (lbs)
Pad shrink system has 82.3 % less RM weight (lbs) when compared to RSC container
• Manufactured using clean production technologies and best practices
bonds the primary containers to the pad during packing
• Made from materials healthy in all probable end-of-life scenarios
• A low cost, recyclable polyethylene (PE) shrink-film securely encapsulates the assembled package
• Physica lly de sig ned to optimise materials and energy
The resulting compact bundle often adds to savings by allowing an
additional layer of packages to be added to each pallet load. As such, the product density is increased and transportation energy and costs is reduced. The system is typically used to ship a variety of primary containers, including cans, rigid plastic bottles, glass jars, plastic jars, tapered plastic cups and paperboard canisters.
• Effectively recovered and utilised in biological and/or industrial cradle-to-cradle cycles While not all of the criteria for sustainable packaging listed above are necessarily achievable in every packaging application, a pad shrink packaging system represents a significant step toward sustainability in secondary packaging. This system reduces both the amount of material required to create the packaging and the amount of waste added to the environment throughout the product cycle.
• A flat corrugated pad forms a base for rigidity • A holt-melt adhesive (applied to the flat pad) temporarily
ENQUIRY NO. 098
The Pad Shrink Packaging System The pad shrink packaging system was developed primarily as a means to control packaging material costs, and secondarily as a means to reduce end-of-life disposal costs for customers. It achieved those primary goals by reducing secondary packaging costs for users by up to 50 percent as compared to trays and 75 percent compared to traditional corrugated cases (see Fig 1). The pad shrink packaging system combines three materials to build a stable secondary package bundle that replaces the traditional corrugated container.
Feb/Mar 2010| industrial automation asia 37 CE ad 111x183mm path.indd 1
1/20/10 5:54 PM
sector spotlight
Transportation T h e e n e r g y co n su m e d fo r tra nspor tation wa s used to calculate its contribution to greenhouse gas production. While the transportation distances were the same for both packaging system s, g re en hou se ga s production varied with the weight and volume of materials shipped. Energy Electric energy was used for manufacturing packaging materials a nd operating the pack a g ing equipment. Tota l energ y consumed wa s used to ca lcu late t he a mou nt of greenhouses gasses produced. 38 industrial automation asia | Feb/Mar 2010
82% Less Packaging To Landfill Or Recycle
200,000
150,000
100,000
50,000
0
Figure 3
Pad Shrink
RSC Case
62% Less Process Energy Consumption
4
3 MJ per Unit
Materials Raw materials include corrugated cardboard, PE film, glue and biaxially oriented polypropylene (BOPP) tape. The total weight of the materials needed by each system was considered for the comparison, along with the amount of energy and greenhouse gasses associated with their production and disposal.
Figure 2
lbs per year
Quantifying The Environmental Advantages While a packaging system that uses fewer raw materials, and results in less waste for landfills was presumed to be more ‘green’, US -based Allied Development Corporation recently confirmed this thesis empirically in a study. In order to help secondary packagers make informed decisions about the system that best meets their packaging and environmental goals, the company compared the total environmental impact of a pad shrink system versus a traditional corrugated RSC case. Allied used an environmental life cycle analysis tool to compare the environmental impact of va r ious comple x pack a g ing scenarios. The study examined the following factors:
2
1
0
Pad Shrink
Study Assumptions As in all formal studies, it is important to understand the basic assumptions made about the test conditions. Following is a list of the underlying assumptions: • PE resins are shipped via rail car, and require no secondary packaging. PE film is usually shipped by truck and requires protection such as cores, liner bags, and end caps. • Materials used in the pad shrink system and corrugated cases were assumed to be sourced and used in the same manner. • Transportation distance for all raw materials was assumed
RSC Case
to be 250 miles (402.3 km). Rail car shipments were assumed to contain 200,000 pounds (99.9 tonnes) of raw material. Tr uck shipments were assumed to be 40,000 pounds of raw materials. • Final product distribution to retailers assumed a distance of 500 miles. The volume of stretch f il m u se d for w rapping individual pallet loads was assumed to be equal for both types of shippers. • Manufacturing processes for each component (corrugated case, corrugated pad, and shrink film) was based on a
Figure 4
55% Less Greenhouse Gas Emissions
0.2
lbs per year
0.15
0.1
0.05
0
Pad Shrink
Figure 5
RSC Case
11% Less Transportation Energy To Point-Of-Sale
MJ per Unit
3
2
1
0
Pad Shrink
typical large scale converting process. • In addition to the energy needed to produce raw mater ia ls, the study calculated the process energy required to produce the finished package components. This includes energy for production, warehousing and support space in each facility. • The method of disposal for all packaging was assumed to be landfill, although cor r u gate d c a rdb oa rd and PE film are recyclable. Reusable items such a s pa llets were a s su me d to b e re u se d twenty times.
RSC Case
• Production volumes were assumed to be the same for the pad shrink system and the corrugated case packaging. Final study results were based on a total volume of five million bottles, which translates to 833,333 pad shrink shippers or RSC cases. The Results When comparing the pad shrink packaging system to conventional corrugated containers, the study found that pad shrink system reduced the amount of material to be recycled or disposed of in a landfill by 82 percent. (See fig 2) Due to less raw material input and less material handling, the pad shrink system reduced the amount of process energy consumption
by 62 percent. While shrink-film requires more energy per pound to manufacture as compared to corrugated cardboard, its significant reduction in energy consumed during transportation and processing still made it a clear winner, according to the study. (See fig 3) Greenhouse gas emissions were found to be 55 percent lower with the pad shrink system. This was the result of less emission during transportation, and combined with reduced process energy consumption and savings in raw materials. (See fig 4) Due to the system’s lower weight a nd g reater product density, it was found to cut the amount of energy consumed in transporting the products to the point-of-sale by 11 percent. (See fig 5) Round Up The results of this independent study demonstrated that pad shrink packaging system fulfils many of the eight characteristics for sustainability identified by the SPC. The study data also supports the financial and environmental advantages of using the system rather than RSC cases for endof-line packaging. This is due to the system’s 75 percent reduction in the volume of materia l – material that neither has to be manufactured, transported or disposed of in a landfill. Today, all packagers need to be good stewards of natural resources and to act with environmental responsibility as they compete in their various markets. By comparing the sustainability of packaging system alternatives, secondary packagers can make informed choices that will benefit both their businesses and the environment. ENQUIRY NO. 1501 Feb/Mar 2010| industrial automation asia 39
sector spotlight
MES:
Execution Increased Effectiveness
Effectiveness of processes have been known to increase by seven to 10 percent with the application of MES. By Ralf Schubert, head of engineering and assembly, Schubert
M
odern production plants are no longer defined by the manufacturing of products, but instead, by customer orientation and the resulting service features such as adhering to deadlines, flexibility, delivery time and product variety. Above all, product diversity and the shorter product life cycles result in complex processes. In order to achieve competitive advantages, production companies must structure the efficiency of their internal processes as optimally as possible and improve it continuously. This is nothing less than lean manufacturing. Manufacturing execution systems (MES) can help by contributing to increased transparency, responsiveness and economy. Measuring Up Malfunctions lead to deviations from the planned sequence. Examples of these kinds of malfunctions, which are detected by the MES, are missed deadlines, machine downtimes, missing materials, sick employees or sudden quality shortcomings. The system is assigned to the production management department within the company. It serves as a link for a continuous vertical integration between the company management and the production department. Orders for a certain period are transferred to the system from the ERP (Enterprise Resource Planning System). The orders contain data necessary for execution. These include the lot number or the minimum expiration data of the product. 40â&#x20AC;&#x192; industrial automation asia | Feb/Mar 2010
All processes are planned in detail by the MES, while taking the current production status into account. Before the start of a production order, data are passed on to machines, quality sensors, marking devices and other devices, as well as working instructions to employees. After completion of an order, feedback to the ERP is carried out with processed information like the actual produced quantity, waste quantity and material consumption. A n MES idea lly prov ides the production management department with all the functions it requires. These functions can be divided into the three function groups: production, quality and personnel.
The unification of all functions in a software system and the connection of all elements involved in production to the MES enable horizontal integration.
and pie graphs. From industries in which MES’s are already used in all areas, it is known that the effectiveness of the processes can be increased by seven to 10 percent. ENQUIRY NO. 1502
ENQUIRY NO. 093
Strength In Unity The unification of all functions in a software system and the connection of all elements involved in production to the MES enable horizontal integration. Unnecessary double data acquisitions and interfaces are avoided. An escalation management system is assigned to the function groups, which quickly indicates faults via operating terminals, by phone or with instant messaging. A line control panel with integrated quality monitoring was developed, with several MES functions within the control panel. The functiona lity nece ssa r y for ver tica l integration is included. If integration with an ERP is not desired, data can be entered manually. The connection to the machines and devices is made via Ethernet and OPC or XML. The overall equipment effectiveness (OEE) is used for the output analysis of lines, sub-lines and machines. This characteristic number is determined by three subordinate characteristic numbers, which are the availability, the output and the quality. One of the control panel’s features is integrated quality monitoring for entering, as well as archiving and evaluating quality and process data. The reflected light scanner and the cameras for the F44 robots can be directly connected to the control panel. For example, a scanner in the manufacturing process can detect bad products and output warnings long before the products reach a picker line. The data is shown in trend graphs, bar graphs
Feb / Mar 2010 | industrial automation asia 41
energy
Energy Audits & Savings Opportunities
Energy audit kits and training help your staff identify and correct energy waste. By Mark Price, manager, Business Unit, Industrial Marketing, Fluke Corp
T
here’s a hidden opportunity in your facility to save money. It’s in the lights overhead, the draft blowing through your ventilation system, and the air flowing from your compressor. Even the leanest operations are wasting money in the form of unnecessary energy consumption. Now that every dollar counts, it finally makes sense to do some-thing about your utility bills – they do not have to be a sunk cost! The good news: Most facilities can reduce their utility expenses by 18 percent with minimal capital investment, and some by up to 30 percent with equipment upgrades. Energy audit kits and training help your staff identify and correct energy waste. You can learn how to quickly reduce fixed costs, continue innovating and stay competitive. Not all facilities will achieve the same level of savings in all areas – it depends on he size and age and format of the facility and its equipment. Audits typically identify two types of savings: 1. Immediate changes to consump-tion patterns and utility bills that yield immediate savings 2. Upgrade opportunities that pay back within 6 - 12 months
the more you stand to benefit from new practices and equipment. From there, it depends on what kind of systems your facility has – compressed air? Steam? Lots of motors? Everyone has a few common opportunities, while others are building-specific. Then, how is your facility currently run? If your facility already follows proactive maintenance practices, it may already survey equipment the way an audit does, and it may have already achieved many of the savings an energy audit will detect. If your facility runs pretty lean, and if your team spends more time fighting fires than proactively maintaining equipment, then you may find greater savings opportunities. The more pro-active your maintenance program, the fewer big opportunities the audit will find (because you’ve already experienced many of your savings) That said, part of the value of this program is that not only will it help you find the savings, it will help you monetise them (attach actual dollar amounts) and promote them within your organisation. Control Challenging Cost Areas Changing economic conditions put a spotlight on the cost of energy, but it’s a long-term concern no matter what the economy looks like. You will benefit more during hard times if you bring energy expenses under control, but you will also be better poised for growth during healthy times. Energy costs may have stabilised, but they will rise again soon. Energy audits cover many different building systems. If you’re not able to audit all of the systems at once, start with the systems that have the lowest Biggest Savings Opportunities
Electric Utility, IT/Computers
Savings $$$
Biggest Opprtunities
$$
Medium Opprtunities
$
Smaller Long-term Opprtunities HVAC, Motors & Drives Lighting, Compressed Air, Steam Systems
The older and larger your equipment and facility, the more savings opportunities you will find. How Much Can You Save? In general, the older your facility and your equipment, 42 industrial automation asia | Feb/Mar 2010
Building Envelope, Waste/Recycling
Biggest opportunities: • HVAC • Lighting Medium opportunities: • Energy Consumption/Utility Penalties • Compressed Air • Motors And Drives Smaller long-term opportunities: • Building Envelopes • IT/Computers • Steam Systems • Waste/Recycling Almost all audits find equipment on but not in use, inefficient lighting technologies or usage, and HVAC systems that are not optimised. Utilising test and measurement tools, we can identify items like actual lighting levels, detect compressed air leaks, and determine or verify electrical usage and HVAC efficiency. The most successful energy audits are planned out in advance, with specific goals, and may have several different phases depending on the size of the opportunity and the team. Here are the basic steps: 1. Commit leadership and team members to energy savings • Make the audit a priority • Assign a team (three plus people, depending on facility and skills) • Be prepared to think differently about your operations and challenge assumptions • Develop an appropriate schedule and goals • Gather billing data and document usage ahead of time • Ask suppliers and consultants to offer recommendations (allow 1 - 3 months for pre-work before the audit begins) 2. Execute an audit action plan and implement improvements • Hold a 3 - 5 day energy audit on-site • Inspect energy and waste streams • Quantify savings opportunities • Decide which changes to implement, when (create an action plan) • Invest the capital, equipment and time to make
it happen 3. Sustain and continuously monitor improvements • 30 and 60 day progress reviews • Support identified projects and sustain measures introduced during audit • Keep monitoring all of your waste streams to verify your savings • Adjust your maintenance practices to maximise performance • Identify and act on additional opportunities (seasonal, focused areas, business changes, etc) Energy audits cover more than just electricity – they look for savings opportunities in compressed air, lighting, natural gas, water, waste, HVAC, and many other places in your facility. Fluke kits includes measurement tools for electrical, thermal, ultrasound, pressure, light, air, and gas. And because some measurements happen in multiple places, we include multiple tools. As you consider what energy plan is right for you, think about the skills on your team, your utility costs, and your facility. The larger and older the facility and equipment, the greater your opportunity and the bigger the audit. ENQUIRY NO. 1601
Hitachi Variable Frequency Drives Pursuing the Ideal Compact Inverter
WJ200 Series
WJ200 Series (Dual Rating) • 0.1~2.2kW (1-phase 200V class, CT) • 0.1~15kW (3-phase 200V class, CT) • 0.4~15kW (3-phase 400V class, CT)
User-friendly Compact Inverter
&
Designed for Excellent Peformance
Also available: SJ700 Series (SLV)
X200 Series (V/f)
0.4~55kW (3-phase 200V class) 0.75~400kW (3-phase 400V class)
0.2~2.2kW (1-phase 200V class) 0.2~7.5kW (3-phase 200V class) 0.4~7.5kW (3-phase 400V class)
Hitachi Asia Ltd
L300P Series (V/f) 11~75kW (3-phase 200V class) 1.5~132kW (3-phase 400V class)
24 Jurong Port Road, #03-05 Office Block, CWT Distripark Singapore 619097 Tel: +65 6305 7400 • Fax: +65 6305 7401 • URL: www.hitachi.com.sg • Email: ice@has.hitachi.com.sg
Tel: +81 3 4345 6063
ENQUIRY NO. 079
investment with the highest savings opportunities and are easiest to check and implement. Of course, the size of the opportunity depends on what these systems look like in your facility.
Feb/Mar 2010 | industrial automation asia 43
energy
By selectively switching off any consumer loads that are not currently required, the demand for energy and the associated costs can be drastically reduced. By Norbert Brousek, product manager, Industrial Automation Systems, Siemens
P
rofienergy gives users the basis for implementing active energy management in automated plants. By selectively switching off any consumer loads that are not currently required, the demand for energy and the associated costs can be drastically reduced. This applies in particular during downtimes in production. During breaks in production, many consumers continue running even though they are not required. This is where Profienergy is applied, switching off these loads during short breaks in production in order to save energy and money. Fig 1 shows a typical operating curve of a welding robot that was tracked over a period of several weeks. It can clearly be seen that even during the non-production time at the weekend, the energy consumption of this plant is still about 60 percent of its level during actual production. Until now, such loads have not normally been switched off. The reasons are complex: in particular, additional hardware would have to be installed externally on the machines. Many users balk at the engineering work required for this. If, however, an ‘energy-wasting’ component could be directly switched off by the higher-level controller, such additional hardware would be unnecessary. The user would then only have to send a command from his user program to switch off and subsequently another to switch on again. Fig 2 illustrates this situation. Whereas, at present, external cabling – for example, a distributed station equipped with relay modules – is necessary in order to switch off the consumer, this will not be necessary in future due to the use of Profienergy commands.
Fig 1
44 industrial automation asia | Feb/Mar 2010
In Your Hands The consumers themselves ‘speak and understand’ Profienergy, as they have corresponding energysaving measures already integrated in them. By relocating this switching to the device, manufacturers can decide how to optimise their devices in order to save the maximum amount of energy. Hard, external switching means that some loads must continue running during short breaks such as breakfast or lunch, as they would otherwise not be ready to resume operation promptly at the start of production. Flexible Handling With Profienergy, the manufacturer of a machine has the opportunity of reacting flexibly to break times. During short breaks he can switch off a few parts of the machine while during longer breaks more units can be switched off. The handling by the user is extremely easy. He simply sends the device or machine a command containing information about the length of the break. The subordinate device then decides for itself which parts can be switched off, in order to be ready for operation on expiry of this time. It is irrelevant whether this device is an individual component, such as a drive or IO station, or a complex device such as a machine tool or robot. The command structure is always the same. In order to make the device ready for operation again, the user sends a starting command. In this way, a coordinated startup of the plant is possible, dependent on the application in question. In addition,
Fig 2
the user can avoid peak loads in this way. In order that user can switch on devices with different start-up times in a coordinated manner, these devices inform him of their startup time. This enables the user to calculate exactly when the activation command is to be sent. This is the basis for wider acceptance. It also ensures that the minimum amount of engineering work is required. The user only needs to incorporate the two commands into his program. This enables him to make a hard and fast distinction between the actual control logic for the process and the energy management. Device and system manufacturers also have the opportunity to support the user by means of corresponding function blocks that, for example, conceal the processing of the communication mechanisms. In order to take into account the user’s requirement for retrofitting capability and compatibility, these commands are mapped onto existing Profinet services. In this case, onto records. These acyclic services do not occupy any additional addresses in the process image. In other words, the useful data quantity structure of a Profinet device is not modified by Profienergy. This means that Profienergy can be used in existing program libraries and factory standards, such as those that exist in the automobile industry. Likewise, the device manufacturers can upgrade their existing components to Profienergy by using a firmware update. This facilitates a swift implementation – even into existing products.
to shut down plant sections during breaks. These are, however, very application-specific. Frequently the actual control task and the energy management are amalgamated. This all makes the program generation, but especially the maintenance of such software, very difficult. In addition, external hardware is necessary for the execution of the actual switching process and this hardware must be configured, installed and maintained. The cost of doing this soon outweighs the actual savings, so that users frequently do not take such measures. Here, too, there is an economical solution. This is a matter of a pure data interface, as the switching functions are already integrated in the devices. In addition, there is a clear separation between the program sections for the energy management and the control logic. Both parts are clearly separated from one another and can be tested and put into service independently of one another. In the long term, the care and maintenance of the user program is significantly simpler due to structured programming. This enables users in turn to integrate Profienergy easily into their own (factory) standards and program libraries.
Potential Savings The main benefits for the end user are the saving of energy and the associated costs. Measurements revealed that even during non-productive periods many plant sections still require between 40 and 60 of the energy that is required during actual production. Whereas in operation the focus is on energysaving products such as motors with a better energy efficiency class, Profienergy relies predominantly on the non-productive periods (nights, weekends etc). In this case, it is a matter of partially or completely switching off unnecessary systems. Users can expect energy savings of up to 80 percent. A further key factor is the sensible deployment of the energy available during production. Here, too, certain auxiliary processes can take a break during production. Profienergy thus has the task of managing and making most efficient use of the energy available. Partial load operation must be possible.
New line of Non-Drip / Stainless Steel Quick Connect Couplings
The Global Quick Connect Specialist Fluid Non Drip Series
• No Spillage • Design exclusively for fluids • Color Coding • Different safety levels • Unlimited combination possibilities • Functionally and quality tested • Stainless Steel / Brass material CEJN’s new product range of modular non drip couplings is adaptable to most fluid application and system requirements. This couplings are compatible with working pressure up to 20 Bar (290 PSI) and temperatures up to 315°C (600°F), making it suitable for a variety of low-pressure fluid applications in which lines needed to be connected and disconnected easily, safely and without leakage. Sizes available include body sizes from 1/4 inch to 1 inch.
Stainless Steel Quick Connect For Higher Demand Up To 250 Bar Working Pressure X66 Series
526 Series
ISO B Series
Visit www.cejn.com.sg for more information
CEJN Products Far East Pte Ltd
70 Bendemeer Road #03-03 Luzerne (Hiap Huat Hse) Singapore 339940 Tel: 65-6748 6434 Fax: 65-6747 0375 Website: www.cejn.com.sg, www.cejnsafety.com, E-mail: mkt@cpf-cejn.com.sg
ENQUIRY NO. 096
Engineering, Commissioning, Care & Maintenance Selective measures are already taken today, in order
ENQUIRY NO. 1602
Feb/Mar 2010 | industrial automation asia 45
features
Sustainability:
Take It, It’s
Yours! SMC’s Dr Song Bin discusses his vision for the newly launched centre. By Joson Ng and Derek Rodriguez
U
nveiled to the public late last year, SIMTech’s (Singapore Institute of Manufacturing Te c h no lo g y) S u s t a i n a ble Manufacturing Centre (SMC) is already actively collaborating with several government agencies and companies. SMC director Dr Song Bin reveals that the setting up of the centre has been a long time coming. For many years, SIMTech has been developing sustainable technologies, but on an ad hoc basis and did not use terms like ‘sustainability’ or ‘environmental’. According to Dr Song, the centre was set up “with the belief that the manufacturing industry is undergoing a paradigm shift towards green manufacturing to minimise the emissions, waste and the toxicity in the manufacturing process”. To achieve such an objective, he believes that the key will be “technology innovation and the implementation in the industry”. “Since 2007,” says Dr Song, “we have started to put in a more systematic effort to research into technologies for sustainability in manufacturing. Included are tools that can help companies to quantify sustainable performance like carbon footprint, depletion of resources 46 industrial automation asia | Feb/Mar 2010
and the impact on human health from a manufacturing process; and technologies that reduce toxicity, increase energy/resource efficiency, recovery and recycling waste, and processing and application of ecofriendly materials.” Open To All Industries There are many industries in which sustainability can play a huge role, suggests Dr Song. In the aerospace and automotive industries, weight reduction is crucial; in the food industry, manufacturers want to reduce energy consumption and improve packaging in terms of environmental impact. Other industries, he says, include machinery, moulding, stamping, electronics, mechanical etc. Companies that are interested in sustainability but are unable to pursue it due to lack of resource can still consider sustainability as a viable avenue.
Says Dr Song: “We don’t provide funding but there are orga n isat ion s in Singap ore that will support companies to innovate technologies that help to reduce waste and improve energy efficiency. For example, SPRING have this capability development fund, companies that have the need or idea to come up with new capabilities they can apply for this funding, which can be around 50 percent or higher, to offset the cost. NEA have this 3R fund; companies that want to implement some sort of technology or process to reduce waste can apply for funding from NEA. And IE Singapore can help companies that wish to carry out some sort of technology upgrading that can help them to export their goods overseas.” ENQUIRY NO. 1701
Dr Song on SMC’s three areas of focus: Quantifying Carbon Footprint “To help companies quantify their carbon footprint, we are developing our own methodology and software toolkit embedding relevant international standards like PAS 2050, ISO 14064, and the coming 14067. More and more companies are very keen to do this with us. Companies are very keen to improve their carbon emissions and reduce, looking for ways to reduce the consumption of resource in manufacturing process. That will help the companies to be more competitive, and open a lot of opportunity for research.”
Remanufacturing “We have all these precision engineering companies, they’re quite strong in their core competence, but the electronic industry which they have been supporting, is declining in Singapore. However, their capabilities are very suitable and provide the base requirement for remanufacturing. In the meantime the EDB is attracting large remanufacturers in Singapore and these manufacturers need support. We also have a strong trading industry distributing products and components worldwide. Through taking-back schemes and partnering with precision engineering companies, used products/components can be remanufactured and marketed. All these open up opportunities for business growth with environmental benefits.”
“Packaging is often the first area for a company to improve their environmental performance while gaining cost benefits. We are looking into the use of sustainable materials for packaging, eco-design of packaging, and technologies to reduce costs. Most of the materials used in packaging are not renewable and some are not even recyclable, so we can improve through the use of new materials. To maximise the results, we need to rethink about packaging design from the viewpoint of energy and material optimisation. Once you use the new material you have to develop a new and efficient manufacturing process. This includes preparing the industry to apply the materials and looking for potential applications.”
ENQUIRY NO. 090
Packaging
Feb/Mar 2010 | industrial automation asia 47
products & Services Adlink:
Advantech:
Adlink Technology’s E xpress-CB is a COM Express Type 2 module supporting the 64-bit Intel Core i7/i5 processor with CPU, memory controller, and graphics processor on the same chip. Based on the latest Mobile Intel QM57 Express chipset, the Express-CB is specifically designed for customers who need high-level processing and graphics performance in a long product life solution. Integrated graphics support includes features such as OpenGL 2.1, DirectX10, and Intel Dynamic Video Memory Technology (Intel DVMT 5.0). Graphics outputs include CRT, LVDS and Embedded DisplayPort. Target applications include: Medical Diagnostic Equipment and Medical Imaging, Portable Medical Devices, Instrumentation, Industrial Automation, Transportation, Data Storage, Infotainment, Gaming, Video Preprocessing, POS and Kiosk.
UTC-W101 is a standalone, all-in-one unit with a customisable exterior design that fits a variety of business types. It is suitable in restaurants, healthcare facilities and retail shopping environments. The UTC-W101 is fanless, allowing it to operate noiselessly and its front panel is built to meet IP65/NEMA 4 standards, giving it protection from dust and water. The low-power consuming Intel Atom processor makes it cost-effective, and the 16:9, 10.1” WSXGA display provides end-users with a natural viewing experience. It has two gigabit Ethernet ports which can be configured to support LAN teaming, wake-on LAN, or boot from LAN.
COM Express Module
eService Touch Computer
Enquiry no. 1801
Enquiry no. 1802
Baumer:
Belden:
The Baumer VeriSen Series 1500 and 1800 vision sensors feature stainless steel housings, IP69K protection class and Ethernet interface. They can reliably meet tough hygienic and bio-cleaning requiremen t s in r ugged surroundings while also ensuring flexible system integration. IP69K certificated cables are available for integration. The vision sensors with stainless steel housings are versatile imaging solutions for applications which demand high standards of cleanliness and hygienic control. In the food industry, for instance, they can inspect packaged foods and read the ‘best-before’ dates. Food products can also be inspected before packaging with well-proven functions to check location, position, presence and completeness.
The Hirschmann RSB20 series of managed switches consists of 16 models that are distinguished by the number and type of ports offered, factory settings for EtherNet/IP and specific operating temperature ranges. This provides an economically attractive entry into the segment of managed switches, where customers only pay for their exact equipment (feature and function) needs. The RSB20 portfolio permits customised, hardened and reliable communications solutions without compromising quality. This series of basic managed switches are ideally suited for OEM and network-edge level managed performance. Plug and play features allow for quick commissioning without sacrificing switch or network diagnostics and performance.
Basic Managed Switches
Vision Sensors
Enquiry no. 1803 48 industrial automation asia | Feb/Mar 2010
Enquiry no. 1804
products & Services
Cognex:
3D Vision Software
Fortress Interlocks:
Safety Switch Key Station
Fortress Interlocks has introduced an ATE X Certified, explosion protected safety switch key station. The CPS4STOPXP key station is designed to release keys which can be used to control mechanical door locks that provide access to machinery and process lines operating in potentially explosive environments. Both the switch and the door locks are suitable for use in zone 1 and 2 environments such as those found in the chemical and petrochemical, paint, pharmaceutical, flour, powders and mining industries; the electrical parts are ingress protected to IP67.
Cognex 3D-Locate delivers accurate, real-time, three-dimensional position information that enables automation equipment to work with a wider variety of parts, including items that are stacked or tilted. Using 3D-Locate can improve vision performance for challenging applications such as logistics and robot-guided depalletising and precision assembly, and it can eliminate the need for expensive mechanical fixtures or measurement devices. Cognex 3D-Locate can also be used in combination with Cognex code reading, gauging, and inspection tools. It uses multiple sets of two-dimensional features found by Cognex’s patented geometric pattern matching tool, PatMax, to determine an object’s precise three-dimensional orientation. Enquiry no. 1805
Enquiry no. 1806
GE Fanuc Automation:
igus:
GE Fanuc Automation’s Durus Controllers are loaded with features such as easy to use built-in display/keypad, high current outputs, multiple communication options. The controllers can be programmed using both the built-in display and keypad or with the Durus Controllers programming software. The controllers are ideal for applications that require some logic, a few timers/counters and real-time clock control. They are designed for simple control applications such as light control, gate control, HVAC, pump control and much more.
Energy chain company igus has extended its range of preharnessed drive cables. In addition to the existing cables for Fanuc, Lenze, Rexroth, SEW and Siemens drives, cables for B&R, Baumüller, Beckhoff, Berger Lahr, Danaher Motion, ELAU, Fagor, Heidenhain, NUM and Stöber have now been included in the range. The power, servo, sensor, signal and motor cables (PVC, PUR, TPE) with minimum bending radii from 7.5xd in the energy chain are available in any length, without minimum order values, surcharges for small quantities or cutting charges. All pre-harnessed cables are available with the manufacturer drive number. A computer-supported digital and high-voltage check in the company’s own technical centre guarantees quality.
Programmable Logic Controllers
Enquiry no. 1807
Pre-harnessed Drive Cables
Enquiry no. 1808 Feb/Mar 2010 | industrial automation asia 49
products & Services
Misubishi Electric:
Moxa:
Today’s innovative building services impose a wide variety of ‘green’ demands on frequency inverter systems. Mitsubishi Electric’s inverters are optimised for heating, ventilation and airconditioning (HVAC) applications such as pumps and fans. These inverters are able to achieve power savings, particularly in the crucial low speed range and the braking and acceleration phases. For example, at a frequency of 35Hz, the inverter achieves a saving of 57 percent over conventional solutions. Additional power savings of 10 percent are achieved by Mitsubishi Electric’s OEC (Optimum Excitation Control) technology, which ensures that the optimum flux is applied to the motor at all times.
Moxa’s DA-710 is an x86-based fanless rackmount embedded computer with modular flexibility. This is based on the Intel x86 processor and supports USB, VGA, and CompactFlash, and is equipped with four Ethernets ports and two RS-232 serial ports. It makes for an ideal platform for industrial applications thank to its standard 19-inch, 4U high form factor. In addition, the modular expansion design allows users to tailor their embedded computers. The DA-710 is designed for power substations ; this rugged industrial computer offers a wide range of applications for multitasking in a single power substation central management system.
Frequency Inverter Systems
Fanless Rackmount Embedded Computer
Enquiry no. 1809
Enquiry no. 1810
Omron:
Ophir-Spiricon:
The Omron 3G3MX2 Inverter has built-in safety function which conforms to ISO138491:2-6 ( PLd) and IEC602041 Stop Category 0 with its dual STO Inputs & EDM Output equipped as a standard feature. With its Precision sensor-less vector control, torque characteristics achieve very high starting torque of 200 percent at 0.5 Hz. Likewise, features such as over-current suppression and over-excitation function ensure tripless Inverter operation even in extreme application requirements. The ability to accept phase-differential pulse input directly enables the 3G3MX2 to do simple positioning applications. Communication between inverters is greatly simplified with the co-inverter communication function.
Ophir-Spiricon’s PD300-R line of Circular Photodiode Sensors feature round geometry for easy mounting and centring on collinear optical bench systems. SM-1 mounting threads on all components ensure a fit with most optics. Each device has a built-in filter that reduces the light level on the detector and allows measurements up to 30mW without saturation. A second, removable filter allows measurement up to 3W. The sensors work with all Ophir smart meters and PC interfaces. Each display features a ‘smart connector’ interface that automatically configures and calibrates the display when plugged into one of the company’s measurement heads.
Multi-Function Compact Inverter
Enquiry no. 1811 50 industrial automation asia | Feb/Mar 2010
Circular Laser Energy Sensors
Enquiry no. 1812
products & Services products & Services
Planit Software:
Printed Motor Works:
Planit Sof t ware’s manufacturing management system e2i, tracks and manages cost and quotations throughout the design and manufacturing process. Included in 2010 R1’s developments is stock control. Users can now manage the total quantity of a stock item in relation to real time supply and demand, rather than individual allocations. It also benefits from enhancements to the Sybase PowerBuilder and InfoMaker tools. These upgrades give customers a much improved environment to create reports. In addition these developments have enabled users to benefit from new reporting tools, which allow the creation of new tree-style reports.
Modern manufacturing techniques and intelligent design have also made the GSR range of pancake motors even flatter, down to just 19mm deep for a 70W motor and 41mm for a 1.6kW motor. Printed Motor Work’s development schedule has been driven by customer requests to make this ‘cool’ product more mainstream, initially to compete with a universal motor. The GSR range still offers all the features and benefits associated with pancake motors such as rapid response, long brush life, low EMC emissions has zero torque ripple. Applications as varied as highly dynamic industrial robotics and medical equipment through to basic pump and fan drives use pancake motors.
Manufacturing Management System
Pancake Motors
Enquiry no. 1813
Enquiry no. 1814
Sick:
Turck:
The ICR890 Camera System is the ideal solution in linear and 2D code reading for all high-end applications in sortation, transport and logistics processes. In addition the excellent image quality provided by the ICR890 makes it suitable for all kinds of OCR and video coding tasks. The modular camera design includes integrated illumination, focus control and a high-performance decoder. Depending on the application, proprietary products such as volume measurement system can be integrated.
Tu r c k ’s D - S i z e ( 13 / 8 inch ) power fast modular wiring system is designed to handle high current applications for machine power distribution and motor control. The complete D-Size power distribution sys tem includes 3 and 4-pin cordsets, receptacles and tees that provide up to 600 Volts and 30 Amps. Additional powerfast components include field wireables, closure caps and a tee with an integrated cable drop, which eliminates the need for two separate connectors. The D-Size powerfast system may be used in place of traditional conduit installations and is compliant with NFPA 79 standards.
Camera System
D-Size (1-3/8 Inch) Modular Wiring System
Enquiry no. 1815
Enquiry no. 1816 Feb/Mar 2010 | industrial automation asia 51
EVENT PREVIEW
SPS
Industrial Automation Fair Guangzhou
Four exhibition organisers from China and Germany have joined together to launch a show in China aimed at the industrial automation solutions sector. SPS – Industrial Automation Fair Guangzhou will make its debut during March 2010 in Guangzhou, China. It is organised by China Foreign Trade Guangzhou E xhibition Corp, Guangzhou Gua ng ya Messe Fra nk fur t, Guangzhou Overseas Trade Fairs and Mesago Messe Frankfurt. Sponsored by China Foreign Trade Centre (Group) and Messe Frankfurt Exhibition, the fourday SPS - Industrial Automation Fair Guangzhou will be held at the China Import and Export Fair Pazhou Complex, Guangzhou on March 8 – 11, 2010. Chen Chaoren, vice GM of China Foreign Trade Centre (Group) said: “By combining our past experience and strong support from local associations and industry, with our international partners, the new show is set to become the primesourcing platform in China for 52 industrial automation asia | Feb/Mar 2010
manufacturers wanting industrial automation and intelligent motion solutions.” Aiming for the expansion of the SPS fair and the strengthening of its presence in China, Joseph Rath, president of Mesago Messe Frankfurt said: “SPS has been successfully held for more than 20 years in Germany. The 2008 fair welcomed 1,386 exhibitors and 40,105 visitors in a gross exhibition area of 94,700 sq m. We aim to make SPS – Industrial Automation Fair Guangzhou one of the top trade events in the world catering to the manufacturing sectors.” To meet exhibitor and buyer expectations, SPS – Industrial Automation Fair Guangzhou will offer a comprehensive product category that includes drive systems and components, electrical and mechanical components and peripheral equipment, low voltage switching devices, sensor and control technology, and assembly and dismantling equipment. The show will be of particular interest to exhibitors whose
bu si ne s s i s re late d to t he equipment/devices and automation system software sectors as well to consultants, trainers, engineers and trade associations. It is an ideal market place for those in these user sectors: paper a nd printing; env ironmenta l a nd wa ste ma na gement; plastic, rubber and asbestos processing, chemical industry, energ y pro ducing indu st r y, plant engineering, automobile engineering; computers a nd networks; electric measurement and controls; factory automation; mechanical engineering; electric drives and controls; electrical engineering; import and export; procurement officia ls a nd government agencies; research institutes; and technicians and engineers. March 8 – 11, 2010 China Import & Export Fair Pazhou Complex Guangzhou, China ENQUIRY NO. 1901
ENQUIRY NO. 091
EVENT review
Automechanika Shanghai The fifth edition of Automechanika Shanghai was held from December 9 – 11, 2009 at the Shanghai New International Expo Centre, China. Exhibitor numbers increased by nearly 22 percent to 2,414 from 24 countries and regions, compared to the 2008 event. Showing an even larger increase were the visitor numbers with 38,551 visitors from 132 countries and regions attending the show. This is an increase of nearly 25 percent compared to the previous show. Automechanika Shanghai has further confirmed its position as an international show with 29 percent of the visitors coming from overseas, compared to 16 percent in 2008. The top 10 visitor countries and regions outside China were (greatest first) Taiwan, South Korea, Malaysia, Iran, Japan, Russia, Turkey, India, the United States and Hong Kong. Business Opportunities Heads of sourcing and procurement departments from 15 companies including China, France, Italy, Japan, New Zealand, South Africa and UAE attended the Automechanika Matchmaking Forum to meet oneon-one with suppliers. Dubai company Dynatrade 54 industrial automation asia | Feb/Mar 2010
specialises in a diverse range of automotive products such as tyres, batteries and vehicle parts. Manager, V Rajkumar was very satisfied with the event: “This is the first time that I’ve participated
Other events included the Automechanika Academy which was attended by many prominent industry speakers who explored the latest topics. I n 2 010 , A u to m e c h a n i k a Shanghai will become a four day event, instead of a three day event, running from December 8 – 11 2010. Jason Cao explains: “As the show is becoming bigger and bigger, we see the need for an
in the matchmaking event,” he says. “Since there are too many companies at the show, the matchmaking forum is like a shortcut for me to quickly make contact with the leading suppliers.”
extra show day. We also received feedback from exhibitors and visitors who wanted to extend the show by one day to further ma ximise their benefits and opportunities.”
Latest Industry Topics Other industry events at the show included the fifth International Forum and Showcase of Service Outsourcing in the Manufacturing Industry.
December 9 – 11, 2009 Shanghai New International Expo Centre Shanghai, China ENQUIRY NO. 1902
ENQUIRY NO. 089
EVENT rEViEw
Singapore International
Energy Week
The SIEW proved to be a platform for international and regional policy makers, industry players, and academics, to discuss pertinent energy issues, strategies and innovation. By Augustine Quek
JOINTLY organised by the Energy Market Authority ( EMA) and Energy Studies Institute (ESI), the five day Singapore International Energy Week (SIEW), now in its second year, ran under the theme of ‘Clean Energy: Sustainable Solutions for Urban Cities’. The week opened with the Singapore Energy Lecture, given by Pulitzer-Prize winning author of ‘The Prize’, Dr Daniel Yergin. He predicts a future dominated by natural gas, especially in energy hungry Asia, where economic growth will require immense energy resources. He elaborated that the quest for clean energy to provide for economic growth would also spur an intensified drive for new energy technologies. “If the 20th century was the Century 56 industrial automation asia | Feb/Mar 2010
of oil, the 21st century will be the Century of Energy Innovation.” declared Dr Yergin. Energy Innovation Indeed, energy innovations were the focus throughout the week, with several initiatives to promote advances in clean and efficient energy use being announced. These were in the areas alternative energy, clean transport and smart girds. In a lternative energ y generation, solar power is being promoted by the Solar Capability Scheme, bonus points for solar energy under the Green Mark Scheme and a new research i n st itute , t he S ola r E ne rg y Research Institute of Singapore (SERIS). Later in the week, announcements
were made for a S$20 million (US$14.2 million) Transport Technology Innovation and Development Scheme (TIDES) to test-bed electric vehicles and its associated infrastructure, and an Intelligent Energy System (IES) pilot project for testing the integration of various components of a smart grid. Through these various initiatives, many solutions can be tested and refined and a body of knowledge can be accumulated. Singapore would then be better positioned to make informed decisions on our future energy options. Need For Change A defining moment of the week ca me when the Pa ris - ba sed International Energy Agency (IEA) released a scathing report on
the world energy use. Presented by I E A e xe c u t i ve d i re c to r, Nobuo Tanaka, it paints a bleak future, of increasing fossil fuel consumption, with world primary energy demand increased by 40 percent between 2007 and 2030, if governments continue with business-as-usual. This trend is predicted to lead to a large increase in greenhouse gases in the atmosphere, in excess of 1000 parts per million (ppm) with global average temperatures rising by up to 6 deg C. However, the report offers an alternative scenario, where atmospheric greenhouse gas stabilised at 450 ppm, with global average temperature increasing less than 2 deg C. This requires US$10.5 trillion more investment than the businessas-usual case, mostly by the private sector. Further warnings were given that the cost of transforming the energy sector is estimated to increase by US$500 billion for every year of delay. The scale and breadth of the challenge is enormous, but a note of optimism was sounded that it can be met. According to figures released by the United Nations, some US$140 billion was invested in renewable energy globally in 2008, and was for the first time, more than the US$110 billion invested in fossil fuels. A similar view was echoed by Michael Liebreich, chairman and CEO of New Energy Frontier. He gave an overview of the investments in clean energy over the last few years and projected a huge increase from now till 2020. He gave an optimistic view that about US$350 billion will be invested in 2020. But an additional US$150 billion more will be required to reach a target of 450 ppm. He gave a future outlook on energy management, where an explosive growth in energy data is expected, and management of this data is currently overlooked
by energy companies. The best candidates, according to him, are telecommunications and network companies who can fill this gap. Product Presentation There was no lack of solutions from the private sector. Many pro duc t s were pre sente d throughout the week, from smart meters to electric vehicles. Two innovations in smart gird solutions were presented by Oracle and GE Energy. GE’s WX-110 WiMAX SmartMeter, an advanced meter ing dev ice, integ rate s advanced computing, metrology
and networking communications functions according to Institute of Electrical Engineers (IEEE) 8 02 .16 e sta nda rd. T he W X110 has a broadband WiMA X communications router with full Quality of Service (QoS), Security, Virtual Private Network (VPN), and Firewall capabilities. It can sense, record and monitor energy usage in the home through wireless internet services via HomePlug local area network interface. With information provided by smart meters, accompanying software can be used to further analyse the data and provided
Feb/Mar 2010 | industrial automation asia 57
EVENT review
value-added solutions. Oracle Utilities Meter Data Management is an example that was exhibited at the Smart Grids 2009, a SIEW e v e nt . T he s o f t w a re he lp s decouple the handling of meter data from other mission-critical utility operations. It integrates with multiple advanced metering solutions and acts as a central data repository. Johnson Controls featured its Integrated Building Management System (iBMS), an intelligent building system that centralises control of HVAC, lighting, security and fire control functions on one single platform. The Metasys System includes complete families of application specific control solutions for HVAC, fire, lighting and security systems within a building. Another product range featured at the Clean Energy Expo Asia was solar thermal driven chillers from Cyclect. The Singapore-based company showcased three types of solar cooling systems based on the principle of sorption chilling using lithium chloride, silica gel or lithium bromide; and water to absorb and release heat throughout the system. Cyclect also showcased its patented Cynergy valveless adsorption chiller using silica gel which utilises low temperature hot water (65 to 85 deg C) to produce chilled water. F rom preve nt i n g cl i mate cha nge to sav ing consumer energy costs, the week saw plenty of solutions. From propositions to test-bedding to commercial products, the SIEW has become an important event not just for experts in the field, but also for all decision makers in energy consumption in Singapore. November 16 - 20, 2009 Singapore International Energy Week Singapore ENQUIRY NO. 1903
58â&#x20AC;&#x192; industrial automation asia | Feb/Mar 2010
ENQUIRY NO. 087
EVENT review
CIA2009 CIA2009, together with EnviroAsia2009, attracted 6,244 business and trade attendees from more than 30 countries. Exhibitor s and visitors at CIA2009 concluded a rewarding week at the show which showcased the latest technologies a nd solutions. Excitement on the show floor was apparent as exhibitors met prospective new clients and touched base with existing partners, paving the way for potential business deals. CI A 20 0 9 continue s to be an important trade exhibition for Asia’s process engineering, controls, instrumentation and scientific equipment industries. The value brought about by the show to exhibitors was evident through repeat exhibitors who see benefits in returning year after year. “This is our fifth time at CIA. We
60 industrial automation asia | Feb/Mar 2010
are satisfied with our participation and we find it to be a cost-effective way to meet our customers. It serves our purposes very well,” said Narasimha Murthy Bhatta, Julabo Singapore.
Already, some exhibitors are preparing to be back for CIA2011. “We’ve had good quality leads – we have already signed up to participate in the next exhibition in 2011!” said Shreya Madgulkar Sarpotdar, Forbes Marshall. Visitors at the shows were equally pleased with what they saw. “The new stuff are very interesting. It is a good show with a lot of things, so there is no need to go abroad to look for what I want,” said Pan Han Seng of ParexDavco, a manufacturer of building and construction materials. Industrial Bus & Wireless Conference At the inaugural Industrial Bus and Wireless Technology Conference,
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critical issues pertaining to plant designs for long-term operability based on industrial bus technology and the deployment of wireless network ing were discussed. Spea kers from the industr y provided delegates with insights on how to handle key challenges and opportunities available. “The conference enabled me to see the innovative products that companies are building for the industrial, biotechnology, and measurement industries. In addition, my discussions with company representatives provided me with first hand information on how technology - wireless innovation, faster processors, and larger digital storage capabilities - will shape the future of their products,” said Jonathan Chua, founder & CEO, Duration Inc. Wireless technology looks set to reduce cost for businesses, particularly those in the Oil and Gas Industry. According to Said bin Taib, process control manager with Malaysia’s Petronas Carigali, the main advantage of wireless technology is that it can be used under very harsh conditions, without installation of cables. This will improve efficiency, quality and productivity, which ultimately means reduction in business
cost. Wireless is gaining ground in the Oil and Gas industry, and Petronas has plans to “take it further”, he added. Reflecting on a satisfactory
showing this year, Singapore Exhibition Services’ Tee Boon Teong, project director of CIA2009 gave this assurance. “Going forward, we will be making the 2011 show bigger and better, adding in a few extra features, such as focus areas.” C I A 2 0 0 9, to g e t h e r w i t h EnviroAsia2009, attracted 6,244 business and trade attendees from more than 30 countries. The event will return in 2011 as t wo co - lo c ate d e x h ibit ion s - AnaLabAsia2011 and CIA2011. The move to place more focus on AnaLabAsia is aimed at better catering to the growing demand for analytical instrumentation from g row ing indust r ie s in t h e A s i a P a c i f i c r e g i o n . AnaLabAsia2011, CIA2011 and EnviroAsia2011 will return in 2011 from November 22 – 25 at Suntec Singapore December 1 – 4, 2009 Suntec Singapore ENQUIRY NO. 1904
62 industrial automation asia | Feb/Mar 2010
Calendar of Events march 8 – 11 SPS – Industrial Automation Fair Guangzhou China Import & Export Fair Pazhou Complex Guangzhou, China Guangzhou Guangya Messe Frankfurt Email: sps@china.messefrankfurt.com Web: www.siaf-china.com
17 – 20 Dongguan International Exhibition On Foundry & Diecasting Industries Dongguan International Conference & Exhibition Center Guangdong, China World Trade Expo Email: FDI@worldtradeexpo.com.hk Web: www.fdi-expo.cn
24 – 26 Asia Pacific Maritime 2010 Singapore Expo Singapore Reed Exhibitions Email: huihiang.teo@reedexpo.com.sg Web: www.apmaritime.com
25 – 27 Industrial Expo 2010 Penang International Sports Arena Penang, Malaysia Intrenasionale Email: info@intrenasionale.com Web: www.iex.com.my
april 5 – 9 Power & Electricity World Asia Suntec Singapore Terrapinn Email: yaling.ng@terrapinn.com Web: www.terrapinn.com
6 – 8 Asiawater 2010 Kuala Lumpur Convention Centre Kuala Lumpur, Malaysia AMB Exhibitions Email: airin@ambexpo.com Web: www.asiawater.org
19 – 23 Hannover Messe Hannover Fair Grounds Hannover, Germany Singapore-German Chamber of Industry and Commerce Email: info@hf-singapore.com Web: www.hannovermesse.de
21 – 23 RFID World Asia Suntec Singapore Terrapinn Email: yeelim.tan@terrapinn.com Web: www.terrapinn.com
may 5 – 9 Automex Putra World Trade Centre Kuala Lumpur, Malaysia Premier Exhibitions Services Email: info@tradelink.com.my Web: www.tradelink.com.my
5 – 9 MTA Malaysia 2010 Putra World Trade Centre Kuala Lumpur, Malaysia Malaysian Exhibition Services Email: enquiry@mesallworld.com Web: www.mtamalaysia.com
13 – 16 Intermach 2010 BITEC Bangkok, Thailand Intermach Email: intermach@intermachshow.com Web: www.intermachshow.com
19 – 21 Semicon Singapore Suntec Singapore Semi Email: cchan@semi.org Web: www.semiconsingapore.org
25 – 28 KOFAS 2010 Changwon Exhibition Center Changwon, South Korea Koami Email: exhibit@koami.or.kr Web: www.kofas.org
31 – June 2 Interphex Asia 2009 Suntec Singapore Reed Exhibitions Email: jockhong.tan@reedexpo.com.sg Web: www.interphexasia.com
june 2 – 5 Renewable Energy Asia 2010 BITEC Bangkok, Thailand UBM Asia (Thailand) Email: entech@entechpollutec-asia.com Web: www.entechpollutec-asia.com
2 – 5 Manufacturing Surabaya 2010 Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo Email: maysia@pamerindo.com Web: www.manufacturingsurabaya.com
15 – 17 Nepcon Malaysia Penang International Sports Arena Penang, Malaysia Reed Exhibitions Email: huihiang.teo@reedexpo.com.sg Web: www.nepcon.com.my
15 – 18 CommunicAsia 2010
Singapore Expo Singapore Singapore Exhibitions Services Email: vw@sesallworld.com Web: www.communicasia.com
16 – 19 Propak Asia 2010 BITEC Bangkok, Thailand Bangkok Exhibition Services Email: propak@besallworld.com Web: www.propakasia.com
24 – 27 Intermold Thailand 2010
BITEC Bangkok, Thailand Reed Tradex Email: rtdx@reedtradex.co.th Web: www.intermoldthailand.com
24 – 27 Assembly Technology 2010
BITEC Bangkok, Thailand Reed Tradex Email: rtdx@reedtradex.co.th Web: www.assemblytechexpo.com
juLY 6 – 9 MTA Vietnam 2010
Saigon Exhibition & Convention Centre Ho Chi Minh, Vietnam Singapore Exhibition Services Email: events@sesallworld.com Web: www.mtavietnam.com
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