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October/November 2011 IndustrialAutomationAsia

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Oct/Nov 2011

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

Facility Automation | Age Of Mobility | State Of The Water Industry | Getting Hold Of Sustainability

A View From Above:

Facility Automation

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ility b o M f Age O try s u d n I r Wate e h T f State O bility a n i a t s Of Su d l o H Getting

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ENQUIRY NO. 138

ENQUIRY NO. 327

contents October/November 2011

ISSUES & INSIGHTS

24

Case Study: Singapore's First Multi-Plant District Cooling Network

Businesses are forging new territory in building automation. Diversity in vendor technologies and the essential factors forecasted for future efficiencies both contribute to the complexity of the environment.

By Liew ChunWeng, ABB

28

Direct Digital Controllers: Building Management The Smart Way

Modern direct digital controllers provide the brains for intelligent buildings – integrating energy systems, information management and ease-of-use into a single, powerful, compact package. By Philip Tang, Mitsubishi Electric Asia

32

Direct Part Mark Verification: Facilitating Automation

The need to control part marking process is becoming increasingly important, helping ensure the reliable lifetime traceability of parts from production line to end use. By Didier Lacroix, Cognex

CONTROL POINT

34

Reliable & Precise Level Measurement

36

Guided Radar: Contact-Based Level Measurement

Measuring liquids, slurries or bulk solids have been made easier and safer with a wide range of reliable and precise level control instruments. By Mark Jones, ifm electronic Traditional technologies are being replaced by more modern technologies that function with the same accuracy regardless of the medium and that react to changing measurement parameters in a more robust way with a greater immunity to sources of interference.

By Christoph Mueller, Sick AG

SOFTWARE & NETWORKS

38

The Age Of Mobility

40

PLM & ERP: Their Respective Roles In Modern Manufacturing

Manufacturing in Asia has entered a phase where more mobile devices have found their place in the production line. Saj Kumar, VP, Discrete Manufacturing, Industry Solution Group, SAP China shares his views. By Joson Ng

The integration of PLM & ERP will bring much value to the future of manufacturing, allowing companies to develop innovations as well as improve cost and quality. Contributed by Melanie Zhou, Parametric Technology Software

Instrumentation & Measurement

44

Choose Wireless Wisely

What important characteristics of the WirelessHART technology makes it so uniquely adapt for process applications?

By Jonas Berge, Emerson Process Management 2  industrial automation asia | Oct/Nov 2011

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contents October/November 2011

Energy

48

fEATURES

Coming To Grips With Sustainability

Helping manufacturers address ‘green’ manufacturing with vacuum technology. By Josef Karbassi, Piab

52

One For The Future

Automation solutions in the power generation and oil and gas sectors will ensure that the industry continues to be sustainable, in the face of an uncertain ecological future.

By Shahnawaz Abdul Hamid

60

PLM In Red Bull Racing

Industrial Automation Asia speaks to Steve Nevey, relationship manager, Red Bull Racing to find out PLM's role in the world of Formula One racing.

62

Bosch Resroth Case Study: New Metrology For New Strategy

A shift in production strategy can be facilitated by precise metrological equipment. By Birgit Albrecht, Hexagon Metrology

63

Metalworking From Your Cell Phone

The machining apps in smartphones allow it to make the transition from a communication device to a tool in the machine shop, adding mobility to machining. By Michael E Neumann

EVENTS

SECTOR SPOTLIGHT

56

The State Of The Water Industry

64 66

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EDITOR’s PAGE

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As we steam ahead into the unknown, we are reminded to look back and reflect. Reflection is not just a matter of daydreaming, though even that can be of benefit, but to look at our past and plan for our future. To connect the dots.

The more diverse our experiences, the more challenges we have faced, the more times we have stumbled, the more dots we have to connect. Turning experience into fortune, challenge into opportunity, and failure into success is the ultimate end goal.

What is the ultimate end goal of automation? Is it to improve efficiency, is it to reduce costs, perhaps it is to reduce risk and thus safety. But why improve efficiency, reduce cost, and lower risk? Like most, I find these questions and the answers which follow, rather obvious. Though I would argue that the most insightful of answers, and the biggest leaps in our understanding of any topic comes not from the most complex of ideas or dwelling on the meaning of the most complex of problems, but asking why, to the most simplest of questions.

Because when we assume we know, we are faced with an uneasy truth, that we know nothing.

So, always ask why, aways dwell on the trivial and always connect those dots.

In this issue of IAA we focus on topics, such as, facility automation, level sensors, ERP, wireless monitoring systems, sustainability, and water/wastewater treatment. Again, if you have any feedback or are interested in contributing content, or working with us in your marketing strategy, or you simply want to ask ‘why’, then do not hesitate in contacting us, at IAA.

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Emily Wang emilywang@epl.com.sg Contributors

Liew ChunWeng, Philip Tang, Didier Lacroix, Christoph Mueller, Mark Jones, Melanie Zhou, Jonas Berge, Josef Karbassi, Shahnawaz Abdul Hamid, Augustine Quek, Michael E Neumann, Birgit Albrecht Editorial Consultants

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ENQUIRY NO. 312

Industry News

Ilker, Izmir, Turkey

FiberLight Selects Juniper Networks And IBM For Next-Generation, Multi-State High Performance Network

Singapore: Juniper Networks has announced that FiberLight, a provider of mission-critical fibre optic network services for enterprises, government agencies and wholesale carriers in 23 US metropolitan areas, selected Juniper Networks MX Series 3D Universal Edge Routers to deliver its next-generation dedicated IP platform. FiberLight relied on IBM for its design and engineering expertise to implement the new network infrastructure.

Drawing on their strong global alliance, Juniper Networks and IBM worked together to design a complete, open, pre-architected, pre-integrated and pre-tested infrastructure, based

on Juniper’s MX Series edge routers.

The Juniper and IBM solution enables FiberLight to bundle its core fibre network product with high-speed Internet connectivity on a single, consolidated network, allowing FiberLight to offer its customers secure and resilient network services that can scale to meet changing demand at highly competitive price points.

With the launch of its new, nextgeneration IP platform, FiberLight can help its customers avoid the congestion and security threats typical of competing networks that combine traffic from webcentric companies and service providers in a single network. By updating and expanding its network with Juniper

Networks MX Series, FiberLight is able to service new market segments with increasingly challenging demands, driving continued growth and opening up new revenue opportunities for the future.

“In order to meet the stringent performance requirements of our customers, including leading telecom carriers, enterprises, content providers and government organisations, we have to maintain a network with very low latency but also high scalability,” said Judd Carothers, executive VP of operations at FiberLight. “With the combination of Juniper’s MX Series routers and IBM’s implementation skills, we have built an advanced high-capacity network that meets our current and future scalability requirements, while also delivering the flexibility that enables us to rapidly introduce new services.”

FiberLight selected the MX Series because of the widespread acceptance of the platform for Ethernet and IP services as well as the reliability and scalability of the Juniper Networks Junos operating system. While FiberLight’s current focus is providing dedicated Internet access and other IP-based services, such as Layer 2/3 VPNs for enterprise customers, the company is interested in adding additional services and capabilities down the road.

Juniper’s solutions have already enabled FiberLight to make a move into the Layer 3 space with new capabilities and will allow for further expansion and growth.

Third JEC Innovative Composites Summit (ICS) To Showcase Advances In Composite Technology In Asia-Pacific Singapore: JEC Composites has announced the third staging of its Innovative Composites Summit (ICS), to be held in Singapore from October 18-20, 2011. ICS aims at delivering a range of industry-specific seminars and conferences, and is the only summit in the 8 industrial automation asia | Oct/Nov 2011

Asia-Pacific region that gathers the widest range of technical papers, composites experts and qualified industry delegates in a single event. This year, a special emphasis is put on the carbon fibre market with the launch of a new conference.

“As the Asian composites sector

adapts to significant industrial and market changes, this year’s ICS program will help expose Asian firms to the latest technology trends and developments that are impacting their business,” says Frédérique Mutel, president and CEO of JEC Group.

Industry News

Frost & Sullivan: SEA And ANZ Industrial Control Valves Market To Grow At 12.3 Percent CAGR From 2010-2017 Singapore: The industrial control valves market in Southeast Asia and Australia and New Zealand is on course to achieving the forecast revenues of US$1.85 billion in 2017, mostly due to the sustained demand from conventional end users such as oil and gas, paper and pulp, and mining, especially in Australia. The receding effects of the economic downturn have pumped up the demand for control valves again.

New analysis from Frost & Sullivan, Southeast Asia and Australia New Zealand Industrial Control Valves Market, finds that the market earned revenues of US$825.0 million in 2010 and estimates this to reach US$1.85 billion in 2017.

“As markets gradually limp back to normalcy, end users will be attracted to control valves’ benefits of direct

savings by way of fewer valve failures, reduced downtimes, technical support, and process improvement,” says Frost & Sullivan research analyst Krishnan Ramanathan. “Newer and more advanced control valves are being introduced to cater to an expanding end-user base.”

Control valve manufacturers are focusing more on safety, as nuclear energy is becoming a major source of power generation in several countries.

Another area of revenue generation is industrial control valve asset management, as cost avoidance is a key focus area for companies that are still shaking off the effects of the slowdown.

The recovery in the control valves market is likely to be protracted, without any spurts in growth in the next two to three years, as revenues have barely reached the pre-2008 levels. As in almost

every market during the downturn, the lack of credit had resulted in lower investments in R&D. Smaller participants with sparse R&D resources were especially hard hit by the competition from larger participants.

However, the market is highly fragmented despite most end users preferring to obtain all their resources from a single manufacturer.

“Countries such as Singapore, Malaysia, Thailand, Australia and New Zealand are home to several multinational companies in the control valves sector and companies have started investing in newer technologies,” notes Mr Ramanathan.

“While retrofits can serve as a source for control valves in developed regions such as Australia and Singapore, newer projects will serve as a driver in the developing markets of Indonesia and Thailand.”

Singapore: SKF has announced that for the 12th successive year the company has been selected to be a member in both the Dow Jones Sustainability World Index (DJSI)and the pan-European sustainability benchmark for the Industrial Engineering sector. The DJSI represents the leading global companies from 57 sectors in the area of sustainability.

"Sustainability is a long-term commitment for the company and I am very proud that we have been recognised for our efforts, particularly in the areas of promoting sustainable products," says Tom Johnstone, president and CEO. He continued: “SKF is committed to sustainability not only as a responsibility, but also as a way of developing our business. We see this as one of our competitive advantages in working with our business partners and in attracting, retaining and developing our employees.”

The company defines sustainability as SKF Care, which encompasses Business Care, Environmental Care, Employee Care and Community Care. The company has a strategy called Beyond Zero which focuses on both reducing the environmental impact of its own operations and on helping its customers reduce the environmental impact in their operations and in the use of their products.

A recent example of the Beyond Zero strategy involves the application of the company’s products, knowledge and solutions, including the electromechanical control of the pump, the bearings and the associated engineering analysis to enable an innovative device at the heart of wave energy conversion. Although still in prototype, the device is capable of significantly increasing the amount of wave energy converted to useful energy compared to previous technologies.

The company is also working

Simon Gray, Birmingham, West Midlands, UK

SKF Among World’s Leading Companies Committed To Sustainability

continuously to reduce the impact of its own operations and has adopted the US Green Building Council’s LEED (Leadership in Energy and Environmental Design) standards ensuring world class environmental performance in new SKF buildings/factories. The company head office in the US is a LEED Platinum building and the new bearing factory in Russia has been granted a LEED Gold certificate. New factories under construction in Asia are being built to LEED standards.

Oct/Nov 2011 | industrial automation asia 9

Industry News

Singapore: FICO, a provider of analytics and decision management technology, has announced that the latest version of the company's Xpress Optimisation Suite has beaten the other leading optimisation software packages on established benchmark tests. The company's optimisation suite achieved record-breaking speeds on benchmarks that test how fast optimisation solvers can execute different types of problems.

Optimisation tools are used to find the best solutions to massively complex problems, involving thousands or millions of variables and billions of feasible solutions. Advances in optimisation sof t ware can drive

dramatic improvements in operational efficiency and effectiveness. The latest benchmarking tests show the speed advances made by the company's latest release.

In tests, the optimisation suite ranked fastest on three of four critical benchmarks and tied for fastest on the fourth.

Organisations with large-scale operations, from global banks to professional sports leagues, use the company's Xpress Optimisation Suite to ensure that they are making the most efficient and profitable use of resources such as capital, human resources and technology. Financial institutions benefit

Ambrozjo, Grodzisk Wlkp., Wielkopolskie, Poland

FICO Xpress Optimisation Suite Races Ahead Of Competitors In Benchmark Speed Tests

from FICO Xpress for pricing, portfolio management, trading and other critical applications. Technology for solving large-scale, complex operational challenges is becoming popular with companies throughout Asia Pacific.

Siemens Begins Fiscal 2012 With New Structure Singapore: Siemens starts off fiscal 2012 on October 1, 2011 with a further developed structure. The newly founded Infrastructure & Cities sector begins operation on that day, as planned. In the future, the operating businesses of the company will be organised in the Industry, Infrastructure & Cities, Energy, and Healthcare sectors. By forming the new sector, the company plans to be a leading participant in the dynamic growth of cities and infrastructure investments.

The new Infrastructure & Cities sector will manage the company’s global business with cities and infrastructures from Munich, Germany. The company is bundling its competencies and business activities in one unit in order to offer cities solutions for mobility, environmental protection and energy saving. The new sector, with around 87,000 employees, will contain the Mobility and Building Technology divisions from the Industry sector, as well as the Power Distribution division and Smart Grid business from the Energy sector.

Infrastructure & Cities will comprise five divisions: Rail Systems (rail vehicles), Mobility and Logistics (traffic, transport 10 industrial automation asia | Oct/Nov 2011

and logistics management), Low and Medium Voltage, Smart Grid (intelligent power grids) and Building Technologies.

Under this new setup, the divisions can orient their respective businesses even closer to their target markets and, through close cooperation within the sector, develop additional business opportunities in the growth market of cities.

To take advantage of this additional growth potential, the company will employ a new approach for sales as well as for research and development in its urban business. The sector’s Centres of Competence, in which Siemens will bundle its expertise for urban infrastructures, are an important element in this strategy. The first centre is currently being built in London and two others are planned for Asia and the US. Here, the company's experts will conduct research for new urban solutions and tailor special packages of the company's products for urban planners and mayors. These include integrated traffic solutions for preventing congestion as well as innovative concepts for reducing power consumption — and thus city costs — on a broad basis. Even in times of limited public budgets, the

company’s solutions — such as EnergySaving Contracting — help cities and communities cut costs and improve their environmental protection balance.

Moreover, the company’s solutions like traffic tolling systems offer cities and communities new sources of income.

The company meets with urban decision-makers directly through a team of city account managers. As a central contact partner, they can offer their respective city the entire company’s portfolio from one hand. In addition, they contribute their experiences to help further develop the company’s portfolio for cities. Customer proximity is a key driver for ensuring sustainable company growth and is part of the One Siemens target system.

The Industry sector and its new organisation will focus on industry customers. The sector will further reinforce its industry-specific and service business and expand its leading role in industrial software. The sector and its roughly 100,000 employees will have three divisions: Industry Automation and Drive Technologies as well as the newly founded Customer Services.

Industry News

Honeywell Unveils Virtualisation Support For Experion Process Knowledge System Perth, Australia: Honeywell has announced the availability of virtualisation support for its core product line, Experion Process Knowledge System (PKS) for both Distributed Control System (DCS) and SCADA applications. The latest additions to the company’s virtualisation portfolio establish Honeywell Process Solutions (HPS) as the only process industry vendor to offer a comprehensive virtualisation solution.

For many of today’s manufacturers, the process control environment requires separate servers to support different applications. Virtualisation resolves this issue by allowing a single server to simultaneously run multiple operating systems and applications. It also improves reliability by insulating these operating systems from hardware changes and the net benefit to users results in lower

operational costs.

HPS’ virtualisation offerings are developed with VMware, the world’s largest supplier of virtualisation products and solutions. These solutions help industrial plants reduce PC hardware requirements and minimise the frequency and impact of operating system and hardware changes while simplifying overall system management and improving availability, reliability and disaster recovery.

The popularity of virtualisation is growing rapidly throughout the IT industry as a whole, with a recent study by Gartner showing that over 40 percent of servers are virtualised today and that figure will rise to 75 percent by 2015. HPS’ holistic approach to industrial virtualisation encompasses the delivery and support of virtualisation

infrastructure uniquely tailored to the needs of the process control industry.

Additionally, the company provides a full range of applications that can be supported through virtualisation, providing end users with a complete solution right out of the box.

“As the broad shift in the IT industry towards virtualisation extends to the industrial marketplace, it is becoming more and more common to see applications and infrastructure deployed virtually rather than physically,” said Paul Hodge, Experion Infrastructure & HMI product manager, Honeywell Process Solutions.

“Honeywell is the only company able to deliver total virtualisation support for process automation environments. We see virtualisation as game- changing, and our offerings have been developed as strategic, long-term automation tools.”

Endress+Hauser Inaugurates New Building In The Netherlands Naarden, The Netherlands: Endress+Hauser continues to invest in its future: The measurement engineering specialist’s Dutch sales centre has moved into a new building in Naarden.

The modern office building cost just under eight million euros, and took under one year to construct.

“We wanted a groundbreaking office building which creates the best possible working conditions for all our people,” says Rob Hommersen, MD of the sales centre. He continued: “We also stressed that the architecture should reflect openness, sustainability and transparency.”

A high atrium with glass frontage characterises the new building; a masonry facade lends it elegance. The building has been constructed with eco-friendly materials and meets high standards in terms of energy consumption. Almost 5,000 square metres of floor area accommodate offices, a workshop, a logistics area and a restaurant. If needed,

Inauguration of Endress+Hauser Netherland’s new building: MD Rob Hommersen; Major of Naarden, Joyce Sylvester; CEO of the Endress+Hauser Group, Klaus Endress; and president of the Dutch Federation of Technological Industry, Jan Kamminga, cut the ribbon.

the building can be easily enlarged.

In 1960, a small sales office in the Netherlands was the first foreign subsidiary of the young company. Today, the sales centre employs over 130 people. The new building in the small town of Naarden, 20 kilometres south-east of Amsterdam, was erected immediately next door to the previous headquarters.

In the Netherlands, the company cooperates mainly with global customers in key industries such as water & wastewater, food & beverage, oil & gas and chemical. Thanks to the development of the business with service offerings and automation solutions, the Dutch sales centre has seen above average growth in the past years.

Oct/Nov 2011 | industrial automation asia 11

Industry News

ABB Wins US$15 Million Pulp And Paper Order In India India: ABB has won an order worth more than US$15 million to supply integrated automation and power equipment and related engineering and commissioning services to JK Paper for its expansion project. The company is a major player in the Indian paper industry and is the largest producer of branded copier papers in India.

The order is for capacity enhancement for one of its units, JK Paper Mills.

Located in Rayagada in the state of Orissa, southeast India, this mill annually produces 125,000 tonnes of branded printing, writing and copier paper. The mill expansion and modernisation project will more than double its production capacity.

It will add a new paper machine with a capacity of 165,000 tonnes per year, a pulp mill that will produce 215,000 tonnes of wood pulp per year, and a 55 MW

power plant. This expansion project is one of the largest in the Indian paper industry involving close to US$400 million.

The company’s delivery for the mill will help to improve its overall production efficiency and capacity. While maximising energy efficiency and ensuring a reliable source of power, it will provide further impetus to the company’s resource conservation efforts in energy and water.

“Our ability to deliver a complete mill solution, with leading edge automation and power technology and industry standard equipment, and related pulp and paper industry expertise will help this project to be implemented and operated successfully from design to start-up," said Veli-Matti Reinikkala, head of ABB’s Process Automation division.

The company will deliver energy

Hsosa5150, US

US$39.5 Billion Will Be Spent On Smart City Technologies in 2016

London, UK: ​While US$8.1 billion was spent on smart city technologies in 2010, by 2016 that number is projected to reach US$39.5 billion. A smart city is determined by six dimensions: smart economy, environment, governance, lifestyle, transportation, and community.

There are currently 102 smart city projects worldwide, with Europe leading the way at 38, North America at 35, Asia 12 industrial automation asia | Oct/Nov 2011

Pacific at 21, the Middle East and Africa at six, and Latin America with two.

Two examples of cities undertaking smart city projects are Holyoke, Massachusetts and Amsterdam. Cisco teamed with Holyoke in February 2011 and promised to change the former mill town into a smart and connected community within a year. Cisco’s plans for Holyoke include using technology to

efficient drive systems for the new paper machine, standalone drives and motors, and intelligent Motor Control Centres (MCCs). The scope of supply also includes electrical infrastructure equipment such as transformers, transmission lines, other power equipment, and power management system for the pulp mill & paper machine. The company’s automation System 800xA will control the new pulp mill and provide a common control and visualisation platform for all mill systems to optimise energy efficiency, the use of production resources and overall mill maintenance.

The company will also provide design, engineering, commissioning and related on-site services. Project commissioning is scheduled for the early fourth quarter of 2012.

deliver urban services in order to generate new economic opportunity, improve education, and bolster population retention.

Josh Flood, senior analyst at ABI Research, comments, “Smart city concepts are really taking off globally.

Currently, the largest spending on smart city technologies is for smart grids; however, over the next five years we will see a significant increase on spending for smart transportation technologies such as automatic vehicle ID and smart governance systems such as e-ID and ID document systems.”

Amsterdam’s smart environment project, launched in 2009, is a collaboration between Utility Liander and Amsterdam Innovation Motor. The program aims to set up a unique partnership with the city’s residents, businesses, and government to save energy now and in the future.

The program’s ultimate goal is to reduce CO2 emissions in Amsterdam, as well as eventually all of Europe. While Amsterdam had previously committed to reducing its carbon emissions by 40 percent by 2025, compared to a baseline of 1990, the smart city project aims to achieve that goal 10 years earlier by 2015.

Industry News

São Paulo, Brazil

Tampere, Finland/ São Paulo, Brazil: Confidex, an RFID technology company with RFID tag and ticket solutions worldwide, continues its geographic expansion by establishing a team in São Paulo, Brazil, to better serve its growing customer and partner base in Latin America.

The company has opened an office

in Brazil in order to be closer to the Latin American market. In Latin America, the company has already built up an extensive partner network and is engaged with key players in the industry to provide solutions for large deployments across the continent. Many of these markets are actively applying RFID solutions in both industry- and government-driven initiatives to improve efficiency, security and to optimise transactional activity.

To better serve its partners and the increasing number and size of project opportunities in Latin America, the company has established an office in São Paulo, Brazil. This office will be led by its new GM, Latin America, Alexander Dannias. Mr Dannias has many years experience in business development, management and operations in Latin America, with particular focus on technology in both software and hardware. He also has a background in leading the expansion of multinational companies across Latin America. “I believe Confidex is uniquely positioned through

ISA Announces Safety And Security Track At ISA Automation Week 2011 Alabama, US: The International Society of Automation (ISA) has unveiled the sessions of its safety and security track at ISA Automation Week 2011: Technology and Solutions Event. The annual conference will take place in Mobile, Alabama, US, October 17-20, 2011, at the Arthur R Outlaw Convention Centre.

The safety and security track offers sessions on issues that have affected many industries over the last year, and on the actions automation professionals can take to make their plants and facilities safer and more secure in the future.

The safet y and securit y track sessions include: • Stuxnet and Securing Control Systems • Safety Instrumented System Applications

• New Approaches for Detection and Response to Safety Critical Situations • Threats and Modeling • The Convergence of Safety and Security for Industrial Controls Systems • SIS Testing and Documentation Practices • Industrial Control System Security Standards • Findings from the Field • Partial Stroke Testing of SIS Valves “ISA has put together another excellent program on functional safety through instrumentation and control.

Only ISA can put together this diverse group of experts in a non-commercial forum that provides learning and

its combination of technology, product offering and operational model to reap the benefits of the rapid adoption of RFID and contactless ticketing in this market.

I am very excited to join the team and to be able to contribute to Confidex’s ambitious plans for the continent,” said Mr Dannias.

The company centralises its R&D activities in Finland, where it is based, and has offices across Western Europe, the US, India and China. Cementing its presence in Latin America with this new office is one additional and natural step in its global expansion strategy.

“The development of our business in Latin America over the last 12 months has been impressive and we have made a strategic decision to place additional emphasis on addressing this rapidly expanding market for RFID tags and contactless ticketing solutions. We have no doubt that Latin America will represent an increasingly significant share of our business going forward,” says Timo Lindström, CEO of Confidex Group.

Ariel da Silva Parreira, Patzcuaro, Michoacan, Mexico

Mokra, Brazil

Confidex Expands In Latin America

interactive discussion, resulting in the most valuable conference experience,” said safety track chair, Ed Marszal.

“Since Stuxnet was discovered last year, everyone has taken an interest in critical infrastructure security. These sessions will hopefully ensure your company does not become another casualty,” added security track chair, Graham Speake.

Oct/Nov 2011 | industrial automation asia 13

Industry News

Dow Chemical Optimises Capital Cost Decision-Making For Petrochemicals Projects

Michigan, US: Aspen Technology, a provider of software and services to the process industries, announced The Dow Chemical Company is optimising capital cost decision making for large-scale petrochemicals projects using the aspenONE Engineering

software suite. Dow has reduced the time it takes to produce accurate engineering estimates from months to weeks by using Aspen Capital Cost Estimator (ACCE). The application provides powerful estimating and collaboration capabilities that can scale to manage very large, global projects.

Previously, estimators were unable to model large, multi-plant facilities as one integrated project. Now, ACCE users can save time by increasing scope visibility across the entire project, which allows Engineering & Construction (E&C) firms and owner operators to regularly achieve efficiency improvements of 50 to 75 percent in their estimating activities.

ACCE helps estimating professionals rapidly and reliably conduct conceptual estimates at the earliest stages of project definition, which typically requires

multiple, large engineering teams to design, estimate and construct. ACCE users working on projects of all sizes also benefit from these same capabilities.

With critical decisions made early in the capital project cycle having a major impact on project economics, scalable ‘mega projects’ push the limits of engineering, fabrication, construction and transportation resources. The latest ACCE enhancements provide the ability to handle projects of expanded scope and scale, empowering estimators and executives to make effective capital cost decisions among different alternatives.

As with previous releases of AspenTech’s cost estimation software, ACCE incorporates yearly updates for capital materials and equipment pricing to improve the accuracy of project estimation activities.

IP Networks Selects Tinet To Help Leverage Its Market Assets To Worldwide Carrier Partners California, US, and Milan, Italy: IP Networks (IPN) a highly scalable EthernetOver-Fibre solutions provider, has announced its selection of Tinet, a Neutral Tandem company and a global carrier focused on the IP and Ethernet wholesale markets, to strategically market its network assets to the company’s worldwide carrier partners. IP Networks will utilise Tinet’s EtherCloudSM service in order to offer its customer base cost effective Ethernet services outside its footprint of 50-plus carrier partners without the need to set up External Network to Network Interfaces (E-NNIs) with each provider.

“Tinet, is an ideal choice for IP Networks and for our customers’ network assets, particularly now that we gain access to Tinet’s EtherCloud service,” states Mark Brown, director of sales for IP Networks. “IP Networks operates the largest legacy-free, Ethernet access network in the San Francisco and Silicon Valley regions 14 industrial automation asia | Oct/Nov 2011

connecting enterprise buildings and data centres. With EtherCloud, IP Networks can now quickly and efficiently source, price, and order services through the dedicated EtherCloud portal, and actively monitor connectivity of the circuit, among other advantages.”

EtherCloud is a Layer 2 platform connecting diverse partner networks into a seamless Ethernet cloud that delivers end-to-end connectivity around the world. EtherCloud relies on Tinet’s global MPLS backbone as a distributed switched network. It is currently available at 120 Points of Presence (PoPs) in four continents, to interconnect partners’ networks through

standardised E-NNIs. “We are pleased to be working with IP Networks, a robust, all-fibre partner in the high-tech region of the San Francisco Bay Area,” continues Paolo Gambini, chief marketing officer of Tinet. “IP Networks’ diverse access to fibre facilities is unique; the company is able to utilise existing electric utility infrastructure and position itself as physically independent of other carrier access points. Additionally EtherCloud offers IP Networks access to multiple new routes from other providers. In turn, this provides a benefit to Tinet by allowing us to offer our EtherCloud partners this redundant and diverse access.”

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Industry Updates

PROFINET

Communication Now Even More Powerful And Versatile The new PROFINET functionality revolutionises the flexibility and efficiency of automation tasks.

New functions are available in the market such as shared device, Intelligent Device (I-Device) and Media Redundancy Protocol (MRP). These features facilitate easier system configuration, for example, in failsafe applications, leaner and more versatile topology architectures with multiple networked controllers and higher plant availability. The new features also provide improved diagnostic functions via user-definable web pages and supports isochronous mode via PROFINET.

Shared device functionality, two IO-Controllers can access the same remote IO-Device and share the slots.

16  industrial automation asia | Oct/Nov 2011

MRP Functionality based on Ring topology increases the plant availability.

With shared device, several controllers can access a PROFINET input/output device, such as a distributed I/O system. This makes system configuration easier, for example in failsafe applications. It also means that both standard and failsafe PLCs can utilise the same distributed I/O system.

Intelligent Device (I-Device) allows I/O communication of a PLC to other higher-level or central controllers. Previously only hierarchical access from the central PLC to lower-level I/O devices was possible. With I-Device, leaner and more flexible topology architectures with multiple networked controllers is possible.

It is easier to network controllers from several different projects, for example, or integrate controls from different manufacturers within a communication network.

The IO-Controller is capable of working as Controller and I-Device at the same time.

The Media Redundancy Protocol

(MRP, IEC 62439) increases plant availability. This requires that the network infrastructure be installed redundantly in a ringtype topology, using Industrial Ethernet switches or via the integrated PROFINET interfaces of the PROFINET controllers and distributed I/O systems, for example. If communication is interrupted in one section of the ring installation, only this segment is affected without a complete plant standstill. This means that maintenance and repair work can be carried out without time pressure. The MRP protocol ensures a reconfiguration time of less than 200 milliseconds.

With this new functions a wide range of new possibilities are available to save money, reduce the footprint, increase plant availability which reduces the downtime of a plant and implement distributed intelligence in the field level of a plant.

ENQUIRY NO. 7101

ENQUIRY NO. 316

Newsdesk CANopen-EDS In XML

CANopen Lift At Interlift 2012 At the Interlift 2012 exhibition, the nonprofit CiA organisation will show its CANopen Lift Demonstrator on its booth (hall 5/119). It comprises three independent lift control systems using the CANopen-Lift network technology.

The CANopen lift application profile (CiA 417) version 2.0 is downloadable (free-of-charge) from CiA’s website. It has been implemented by an increasing number of companies. The benefit for the lift manufacturers is that they can chose devices from different suppliers, which are interoperable. In order to demonstrate this, CiA members have developed the CiA 417 demonstrator.

The following companies have contributed devices: Baumer, Böhnke + Partner, Controltechniques, Elgo, Henning, Kronenberg, Liftequip, Masora, Pepperl + Fuchs, Posital, Safeline, Schaefer, Schermsal, Weber, Wittur, and Ziehl-Abegg.

“The CANopen Lift profile is an open communication technology, which provides a plug-and-play functionality as well as an easy adaptation of applicationspecific requirements,” said Holger Zeltwanger, CiA’s MD. He continued: “With the lift doors by Wittur and the positioning sensors by Schmersal, we have two new partners in our demonstrator.”

Additionally, CiA organises for its members so-called plug-fests, in which the interoperability of the CiA 417 compliant devices is tested. Of course, also the CiA 417 specifications are extended and improved by CiA’s Special Interest Group CANopen-Lift.

ENQUIRY NO. 7102

18 industrial automation asia | Oct/Nov May 20092011

Electronic data sheets are formalised device descriptions, which are used as exchange format for software tools, too.

In the early days of CANopen, there was just a textual format standardised (CiA 306). The XML format introduced in 2007 has not been accepted that well, due to the limited advantages compared to the ASCII format. With version 1.1 the XML schema definition (CiA 311) is improved: It is now possible to describe modular CANopen devices as well as ‘field’. ‘Fields’ are sub-structures of parameters and sub-parameters (used in Arrays and Records). Still missing are description possibilities for Finite State Automata (FSA) and constraints between parameters and sub-parameters.

The CiA 311 conformant XSD files

describing the communication and application behavior of a CANopen device could be generatored by means of tools and also be proofed by tools. The XSD files are suitable for device design, device configuration, system integration, and diagnosis. Many CANopen tools will understand XML files. If not, there are also parsers available, which translates the ASCII format into XML format and vice versa.

“The acceptance of the XML format will increase significantly due to the additional functionality,” said Thilo Schumann, XML expert in the CiA office.

He continued: “In this fall, we will see the first tools supporting the improved XML-Schema.”

ENQUIRY NO. 7103

Standardised Interface For Contrast-Media Injector The nonprofit CiA international users and manufacturers group has released the version 2.1 of the CANopen application profile for medical diagnostic add-on modules (CiA 425). This specification describes the standardised communication interface between the contrast-media injector and the image-processing device (x-ray, MR, CT, and angiography devices). The new version is released as Draft Standard.

The involved companies – scanner manufacturer as well as injector provider – are working on a joint test-environment.

The test tool under development will improve the interoperability and conformance testing.

The standardised interface is based on the Controller Area Network (ISO

11898-1/-2) serial network, which is one of the most robust and reliable communication systems. The CANopen application layer provides a lot of communication flexibility. The CiA 425 profile specifies a common behaviour and guarantees the interoperability between medical devices and injectors developed and manufactured by different companies. The standardisation of interfaces in the healthcare business is saves time and cost.

European, American, and Japanese experts have developed the CiA 425 profile. The new version provides some additional functions such as injector configuration check, indication of mixed flow capability, and setting of display unit increments.

ENQUIRY NO. 7104

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ETG

Launches Semiconductor

Technical Working Group

EtherCAT is growing rapidly in the Semiconductor and Flat Panel Display (FPD) manufacturing industry — including Photovoltaics and LED manufacturing. Several major equipment and toolmakers have adopted EtherCAT, and many Semiconductor component suppliers have first products readily available. Following 20 industrial automation asia | Oct/Nov Dec 2010/Jan 2011 2011

the request from its members, ETG is now establishing a Semiconductor Technical Working Group (Semi TWG), which will address Semiconductor specific device profiles, installation guidelines, and device tests in order to meet the special requirements of this industry.

The kick-off meeting, which will shape the future work of this Semi TWG, will take place from October 26-27, 2011, in Silicon Valley, California, US. For this meeting ETG has secured the active participation of premium tool makers, in order to ensure that the results meet their requirements; presentations are scheduled by

Applied Materials, LAM Research, Aixtron and Brooks Automation to talk about their expectations regarding EtherCAT enabled Semi components. Further presentations are expected from Asian ETG members as many Semi related EtherCAT users and potential users will join this meeting.

Applied Materials, the world’s largest supplier of semiconductor manufacturing equipment, was among the founding members of ETG back in 2003. Furthermore, the company is sponsoring the EtherCAT seminar series that takes place in six US states in October this year.

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Fieldbus Foundation Issues

Transducer Block Specification For Wired HART And WirelessHART Devices The Fieldbus Foundation has announced that it has issued a Foundation Wireless and Remote I/O (WIO) preliminary specification addressing fieldbus transducer blocks for wired HART and WirelessHART devices, together with updates to the WIO System Architecture and WIO Data Structures related to the transducer block specification.

Part of the Foundation for Remote Operations Management (ROM)solution implementing wireless and remote I/O, the new technical specification defines a fieldbus transducer block used to represent HART devices within Foundation for ROM devices. Both wired HART and WirelessHART devices may be represented in this block. In addition, the specification describes the expected method for HART configuration tools and asset-managing hosts to access HART devices using the native HART command protocol transported through the Foundation High Speed Ethernet (HSE) network. The specification also defines structures to identify and maintain HART device status in wired multi-drop networks as well as in WirelessHART mesh networks connected to Foundation for ROM devices.

The Fieldbus Foundation’s director of technology development, Dave Glanzer, commented: “The new transducer block specification will benefit end users who need to be able to 22 industrial automation asia | Oct/Nov 2011

interface HART and WirelessHART devices to Foundation fieldbus to improve their integration with a control system, or with Foundation devices. They may also require a networked method for an assetmanaging host to access a large set of HART and WirelessHART devices for HART configuration and maintenance purposes.”

Within the Foundation architecture, H1 and HSE provide a distributed function block capability with HSE serving as a larger pipeline offering increased speed and throughput. The WIO development expands these capabilities by establishing open, non-proprietary specifications for a wired or wireless HSE backhaul network integrating various wireless Foundation for ROM devices with interfaces to wireless field device networks.

HSE provides an efficient way to bring large concentrations of discrete and analogue field I/O from modular devices back to the control room using a high-speed HSE connection. Employing HSE devices functioning like a smart remote terminal unit (RTU), the technology brings all forms of conventional I/O into the native fieldbus environment easily.

This solution makes discretein, discrete-out, analogue-in, analogue-out and H1 fieldbus available over a common Ethernet network. The addition of remote I/O further tightens the integration of process instrumentation within

a Foundation control system infrastructure.

ENQUIRY NO. 7106

Fieldbus End-User Seminars Planned Throughout Americas The Fieldbus Foundation will be hosting a number of end-user seminars in the Americas region in 2011. The aim is to help those in the process industry to understand the advantages of the Foundation Automation Infrastructure.

The remaining dates and locations for the 2011 seminars will be: • Corpus Christi, TX, USA: November 7 • Baton Rouge, LA, USA: November 9 • Beaumont, TX, USA: November 10 • Mexico City, Mexico: November 10 The seminars are aimed at end-users and engineering firms in the process control field. The seminars aim to cover a wide scope of Foundation automation infrastructure management over oneday. Some of the topics the seminar will focus on are Open, Scalable Integration/ Segment Design & Layout; Process Integrity/Safety Integrity Levels (SIL) and Safety Instrumented Functions (SIF); and Business Intelligence/Maintenance & Troubleshooting. Time allotted for discussion ranges from 45 minutes to one hour, followed by a hands-on demonstration lasting 15-20 minutes. The day typically starts at 8am and lasts until 4:30pm, lunch is included for free as well as morning and afternoon breaks.

ENQUIRY NO. 7107

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Hydropower – Clean Energy Generation With Tradition ifm electronic gmbh, a company with tradition, develops, produces and supplies suitable sensors.

Hydroelectric power plants depend on high investments and become profitable only after decades. Thus, it is understandable that these types of power plants are planned and built for a long lifetime. Only high-quality and reliable machine parts and sensors are used.

A distinction is made between running water, storage power and pump storage power plants.

The differences in height between the upper and lower reservoir as well as the volumetric flow quantities in the turbine are decisive for the electricity output. With the hydrostatic submersible pressure transmitter PS3407, ifm electronic offers the ideal prerequisites for water level measurement with long-term stability.

What type of turbine is selected depends on local factors such as water quantity and height of fall. The Kaplan turbine is used for great heights of fall and volumetric flow quantities, the Francis turbine for average heights of fall and volumetric flow quantities and the Pelton turbine for great heights of fall and small volumetric flow quantities.

The mechanical energy of the turbines is transferred to the generator by means of a shaft. Slide bearings ensure that there is almost no rotational loss.

This is where the temperature sensors come in. The temperature of the bearings is an important sign of a ‘friction-free’ and therefore low-loss transmission of energy.

The slide bearings are supplied by a central lubrication block. The temperature of the bearings and coolants is recorded via the temperature control monitor TR2432 as well as the type TTxxxx temperature sensors Pt1000 and is provided to the PLC as a scaled 4…20mA analogue signal. This way, viscosity and lubricity of the coolant can be monitored.

In automation and process technology, monitoring and control of temperatures is one of the most important measuring tasks.

The correct temperature often influences the quality and efficiency of the corresponding processes. Critical states are to be prevented.

This is achieved by compact temperature switches and transmitters as well as by cable and probe sensors, which are connected to an external control monitor.

Apart from measuring the temperature, it is of course necessary to continuously monitor the level in the supply tank of the central lubrication block in order to avoid insufficient lubrication.

In addition to the central lubrication block, the hydraulic power pack plays an important role.

It is used for servo-hydraulic adjustment of the guide vane apparatus, eg: in Francis turbines.

Here as well, continuous availability of sufficient hydraulic fluid quantities must be ensured.

Especially suitable is the LK3xxx, which is working on a capacitive basis. For continuous level measurement the level is detected continuously, converted into an electrical signal and indicated. Depending on the type, the units have freely programmable switching outputs or an analogue output for further processing.

When bearings are subject to wear and tear and damage is caused, the friction increases.

Heat loss occurs and the bearing damage – depending on how far advanced it is – can lead to a blockage of the shaft. In turn, this can immediately lead to a destruction of the entire periphery and thus to increased repair costs. ifm customers have been asked why they use the ifm diagnostic system. They have told unisono that the system of ifm electronic – the type VSA001 vibration sensor and the VSE002 evaluation unit – stands out due to its excellent price/performance ratio compared to competitors’ products. So, condition monitoring is no longer a matter of price.

For capacitive measurement the tank and the material form an electrical capacitor. The capacity changes with the level and is converted into a level measurement by a microprocessor.

This is widely used with a great variety of aggregates in different application areas, for example in the machine tool industry. The electronic sensors of ifm do not require any mechanical components and are thus especially robust, reliable and long-term stable. Unlike with mechanical components, deposits or ‘wear and tear’ do not lead to error messages. Regular maintenance and cleaning are not necessary.

Even critical process conditions such as emptying a hydraulic tank or the unintentional overspill of a tank are monitored by level sensors.

Apart from slide bearings, depending on the type of generator, rolling element bearings are used. This is where the modern rolling element bearing diagnosis with ifm vibration sensors helps to establish a condition-based maintenance. The diagnostic system octavis offers a user-friendly and reliable way of diagnosing early wear and tear of the bearings as well as the damage progress.

VSA001 vibration sensor

VSE002 evaluation unit - LEDs indicating the state of the rolling element bearings on site. Pre-alarm and alarm are signalled via switching outputs. The trend is stored in the unit with a time stamp.

Another benefit of the ifm system, which has been highlighted and distinguishes it from competitors’ units, is that the parameter setting software is easy to use while at the same time allowing extensive diagnosis. efector octavis is a vibration monitor which not only detects vibration data, but also carries out signal analysis and machine diagnosis directly on the machine. The machine condition is determined right on the site of measurement and forwarded to the PLC or to SCADA software via alarms or as condition values.

The main requirements for modern machine monitoring are fulfilled: compatibility, modularity and transferable configuration. If the damage is not detected in time, the costs are usually not just incurred by the generator component, which must be replaced and can amount to several €10,000 in case of a total failure, but rather by mounting, transport and down-times as well as the resulting deficit in generated and sold electrical energy.

Conclusion Reliable sensors and evaluation systems of ifm ensure a minimisation of down-times – thus, investments pay off quickly and hydroelectric power plants can produce clean energy on a long-term basis.

ENQUIRY NO. 337

issues & insights

Businesses are forging new territories in building automation. Diversity in vendor technologies and the essential factors forecasted for future efficiencies both contribute to the complexity of the environment. By Liew ChunWeng, automation engineering manager, ABB

Case Study:

Singapore’s First

Multi-Plant District Cooling Network F

acility automation is defined as the control and monitoring of utilities and sub-systems used in the distribution of conditioned air to zones (eg: production suite).

Singapore has the distinction of having the largest and most ambitious district cooling project ever undertaken.

Hailed as the ‘multi-billion dollar city within a city,’ Marina Bay is a 360-hectare extension to Singapore’s existing business district and downtown area. Built on reclaimed land at the southern tip of the island-state, Marina Bay and its distinctive signature 24 industrial automation asia | Oct/Nov 2011

skyline has already become the city’s new business, commercial and entertainment hub.

During the 1990s when the Marina Bay project was initiated, district cooling was quickly identified as the energy-efficient and cost-effective method to provide buildings in the area with an optimal indoor climate.

Singapore has a hot and humid equatorial climate, in which daytime temperatures are rarely below 30 deg C. To date, phases one and two of the district cooling system are in operation, providing 1.1 million sq

m of accommodation with cool air via two chilled water production plants and a 5 km piping network.

Among the landmark buildings cooled by the network are the Marina Bay Integrated Resort (a vast commercial complex comprising a casino, hotel, conference centre, museum and theaters), the Marina Bay Financial Centre, One Raffles Quay (an iconic office building which headquarters five major banks), and the Asia Square office, hotel and retail scheme.

In time, the network will be expanded to five inter-connected plants with a total installed

Technologies That Are Playing A Key Role ABB is playing a key role in this vast district cooling project by providing a complete electrical, control and instrumentation solution to Singapore District Cooling (SDC). SDC owns and operates two chilled water production plants (total planned c a p a c i t y 3 3 0 M Wr ) , p i p i n g network, and intake stations which are the interface between the district cooling system and the buildings.

T h ro u g h t h e c o m p a n y ’s Industrial IT Extended Automation System 800xA, it provides a technical platform for productivity gains and efficiencies.

Integration With a project of this scale, SDC handles vast and diverse information from a multitude of systems — from process control, condition monitoring to energy metering, to name a few — including external data sources such as the real time electricity prices. With System 800xA, all this relevant information is delivered in a single platform and interface, in a context that is customised to the needs of the user. This enables SDC to make proactive monitoring and informed decisions around productivity, cost projections and consumption, including daily production reporting. This is the power of integration.

Operator Effectiveness The company’s solution features the System 800xA, which monitors and controls the entire network of intake stations. It provides operators with realtime information on network and equipment performance. Armed

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capacity of 900 megawatts (MWr), capable of providing energyefficient cooling to eight million sq m of floor space.

Oct/Nov 2011 | industrial automation asia 25

issues & insights

Solutions that make better use of Singapore’s water resources are a focus for the country’s government.

The network sets a new international energy efficiency benchmark for cooling commercial buildings. with this information, the operator is then able to fine-tune production in line with demand and energy prices. This capacity results in improved energy efficiency and lower operating costs. The control system for the district cooling plants and the distribution network includes some 45 controllers, a p p ro x i m a t e l y 6 , 0 0 0 I / O s , 10 operator workplaces, three engineering stations and three information management servers.

The solution is also comprised of medium-voltage switchgear, transformers, low-voltage motor control centres, low-voltage and medium-voltage drives, and instrumentation for pressure, flow, temperature and energy metering.

Asset Optimisation The primary task of plant asset management is to reduce costs by identifying performance problems, improving predictive maintenance, and optimising asset lifecycles. The 800xA system provides real-time asset monitoring and notification, of SDC’s entire range of assets.

26 industrial automation asia | Oct/Nov 2011

ABB’s solution makes better use of water at projects across the city.

Proven Reliability, Historically…

Phase one was completed in 2005. Six years later, the plant continues to run efficiently and at optimum level. System 800xA is specially designed for 24/7 operating conditions of the district cooling system, delivering reliable and high-efficiency power and control. … And Evolution For The Future With its plans to build up to Phase five, SDC can leverage its existing infrastructure and investment in ABB technologies to manage and fulfill its future requirements. The

company’s System 800xA is the most scalable process control platform in the market today, with capacities for increased capacity and productivity — at shorter lead times and maximum uptime and consistency.

The network sets a new international energy efficiency benchmark for cooling commercial buildings.

According to SDC’s submission paper for the “Global Climate Award 2011,” the district cooling system reduces CO2 emissions by 23,000 tonnes a year at the current level of demand compared to alternative solutions in Singapore.

The company has a long and successful track record in the district heating and cooling market, having supplied numerous integrated electrical, control and instrumentation solutions for large and small networks in Europe, China, and Central and Southeast Asia.

Marina Bay Sands Integrated Resort is just one of the sites that the district cooling network — powered, controlled and optimised by the company’s solution — provides with chilled water. The resort features a 2,560-room hotel, a 120,000 sq m conventionexhibition centre, a shopping mall, museum, two theatres, six ‘celebrity chef’ restaurants, two floating pavilions and a casino with 500 tables. The complex is topped by a 340 m-long SkyPark with a 150 m infinity swimming pool, set on top of the world’s largest public cantilevered platform, which overhangs the north tower by 67 m.

ENQUIRY NO. 7201

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issues & insights

Direct Digital Controllers:

Building Management

The Smart Way

Modern direct digital controllers provide the brains for intelligent buildings – integrating energy systems, information management and ease-of-use into a single, powerful, compact package. By Philip Tang, account manager, Mitsubishi Electric Asia

I

n today’s increasingly competitive commercial markets, businesses face pressures to produce greater results with limited resources — besides endeavouring to reduce waste and meet the requirements of green initiatives. The latest generation of Direct Digital Controllers (DDC) can help building owners to meet these performance

goals in conventional building management, while providing a complete energy management solution that reduces the carbon footprint.

These DDCs are equipped with multiple features to enable modern buildings to be both smart and green. Key development emphasis in areas such as flexibility, scalability

Enterprise Applications

Legend Legend Subtitle Symbol

Description Web server Ethernet Database server

Facility Management Building Management Energy Management Security Management Maintenance Management

Comm-link Smart phone Firewall Wireless access point IO Server Printer

Ethernet TCP/IP Electrical & Power Quality Monitoring

Fire Alarm System

BMS

Card Access System

Security System

LCD monitor Modern Ring network

Power Meters

Laptop computer

LDDC

Tablet computer

DVR

User

Chiller Plant Room

Intelligent Switchgear

AHUs / FCUs VAV controlers Energy & Demand Monitoring controlers Heat Detectors Water & Gas Meters

Smoke Detectors

Call points

Lighting Control

28 industrial automation asia | Oct/Nov 2011

IP Cameras, CCTVs

VSDs

Building Management System architecture

and programmability, has resulted in a cost-effective solution for the Heating, Ventilation and AirConditioning (HVAC) market.

Open Protocol Networking The latest DDC technology can benefit system integrators and endusers in a number of different ways.

Designed to be a truly open system to allow seamless integration with third-party devices, modern Building Management System (BMS) architecture utilises Ethernet as the system’s backbone to communicate with Supervisory Control And Data Acquisition (SCADA).

In the traditional sense, Information Technology (IT) networks and BMS are typically operated as completely separate entities. However, as tasks and data collection are increasingly required by the BMS, the high data

transmission speeds and flexibility that are provided by Ethernet — on which most IT networks are based — become more significant and relevant. This is especially true in cases where data traffic to the SCADA may reach high levels. For instance, a power failure in a major building could simultaneously activate several hundred systemgenerated alarms. As Ethernet can support data transfer speeds of 100 mbps, it provides the network with the capacity and ability to manage this sudden surge of traffic.

Facilitating Monitoring Integration with IT also makes it easier to provide personnel with access to the BMS. These individuals are typically ordinary users who may never be in close proximity to the BMS, and who are probably unaware of its existence.

Such users can still benefit from a facility that enables them to view system-monitored data, such as the temperature levels in their workspaces. Where appropriate, users can also make changes to set points by using simple network software applications.

The IT network is therefore capable of providing a convenient medium for channeling BMSgathered data to a variety of applications. For example, as part of a corporate energy management program to encourage energy usage reduction, employees can access data that pertains to the current energy consumption levels of the office, factory or shop floor, via his or her workstation.

Using Ethernet as the communications backbone also facilitates the expansion of the BMS into an Integrated Building

Management System (IBMS).

IBMS is growing in popularity as it offers a complete information delivery system that controls a variety of other systems (eg: security system, fire alarm system, facilities booking system, carpark management system) and functions (visualisation, alarm management, scheduling, reporting and analysis) at an optimal level of efficiency.

This efficiency translates into multiple systems that can be seamlessly linked into a single application, with a common operational view to aid the facility m a n a g e r ’s d e c i s i o n - m a k i n g processes. The system is capable of analysing the multiple sources of data that are required to run an entire facility. For example, security and access systems can activate HVAC and lighting systems when the building is occupied; fire systems

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LM PLC

subway

HollySys (Asia Pacific) Pte. Ltd. 200 Pandan Loop, #08-01, Pantech 21, Singapore 128388.

Tel: +65-6777-0950 Fax: +65-6777-2730 please forward all enquiries to sales@hollysys.com.sg

ENQUIRY NO. 321

Power

Oct/Nov 2011 | industrial automation asia 29

issues & insights

can control lifts; Closed-Circuit Television (CCTV) systems can be used to check on fire alarms.

To achieve this, IBMS calls for tight interoperability between various facilities such as HVAC, lighting, security, the fire alarm system and the energy management system. Providers of such facilities/ services are catching on to this trend and have also built their product lines to utilise the Ethernet communications protocol.

Designing services to ride on the building’s IT Ethernet backbone can therefore bring about distinct advantages and substantial cost savings. These benefits can be enjoyed by the building owner when DDCs are integrated via the built-in Ethernet communications port (ie: there is no need to install a separate backbone network solely for BMS). Savings comes in the form of reduced network cabling and its associated installation costs. By adopting open-standards such as Ethernet, building owners also avoid being ‘locked in’ by proprietary protocol and technology when the building is due for upgrading or any Addition and Alteration (A&A) works.

• Data Logging At DDC Level Data logging has traditionally been performed at the SCADA level. If however, the SCADA is down or goes offline for scheduled maintenance, it becomes impossible to record data until the system is put back online. This means that important information (eg: temperature, energy consumption, tonnage) that requires periodical logging could be lost. Depending on the period of downtime, large amounts of data could go missing, resulting in disastrous consequences. For example, disputes could arise if the data is required for tenant billing purposes; or the integrity of monthly reports that are meant for Greenmark certification is compromised.

30 industrial automation asia | Oct/Nov 2011

• Scalable Architecture & Small Footprint There are several key challenges when carrying out A&A works.

Some of the key constraints include the availability of space and the re-use of existing resources. There could be instances where more I/O points need to be added but there is insufficient room for an additional DDC panel. Taking into account this constraint, the newer DDCs on the market are designed to take up less physical space but yet maintain the same number of I/O. This improvement allows the reuse of existing panels even if more I/O points are added to the configuration.

As land prices continue to rise, architects are designing buildings to maximise occupant space while minimising space for Mechanical and Electrical (M&E) installations such as Air Handling Unit (AHU) rooms, chiller plant rooms, risers, etc. Traditional DDC controllers employ a Central Processing Unit (CPU) that is able to connect to very few I/O points (approximately 128 points).

To overcome this limitation, the conventional solution is to install an additional CPU, which then contributes to the overall hardware costs. The size of each panel is usually big (800mm x 600mm) and a number of panels need to be used for each single application (eg: for a chiller plant room).

In some situations, DDC panels have to be installed in difficultto-access areas, which makes it inconvenient for maintenance and troubleshooting.

The newer generation of DDC panels overcomes this problem by employing a ‘use-as-you-need’ approach to configure the system.

These panels adopt a larger capacity CPU which supports up to 4,096 I/O points, meaning that more I/O can be processed by a single DDC panel. As CPUs usually form the main bulk (about 50 percent)

Mitsubishi Direct Digital Controller

of the cost of a DDC system, fewer CPUs mean lower costs. Field wiring expenses are also reduced as a smaller quantity of installation materials such as trunking and conduits are required.

• Ease-Of-Use In the programming phase, the traditional approach is for the programmer to perform programming at the controller level, create the corresponding tags at SCADA level and then map them together — taking up much time and human effort. An intelligent DDC that is equipped with an advanced software platform can help engineers and programmers to accomplish their tasks just as efficiently, while alleviating the strain on resources.

This software integrates SCADA and controllers via predefined function blocks for typical HVAC equipment (eg: chillers, AHUs and pumps). Intensive programming is no longer necessary and is replaced by a user-friendly graphical configuration interface. This allows junior level engineers to perform the job with minimal supervision, while experienced engineers can be redeployed for greater valueadding tasks that require greater decision-making.

party controller. Analogue and digital outputs can be configured for a predefined response to communications or controller failure, in order to achieve fail-safe mode.

• Built-In Display Since sensors are usually located in hard-to-reach locations, it can be difficult for maintenance personnel to perform onsite status and health checks on these devices.

Recognising this limitation, designers have incorporated a localised display directly on the DDC panels. This allows maintenance staff to check on the system status and to carry out any necessary changes directly via the display – making it easier for troubleshooting tasks to be performed.

This means that there is no longer a need for such personnel

to rely on another engineer who is located in the Fire Command Centre (FCC); or to connect a PC to the controller. With a local display, error status is clearly indicated. Error investigation and troubleshooting can be carried out without the need for any additional connections or engineering software.

With a powerful DDC in control of a system that comprises of equipment like variable frequency drives; energy monitoring devices; and low-voltage switchgears, energy savings and cost performance benefits can be reaped. Beyond these, building owners can look forward to harnessing technology that improves the efficiency of building management, while slashing expenses off their utilities bill.

ENQUIRY NO. 7202

ENQUIRY NO. 333

• Reliability In Control In mission critical applications such as hospitals, controller failure could affect the continuous and proper functioning of airconditioning in critical areas such as operation theatres. Failure to maintain the required temperature and humidity levels could result in contaminations and infections and compromise air quality. This in turn could lead to loss of life and expensive downstream litigation.

In the manufacturing space, such failures could typically result in production downtime and adversely affect profits. Traditional DDCs are not equipped to manage such controller failures and usually have to rely on industrial controllers to achieve redundancy.

The newer generation of DDCs support standby configurations and eliminate the need for a third

Oct/Nov 2011 | industrial automation asia 31

issues & insights

The need to control the part marking process is becoming increasingly important, helping ensure the reliable lifetime traceability of parts from production line to end use.

By Didier Lacroix, senior VP, International Sales & Services, Cognex

Direct Part Mark Verification:

Facilitating Automation M

anufacturing facility managers are consistently under pressure to increase production volumes while ensuring that quality is maintained. In such an environment, manual forms of quality assurance and product tracking are no longer feasible for many types of operations, ranging from F&B and medical devices to automotive and aerospace.

Track & Trace As manufacturers in Asia rapidly adopt Direct Part Mark (DPM) identification programs for part traceability, the need to control the part marking process is also becoming increasingly important.

The original quality of a two-dimensional (2D) code, which serves as a part’s permanent identity, can greatly affect the readability of a part as it moves through the manufacturing process, throughout the supply chain, and eventually to the end use of the part.

Given the quality of a direct marked 2D code is vital to the success of lifetime part traceability, many manufacturers regard the 2D mark as an important 32  industrial automation asia | Oct/Nov 2011

attribute of the part itself. This is because the mark serves as the part’s identity. In the event that a mark is poorly formed, its corresponding part cannot be further processed in the manufacturing line or moved down the supply chain.

In line with the need for quality marking, 2D mark verification capability is becoming a requirement for parts suppliers and manufacturers, so as to ensure that part marks can meet the quality levels that are defined by industry standards.

While 1D bar code verification technologies have already been in existence for a number of years, the use of verification systems for evaluating and optimising the quality of DPM 2D codes is a trend that has only just begun to emerge.

This has given rise to the importance of Direct Part Mark Verification (DPMV) systems. For some companies, the goal of DPMV is process control, while for others the aim is to achieve contract compliance.

In both situations, DPMV aids manufacturers in improving the marking process, increasing read

Applying The Rules Measuring each code against defined standards for quality assurance.

Various metrics and methods make up the Association for Automated Identification and Mobility (AIM) DPM standard for assessing a mark’s overall quality. Some of these include: Decodability — This pass/fail metric adopts a reference decoding algorithm to address and decode marks that have disconnected finder patterns. The reference decode algorithm is responsible for establishing the grid centre points that are required for verification.

Cell Contrast (CC) — Instead of determining differences between the brightest and darkest values, CC measures the difference between their means. The ability to distinguish between a black and a white cell depends on the closeness of the two distributions in the histogram.

Cell Modulation (CM) — A well-marked code needs a tight distribution for both light and dark values. If each peak’s standard deviation increases, some centre points will approach the threshold, possibly even crossing over. Cell modulation analyses the grid centre points within the data region to ascertain the proximity of the grayscale value to the global threshold. This happens after taking into consideration the amount of error correction that is available in the code.

Grid Non-Uniformity (GNU) — Qualifies a module placement by comparing to a nominal, evenly spaced grid.

Axial Non-Uniformity (ANU) — Describes a module’s ‘squareness.’

part is necessary for part tracking applications. If manufacturers can understand the root cause of poorly formed codes using universal standards, marking equipment can be fine-tuned for better results. These procedures help to prevent bad codes from entering both manufacturing lines and supply chains.

Taking it from a contract compliance standpoint, DPMV systems are necessary in ensuring that marked codes comply with specific contract requirements.

For example, the US Department of Defense (DoD) Unique Identification (UID) program initiative requires suppliers to mark and verify DPM codes on serialised, mission-critical and spare/repaired items as well as items that have an acquisition cost of over US$5,000 as part of contractual obligations.

By complying with this regulation, suppliers can improve their own ability to read codes, while helping the DoD improve data capture, part lifecycle management activities, and logistics support. Contract compliance is also starting to come into play in other industries. To illustrate, automotive companies need to have confidence on the readability of parts before these components are delivered to the assembly plant. Understanding the benefits this technology offers, such companies are also encouraging the adoption of DPM verification further downstream in the supply chain.

ENQUIRY NO.1 7204 2011_01_07_Triflex RS_Layout 1 21.01.11 11:04 Seite

Triflex RS Universal module for all motions.

rates, and reducing the cost of rejecting parts due to unreadable codes. It also helps to ensure that parts do not lose their lifetime identity.

Code Control Looking at DPMV from a process control standpoint, ensuring the quality of the mark that is made on the

igus Singapore Pte Ltd asia-sales@igus.com.sg

15 Shaw Road #03-02 Singapore 367953

ENQUIRY NO. 319

Unused Error Correction (UEC) — Data Matrix incorporates Reed/Solomon error correction. Every grid centre point should fall on the correct side of the global threshold. When this happens, the binarised image will look like a perfect black and white representation of the code. It is common for some centre points to fall on the wrong side. These bits are taken as bit errors that require processing through the Reed/Solomon algorithm.

The amount of error correction that is needed increases with the number of bit errors. A perfect mark that requires no error correction would obtain a UEC score of 100 percent. The greater the error correction, the lower the score.

ENQUIRY NO. 7203

Oct/Nov 2011 | industrial automation asia 33

control point

Chris Agiasotis, Sydney, Australia

Measuring liquids, slurries or bulk solids have been made easier and safer with a wide range of reliable and precise level control instruments. By Mark Jones, MD, ifm electronic

Reliable & Precise Level Measurement P

rocess control accuracy and security have become driving factors in the development of hundreds of ingenious industrial level control instruments.

These technologies have continually evolved, with common objectives in mind: improvement of measurement reliability, accuracy and general process safety. In summary, all level control instruments fall into either one of two categories, contact or noncontact devices.

Contact devices refer to instruments that detect a process medium directly, and produce an output at a specific level. This output may occur at a point (such as a high level), or over a predetermined range of interest within a process tank.

In recent times, non-contact devices have been designed to achieve this without needing to be immersed in the media. Typically these instruments are used where the medium is chemically aggressive, highly viscous or where other variables like excessive 34  industrial automation asia | Oct/Nov 2011

temperature or pressure warrant their use.

Ultrasonic, radar and laser technologies all fall under the categor y of non-contact measurement devices. These instruments are typically ‘topmounted’, and make an inferred measurement, based on the time it takes for a sound wave, microwave or laser beam to reach the process media, come in contact with it, and return. The challenge associated with non-contact level measurement instruments stems from having to overcome an array of environmental factors such as gas, heat, dust, pressure and vacuum.

Ultrasonic Systems Ultrasonic systems employ acoustics or sound energy in the form of waves with frequency above that of the human range of hearing (ie: approximately 20,000 Hz). This is where the sonic range ends, and ultrasonic range begins.

These systems are often used where accuracy is not critical, and where there are few environmental

complications to obstruct the sound waves. A downside of ultrasonic technology is the relatively slow response time, making accuracy an issue in dynamic applications.

Guided Wave Radar (GWR) GWR is a radar system featuring an ultra-high frequency, typically in the microwave section of the electromagnetic spectrum, and is commonly used in applications where highly accurate readings are required, such as monitoring the oil level in custody transfer storage tanks.

GWR sensors are commonly used in applications where ambient conditions must be overcome, and where accuracy is critical. Cost is generally proportional to accuracy and range, making it prohibitive to some users.

Laser Technology Laser technology works by measuring the time it takes a laser to hit a target and reflect back to the transducer. It is commonly known for high speed and accuracy.

This technology was introduced within the last decade and is now commonly used in fast process and factory automation applications.

Its relative low cost makes this a viable option where the target is not translucent.

A Glimpse Into The Future In the field of level control in process and factory automation, 3D technology has been developed in recent years to simplify level measurements of solid objects or bulk materials.

Such technology allows for accurate, fast, real-time measurement of packaged goods, complex shapes, and detection of missing goods. In fact, a multitude of new level and volume measurements for industrial users are now within our grasp.

ENQUIRY NO. 7301

ENQUIRY NO. 334

control point

Guided Radar:

Contact-Based

Level

Measurement Traditional technologies are being replaced by more modern technologies that function with the same accuracy regardless of the medium and that react to changing measurement parameters in a more robust way with a greater immunity to sources of interference. By Christoph Mueller, business unit manager, Sick AG

36 industrial automation asia | Oct/Nov 2011

T

he importance of sensors in liquid processes found in industrial production is increasing for a variety of reasons. Firstly, modern sectors, such as the electronics and solar industries, tend to exploit considerably more wet processes than the traditional metal-processing industries. This is because these new sectors are more chemically aligned, whereas the fluid sensors of the older industries are mainly involved in hydraulic, cooling, lubrication and cleaning processes.

Secondly, the trend towards reducing the number of maintenance and commissioning personnel and towards flexible production (whereby equipping times and parameter changes take place with as little productivity loss as possible) affects fluid processes in particular — and as such, the sensors involved. Last but not least, more sparing use of industrial fluids offers major potentials for reducing material consumption and cutting the amounts of hazardous wastes.

Against this background, the technological basis employed by the fluid sensors must change considerably during the coming years. Traditional measurement principles — electromechanical and simple electromagnetic sensors, for example — will be replaced by more modern technologies that function with the same accuracy regardless of the medium and that react to changing measurement parameters considerably more robustly and with greater immunity to sources of interference.

Time-of-flight based technologies have a key role in level measurement because their measurement results are hardly influenced by the liquid to be measured. These include both non-contact processes, such as radar and ultrasonic measurement, as well as technologies involving contact with the medium, such as guided radar.

As a result of its price positioning, but particularly also due to its robustness against environmental influences (such as foams and dusts), the technology of guided radar — time domain reflectometry — is of particular importance here. Whereby the fact that this technology must not be calibrated for the medium, but can merely be parameterised in a dry state, is particularly advantageous.

No subsequent recalibration is necessary when the medium is changed or there is an alteration in the tank geometry. The high tolerance towards foams and other surface effects is a further plus point compared to other technologies, such as ultrasonic or capacitive processes.

The principle of guided radar (often also described as guided microwaves) is a time-of-flight process in which a microwave pulse is coupled into a metallic probe and runs along it. If the pulse meets a change in the dielectric constant, as is found at the surface of the

medium in the tank, some of the energy is reflected and received again by the sensor with a time delay.

The distance of the reflection point, and as such, the level of liquid or bulk material present in the tank, is determined from the time-of-flight of this signal.

Because the time-of-flight is evaluated, the process is unaffected by media properties and as such requires no calibration. The only medium property that influences the quality, but not the applicability, of the measurement principle is the dielectric constant εr (relative permittivity) of the medium, which affects the strength of the signal reflected by the surface interface. The measurement process can be used in large or small tanks, with differing challenges for the evaluation electronics employed.

Advantages & Limitations While the advantage of the non-contact processes is that they do not have any direct contact with the medium and therefore, at least in theory, have a lower susceptibility regarding chemical resistance problems they are, however, limited regarding their mounting capabilities and are sensitive towards fixtures and environmental influences in the gas phases above the liquid.

Moreover, with contact-based time-of-flight measurement, a variety of probe designs expand

the scope of application considerably and can substantially improve the quality of the measurement signal. As such, a coaxial design with an internal conductor that guides the signal and an external conductor that protects the signal from interference provides highly accurate measurement results, despite difficult or moving tank fixtures.

Alternatively, a simple mono-cable probe, for example a stainless steel rod with a diameter of 7 mm, offers the advantage that it is insensitive to the formation of deposits or caking in dirty media and is also easily cleaned in hygienic processes. This cleanability is also a major advantage compared to electromechanical float switches whose floats always present a cleaning problem and necessarily offer space for process-endangering ‘nests’ of dirt and bacterial contamination.

While guided radar has already been an established technology for many years in the larger tanks of process automation, its use in the smaller buffer, storage and waste tanks of factory automation has only been possible up to now to a limited extent, due to insufficient accuracy and the large inactive areas.

Designs and evaluation units optimised for small tanks have now opened up this new field.

ENQUIRY NO. 7302 2011_01_07_CF.INI_Layout 1 21.01.11 08:16 Seite 1

Hitachi Variable Frequency Drives

SJ700B Series Advanced Industrial Inverter for Fan, Pump and Conveyor applications, Built-in Programming Function with VT, CT, SLV Control modes

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igus Singapore Pte Ltd asia-sales@igus.com.sg

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ENQUIRY NO. 320

for small radii up to 4xd.

Also available:

Oct/Nov 2011 | industrial automation asia 37

software & Networks

Manufacturing in Asia has entered a phase where more mobile devices have found their place in the production line. Saj Kumar, VP, Discrete Manufacturing, Industry Solution Group, SAP China shares his views. By Joson Ng

Age Of

The

Mobility IAA: The future of manufacturing in Asia seems to be moving towards mobility. Can you explain this shift?

Saj Kumar (SK): What I am seeing is a shift towards the use of mobile devices on the shop floor.

It can range from simple bar code scanners to more sophisticated devices like the tablet or the smart phone. Since the very nature of manufacturing is mobile, with people always moving around the shop floor having no access to their desktop computers, there is a good business case for people to implement mobile technology on the production level.

IAA: Tell us about Dashboards (visualisation tool) in production.

SK: In terms of mobile technology, various activities of people on the shop floor can be adapted to a particular mobile infrastructure.

When you go to any factor y you will see display broads and production charts. Some of them are simple blackboards and some are electronic display boards.

Instead of displaying information on those platforms, we can provide 38  industrial automation asia | Oct/Nov 2011

them on a tablet/smart phone format. For example, the president of operations in a company can have complete visibility looking at a dashboard right from his phone.

He can identify very conveniently which plants are operating below standards and likely to fall short of meeting KPI targets. A plant manager, can have plant and operator information, for instance, how many workers are on leave on a particular day.

IAA: With the influx of tablets and smart phones in the manufacturing environment, does it take away the human touch?

SK: It does to a certain extent.

It takes away the human touch to the extent where you do not need to speak to a person to get relevant information. That is one aspect that has to be taken into consideration before implementing this technology because manufacturing is all about teamwork.

If face-to-face interaction is taken out, the team dynamics is somewhat changed because there may be other subtle information

that can be extracted during verbal communications. So I think it is important to maintain daily meetings. For the rest of the time, information can be obtained off the tablet, without wasting time speaking to people for extracting information. This is extra pertinent for tracking operations after office hours. At the end of the day, it is about finding a good balance between maintaining the human touch and leveraging technological innovations for efficiency.

IAA: Is manufacturing in Asia ready for mobility?

SK: Mobile devices as a consumer product have already been embraced in Asia. With such high adoption rates, it is a matter of time before those devices find their way into manufacturing. I would say in a year, you would find this technology pervasive in manufacturing. After all, it has only been 18 months since tablets have been launched. For SAP, in the last one year, we have seen some 6,000 tablets deployed in our company.

IAA: Do you foresee any problems in implementation?

SK: The devices right now are still very fragile. Maybe you will see a ruggedised version being used on the shop floor in the future.

IAA: What are the advantages of having mobility in manufacturing? How can that be translated into dollars and cents?

SK: The number one concern in manufacturing is while moving to low cost countries in Asia, how do you balance cost against efficiency? In USA, you have higher efficiency but high cost.

However, over here (in Asia), you get lower efficiency and lower cost. While keeping the cost low,

SK: The problem with introducing any new device or technology from the IT perspective is security.

Moreover, these devices are not tested on a large scale. As such, there is this question of how do these devices scale up to an enterprise level where you can easily have more than a thousand people using it.

For security, the management will need to decide on the right employees to arm with mobile devices. They would also need to think about decommissioning procedures should someone lose the device.

IAA: Do see any flaws that come with the usage of mobile devices in manufacturing?

S K : Thir ty-eight years ago, we started off as a business applications company offering

IAA: ERP — how does it help manufacturing in Asia?

financial sales, distributions and procurement applications. We realised that while awareness of ERP was high in the management level, this was not the case on the shop floor level. We identified the gaps that existed.

ERP helps businesses to connect financial and manufacturing arms, regardless of geographic locations.

For example, an ERP would help to seamlessly connect manufacturing operations in India and China to HQ operations in Singapore. This direct link between manufacturing and finance, helps to foster greater efficiency and transparency in the system.

This trend is going to be more visible in the future especially with mergers and acquisitions.

ENQUIRY NO. 7401

ENQUIRY NO. 318

improvements must be made on efficiency. Having visibility into issues on the floor will help you achieve that. An example would be quality control. If there is a particular problem on a machine during a shift, technology can allow instantaneous feedback.

Another example can be illustrated in equipment utilisation.

Equipment up-time, especially in the semiconductor industry where expensive machines are often deployed, is crucial. The plant operator would want to make sure the maintenance is up to the mark.

This is where automation can help.

It tells you when you need to do preventive maintenance to help you keep the machine up.

Oct/Nov 2011 | industrial automation asia  39

software & Networks

PLM & ERP:

Their Respective Roles In

Modern Manufacturing T

he recent histor y of ma nufacturing I T ca n be viewed as two overlapping technological waves. The first came in the 1990s with the rise of Enterprise Resource Planning (ERP), as companies worked to increase the efficiency of their operations and better manage the supply chain.

Today, Product Lifecycle Management (PLM) is leading a new wave — one focused as much on accelerating innovation and supporting global collaboration a s it is on driv ing proce ss efficiencies to improve business performance.

How does one ensure that ERP and PLM deliver maximum value?

With the rising adoption and expanding reach of PLM in recent

40  industrial automation asia | Oct/Nov 2011

years, it has become increasingly important for manufacturers to understand the relative strengths of PLM and ERP in addressing critical business needs, and what added benefits PLM brings to the enterprise.

A Historical Perspective In the early 1990s, manufacturers began to see the value of having a single, enterprise-wide software suite that integrated all the major functional areas of the business, including manufacturing, logistics, distribution, inventory, shipping, human resources and accounting.

Vendors offering these suites, now known as ERP, promised better alignment of operations, improved planning and productivity, greater

efficiency, and better visibility and control. Large manufacturers were quick to adopt ERP solutions, such as SAP and later Oracle. According to The McK insey Qua r terly, companies invested US$300 billion in ERP solutions in the 1990s.

W h i l e co m p a n i e s we r e deploy ing E R P solutions to squeeze inefficiencies out of the ma nufacturing supply chain, an equally far-reaching opportunity was envisioned. As industries embraced CAD tools, manufacturers were generating vast amounts of complex design data, which they wanted available to their suppliers and global collaborators.

I n i t i a l l y, P r o d u c t D a t a Management (PDM) worked well to keep track of the product design

John Boyer, Jacksonville, Florida, United States

The integration of PLM & ERP will bring much value to the future of manufacturing, allowing companies to develop innovations as well as improve cost and quality. Contributed

by Melanie Zhou, Parametric Technology Software.

information. PLM then emerged in response to the need for better ma na gement of eng ineering processes and improved workflows in global, distributed supply chains via web-based applications.

The realisation that engineering d a t a co u l d b e re p u r p o s e d throughout the enterprise and beyond, to help optimise product designs, shorten time-to-market, a nd strea mline dow nstrea m processes, transformed how products were developed. These were formidable challenges.

However, by the dawn of the new millennium, this PLM vision began to be fulfilled.

Today, companies around the world use PLM to leverage the data generated in the product design and engineering process to accelerate innovation and improve productivity, not only within the engineering department, but also across all ancillary and downstream functions, from product analy tics to service documentation.

The Growing Scope Of PLM Having originated from different disciplines with different goals, and evolved at different speeds, ERP and PLM have, until recently, e x isted a s la rgely sepa rate entities. However, these formerly discrete realms are drawing closer together.

Today, ERP systems consistently rely on product information supplied by PLM, so much so that several ERP vendors have begun to incorporate PLM capabilities into their offerings. Their objective is to help customers understand the impact of product design decisions on other areas, such as sales forecasting and labour resource planning. Meanwhile, PLM vendors see their value to the enterprise growing beyond the engineering department, as PLM’s strengths in collaboration and accelerated innovation have

emerged as a strategic advantage for many manufacturers.

Challenges Facing Manufacturers Today To understand the proper roles and respective strengths of ERP and PLM, it is helpful to begin by looking at the critical challenges companies are trying to solve by using these solutions. These challenges include the need to: • Increase productivity • Improve asset utilisation • Develop higher quality products at lower cost • Increase the number and variety of products, without driving up costs and negatively affecting delivery schedules • Deliver products that meet customers’ demands • Coordinate the work of global, diverse, cross-functional development teams • Enable and accelerate innovation • Comply with corporate standards and procedures • Implement company initiatives across the enterprise • Ensure regulatory compliance • Support sustainability initiatives Both ERP and PLM can play key roles in addressing these challenges, but it is important to understand their respective strengths. That understanding begins with a look at ERP’s and PLM’s different origins.

The DNA Of ERP ERP was developed in response to the ‘islands of automation’ problem: compa nies had deployed a variety of stand-alone departmental software products that were not integrated.

This lack of integ ration caused inefficiencies in business

operations, particularly in the area of supply chain management, which depends on a smooth and reliable flow of materials data from one functional area to the next. Without this integration, organisations could not plan and schedule resources properly, leading to the over- and undersupply of parts and finished products, procurement d i f f i c u l t i e s , m a nu fa c t u r i n g scheduling issues, order fulfillment and distribution problems.

ERP’s primary source of value is its ability to link manufacturing and supply chain processes to reduce delay and increase efficiency. ERP solutions, which grew out of accounting software products, are primarily focused on physical assets and the flow of materials, and this is reflected in the attributes and requirements of ERP solutions.

E R P s o lu t io n s p e r fo r m particularly well when managing recurring transactions. Since ERP solutions are geared toward planning and accounting for production, they only require whatever information is necessary for production.

For example, if a tractor manufacturer purchases fully assembled engines for its tractors from an engine supplier, its ERP solution does not need to know all the details about the individual components that comprise the engine. For the ERP solution’s purposes, the engine is a single part. The ERP solution can perform its planning and accounting functions perfectly well without further detail.

T he se att r ibute s a nd requirements make ER P especially effective at executing manufacturing and distribution processes involving well-defined physical assets. However, as its common characteristics suggest, ERP is less effective than PLM at managing design changes and is unsuited to enterprise activities Oct/Nov 2011 | industrial automation asia 41

software & Networks

that involve less tangible, but more strategically vital, assets, such as the intellectual capital typically found in product data and the product’s Bill-Of-Materials (BOM).

Common attributes of ERP include: • Execution-focused • Repeated transactions • Inventory/order lifecycles • Controlled, well-defined business processes • Simple BOM hierarchy • BOM to procured part/ assembly level • Released versions • Central theme of control • Demand-focused • Rigid data model • Structured data • Hierarchical data relationships • Data mining • Text-based with some static 2D and 3D images The DNA Of PLM PLM arose in response to the growing needs of product design organisations, as they struggled to manage and share increasingly complex, interdependent CAD files among global teams involving both internal and external members.

They needed a power tool to keep the team collaborating effectively, and required capabilities beyond those of PDM to serve as a ‘data vault’ for product designs.

PLM enabled product engineers to work and rework products to optimise designs — and with the rise of the Internet, to collaborate on that goal globally, in real time.

As product development solution vendors created solutions to enable better collaboration on a global scale involving distributed supply chains, new needs were revealed.

Vendors realised that all the data generated in the process of developing products had to be captured, continuously updated, 42 industrial automation asia | Oct/Nov 2011

and made accessible to all team members in usable formats. Given the iterative nature of design, and the complexity of products incorporating many mechanical, electrical and software components, the product data vaults of these organisations had to be powerful and flexible enough to link multiple layers of data, as well as robust and dynamic enough to support frequent change.

In addition, as the nature of product development became truly global in response to lowcost outsourcing and emerging market opportunities, vendors had to accommodate demands for more product configurations, and be able to manage the multiple CAD systems used in increasingly complex product structures.

Through providing these capabilities to global engineering teams, solution vendors also became aware that the digital product data being captured throughout the design cycle was of tremendous value to upstream processes and to future design work.

Fur thermore, the PL M paradigm they were developing could act as both a platform and an engine to guide the entire product development process.

These solutions could also provide management with visibility into product development processes, for better decision-making earlier in the lifecycle. The ability to make changes early, while the products are in a digital state in the PLM system, results in savings, when compared to the cost of making changes once the product is released to manufacturing and in production.

Common attributes of PLM include: • Innovation-focused • Creation, design, iteration and revision • Dynamic change management • Visibility across the entire

product lifecycle • Disciplined, but flexible design processes • Complete BOM management (combined MCAD, ECAD, and software content in a single product structure) spanning as-designed BOM, as-planned BOM, as-serviced-BOM, as-built BOM • Full product structure to component or raw material level • Product and process iterations, revisions, and decision history • Central themes of speed and managed creativity • Focus on design/ requirements/configuration/ project/program • Flexible data structure • Documents, structured and unstructured information, metadata • Complex design relationships; dynamically related, networked data relationships • Knowledge search and retrieval; geometric search • Visual, 3D models, simulation, animation

What PLM Brings To ERP Customers Even for manufacturing companies that have deployed ERP successfully, many areas of product development are beyond the reach of ERP. ERP solutions must wait until product designs are finalised before information can be shared with downstream functions or suppliers.

PLM solutions, on the other ha nd , a l low m a na ge r s a nd

PLM/ERP Integration Going Forward Today, many manufacturers are integrating PLM and ERP to improve efficiency and quality.

While these organisations may be initially motivated by a desire to eliminate the inefficiency of re - entering data, along with t he hu ma n er ror t hat c a n accompany it, the benefits go well beyond that.

Organisations can also ensure that BOM data, captured by the PLM system, is made available to all functions that need it. As the PLM system can provide routing a nd ma nufacturing process plans as well, critical upstream and downstream processes are linked and made more efficient and productive.

For the vast majority of manufacturers, the question should not be ERP or PLM, but how to most effectively implement and integrate these two solutions.

Choosing the right ER P and PLM systems for the business is crucial, and manufacturers should not have to compromise on the benefits of either to fully realise IAA_June11_NTRON:Layout 1 copy

the value in both. The value begins when product development and execution processes are no longer implemented as islands, and the functions of PLM and ERP are deployed in a seamless, end-to-end solution.

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designers to design, test, update and refine every detail of the ultimate physical product while it still resides in its digital state.

This difference allows staff, not only in engineering, but also in related functions such a s ma nu fac t u r i n g, qua l it y, purchasing, and service, to work concurrently and address issues in their web browser before production even begins, resulting in both time and expense savings and a higher quality product.

In addition, PLM defines BOMs in a comprehensive way that ERP solutions cannot. This, in turn, has a positive effect on the efficiency of ERP and supply chain activities. It is important to note that companies can capture all of these benefits today — without the need to integrate their ERP and PLM solutions.

However, the potential benefits of ERP and PLM, in combination, can be expected to grow as ERP and PLM are integrated to enable the bi- directional sharing of information, and as PLM takes on more product-related processes over time.

Oct/Nov 2011 | industrial automation asia 43

instrumentation & Measurement

Choose

What important characteristics of the WirelessHART technology makes it so uniquely adapt for process applications?

By Jonas Berge, director of PlantWeb Consulting, Emerson Process Management

Wireless Wisely T

he re a re m a ny w i re le s s technologies available, but choose w isely, for while the right technology will bring you piece of mind, the wrong technology will take it from you.

The Only Standard I n du s t r i a l w i r e l e s s s e n s o r networks have existed for more than 10 years. However, the first generation of wireless sensors were impractical because every manufacturer had a different proprietary protocol. Products from different suppliers did not work together. Multiple gateways and configuration software would be required to use different kinds of sensors.

This mirrors the early days of ‘smart’ protocols for 4 -20 m A transmitters: ever y DCS manufacturer used a different protocol and only supported their own devices, locking the plant in.

Multiple handheld terminals were required.

In the end, the HART protocol prevailed, and thanks to 4 -20 mA/HART, most DCS can now communicate w ith a ny 4 -20 mA device, and only a single field communicator is required.

WirelessHART is doing the same for wireless.

WirelessH A RT security measures include encryption,

44 industrial automation asia | Oct/Nov 2011

authentication, verification, key rotation, and sequence number etc, but if not enabled it would be useless. For this reason, WirelessHART security cannot be turned off, ensuring these security measures are constantly active.

Meeting Process Users’ Needs WirelessHART was developed to meet the requirements of process industr y users. In the early phase of development the HART Communication Foundation (HCF) collected wireless requirements from end-users in the process industries. Users dema nded coexistence, reliability, long battery life, security, and multivendor interoperability — all that plants need to solve process problems — and end-users are experts on their process.

However, end-users are not necessarily experts on RF design or communication protocol stacks, so HCF member companies sent their experts on RF and digital communication to design the WirelessHART technology to meet these process requirements.

Verified By End Users The NA MUR organisation of chemica l compa nie s ha s a requirement specification for wireless known as NE 124.

A field trial was organised by NAMUR at the BASF plant in Ludwigshafen, Germany in 2009.

The trial included gateways and devices from A BB, Emerson, E n d r e s s + H a u s e r, M A C Te k , Pepperl+Fuchs, and Siemens. The trial proved that WirelessHART meets process user requirements.

By now, WirelessHART has been put into operation in more than 2,100 plants.

What About A Wireless Plant Network?

WirelessHART is a wireless level one

WirelessHART is able to coexist with these technologies.

HART Communication Foundation T h e H A R T C o m mu n i c a t i o n Foundation (HCF) is a not-forprofit organisation with more than 200 member companies including instrumentation manufacturers

a nd users, which prov ide worldwide vendor neutral technical and application support for HART technolog y, new technolog y developments, education, marketing, and interoperability compliance testing.

The Battery One misconception is that some

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Devices in each plant area join the network for the associated DCS controller

network for sensors and actuators that complements the existing level two industrial protocols that may use Wi-Fi (wireless Ethernet) such as Modbus/TCP, EtherNet/ IP, Foundation fieldbus HSE, and PROFINET etc. as well as level 3 and four standard protocols for web browsing, email, file transfer, voice, and video etc.

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Optimised For Process Applications Because WirelessHART requirements were collected from end-users only in the process industries, not from factory automation, building automation, or power grid, the WirelessHART protocol is optimised for process application, not a compromise with the diverse needs of other industries. An advantage of this application optimisation is that a multitude of communication options need not be set at commissioning. This prevents errors a nd reduce s delays.

W i re le s sH A R T i s de sig ne d specifica lly for process applications.

Oct/Nov 2011 | industrial automation asia  45 335 Belden.indd 22

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instrumentation & Measurement

wireless protocols use standard D-cell batteries. However, although the size is the same, no wireless devices use regular carbon-zinc or alkaline batteries. All wireless transmitters use Lithium Thionyl Chloride batteries, which have very high power, long life, and wide temperature range but cannot be found in regular stores.

They must be purchased from a specialty supplier or through wireless device suppliers. If users replace individual cells, special care should be taken to replace with proper, new cells to prevent potential safety issues.

Technology Ready For Control When You Are WirelessHART transmitters are predominantly used for process monitoring and asset monitoring.

However, the technology is ready for control when you are.

WirelessHART is time synchronised and scheduled with a precisely periodic macrocycle (called superframe), and makes use of publisher/subscriber (called burst mode and catch) communication similar to Foundation fieldbus. The result is deterministic communication.

Most WirelessHART products available today support a foursecond-update period with onesecond-update periods available in 2011 from many suppliers.

Master-slave communication is used for remote configuration and diagnostics just like 4-20 mA/ HART. WirelessHART is purely digital communication; there is no analogue.

Redundant WirelessHART gateways ensure high availability.

WirelessHART discrete output and on/off valve couplers are also becoming available this year, enabling wireless actuation.

Full Mesh Topology Although opinions of wireless experts differ on many points, all 46  industrial automation asia | Oct/Nov 2011

WirelessHART full mesh topology requires only one (optionally redundant) gateway [G] to network devices [D]

agree on at least one point: that self-organising mesh-topology is the most robust.

Mesh-topology is more robust because devices establish multiple paths among themselves, routing messages at device level, in a ‘mesh’. If one of the paths is disrupted, the network automatically switches to another path, thus maintaining a reliable connection.

T h a t i s , re d u n d a n t d a t a pathways eliminate single points of failure. Actual installations consistently demonstrate greater than 99 percent data reliability.

Mesh topology is therefore best practice. Star topology is typically not used although supported by the technology.

WirelessHART uses a unique full mesh-topology as many as seven hops deep, providing an important advantage: WirelessHART does not need a costly infrastructure of multiple backbone routers to be installed throughout the plant within range of every wireless device. Running costly hazardous area power supply to backbone routers is therefore also not required. Mesh topology is truly wireless and low risk.

The self-organising network optimises itself for greatest reliability and minimal power consumption. The ability to self-

Star topology requires multiple backbone routers [BR] with wired power to network devices [D]

organise is critical in a plant environment with intermittent sources of noise and temporary obstr uctions. With sources of noise ranging from motors and pumps starting and stopping to walkie-talkies, the RFI environment is constantly changing, but a self-organising network can easily adapt and maintain high data reliability. It also makes adding and removing devices very easy, as manual configuration is not required.

Going The Distance Another misconception is that one protocol using IEEE 802.15.4 radio is longer range than another protocol also using IEEE 802.15.4 radio. This is not the case. The protocol has no impact on distance. All protocols using IEEE 802.15.4 have the same limitations. Range is determined by three factors: 1 Transmission power 2 Antenna gain 3 Receiver sensitivity Transmission power and antenna gain are limited by national regulations, the only range difference is in radio chip sensitivity.

The same IEEE 802.15.4 chip can be used for WirelessHART or any other protocol and they will

Deploying Wireless After thousands of installations in industries around the world, users have found that choosing their wireless network can be simple with a few rules of thumb.

Chose a wireless technology that is an international standard supported by your preferred transmitter suppliers and has all the device types required for your current and future applications. Narrow it down to a single protocol which ensures ease of deployment and longterm device maintenance, and which makes use of your existing commissioning tools and requires less training.

Make sure to use a self-

organising mesh topology for maximum robustness and ease of management. One common protocol customised for process automation users eliminates the need for superfluous configuration. Last but not least, security that cannot be turned off greatly reduces cyber security risks. Many sites have said that

the question is not ‘if’ they will use wireless, it is merely a question of ‘when’. By choosing your wireless network wisely, the investment will be repaid not only on the first application, but also for every additional application that is added to the same network in the future.

ENQUIRY NO. 7501

ENQUIRY NO. 325

achieve the same distance so there is no range difference between protocols. An unobstructed range of several hundred metres is possible with raised antennas.

However, this is line-of-sight (ie: no obstruction) as in an open field — which you may find in a flat desert oil field.

However, inside a plant full of metal pipes and vessels as well as structural steel, there might be line-of-sight only above the pipe racks because there is less obstruction at that height.

However, down among all the steel, the range is far shorter, as little as 30 m. Line-of-sight range of hundreds of metres becomes irrelevant. Once down among the steel, the extent of coverage is a matter of how well the wireless technology can get around all these steel obstacles.

Mesh topology, with its ability to ‘hop’ from device to device, circumventing obstacles, has proven successful. Moreover, using mesh topology, overall distance is increased by automatically relaying messages from one device to the next.

Many hops means longer total distance.

Oct/Nov 2011 | industrial automation asia 47

energy

Coming

To Grips With

Helping manufacturers address ‘green’ manufacturing with vacuum technology. By Josef Karbassi, VP marketing and communication, Piab

O

ne of the biggest shifts in the manufacturing industry in recent years is the growing focus on sustainability. What started as a concern amongst a relatively small group has gathered force to become a key mainstream issue.

However, a rise of cynicism around ‘green washing’ within the consumer and business worlds alike means companies can no longer get away with claiming sustainable credentials for token efforts in only one area of their business. Instead, environmental considerations have spre ad from a focus on consumer-facing products to encompass all aspects of a manufacturer’s operations,

48 industrial automation asia | Oct/Nov 2011

requiring them to implement a robust, long-term strategy across their entire supply chain.

In addition to vital environmental benefits, companies have also realised that sustainability initiatives can have a positive impact on their bottom line by ident if y ing a re a s where energ y costs and waste can be reduced. The result is that more and more manufacturers are starting to see sustainability as a crucial business driver, and are taking a strategic approach to improving the environmental profile of their operations by developing and implementing their own sustainability policies.

Manufacturers will be scrutinising

Highland_s, Japan

Sustainability the practices of their suppliers, and looking to them to provide solutions that reduce waste and achieve energy reductions on their lines.

As the demand for ‘green’ suppliers is increasing, suppliers need to make strategic changes w i t h i n t h e i r o r g a n i s a ti o n s to align their product development processes with the sustainability goals of their clients. To do this, factors such as CO2 output from transportation, compliance with standards and energy used in production are important factors to consider.

Vacuum technology is one area in the production process that manufacturers can focus on to make a meaningful difference to the environment. Below we explore three key considerations for manufacturers as they strive for supply chain sustainability.

Efficiency In Production A reduction in energ y usage and CO 2 emissions can help ma nufacturers achieve both sustainability and economic goals, so it is no wonder that these form the core of most sustainability programs.

Va c u u m t e c h n o l o g y i s continua lly adva ncing. With new energy-efficient pumps and ejectors/generators constantly being introduced to the market, manufacturers are presented with various ways to reduce energy

use. Ejector technologies that utilise the energy as efficiently as possible can help maximise efficiency.

Another technological advance wh ich i s i mprov i n g e nerg y efficiency in the use of vacuum technology is the incorporation of lighter materials into machinery.

Exchanging metal for high-tech plastics in the construction of machines and robots, for example, means they can be reduced in size, and require less energy to operate.

Although it is relatively small, the suction cup itself can also pack a big punch in terms of energy savings. Suppliers seeking energyefficient options should opt for cups that offer the highest levels of performance. Enhanced sealing capability, even on non-smooth surfaces, means less flow capacity

is needed from the system to get a strong grip on handled objects.

Suction cups built to more easily collapse and return allow smaller pumps to be used to complete the task, contributing to additional energ y savings. High- quality cups also provide greater lifting power compared to conventional alternatives, meaning fewer cups are required and less energy is used.

In addition to new technologies, energ y sav ing units present another useful tool for further optimising energy consumption in a vacuum system. These optimisers allow the use of atmospheric air instead of compressed air to release a handled object. They also ensure the vacuum pump is only running when needed and switch it off when the required vacuum level for the application

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ENQUIRY NO. 330

C O M M U N I C AT I O N F O U N D AT I O N

Oct/Nov 2011 | industrial automation asia 49

energy

Ultimately, successful manufacturers will be those that recognise and embrace the move toward sustainability... is reached. Energy waste can also be reduced by installing units that monitor pumps to ensure they run at optimal pressure.

Ma nu fac tu rers a lso have choices when it comes to the set up and design of their vacuum s y s te m . W he re ce nt ra l i s e d vacuu m te chnolog y cre ate s considerable pipe losses and transporting vacuum requires a lot of energy, manufacturers can choose to install a decentralised system as an energy efficient alternative. Less transporting of vacuum is needed, lowering loss of vacuum through the pipe.

Adding to this, smaller pumps and ejectors can be used with a decentralised system, requiring less energy consumption and producing significant savings.

Manufacturers can also consider the use of cartridge integration systems, which allow integration closer to the point of use and further reduce flow losses.

Energy

In s t a llin g a d e c e ntr a li s e d system provides an energy efficient alternative for manufacturers as less transporting of vacuum is needed, lowering loss of vacuum through the pipe. Adding to this, smaller pumps and ejectors can be used, requiring less energy consumption and producing significant savings.

Distance from point of suction

Another way manufacturers can improve the sustainability of their operations is by partnering w ith suppliers that prov ide 50 industrial automation asia | Oct/Nov 2011

e ne r g y au d it s. A t horo u g h assessment of existing vacuum systems as well as advice on possible improvement s w ill allow manufacturers to gain a competitive advantage in what is an increasingly green business environment. vonGAL , an Alabamab a s e d co m p a n y p r o d u c i n g high-performance palletising solutions, recently experienced the energy savings that vacuum technology can provide when they successfully delivered a 34 percent reduction in energy consumption to a customer.

The customer requested a robot ic pa llet ising solut ion that was capable of handling recycled cases of various sizes and weights with a single end-ofarm tool, while adhering to strict compressed air consumption and energy usage guidelines.

The company’s answer to this challenge was the installation of Piab’s VGS (Vacuum Gripper System) 3010, which features a decentra lised de sig n that generates vacuum directly at the point of suction. The system is equipped with a Pi12-3 Coax cartridge allowing it to be run at very low pressure, and Duraflex suction cups that lower energy consu mpt ion by prevent ing micro-leakage and allow the use of a smaller vacuum cartridge.

The system’s flexible design eliminates the need for multiple end- effectors when handling cases of different shapes and sizes, making changeover quick and easy, reducing downtime and allowing the customer to costeffectively produce shorter runs of products to match consumers’ buying habits. A combination of

increased efficiency and energy savings of more than a third compared to the previous system highlights why it is extremely beneficial for suppliers to be aware of the latest technological advances.

Why Waste?

The disposal of waste is a key issue worldwide, and reducing the amount dumped into landfills is becoming more and more important. When it comes to selecting the consumables used in the manufacturing process, it is crucial for manufacturers to consider not only the product’s efficiency but also the impact it has on the environment once it is disposed of at the end of its lifecycle. The most thorough approach to waste reduction is for manufacturers to partner with suppliers that offer a combination of long-life, recyclability, and modular design formats.

T he abilit y to rec ycle equipment a nd pa r ts ca n play a large role in reducing production scrap. Therefore, there is a growing demand for suppliers to provide products that a re ma nufactured from recyclable materials. Suction cups made from ThermoPlastic Elastomers ( TPE) can be 100 percent recyclable, depending on the material qualities chosen.

Even the scrap created in the production of the cups can be re-used, reducing waste from further up the supply chain.

Longev ity should also

The ability to recycle equipment and parts can play a large role in reducing production scrap. Suction cups made from TPE are 100 percent recyclable, helping manufacturers to reduce waste and achieve their sustainability goals.

Leading By Example A s ma nufacturers continue to focus on sustainability, the demand for ‘green’ suppliers is increasing. Suppliers need to focus internally on their inhouse operations and consider their ow n env ironmenta l credentials. They need to make strategic changes within their organisations to align their product development processes with the sustainability goals of their clients.

To do this, factors such as CO2 output from transportation and compliance with standards, namely the ISO 14001 certification for environmental management, will become more significant. The energy of component production should a lso be considered.

The materials used play a big role here a s the a mount of energy required to produce the same components in different materials can vary enormously.

For example, suction cups made of TPE require much less energy to be produced than traditional rubber versions, and have lower manufacturing costs. Add to that a better product consistency and greater flexibility of design, and TPE cups become the clear choice from environmental, economic

and quality standpoints.

U l t i m a t e l y, s u c c e s s f u l manufacturers will be those that recognise and embrace the move toward sustainability and who carefully select suppliers that are able to provide solutions that address key manufacturing challenges such as reducing energ y u sa ge in inter na l

proce sse s a nd minimising waste. Partnering with ‘greener’ suppliers that offer sustainability support on both levels and are also sustainable themselves can help manufacturers achieve their environmental goals.

ENQUIRY NO. 7601

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ENQUIRY NO. 323

be a major consideration for manufacturers. Reducing the frequency by which a piece of equipment or part needs to be replaced ultimately creates less waste.

Suctions cups that offer a modular design also provide a ke y to o l fo r a dd re s si n g sustainability as they allow partial component replacement.

Industr y leaders in vacuum technology are designing suction cups that allow the replacement of just the lip, which tends to suffer wear and tear more quickly, rather than the entire cup, further reducing waste.

Oct/Nov 2011 | industrial automation asia 51

energy

One For The Future

52 industrial automation asia | Oct/Nov 2011

efficiencies. This has led to innovative solutions that will hopefully, improve energy efficiency and reduce the sector’s carbon footprint.

Carbon Capture One industrial solution to mitigate the harmful effects of fossil fuel emissions is Carbon Capture and Storage (CCS). Given its huge potential, the IPCC predicts that

Naotake Murayama, Tokyo, Japan

T

he world’s dependence on energy is growing, as global population and incomes rise. The International Energy Agency (IEA) predicts that energy consumption is set to increase by fifty percent by 2030 and could triple by 2050. In particular, the demand for gas has risen rapidly, doubling between 1980 and 2004.

Given that much of the energy we require comes from coal and other fossil fuels, it is rather obvious that this increasing thirst for energy will result in an increase in the amount of greenhouse gases in the earth’s atmosphere. In the power generation sector, fossil fuels are burnt to produce electricity, which is then used to power homes and industries. The burning of these fossil fuels produces carbon dioxide and other greenhouse gases.

The Intergovernmental Panel on Climate Change (IPCC), in a report released in 2007, warned that unless major changes with regards to the release of greenhouse gases are made, the world would face a warming of the climate system. It therefore comes as no surprise that the power generation and oil and gas sector have been pressured to improve their process

Michael Cote, Texas, USA

Automation solutions in the power generation and oil and gas sector will ensure that the industry continues to be sustainable, in the face of an uncertain ecological future. By Shahnawaz Abdul Hamid

Power plants are eager to reduce their carbon footprint.

of a flask, where they rise. Carbon dioxide binds with amine, a chemical, while hydrogen continues to rise up and out of the flask.

And Storage…

Once the carbon dioxide has been captured, it then has to be transported to a storage site. Currently, the industry transports the carbon dioxide via a pipeline, usually located several metres beneath the ground.

The third stage of CCS involves injecting the carbon dioxide into underground rock formations such as basalt, where pressure is high enough to cause the carbon dioxide to behave more like a liquid, instead of a gas.

However, several issues threaten to limit the potential of CCS. One, the technology consumes a fair amount of energy, reducing many of the efficiency gains power plants have made in the past few decades.

Secondly, storage technology has not been certified completely safe. Leakages can occur, although their probabilities are small. Third, like all other issues concerning sustainability, the question of cost is an important one, and can eventually lead to consumers having to pay more for their electricity.

ENQUIRY NO. 329

CCS could form between 10 and 55 percent of the total carbon mitigation effort until the year 2100.

The first stage of CCS involves trapping and separating carbon from its point source, usually a coal or natural gas-fired power plant. In the field of industrial automation, there are two main ways in which this may be achieved: post-combustion and pre-combustion.

In post-combustion capture, the carbon dioxide is contained after combustion has taken place. The burning of coal or natural gas produces flue gases, which include carbon dioxide, water, sulfur dioxides and nitrogen oxides. During the process, carbon dioxide is separated from these flue gases, by adding a ‘filter’, such as an absorbent scrubber, helping trap the carbon dioxide, which is then compressed before storage.

Pre-combustion capture traps carbon dioxide before the fossil fuel is burned, preventing it from being diluted by other flue gases. The fossil fuel is heated in pure oxygen, resulting in a mix of carbon monoxide and hydrogen. This mix is then fed into a catalytic converter together with steam, which results in the production of more hydrogen, and carbon dioxide. These gases are channeled into the bottom

Oct/Nov 2011 | industrial automation asia 53

Idaho National Laboratory

Cogeneration & Trigeneration Another method employed by the power generation sector is to use cogeneration and trigeneration power plants, where using captured waste heat in a manner that is useful increases the overall efficiency of the plant. The waste heat can be used to produce steam, which is then piped around the building to provide heating, or used together with absorption chillers to cool.

Power plants do not convert all the heat that is burned into electricity. Often, more than half of the heat is lost. By using cogeneration and trigeneration power plants the overall efficiency of the plant can be improved, reducing the total amount of fossil fuels consumed. This practice is seen as more sustainable in the long run.

Cogeneration and trigeneration plants allow for a future of distributed generation, where electricity no longer needs to be transported over long distances, reducing the amount of energy lost in transmission.

More importantly, distributed generation allows a microanalysis of electricity use, allowing for a more targeted dose of energy generation. To put it simply, it is more difficult to predict the electrical consumption of an entire country, as compared to that of a campus or facility.

Distributed generation systems may utilise other industrial automation elements such as fuel cells, wind turbines and solar panels to run effectively. Needless to say, the technology is sill in its infancy, and will require much research before it can be extensively adopted.

Studying rock formations such as basalt will open up more avenues for the storage of carbon dioxide.

Meeting Energy Demand The issue of sustainability is not simply an issue of reducing the carbon footprint of a process. It also involves meeting the energy demands of the world’s growing population, while keeping prices of electricity and fuel from rising too quickly.

In this regard, the oil and gas companies have explored various technologies, all of which appear 54  industrial automation asia | Oct/Nov 2011

Dave Conner, Scotland

energy

Extracting oil and gas efficiently will be crucial to sustainability efforts.

to ensure that fossil fuels can shoulder the burden of providing electricity and fuel until the market entrance of renewable technologies such as wind and solar.

To this end, extracting oil and gas efficiently and maximising production of fields is vital. Current sensor technology, equipped with fibre-optic cables, relay information on temperature, pressure and other field conditions to control centres. This allows engineers to respond quickly to problems associated with oil flow, such as blockages.

Effective extraction also involves using injection methods to squeeze out barrels of oil left in fields after production. Three common injection methods are steam injection, gas injection and chemical injection.

Injecting steam, miscible gas and chemicals such as polymers and surfactants result in the oil flowing more easily, increasing recovery capacity. However, these methods may require expensive injection wells, which are deep-reaching vertical pipes built into the ground.

Piecing It Together As the practice of sustainability becomes ever more pervasive, various industries, not just in power generation and oil and gas, will realise the significance of making the necessary changes to their daily operation processes. Apart from improving the industry’s image, sustainability also ensures the survival of various companies, as they attempt to remain nimble to changes in the business environment.

Ultimately, no one company or industry can help delay the effects of climate change. However, with the help of all responsible parties, such as corporations, academics, governments and active citizens, there is no reason why the issues facing our planet cannot be dealt with in a logical and systematic manner through the vehicle of sustainability.

ENQUIRY NO. 7602

ENQUIRY NO. 339

sector spotlight

Water, covering more than 70 percent of the Earth’s surface, is the sine qua non of life. However, with increasing population and urbanisation worldwide, meeting humanity’s water needs without harming the environment has become a more serious issue than ever. By Augustine Quek

The State Of The

Jeremiah Castro, Spokane, WA, United States

Water

Industry T

he world population increased fourfold over the 20th century, but the amount of freshwater it used increased nine times over. As of 2010, more than 1.2 billion people lack access to clean water, yet as 80 percent of all disease is borne by dirty water.

According to the Organisation for Economic Co-operation and Development (OECD), by 2030, the number of people living under severe water stress is expected to rise to 3.9 billion. The World Health Organisation (WTO) also estimates that one third of the world’s population lack water to meet their daily needs.

By 2050, nine billion people will be sharing the planet’s resources; feeding them — and growing crops for biofuels — will spur even greater demands from agriculture, which already takes up 70 percent

56 industrial automation asia | Oct/Nov 2011

of available fresh water. The latter is also waning due to a warming world; if sea levels rise as scientists predict, coastal regions’ aquifers will be affected. The trend towards urbanisation further exacerbates the problem.

It is clear that both developing and developed countries will require huge investment capital to meet the basic water needs of their populations. Providing access to drinking water and sewerage, conserving resources and building reservoirs and dykes to cope with water stress and water excess would cost rich countries alone around US$200 billion per year, according to estimates.

The global water market, including wastewater treatment, desalination plant construction and water recycling, is estimated to be worth around US$316 billion,

according to a 2008 estimate by Morgan Stanley. Surprisingly, the private sector currently operates only a small amount of the global water supply, serving about five percent of the world population.

But their revenues are growing exponentially.

According to a World Bank report, only seven percent of all developing country water projects with private sector participation were cancelled or distressed between 1990 and 2004.

For those that failed, privatisation advocates say, it was likely due to government corruption or incompetence, resulting in private companies as scapegoats for in their legacy of mismanagement. Corrupt or not, governments cannot substantially increase water provision unless they are assisted by the private

sector. According to Helmut Kaiser Consultancy, the world market for water and waste water is estimated at US$412.4 billion in 2010.

Against this backdrop of a competitive market, private water companies are offering c o m p re h e n s i v e w a t e r a n d wastewater treatment solutions of increasing sophistication.

Of these, advanced control is getting increasingly demanded in water and wastewater treatment systems.

The Technology The key elements that form the foundation of automating water and wastewater applications are a Supervisory Control And Data Acquisition (SCADA) software and control centres, Ethernet, fieldbus and radio networking, OLE for Process Control (OPC) software, flow controllers, process indicators, signal conditioners Proface OK (chin).pdf 7/18/11

and text and/or graphics-based Human Machine Interface (HMI) stations.

SCADA systems allow support for platforms such as Linux, UNIX, VMS as well as Microsoft Windows to collect and record data real-time from literally millions of points in the process.

The system also allows sending signals to these points of control.

Networking solutions include the popular fieldbus/PLC and Ethernet communications, over copper and fiber optic connections, and Multiple Address System (MAS) networks and Spread Spectrum radios.

OPC software provides an open, flexible, plug-and-play software standard for software interoperability, for example, between MS-Windows applications and industry standards like DNP 3.0, IEC 60870-5 and Modbus communications protocols. Flow controllers include standalone 4:09:11 PM

devices that can measure and/or control and communicate, as well as embedded flow measurement I/O modules that turn a PLC into a highly accurate flow computer.

Panel and field mounted devices provide local indication of key process variables, while local HMI functions at locations remote from the main SCADA control centres.

The Companies Many companies, especially the big names with sizable waterservices divisions such as Siemens, General Electric, Rockwell, Schneider Electric, have complete automation solutions for water and wastewater treatment.

Schneider Electric has Plant S t r u x u re a n d E c o S t r u x u re integrated systems architectures that manage water and wastewater plants more efficiently and productively. One special feature is the Schneider-Electric Quantum redundant Hot STBY PLC, which

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sector spotlight

Technology that coverts water into usable energy to power cities in a sustainable manner is an important industry for developed and developing countries alike.

functions as the central plant process control that works with intelligent field device management FDT/DTM, PROFIBUS DP V1, and integrating PROFIBUS device level to its PLC. It can support more than 100 device types and more than 10,000 I/Os. Another feature is the Unity Application Generator (UAG) which includes a smart water object library that is process oriented. This tool offers a complete view and tracing of the water installation and is designed to optimise cost structures, from training, qualification, to implementation.

Rockwell’s PlantPax Process Automation System is an enterprisewide integration technology that combines advanced systemwide capabilities of Integrated Architecture, intelligent motor control devices, and process automation control systems. The PlantPax solution integrates all the process operations controls and motor controls into one system, and can be made accessible from any number of Remote Terminal Units (RTU) scattered throughout the water/wastewater plant.

It offers real-time visibility into monitoring water quality, trending 58 industrial automation asia | Oct/Nov 2011

of loads, levels and clarity, and detailed alarming, data collection and automated reporting. Each RTU also has its own HMI screen and is integrated with the other processes and the plant office via a high speed, dual fiber optic network. Wireless transmitting allows remote operation, data visibility, monitoring and control of any process from any location in the plant. The main work station can run on RSView 32, an integrated, component-based HMI with touch-screen operation using Allen-Bradley VersaView 1700P integrated display computers.

Allen-Bradley Smart Motor Controllers with IntelliCENTER provide soft start and stop of the continuous-run motors, and provide integrated intelligence that connects to the rest of the PlantPAx process automation system. The Allen-Bradley PowerFlex 700 variable frequency AC drives also have integrated intelligence for additional monitoring. The advanced motor control performance helps gather process information at the drive level and automatically disperse it to any part of the plant through the Integrated Architecture.

Siemens’ Totally Integrated Automation (TIA) and Totally Integrated Power (TIP) provides a complete and coordinated product portfolio for the entire energy distribution and automation technology — from the field level to the control level, from the small electric motor to the medium voltage feed. It includes the SIMATIC PCS 7 or SIMATIC Windows Control Centre (WinCC).

The SIMATIC PCS 7 handles the complete automation of all processes in the water industry, including integration of telecontrol technology, and ACRON — for reporting in accordance with ATV-DVWK-M 260. The system can be scaled flexibly from a small individual system with approximately 150 device list to more than 60,000 device list.

SIMATIC WINCC provides all functions for operation and monitoring and can be expanded at any time by sector-specific options — for example for telecontrol technology or for the specific archiving and reporting functions associated with the water industry.

Controllers include the faulttolerant SIMATIC S7-400H controller, for hardware redundancy (hot standby) for uninterruptable processes such as frequently required with desalination plants or important pumping stations. Other products include the SIRIUS soft starter 3RW44, for soft-starting and ramping down applications such as high-performance compressors commonly found in the water industry, SIVACON S8 switchboard and busbar trunking system LR for power conveyance in corrosive wastewater atmospheres.

Of particular relevance is the free water library that provides engineering support for the SIMATIC PCS 7 process control system. It contains more than 100 tested water-specific function blocks including sector-specific

faceplates. Together with the powerful and intuitive SIMATIC configuration tools, the water library accelerates engineering and minimises the commissioning overhead. Since it also executes on SIMATIC S7-300 PLCs and SIMATIC WinCC, it is also suitable for use in smaller plants with SCADA systems and for complete integration of package units in SIMATIC PCS 7.

The water treatment, supply and distribution industry also exerts high demands on the energy required. Automation technology integrated in water and wastewater treatment plants, pump stations and desalination plants can help to improve energy efficiency and economics in the plant’s daily operation.

In Conclusion Automation technology now

allows many processes in the water and wastewater plant to be continuously variable, such as feed rates for water, chemicals, p re s s u re , a n d e v e n t a rg e t setpoints. The use of variable speed drives with frequency controllers, for example, is more energy efficient, because large pumps are often the most energy demanding equipment in the plant. The ability to continuously vary the flow rate, and thus the energy required, through variable speed compressors saves energy significantly.

Despite a widespread failure of the water industry to provide clean water to everyone across the planet, private water companies’ profit margins remains impressive.

This is due to the expensive, state-of-the-art technologies that companies employ to optimise the

process of water and wastewater treatment to the highest standards.

To deal with the demands of an ever more crowded, urbanised planet, governments must work more effectively with the private sector to ensure that the outsourcing of public services like water is a seamless process that produces an affordable product.

This will require substantial funding not just to replace aging infrastructure, but also investments in future water supply. Not only are improvements in supplied water quantities and quality required, but also the optimisation of these water processes to use less energy and resources. Automation technology has so far been the best answer to these problems.

ENQUIRY NO. 7701

Products and solutions, innovations and trends Experience at Europes #1 platform for electric automation…

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ENQUIRY NO. 314

• • • • • • • • •

Oct/Nov 2011 | industrial automation asia 59

features

PLM

Industrial Automation Asia speaks to Steve Nevey, relationship manager, Red Bull Racing to find out PLM’s role in the world of Formula One racing.

In Red Bull Racing

How are PLM software programs deployed at Red Bull Racing to make the cars go faster (indirectly)?

In your opinion, how does PLM translates design and engineering ideas into parts that are crucial for racing applications?

We are using CAD, CAM, CAE and ERP systems at Red Bull Racing. We refer to the PLM system as our ‘Digital Backbone’, through which many people access the data they need and are, therefore, able to make smart and rapid decisions. The ‘seamless’ integration between CAD, CAM, CAE and ERP using PLM means that engineering and design data is available to all who need to see it, immediately and in a controlled way.

In the fast-paced world of F1, how important is PLM in the designing and manufacturing process?

PLM is essential to racing success, as it is in many other high-pressure industries. The ability to get a design improvement through R&D, manufacturing and then onto the car, means that we get the performance immediately, rather than having to wait until after one or two races. Also, the electronic workflow and easy-touse visualisation tools mean that design approvals are not held up by busy work and travel schedules. Senior design and engineering colleagues can see exactly what is going on and can make appropriate choices about which aspects of the car we should focus upon to maximise our competitive advantage.

How important is PLM in the current economic climate?

PLM supports effective collaboration and rapid decision making. This is vital, not only for us, but for innovators in other, more commercial, industry sectors. The current economic climate requires agility and smart decision making as the marketplace shifts and changes. Presenting all stakeholders with appropriate and accurate data enables flexibility and 60 industrial automation asia | Oct/Nov 2011

minimises guesswork. A well-defined PLM system delivers this.

What is the typical lead-time for a part in F1?

How can PLM help shorten that lead-time?

This is a difficult one. When we are developing and ‘building’ the first car for the start of the season, we have many components going through the system at the same time. It can take several weeks to make some parts from start to finish. However, when we need a part for the next race, it can take, literally, hours. We are good at being flexible. We can switch from one project to another rapidly. This is one of the reasons why we try to keep as much of the process in house as we can. PLM helps, because it gives everyone who is involved in the process, visibility of the project, its status and its objectives.

In your opinion, do you think PLM software, while understood by vendors, has yet to be fulfilled by users?

Again, this is a difficult question to answer definitively.

Some ‘users’ have very clearly defined processes that are limited only by their ability to communicate and collaborate comprehensively. PLM enables a significant improvement in this facet of a business. The popular misconception is that PLM is a ‘golden bullet’ that can be installed on your network and solve all of your lead-time and time-to-market problems. PLM is, of course, a concept. If the concept is understood in the context of your business and is aimed at solving your problems and enhancing your existing processes, it is immensely powerful. That is where the vendors — and especially Siemens PLM — come into their own.

Not only do they understand their own suit of tools and how they integrate with each other, they have a wealth of knowledge and experience from deploying PLM in a wide variety of industry sectors. They will

quickly understand your environment, will identify your bottlenecks and process deficiencies, and will work with you to develop your processes to maximise the implementation of, not only their own numerous products, but those of third party vendors.

If you had to name one element of the design process that brought you to the championships, what would that be?

Please share with our readers the difference between the production floor at Red Bull Racing and a regular metal jobshop?

For one, it is not just metal. We are increasingly producing more detailed and accurate components in composites. This, of course, means that we have to include colleagues with a wide diversity of skills and expertise. Collaboration is essential. Yes, there is a strong R&D and developmental element to what we do, but it is not guesswork. We are drawing together a wealth of knowledge and expertise from all corners of our organisation.

Specifically, how did the inclusion of PLM software help in getting the Red Bull Racing team the championship?

PLM opened up fast, reliable and easy-to-use channels of communication and data sharing that enables

SUNTEC SINGAPORE

22 - 25 November 2011

immediate and smart decisions to be made. Speed of appropriate development is key to our success, as it is with many businesses; and that results from good decisions being made throughout the organisation.

The people. PLM enabled us to get the best out of them quickly.

What kind of improvements would serve to keep the Red Bull Racing team at the top of their game?

Obviously, a continual improvement in the cars physical characteristics around aerodynamics, structures and vehicle dynamics make it more efficient and effective on track. That is served best by accurate and reliable simulations. The trick is to understand those simulations in context with each other. This means accurate data sharing across the company and then smart decision making, to choose which of the available improvements provide you with the best holistic result.

ENQUIRY NO. 7801

Featuring OFFSHORE AUTOMATION

PROCESS SOLUTIONS FOR ENERGY AND PLANTS www.cia-asia.com Organiser :

Singapore Exhibition Services Pte Ltd The 13th International Scientific & Analytical Technology & Equipment Exhibition and Conference

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Held H ld in i :

ENQUIRY NO. 326

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Oct/Nov 2011 | industrial automation asia  61

features

Bosch Rexroth Case Study:

New Metrology For New Strategy

A shift in production strategy can be facilitated by precise metrological equipment. By Birgit Albrecht, marketing manager, Hexagon Metrology

O

ver in a factory in Nuremberg, the mobile hydraulics division of Bosch Rexroth manufactures external gear pumps and motors.

The company’s products achieve their degree of efficiency through their pressure-sensitive gap sealing and precision production technology. “With such a level of process reliability, we can ensure that the gap dimensions comply with the specified tolerances,” says Felix Zacharias, quality management external gear machines.

The individual components — gears, housings and bearing bushes — are subjected to tight tolerances. For example, the tolerance for some features on gear wheels is as small as 2 microns.

62 industrial automation asia | Oct/Nov 2011

Only if the components match one another at the detailed level can the assembled unit perform to its maximum.

Production operators use special gear inspection machines, optical metrology and in-line measuring machines to ensure that everything matches down to the finest detail.

A climate-control measuring room provides even more accuracy for special cases. Each shift selects and inspects the specified number of components from the production floor. The company inspects bearing bush and pump housing characteristics such as flatness, parallelism or cylindricity with a Dea Global Image 7.7.7 3D CMM. On top of this, the inspection

technicians in the measuring room perform special inspections for new production runs or machine capability analyses.

Intensive Metrology For intensive gear inspection, the company uses a Leitz Reference HP 5.4.3 CMM, which was recently received.

“With the Leitz Reference, we are meeting the challenges presented by modern gear manufacturing.

The CMM is suitable for high tolerance features on gears (eg: for scanning measurements of the form and position of bearing pins in gear assemblies or for scanning faces of gears to check flatness).

The machine also has the benefit of being universally applicable. We can use the same machine equally well to measure the form and position of bearing bushes, housings and gears,” says Mr Zacharias.

From Job Shop To Modular Production On the production floor, Bosch Rexroth is switching in gradual stages from job shop production to modular production. The external gear pumps and motors are now to be manufactured completely in a module using efficient methods.

Measuring master parts will take the place of testing random production samples.

The master part is measured by a measuring machine in the module and in the measuring room. The results from the manufacturing module and the measuring room are then compared with one another. If the values remain within the specified tolerance band, the company can be sure that its quality requirements are being met. This shift in production philosophy was met with a boost with the addition of Leitz Reference HP 5.4.3 as it achieved a volumetric accuracy of MPEE = 0.8 + L/400 μm.

ENQUIRY NO. 7802

Metalworking From Your Cell Phone

T

he influx of smartphones today has altered the way people think and work. For better or worse, this disruptive technology has penetrated many aspects of our lives and even in metalworking too. Picture this: an engineer on the shop floor can determine cutting paramewters for a required operation without having to head back to his office.

He can now also work out the complex calculations while on the go, saving valuable time.

With connectivity and mobility an increasingly prized asset in production, it is hardly surprising that the cutting tools makers like Iscar, Seco Tools, Sandvik Coromant and Walter among others have apps available to help machinists in their work wherever they are.

What Can They Do? In the Walter version, users can, with their iPhone, determine cutting parameters for tools for the required operation and also place their orders online. It can compare the cost efficiency of two tool solutions, order tools and access online content from the company.

The app can be used to calculate the parameters for face, shoulder and slot milling processes; hole

making, including both drilling and boring; and turning (ISO turning and grooving).

For these operations, the user can calculate the torque, driving power and machining volume, main cutting time, cutting force and also chip thickness. The calculator also takes the material group, rake angle, machine efficiency and wear factor into consideration.

The Machining Calculator App

by Sandvik Coromant features a help button that provides additional information on the calculation being executed and the input needed to generate results.

The app also contains a process cost comparison that determines how tool optimisation can provide cost and time savings.

Like their counterparts, Seco Tools and Iscar have come out with the Seco Tools Assistant and Iscar Tool Advisor respectively.

The Seco Tools Assistant is an application that covers the basic calculations that is needed on a daily basis in a machine shop.

It is able to calculate operations in milling, turning and drilling.

The company has stated more functions will be added over time.

Iscar Tool Advisor provides cutting tool recommendations and cutting data on iPhone or iPod Touch.

Ian Lamont

The machining apps in smartphones allow it to make the transition from a communication device to a tool in the machine shop, adding mobility to machining. By Michael E Neumann

By entering a few machining parameters, it will calculate the preferred cutting tools for a job.

Other Apps & New Media In a world where QR codes are slowly becoming more prominent, where the number of ‘likes’ on a facebook page is the unofficial marketing KPI, new media cannot be ignored even in engineering fields which in the past, the relation between the two can be classified as distant at best.

This gap however has come down considerably in the past few years, prompting more companies to embrace new media. Like many of its counterparts, Kennametal has ventured into the world of social media. With its Interactive C at a log A pp, t he comp a ny recognises the role social media plays when it comes to accessing industrial resources.

Available on the iPad platform, users can download the company’s product catalogs, review products and specifications among other functions. The company has also reached out to its users on facebook, LinkedIn and Twitter in order to engage them on a brand new level.

ENQUIRY NO. 7803

Oct/Nov 2011 | industrial automation asia 63

EVENT PREVIEW

Exhibitions

For A

Growing Asia Asia is fast emerging as a global powerhouse in the research & development front, given the sheer market growth and the size of its talent and resource base. While North America remains dominant in terms of g ross dome stic expenditure on R& D (GER D) with 37 percent share, Asia is fast catching up as the second largest investor in R&D with 32 percent share, overtaking Europe.

In Singapore, at the Suntec I nter nat iona l Convent ion & E x hibition Cent re, CI A 2011, A n a L a bA sia 2 011 and EnviroAsia2011 exhibitions will be held concurrently over four days from 22-25, November 2011.

AnaLabAsia2011 Businesses in the analy tical technology, laboratory technology, biotechnology and diagnostics i n du s t r y c a n n ow l o o k to AnaLabAsia2011 as the region’s timely platform to meet new customers and partners, seek latest industry knowledge, and source for business opportunities.

64 industrial automation asia | Oct/Nov 2011

EnviroAsia2011 EnviroAsia2011 gathers leading environmental technology and solution providers from across the globe to address the urgent dema nd for governments and industries to alleviate the undesirable outcomes of relentless urban growth in Asian cities.

CIA2011 In view of the vast potential in the offshore industry, Controls Instrumentation and Automation 2011 (CIA2011), Asia’s leading process engineering, controls instrumentation and scientific equipment exhibition, will present a new offshore automation feature this year, where visitors will see the latest process control and instrumentation solutions for offshore oil and gas.

Strong Presence Of International Industry Players With much of the economic growth concentrated in Asia, leading market leaders will seek to gain a

larger foothold in the continent by participating in the shows. Visitors can expect to see international players like Daihan Scientific, DK SH, EMCLab, Esco Micro, Finetek, Hellma-Asia, Intermass Fischer, IT Technologies, ITS, Johnson Scientific, Magnetrol, S e at Ventilation, Teplocom, United Scientific and Yoshimura at AnaLabAsia2011 and CIA2011.

The Singapore pavilion headed

by The Singapore Manufacturers’ Federation (SMa) since 2003, and the German pavilion led by Baden-Württemberg since 2005 will represent a strong line-up of exhibitors at AnaLabAsia2011.

Following the success in the previous edition of EnviroAsia, The Waste Management & Recycling Association of Singapore (WMRAS) will again bring to the show The Singapore Waste Technolog y Pavilion, and is expected to be boosted by even more exhibitors this year.

Conferences will focus on operations sustainability, process automation and plant safety.

November 22-25, 2011 Suntec Singapore Singapore

ENQUIRY NO. 7901

9th annual 9th annual

22 Co-located with:with: Co-located 17th annual 17th annual

25 25 – 27 April 2012 – 27 April 2012 Suntec Singapore International Convention & Exhibition Centre Suntec Singapore International Convention & Exhibition Centre

Beyond tracking Beyond tracking 5

5

6th annual 6th annual

THE regional exhibition and conference inin THE regional exhibition and conference Asia for the RFID industry Asia for the RFID industry

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It’sIt’s AllAll About Track Record About Track Record

RFIDRFID World Asia Asia has has beenbeen providing an excellent avenue for industry players overover the last 8 8 World providing an excellent avenue for industry players the last yearsyears to learn, network, discuss and do business with one another.

The high-level exhibition and to learn, network, discuss and do business with one another. The high-level exhibition and conference has evolved to betothe attend event for the conference has evolved be must the must attend event for industry! the industry!

Targeted Audience

Targeted Audience 2 2 The conference is attended by your key buyer profiprofi les such as Aviation, Healthcare, Manufacturing, The conference is attended by your key buyer les such as Aviation, Healthcare, Manufacturing, Travel & Hospitality and more!

TheyThey attend RFIDRFID World Asia Asia to learn and share knowledge for the Travel & Hospitality and more! attend World to learn and share knowledge for the growth of the therethere is noisbetter platform to share youryour solutions withwith them! growth of technology; the technology; no better platform to share solutions them!

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Industry andand Thought Leadership Establish Industry Thought Leadership 3 3 Establish Like Like the jewel in theincrown, the event presents a valuable platform for solution providers to articulate the jewel the crown, the event presents a valuable platform for solution providers to articulate industry leadership in RFID. It’s not sales-pitches; it’s about industry leadership!

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To encourage the interaction on the floorfland provide moremore exposure for your products, To encourage the interaction onexhibition the exhibition oor to and to provide exposure for your products, the In-Action Application Zones are for exhibitors to showcase and demonstrate their solutions the In-Action Application Zones are for exhibitors to showcase and demonstrate their solutions and offerings. and offerings.

Generation Campaign Lead Generation Campaign 5 5 Lead Identify your your wishlist of prospects fromfrom the region, and let for you.

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ENQUIRY NO. 324

invitee selection fromfrom our pre-registration database and let the on-site 1-to-1 meetings invitee selection our pre-registration database andusletarrange us arrange the on-site 1-to-1 meetings for you! for you!

EVENT PREVIEW

SPS / IPC / DRIVES 2011 This year’s SPS/IPC/DRIVES, the trade fair for electric automation held in Nuremberg, Germany, will be held from November 22-24, 2011. For the first time it will cover 12 exhibition halls and more than 100,000 sqm of exhibition space.

Almost 1,400 exhibitors from home and abroad are expected to attend the event.

Many International Exhibitors And Visitors Expected To Participate Companies from almost 40 countries will be exhibiting at the event, representing an increase of 20 percent. With 76 companies registered so far, Italy is the foreign country providing the most exhibitors, followed by Switzerland (36), China (35) and Austria (27).

Following 2010’s record total visitor number, more than 50,000 visitors are likely to attend again this year. About 20 percent of the visitors are expected to come 66 industrial automation asia | Oct/Nov 2011

from abroad and the proportion of international trade visitors continues to increase.

With 10,000 sqm of exhibition space, hall three which is in use for the first time will accommodate the companies in the ‘Drive and control technology’ sector. Hall eight where ‘Control technology’ is to be found will also cover the new topic “Human-machine-interface devices. The opening hours on Tuesday and Wednesday from 9am to 7pm and on Thursday from 9am until 5pm will offer visitors an opportunity to explore the sector thoroughly.

Extensive Range Of Extra Activities The three joint stands ‘wireless in automation’, ‘AMA Center for sensor, measuring and testing technologies’ as well as ‘open source meets industry’ will provide visitors with a targeted overview of each of the three topics. The exhibition forums led by the

associations VDMA and ZVEI will offer high quality presentations and panel discussions on the leading issues of the day.

User Sessions Included For The First Time Four user sessions have been included in the conference program for the first time this year.

These will give users the chance to show how certain applications can be achieved innovatively and successfully. The sessions will encourage intensive dialogue between conference visitors and users, and promise interesting field reports. The complete event conference program comprises 69 seminars on topics of electric automation technology, one trend session and three tutorials.

November 22-24, 2011 Exhibition Centre Nuremberg, Germany ENQUIRY NO. 7902

ENQUIRY NO. 305

products & Services

Adcole:

Fluke:

A low-cost LED micrometer for the model 1200 cranshank gauge that validates parts that have been rolled to the proper depth and stress-relieved is available from Adcole Corp.

The LED sensor provides +/- 3 um accuracy, +/- 1 um repeatability, and 0.25 um resolution. Capable of measuring fillet undercut depth at a 35 deg roll angle, journal straightness, and radial distance or journal shoulder to journal, this gauge creates chart reports depicting problem areas.

The gauge features a menu-driven sequence builder utility for developing measurements sequences for new crankshafts and camshafts.

Fluke Corp has developed the 750 Series documenting process calibrators. These field tools calibrate temperature, pressure, voltage, current, resistance, and frequency and have three operating modes — measure, source, or simultaneous measure/source — enabling technicians to troubleshoot, calibrate or maintain instrumentation with just one tool.

The equipment features an easy-to-follow, menu-driven display that guides users through tasks.

Programmable calibration routines enable technicians to create and run automated as-found/as-left procedures to ensure fast, consistent calibrations. The recorded results can then be downloaded to a PC via the USB port, eliminating the need for manual transcription.

Crankshaft Gauge

Perform Field Calibration Operations Faster

Enquiry no. 7903

Enquiry no. 7905

Cognex:

GE Intelligent Platforms:

Cognex Corporation has introduced its next generation wafer identification (ID) reader and accompanying software, the InSight 1740 series and In-Sight Explorer Wafer ID software version 4.5.0. Included are features designed to improve both read rates and reliability, while making it easier to configure and maintain the reader on a wide range of wafer handling and process tools.

Combined, these features help ensure maximum tool uptime, uninterrupted by the need for human intervention in the wafer ID step.

With more processing power, In-Sight 1740 series wafer readers reduce the typical reading time by 40 percent. The faster processing speed also helps In-Sight 1740 series readers to take advantage of new automatic, self-optimisation features.

GE Intelligent Plat forms has announced the Wolverine III Rugged Flat Panel Computer designed specifically to withstand the rigors of deployment in harsh, hazardous (Hazloc) applications.

The Wolverine III’s resistive 15-inch antiglare, scratch-resistant touchscreen is readable even in direct sunlight.

Its rugged design enables it to operate within a temperature range of -20 to +60 deg C as standard and to withstand extreme shock and vibration. Its low weight of 22.5lbs make Wolverine III easier to install and safer and more convenient to transport.

Designed to be upgradable with future generations of processor, the Wolverine III is housed in a NEMA 4 environmentally sealed enclosure with corrosion resistance. An optional heater allows an operational temperature range of -40 to +60 deg C.

Wafer Indentification Reader

Rugged Flat Panel Computer

Enquiry no. 7904 68 industrial automation asia | Oct/Nov 2011

Enquiry no. 7906

products & Services

Juniper Networks:

Marechal Electric:

Ethernet Switch

Electric Decontactor Sockets

The EX3300 line of Ethernet Switches features Virtual Chassis technology to deliver a flexible, cost-effective enterprise access solution for demanding environments that support converged data, voice, and video. Virtual Chassis technology enables up to six interconnected EX3300 switches to operate as a single, logical device, providing enterprises with a level of flexibility and management simplicity normally associated with higher-end access switches.

Multiple EX3300 options are available, offering 24 and 48 10/100/1000-T access ports and four dual mode (GbE/10GbE) SFP/SFP+ uplink ports, with or without support for standardsbased IEEE 802.3af Class 3 Power Over Ethernet (PoE).

Marechal Electric has developed electric decontactor sockets, an alternative socket design to reduce the problems associated with disconnecting plugged equipment. Normal sockets have plug contacts which are susceptible to cold welding due to infrequent use, making the removal of plugs difficult and at times, impossible.

These decontactor sockets come with springloaded butt type contacts that allow automatic ejection to parked position for removal or reinsertion. Equipment can also be disconnected on load and visibly isolated, improving safety. The contacts found on the socket also offer self-cleaning nickel tips, maintaining low contact resistance and a short circuit rating of 10kA.

Enquiry no. 7907

Enquiry no. 7909

Land Instruments:

Mitsubishi Electric:

Land Instruments International has announced efficiency and accuracy improvements to its Cyclops portable infrared thermometers for non-contact industrial temperature measurement in the 200 to 3,000 deg C range.

All models now include Bluetooth connectivity as a standard feature.

This eliminates the need for cable connection to a recording device, making them easier and safer to use.

Two new models, 160B+ and 100B+, have the stability to resolve temperatures in 0.1 deg C increments, improving capabilities as transfer standard instruments in calibration laboratories. Any model can be supplied with full calibration certification, traceable to national standards, from Land Instruments’ accredited laboratory.

The Melsec-L series Direct Digital Controller (DDC) from Mitsubishi Electric is designed for controlling building automation systems.

The DDC comes with a built-in CPU positioning control function that has a start time of 30 microseconds and a maximum output speed of 200,000 pulses per second.

Each unit is equipped with 24 built-in I/O points and has a program capacity of 260,000 steps, along with a basic operation processing speed of 9.5 nanoseconds. Data can be logged and saved onto a SD memory card for operators to perform a detailed operational analysis and problem identification.

Error status is indicated on the built-in display, allowing troubleshooting to be conducted directly without the need for connection to a separate PC.

Infrared Thermometers

Enquiry no. 7908

Direct Digital Controller

Enquiry no. 7910 Oct/Nov 2011 | industrial automation asia  69

products & Services

Omron:

Programmable Logic Controller Series & Related Software

Machine Automation Controller NJ-Series NJ501-

Automation Software Sysmac Studio SYSMAC- SE2

Omron has announced the release of a programmable logic controller series, the Sysmac NJ Series, and its accompanying software, the Sysmac Studio. The release comes as part of the company’s collaboration with Intel and is in line with its 10-year strategy, ‘Value Generation 2020’.

Designed by integrating the Intel’s high-speed MPU and Atom processor with Omron’s range of factory automation know-how, the high-speed controllers allow a seamless connection of a variety of I/O devices such as servo drivers and vision sensors, capable of high-performance motion control.

Renishaw:

Wireless Product With Volumetric Testing Capability

Renishaw has developed a successor to its QC10 ballbar system; a tool for the assessment of machine tool positioning and servo control performance.

The QC20-W ballbar features a linear sensor and Bluetooth wireless technology. This design offers benefits in ease of use and enhanced durability and allows the system to be used for testing even in ‘closed door’ manufacturing, where access for wiring can raise safety and procedural issues.

The design also allows testing in three orthogonal planes through a single reference point. A single, simple hardware set up means quicker testing and the ability to produce a representative volumetric measurement of positioning accuracy.

Enquiry no. 7911

Enquiry no. 7913

Open Mind:

Thermo Fisher Scientific:

Open Mind Technologies is offering a 64-bit version of its CAM solution hyperMill for integration into the Autodesk Inventor and SolidWorks CAD platforms. This enables the latest workstations to be used with 64-bit processor architecture from the design phase right through to CNC manufacturing.

In the past, large detailed components proved a challenge for CAD and CAM systems, with calculations pushing the capacities of the computer hardware to its limits. The introduction of 64-bit architecture allows more than 4 GB of RAM to be targeted directly.

This CAM solution takes full advantage of the option to use extended memory and more efficient multi-core processors resulting in models to be calculated at a significantly faster rate.

Thermo Fisher Scientific has announced a software module to enable high-precision and automated analysis of precious metals and high concentration elements. The Thermo Scientific iTEVA Precision software integrates with the Thermo Scientific iCAP 6000 Series of inductively coupled plasma optical emission spectrometers (ICP-OES) to deliver analytical results with high precision. Designed specifically for the metallurgy industry, the module enhances the Thermo Scientific iTEVA software solution and delivers a simple and efficient workflow for high-precision analysis with real-time data processing using the bracketing standards approach.

Faster Calculations With A 64-Bit Processor

Enquiry no. 7912 70 industrial automation asia | Oct/Nov 2011

Precision

Enquiry no. 7914

Calendar Of Events 2011/12 october

13 – 15 3P Malaysia International Industrial Machinery Expo Danga City Hall Expo Hall Johor, Malaysia Fireworks Event Email: my@asiafireworks.com Web: www.3pexpo.com

18 – 21 SCM Logistics World

Marina Bay Sands Convention Centre Singapore Terrapinn Email: enquiry.sg@terrapinn.com Web: http://www.terrapinn.com/2011/ scm-logistics-world/index.stm

31 – 4 Nov Singapore International Energy Week Suntec Singapore Singapore Reed Exhibitions Email: ask@reedexpo.com.sg Web: http://www.reedexpo.com.sg

07 – 09 Semicon Japan 2011

Makuhari Messe – Chiba Japan Japan Semi North America Email: jshowsinfo@semi.org Web: http://www.semiconjapan.org/en/

JANUARY

SUNTEC Singapore Singapore Reed Exhibitions Email: asg@reedexpo.com.sg Web: www.asiasmartgrid.com.sg

22 – 24 SPS/IPC/DRIVES 2011

Exhibition Centre Nuremberg Germany Mesago Messe Management Email: sps@mesago.com Web: http://www.mesago.de/en/SPS/The_ conference/Welcome/index.htm

22 – 25 CIA

Suntec Singapore Singapore Singapore Exhibition Services Email: cia@sesallworld.com Web: http://www.cia-asia.com

06 – 09 Engineering Expo Indore 2012

Poddar Plaza, Near Gandhi Hall, M G Road, New Siyaganj, Indore 452007. Madhya Pradesh India Infomedia 18 Ltd Email: engexpo@infomedia18.in Website: http://www.engg-expo.com/

18 – 20 ICP - IC Packaging Technology Expo 2012

Tokyo International Exhibition Center (Tokyo Big Sight) Japan Reed Exhibitions Japan Ltd Email: inw@reedexpo.co.jp Web: http://www.icp-expo.jp/en/Home/

DECember 07 – 08 Bioenergy International Asia Expo

FEBRUARY 08 – 11 Enertech World Expo 2012

Bombay Exhibition Centre - NSE Exhibition Complex India Chemtech Foundation Email: conferences@jasubhai.com Web: http://www.chemtech-online.com/enertech/

09 – 10 Intermodal Asia 2012

Intercontinental Melbourne The Rialto Australia Transport Events Management Email: enquiries@transportevents.com Web: http://www.transportevents.com/

14 – 17 CIAACE 2012

Kuala Lumpur Convention Centre Malaysia Pennwell Conference and Exhibitions Email: Headquarters@PennWell.com Web: http://www.offshoreasiaevent.com/

march

november 02 – 04 Asia Smart Grid

21 – 23 Offshore Asia

China International Exhibition Centre (CIEC) China Yasn International Exhibition Co., Ltd. Email: info@yasn.com.cn Web: http://www.ciaacexpo.com/

07 – 09 SIAF Guangzhou 2012

China import and export fair complex sps@china.messefrankfurt.com http://www.siaf-china.com/

14 – 16 Asia Pacific Maritime Marina Bay Sands apm@reedexpo.com.sg http://www.apmaritime.com/

27 – 29 Asia Water 2012

Kuala Lumpur Convention Centre (KLCC) airin@ambexpo.com http://www.asiawater.merebo.com/English/english.html

28 – 31 Inatronics 2012

JIExpo Kemayoran info@gem-indonesia.net http://www.inatronics-exhibition.net/

april 3 – 6 Automation World 2012

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

23 – 27 Hannover Messe 2012

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

25 – 27 RFID World Asia 2012

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

Kuala Lumpur Convention Centre Malaysia Horse Shoe Media Ltd Email: rebecca@horseshoemedia.com Web: http://www.biofuelsinternationalexpo. com/asia/ To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Editor IAA Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building, #02-05, Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 • Email: iaa@epl.com.sg

Advertising Index

64

|

IndustrialAutomationAsia

ADVERTISING I N D E X

ADVERTISER

PAGE NO

ENQ NO

ABB PTE LTD

IFC

138

AGILENT TECHNOLOGIES SINGAPORE

39

318

AUTOTRONIC ENTERPRISE CO. LTD

47

325

BECKHOFF AUTOMATION PTE LTD

IBC

317

BELDEN SINGAPORE PTE LTD

45

335

CARLO GAVAZZI AUTOMATION SINGAPORE PTE LTD

31

333

FIREWORKS EVENT M SDN BHD

67

305

EXXON MOBIL

21

322

FLIR SYSTEMS CO. LTD

53

329

FLUKE SOUTHEAST ASIA PTE LTD

49

330

FUJI ELECTRIC ASIA PACIFIC PTE LTD

7

312

GE INTELLIGENT PLATFORMS CO., LTD

25

331

HITACHI ASIA LTD

37

266

HOLLYSYS (ASIA PACIFIC) PTE LTD

29

321

HONEYWELL PTE LTD IFM IDENTICOM

3

296

OBC/23

338/337

IGUS SINGAPORE PTE LTD

33/37

319/320

JJ LAPP CABLE (S) PTE LTD

57

328

MESAGO MESSEMANAGEMENT GMBH

59

314

MESSE FRANKFURT (HK) LTD

55

339

MITSUBISHI ELECTRIC ASIA PTE LTD

35

334

N-TRON CORPORATION

43

270

NATIONAL INSTRUMENTS

15

250

PRECICON D&C PTE LTD

5

332

ROCKWELL AUTOMATION SOUTHEAST ASIA PTE LTD

1

327

SICK OPTIC-ELECTRONICS PTE LTD

17

316

SCHNEIDER ELECTRIC IT SINGAPORE PTE LTD

27

336

SCHNEIDER ELECTRIC SEA HQ PTE LTD

57

283

SINGAPORE EXHIBITION SERVICES PTE LTD

61

326

TERRAPINN PTE LTD

65

324

YASKAWA ELECTRIC (SINGAPORE) PTE LTD

51

323

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

MEDIA REPRESENTATIVES JAPAN:

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

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| FB11-07E |

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ENQUIRY NO. 317

German Quality ”Made in Asia“.

ifm is one of the leading manufactors in the automation industry worldwide.

More than 3,500 employees in over 70 countries are a competent partner for about 96,000 customers. Since 1976 ifm has been successful in Asia with 20 sales offices and exclusive trade partners thanks to extraordinary reliability, German engineering and quality. ifm will be even closer to you as of October 2011 when the first Asian production site opens in Singapore. ifm electronic – close to you!

ifm electronic – close to you! www.ifm.com

ENQUIRY NO. 338