IAA Oct Nov 2012 by Eastern Trade Media

October/November 2012 IndustrialAutomationAsia

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Oct/Nov 2012

MICA (P) 010/07/2012 | ISSN 0219/5615 | PPS 1561/06/2013 (022960)

Medical Insight | HMI & Operator Interfaces | Safety Instrumentation | Wind Energy

A SENSE FOR

SAFETY Automating A Sense Of Quality

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Elevating Safety By Diverse Redundancy CAM: Better Performance

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contents Oct/Nov 2012

ISSUES & INSIGHTS

Machine Vision: Making A Quality Statement

The successful manufacturing of medical instruments and devices often depends on precise processes and the enforcement of high-level quality controls. Machine vision plays a vital role by ensuring accuracy, repeatability and efficiency in these operations. By Didier Lacroix, Cognex

Process CONTROL

HTML5: Towards A More Open HMI

Elevate Safety Integrity To New Heights

Since the advent of the internet, the non-initiated who try to understand a new technology are often faced, not with too little information, but with too much. HTML5 is no exception. By Andy Gryc, and Marc Lapierre QNX

System redundancy extends the capabilities of automation control systems, and in the case of safety-related applications or Safety Instrumented Systems (SIS) it is diverse redundancy technology that drives and delivers increased safety integrity. Contributed by Vineet Kumar Gupta, ABB

SOFTWARE & NETWORKS

CAM: A Clear Path To Better Performance

Using CAD As An Optimising Tool

Over the past few years, promotional material for new versions of CAM software has been full of claims about the ability to support the latest hardware development, such as parallel processing and multithreading. This article will explain why these developments are important and the benefits that they can give to the user. By Peter Dickin, Delcam

CAD has evolved from its traditional design role to a sustainability driver in production. By VR Srivatsan, Autodesk

Instrumentation & Measurement

Arc Flash And Electrical Safety

Personal Safety By Object Detection

This article is a guide to electrical safety in the workplace, and gives an overview of the NFPA 70E standard, with possible solutions given to common electrical safety concerns. By Marty Kronz, Panduit

Object detection is an effective method for combating safety issues by implementing vision sensor technology to arrive at a solution for improving industrial automation processes. By Wolfram Tanner, Sick 2â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

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ENERGY

SECTOR SPOTLIGHT

A Smooth Path To Efficiency

IAA spoke with Yan Côté, global business development advisor, Mobil Industrial Lubricants on the company's presence in the Asia Pacific region and their involvement in the wind energy sector. By Mark Johnston

Smaller Scale, Bigger Potential

IAA speaks with Russell Tham, president, Applied Materials (Southeast Asia), and David Wilhoit, president and CEO, Siltronic Samsung, on the major industry trends they are facing, and the challenges, in the semiconductor industry. By Mark Johnston

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Medical Manufacturing Asia 2012

Workplace Safety & Health Conference 2012

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Building CostEffective Wind Turbine Generators A wind turbine manufacturer's path for growth and expansion in new markets is not without obstacles. Today's challenges include establishing and managing many variables. By Dave Schaetz and Steve Ludwig, Rockwell Automation

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The Wise Choice Automating a factory has many advantages and innumerable cost savings related to efficiency and cost of operation. However, another big advantage to an automation strategy is safety. The main consideration is that automation machineries are not prone to the errors that are associated with maintenance and monitoring by humans. One of the main reasons why manufacturers put off automation and do not automate at all, is because of initial cost, however, there are signs that this culture is changing. Renewed efforts by governments and official bodies and organisations to inform manufacturers that rather than hesitating to invest on initial expenditure, in the middle to long-term, the company will save money. Investing in automation is not only a cost saver, and considering safety will improve, but the quality of the products the company produces will also increase. In a competitive market, a manufacturer must look beyond the near term expense and consider factors, such as quality and safety to be important contributors to long term growth and success. Although, when considering the cost of manual labour and efficiency savings by adopting an automation strategy, the initial cost may not be as significant as you may think. Referring to the automotive industry, improving quality and safety is an important step in protecting employees from hazardous fumes from paint and chemicals associated with automotive manufacture. Adopting robots also results in a more consistent paint job, as compared to the human alternative. Saving cost, improving quality, increasing speed, and performance are all key driving factors which should spur the manufacturer to greater heights and compete to improve employee satisfaction, and increase consumer demand for your products. In this issue of IAA, we have articles on safety, increasing performance, improving cost, and efficiency. All are key factors for any manufacturer to consider. Our topics span Medical Devices, HMI & Operator Interfaces, CAD & CAM, Safety Instrumentation, Wind Energy, and Semiconductor Fabrication. We also have show reviews for Medical Manufacturing Asia, Workplace Safety & Health Conference 2012, and the National Energy Efficiency Conference 2012. As always, enjoy reading, and we welcome your feedback.

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Kenneth Tan EDITOR

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Didier Lacroix, Andy Gryc, Marc Lapierre, Vineet Kumar Gupta, Peter Dickin, VR Srivatsan, Marty Kronz, Wolfram Tanner, Dave Schaetz, Steve Ludwig EDITORIAL CONSULTANTS

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Industry News Dassault Systèmes Set Up Joint R&D Centre S i n g a p o re : Dassault Systèmes has created a joint R&D centre for hydropower engineering digitalisation with Hydrochina Chengdu Engineering Corp (Hydrochina Chengdu), a company in hydropower engineering design and consulting for hydroelectricity in China, and Simu Tech (SimuTech). The joint centre is committed to providing hydropower industry solution experiences based on the company‘s 3DExperience platform, to streamline construction processes, enhance hydropower engineering industry design capabilities, and help harmonise dams

with nature and life, minimising the impact on both of them. Through this strategic collaboration, it aims to deliver hydropower industry solution experiences, providing competitive edge content and services to spur technological innovation and digitalisation. The solution will enhance the efficiency of design, simulation and management of hydropower projects of various sizes, while reducing errors, maintaining tight budget control, project schedules and safety. Hydrochina Chengdu HQ

Singapore Power Builds S$2 Billion Next-Generation Power Infrastructure Singapore: Singapore power have announced a S$2 billion (US$1.63 billion) Transmission Cable Tunnel Project to ensure that households and businesses in Singapore continue to enjoy reliable, secure and quality power supply to meet future demand. Two cross-island cable tunnels will be constructed 60 m underground to provide a long-term solution to the on-going upgrading and renewal of the power cable grid infrastructure in Singapore. The deep tunnels are designed to overcome the existing congestion of underground space and utility services in Singapore. They will facilitate faster and more efficient maintenance and replacement of cables, thereby reducing the frequency of road-digging works and as such minimising inconvenience to the public in the long run. The company will award six contracts to five construction companies for its largest undertaking to date. From the end of 2012 to 2018, they will build the North-South and East-West tunnels, measuring a total of 35 km in length, to house extra-high voltage electricity transmission cables. The tunnels will be located under major public roads and will not encroach into any private properties. Along

8 industrial automation asia | Oct/Nov 2012

Two cross-island cable tunnels will be constructed 60 m underground to provide a solution to the ongoing upgrading and renewal of the power cable grid infrastructure in Singapore.

with the tunnels, there will be 14 utility buildings built to house ventilation facilities and equipment, and provide access to the tunnels. During the construction phase, the company will work closely with government agencies and community partners to minimise inconveniences to the public. These include steps to control noise, minimise dust, dirt and congestion, and to maintain environmental safety.

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Industry News

Tetra Pak Invests In Singapore Singapore: Tetra Pak has completed a round of investments at its Singapore site to accommodate growth. The latest investment of €42 million (US$54.24 million) includes plant machinery installation and upgrades to increase production capacity, as well as the construction of a lobby and conference facilities. “The role that the Singapore site has played and its significance to our operations are among the reasons that we are able to grow in this region,” says Rusty Kekuewa, the company’s VP of South and Southeast Asia. The plant located in Jurong is the company’s largest packaging material factory in terms of production volume, accounting for about 10 percent of total global production volume. The factory ships mainly to customers in South and Southeast Asia (SSEA). “Demand for food processing and packaging solutions in this region has been on the rise, and is forecasted to increase in the next decade. We firmly believe that Singapore will continue to play a very important role in enabling us to capture that growth,” Mr Kekuewa adds. In SSEA, the company has forecasted the demand for such packages to increase with a 10.4 percent CAGR from

2011 to 2015. The additional equipment installation and upgrades in the factory will boost production capacity by 25 percent from 15 billion to 20 billion packs per year. “This site in Singapore is much more than a factory. It is also home to critical functions supporting the company in the region and globally. These units have been growing in size and capability, resulting in Singapore being increasingly important to the Tetra Pak group,” Mr Kekuewa says. At the same time, more is being done with the opening of the company’s

Coconut Knowledge Centre — one of two such knowledge centres in the world. The other is the Soya Knowledge Centre, which is also located in Singapore. Both are staffed by a core team of specialists, engineers and food technologists. The centre’s focus is to respond to customer requests for technology and innovation support; build knowledge in the characteristics of coconut water throughout its life cycle; develop new flavours in combination with coconut water; and establish a strong international network of coconut experts for knowledge sharing.

Schneider Electric Wins Best Practices Awards Singapore: Schneider Electric took home the ‘UPS Vendor of the Year’ and the 2012 ‘Service Provider of the Year’ awards for Southeast Asia at the Frost & Sullivan Annual Best Practices Awards banquet. Based on performance and excellence, the ‘UPS Vendor of the Year’ award is presented to a standout organisation that has demonstrated the highest level of achievement in its respective market, while the ‘Service Provider of the Year’ award acknowledges an organisation’s leadership in service support infrastructure and customer value. Judging criteria involves measuring market penetration, leadership in customer value, growth strategy and implementation, in addition to product and service innovation.

10 industrial automation asia | Oct/Nov 2012

Philippe Arsonneau, senior VP for Schneider Electric’s APJ IT Business Unit receiving the UPS vendor of the year award for his company.

Frost & Sullivan’s Best Practice Awards identify exemplary achievements, best practices and worldclass performances in a multitude of industries and disciplines.

Industry News

Kuala Lumpur, Malaysia: The Ballast Water Management (BWM) guidelines set by the International Marine Organisation (IMO) has kick-started a fresh industry within the shipping sector, as ship owners look to adopt ballast water systems within their vessels. An analysis from Frost & Sullivan, Ballast Water Treatment (BWT) Market in Asia-Pacific, finds that the market earned revenues of over US$214.6 million in 2011 and estimates this to reach US$3.63 billion in 2017. The IMO guidelines drive this nascent market, as they set compliance targets and timelines for existing and new vessels until 2020. The highest demand for BWM systems is expected from the construction of new vessels, as these will be the least costly to incorporate, although existing vessels are likely to generate revenue in the long term. “The number of countries endorsing BWM is growing, as member nations of the IMO understand the impact crossocean contamination has on local marine biodiversity,” said Frost & Sullivan research associate Prashanth Kay. “International and local compliance requirements, which are on the verge of being enforced globally, will result in the rapid rise of ballast water treatment.” The shipping industry is aware of this, and is looking to incorporate these systems in new ships and retrofit the old ones to settle compliance issues early. However, the key challenge is the high costs involved, especially since there is no return-on-investment. The shipping industry has to embrace BWT as a form of corporate social responsibility, and the challenge is to get ship owners to shoulder it.

NOAA's National Ocean Service

Maritime Policies Opportune For Ballast Water Management

It is imperative that ship owners be educated on how untreated ballast water can impact the environment around the ports that they embark from and disembark at. They need to recognise that continuing with the status quo is unsustainable. Shipbuilders and ship owners are also struggling to understand what their specific needs are, and the types of technology available to them in terms of ballast water treatment. “There is a diverse selection of water treatment technology available, and the costs vary just as much,” noted Kay. “Ballast water treatment systems manufacturers need to expand their capabilities to create the right packages for the needs of different ships that supply different routes around the globe.” This strategic approach by ballast water treatment companies in not only building the right combination of technology, but also educating clients on their options, will push the market ahead.

Allied Vision Technologies Opens Sales Office In Shanghai Shan gh a i, Ch in a : Allied Vision Technologies (AVT) has announced the opening of a sales office in Shanghai, China. Led by Liu Qingtao (James), the Shanghai office will overlook the company’s expanding business

in mainland China and will provide technical support and customer service to local clients. AVT is a manufacturer of highperformance digital cameras for industrial image processing and offers a range of

machine vision cameras with digital interfaces for industrial inspection, automation, medical imaging, scientific research, traffic monitoring, security, and other applications in the visible and non-visible spectrum (infrared).

www.facebook.com/IAAsia Oct/Nov 2012 | industrial automation asia 11

Industry News

Tokyo, Japan: Fuji Electric has decided to establish a factory in Thailand as a new production site, centred mainly on power electronics application products, for the expansion of operations in Asia. Part of a three-year rolling plan starting this fiscal year, the company is expanding its infrastructure-related business, focused mainly on power electronics application products in Asia, and China in particular, where there is significant economic growth, and is targeting JPY 830 billion (US$10.6 billion) in sales in fiscal 2014, with JPY 120 billion coming from Asia. As investment in infrastructure increases in Asia along with market growth, the company expects an increase in thermal and geothermal power generationrelated orders and sales of industrial plant systems to Japanese clients, as well as the expansion of the component business, namely that of power electronics application products. Demand for power electronics application products in the global market is expected to reach approximately JPY 5.4 trillion in fiscal 2014 (assuming 10 percent or higher annual growth), with Asia forecasted to garner an annual average of approximately 12 percent. Specifically, the company is expanding its operations by targeting the growing power supply-related market and industrial plants. To meet these targets, it will expand the application of Uninterruptible Power Supply (UPS) systems and large-capacity power conditioners

Alex Brown

Fuji Electric Expands Asian Operations

The new production site will focus mainly on power electronics application products, for the expansion of operations in Asia.

for mega solar power generation applications and introduce new models of inverters that meet global specifications. In Thailand, the company is building a factory that will serve as its central production site in Asia, which will enhance global production capability in the three key regions of Japan, China and Asia overall. In effect, this will strengthen the company’s cost competitiveness and avoidance of risks such as disasters and exchange rates by bolstering local design, local production and local consumption.

Hypertherm Inaugurates Cutting Technology Centre In India New Delhi, India: Hypertherm has opened the doors to its first Cutting Technology Centre (CTC) in India. Located in New Delhi, the centre is the first and only Hypertherm CTC in India, and one of just three CTCs in Asia. The facility will serve as a gathering point where channel partner employees can train up their technical skills and sales expertise to enhance their capabilities when introducing the company’s products to end-users. Soo Kam Tatt, director, Hypertherm Asia, said: “At Hypertherm, we recognise the significance of our OEMs, system integrators and distributors. 12 industrial automation asia | Oct/Nov 2012

They are our key sales channels in India and are our end-users’ main point of contact. That is why we believe in investing effort and resources in training all channel partners, and we have reinforced this commitment with the new CTC.” The CTC is co-located with the company’s office, which has been operationally ready since August 2012. This larger premise houses an increased number of associates who work to meet the needs of the company’s everexpanding local customer base. “Business in India has been growing since we first entered the country in

1999,” shared Mr Soo. “With the office and CTC, and with the addition of more local associates, we are confident that Hypertherm India will be able to better cater to the demands of our customers, both current and potential.”

Industry News

DNV Kema Awarded Framework Agreement For SoWiTec Arnhem, the Netherlands: DNV K e m a E n e rg y & S u s t a i n a b i l i t y has been awarded a framework agreement by SoWiTec Development (SoWiTec) to provide a range of project development support, technical services, third party expertise, and project management assistance related to 20-50 proposed wind power projects in Brazil, Argentina, Chile, Mexico, Peru, Uruguay and Russia. “Our team in Germany will work closely with SoWiTec locally and provide them with the support they need across the entire project development, construction and operation cycles,” says Jens Goesswein, project manager and

service line leader, DNV Kema Energy & Sustainability. The services provided by the company will help support project financing, and include verification and reporting of wind measurements, wind and energy yield verification and technical due diligence. “Put briefly, we will work with SoWiTec on various fronts and as part of the project scope we will review the design basis of the wind turbines, wind turbine towers, electrical distribution system, substation, additional transmission line and utility interconnection and roads. We will also look into the foundations to determine

(L-R) Harald Rudolph, MD, COO, SoWiTec group, seen here with Kim Mørk, business line director, Renewable Energy Services, Europe, DNV KEMA

whether the design has been completed in accordance with applicable codes, standards and accepted industry practice,” adds Mr Goesswein.

IEEE To Deliver Smart Grid Standards Piscataway, US: The Institute of Electrical & Electronic Engineers (IEEE) has updates to four standards and a new standards-development project that provides communications and operational capabilities needed for smart grids worldwide. The standards activities are among the latest smart grid contributions to come from the IEEE Standards Association (IEEE-SA), which has a portfolio of 100 standards and standards in development pertaining to this industry. The latest IEEE smart grid standards include: • IEEE 1815-2012 — Standard for Electric Power Systems Communications — Distributed Network Protocol (DNP3) — specifies the DNP3 protocol structure, functions and interoperable application options for operation on communications media used in utility automation systems. • IEEE 1366-2012 — IEEE Guide for Electric Power Distribution Reliability Indices — defines the distribution reliability nomenclature and indices that utilities and regulators can use to characterise the reliability of distribution systems, substations, circuits and grid sections. It also defines the factors affecting the calculation of the indices. • IEEE 1377-2012 — IEEE Standard for Utility Industry Metering Communication Protocol Application Layer (End Device Data Tables) — provides common structures for encoding data that is transmitted over advanced metering infrastructure and smart grids. It can be used to transmit data between smart meters,

home appliances, network nodes that use the IEEE 1703 LAN/WAN messaging standard, and utility enterprise collection and control systems. • IEEE C37.104-2012 — IEEE Guide for Automatic Reclosing of Circuit Breakers for AC Distribution and Transmission Lines — describes automatic reclosing practices for transmission and distribution line circuit breakers, establishes the benefits of automatic reclosing, and details the considerations utilities must use when applying automatic reclosing technologies for proper coordination with other transmission and distribution system controls. Additionally, IEEE-SA has approved a new standards development project to categorise and describe applications that are being considered as part of smart distribution system development and distribution management systems for smart grids. The IEEE P1854 — Guide for Smart Distribution Applications will categorise the applications, describe their critical functions, define their most important components and provide examples. The terminology and descriptions used for these systems have previously not been standardised, which makes it difficult to develop specifications for these functions as part of planning and developing smart distribution systems. IEEE P1854 will fill that standards gap. The guide will be a living document that will expand and grow as smart distribution technologies and applications change over time.

Oct/Nov 2012 | industrial automation asia 13

Industry News

London, UK: The total market for standards-based wireless connectivity chipsets is expected to exceed $10 billion in 2012, this includes both standalone and combo chipsets that use Bluetooth, Wi-Fi, GPS, NFC, UWB, and ZigBee. “The market continues to develop with technologies — particularly Bluetooth and Wi-Fi — squaring up for a fight to be the dominant standard,” commented Peter Cooney, wireless connectivity practice director. The number of Bluetooth enabled devices shipped per annum will surpass two billion in 2012, whilst Wi-Fi will creep over 1.5 billion; many of these (such as smartphones) will contain both technologies, often integrated onto a combo chipset. Wi-Fi remains much more costly to implement due to significantly larger die sizes needed and therefore,

chipset revenues from Wi-Fi ICs (both standalone and combo) far exceed those for any other technology. “There continues to be a competitive element to the market as standards bodies vie to push their technologies into new markets and others out,” added Mr Cooney. “However, in general there is a symbiotic relationship with each technology performing at its best in particular functions. This is driving the need for more integrated chipsets, with multiple technologies.” One interesting result of integration is that although Bluetooth or Wi-Fi enabled device shipments continue to grow quickly, overall chipset revenue growth is starting to slow so that from 2011 to 2017, the CAGR is less than 10 percent. As overall chipset revenue growth starts to peak for the main wireless

Manuel Iglesias, Olympia, US

Wi-Fi Chipsets Revenue To Exceed US$10 Billion

connectivity technologies, it brings about even more fierce competition among vendors. Vendors need to keep ahead of the pack by adding new technologies (Bluetooth v4.0, 802.11ac, NFC, etc) to their product portfolios and increasing integration, reducing process nodes, and the likes, where possible. These findings are part of ABI Research’s Wireless Connectivity Market Tracker.

Colorado, US: Network integration between Zayo and AboveNet networks has been completed. The resulting combined network nearly doubles Zayo’s national network reach and provides connectivity that spans over 61,000 route miles in 45 states and seven countries. The company closed the acquisition of AboveNet on July 2, 2012. The integration of the fibre networks includes the combination of the previously separate DWDM (Wavelengths), Ethernet and IP systems. The combined Wavelength network provides high bandwidth connectivity between the company’s connected markets and will be utilised for higher-level services, such as Ethernet and IP. The Ethernet and IP networks allow customers to access the company’s Tier 1 IP network by extending across and into metro markets. The interconnection of the two previously independent fibre networks included creating fibre connections to link key network nodes as well as implementing network equipment that enables the previously independent networks to communicate.

14 industrial automation asia | Oct/Nov 2012

woodleywonderworks

Integration Between Zayo And AboveNet Networks Completed

The consolidation of network management and customer support into a single network control centre has also been completed. Customers will receive support on all services through a single point of contact that can access all their service records, as well as related network elements across the combined network. Customers can now access the company’s national metro networks across points-of-presence in over 200 markets. The integration also brings access to major cities across Europe including London, Paris, Frankfurt and Amsterdam, through the company’s transatlantic capacity and European fibre networks.

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Industry News

watchsmart, Incheon, South Korea

Illinois, US: Inteliquent, a provider of global interconnection and interoperability solutions, has announced the establishment of its Turkish subsidiary, as well as its strategic alliance with Turkey’s operator, Turkcell Superonline. With these initial steps, the company plans to expand its operations and will soon begin to offer service to Turkey and the Middle East via a Point of Presence (PoP) hosted inside the Turkcell Superonline datacentre. Turkey is a dynamic market and a strategic gateway into the Middle East. The agreement between the two companies is a strategic alliance enabling Inteliquent to become an international provider of advanced IP Transit and Ethernet network services from the Istanbul PoP hosted by the telecom operator. “This alliance marks an important step promoting Turkey as an intersection point for the global communication network. We believe that our cooperation with Inteliquent, as one of our global Tier 1 partners, will enhance our service suite for our customers and contribute to the region’s Internet services,” comments Murat Erkan, GM of Turkcell Superonline.

16 industrial automation asia | Oct/Nov 2012

Washington, US: More than half of the world's population live in urban areas, and countries such as India and China are in need of hundreds of additional cities to accommodate growing populations. People in many cities suffer from inadequate transportation, substandard buildings, lack of sanitation, and poor public safety, highlighting the need for sustainable and liveable urban planning. Information and Communication Technology (ICT) can be a useful tool in helping cities improve their safety, cleanliness, and sustainability, according to Diana Lind, contributing author to Worldwatch Institute's State of the World 2012: Moving Toward Sustainable Prosperity. ICT not only contributes to sustainable urban initiatives, but also encourages more environmentally conscious consumer choices. In Singapore, for example, commuters can use mobile phones to avoid hours in traffic by accessing data mapping tools that display traffic and provide alternate travel routes. Commuters can also plan trips on public transportation and be notified of delays or changes in service. In many cases, cities are partnering directly with businesses to boost urban sustainability. The Dutch city of Rotterdam, for example, is working with General Electric (GE) in an effort to reach the city's goal of reducing carbon dioxide emissions by 50 percent compared with 1990 levels. GE will use data visualisations, smart metres, and other technologies to optimise energy efficiency and improve water management. The use of these ICTs will greatly reduce greenhouse gas emissions in Rotterdam, which emits as much carbon dioxide as New York City, while being only a tenth of its size. "ICT can be an excellent tool, but it is not the silver bullet solution to greening cities," said Ms Lind, "To be effective, ICT must be used not only

Jeramey Jannene, Wisconsin, US

Using ICT To Create Cohesive, Sustainable Cities

Inteliquent Expands Reach With Turkcell Superonline

Proper urban design results in a city with sustainability at its heart.

in mapping problems encountered across cities, but also to find sustainable solutions to those problems." A chapter in State of the World 2012 "Information and Communications Technologies Creating Livable, Equitable, and Sustainable Cities," highlights three ways that communities can use ICT to promote sustainability: • Open access to data. • Community mapping. • Community watch. Using ICT helps cities achieve sustainability efficiently while connecting with local communities, to ensure that diverse perspectives are included in the city's plans.

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INDUSTRY UPDATES

Installation Rules For Profibus B e f o r e Fieldbus standards, automation was done with central automation structures. A lot of direct wiring to the central automation stations was required. To communicate between these automation stations, solutions such as a special communication driver were available. That made this kind of solution very limited and inďŹ&#x201A;exible. Out of this experience an open, vendorneutral standard was needed and the answer was Profibus. The Profibus Association was created in 1989 in cooperation with different automation vendors, and has 27 Regional Profibus Associations globally; one of them is located in Singapore and responsible for the Southeast Asia region. Profibus is an international standard (IEC 61158/61784) for the field level. It is the only Fieldbus to allow communication both in manufacturing applications and in process-oriented applications, with over 31 million installed nodes globally. There a many benefits of a Fieldbus solution. Conventional wiring of a 4-20 mA device has many wiring points, such as a junction block, terminal block, IOModule and so on. With a Fieldbus solution like Profibus this wiring will be decreased to two wires, ie: the Bus cable. Another benefit is the central engineering. With Fieldbus it is possible to configure the process devices via the network instead of going directly to these devices and configure them on site. Standards 18

industrial automation asia | Oct/Nov 2012

like Electronic Device Description (EDD) or FDT/DTM are available to simplify the configuration and reduce the software tools to one framework. With this kind of possibility the devices can be configured and parameterised, all this from one central point of engineering. A Profibus solution provides also a wide range of diagnostic and maintenance possibilities, which makes a plant more robust, with increased availability, and shorter downtimes. Profibus DP Decentralise Peripheral (DP) is used for connecting distributed field devices, eg: SIMATIC ET 200 or drives with extremely fast response times. In a Profibus DP system there is always a Master, Slave relation. It is possible to have multiple Masters on a network. The DP-Master is

Profibus cable with connector to build up a daisy chain.

an intelligent controller like a PLC which controls remote IOs. Profibus is based on different physical mediums like RS485 where devices are connected with a daisy chain or fibre optic cable with ring, tree or line network structures. A Profibus segment has a maximum number of 32 devices connected to it. After 32 devices a Profibus Repeater is required to refresh the communication signal. The maximum number of devices on a complete Profibus system is 126 stations. Typically one of them is the DP-Master and one is the engineering station that makes it another 124 DP-Slaves that is able to work with one DP-Master. Profibus has a Bus speed of up to 12 Mbps; the transmission speed determines the cable length of the Profibus segment. For example, with a speed of 1.5 kbps, a maximum length of 200 m is possible, after this 200 m

Profibus Diagnostic Repeater to refresh the Profibus signal, create a new segment and additionally have a line diagnostic.

a repeater is required to extend for another 200m and so on. Each Profibus DP Slave can be used independently on engineering systems because each DP-Slave provides a GSD File which can be imported into any system that is Profibus capable. This is another point that makes the engineering vendor independent. Profibus PA Profibus with its Profibus DP and PA variants supports hybrid automation and is as such suited for all process industry applications without limitation. The application profile for PA devices was developed for the process industry in close coordination with users. This profile is the vendor-neutral standard for a wide range of device types, such as control valves and measuring instruments for pressure, temperature, and flow, and their use in process automation. Profibus PA and Profibus DP works with the same protocol layer.

DP/PA-Link and DP/PA Coupler.

Topology possibilities with Profibus-PA.

The difference is the Bus physics. Profibus-PA uses Manchester Bus Power (MBP) method to communicate. That means the power supply for the instruments and data is on one cable. To transfer the RS485 physical layer into MBP a PA-Coupler is required. Like a Profibus Repeater a PA-Coupler is transparent on the Network. By using a DP/PA-Link it is possible to open up a complete new sub network since the DP/ PA-Link is a Slave on one side of Profibus and a Master for PA on the other side. In this case it is possible to open up multiple

Profibus-PA networks. On Profibus PA there are different possibilities of network layouts. From a single line, up to coupler redundancy and even a ring redundancy is possible. Success Of Profibus More than 2,500 Profibus products from several hundred vendors are available today. As of 2010, the installed base is greater than 31 million devices which are used in more than half a million applications in manufacturing and process automation. ENQUIRY NO. 7101

Oct/Nov 2012 | industrial automation asiaâ&#x20AC;&#x192; 19

Newsdesk Newsdesk

ESP For Light Vehicles & Vans Radar Sensor Helps To Stay In Lane With its Mid-Range Radar (MRR), Bosch (Germany) has developed a technology that uses the 77 GHz frequency band providing precise data about the vehicles on the road ahead. The sensor is used for assistance and safety systems in commercial vehicles. It is connected to the automotive electronics via CAN and Flexray interfaces. In commercial vehicles, safety and assistance functions help drivers and freight to reach their destinations safely. Under an EU regulation, most of the heavy commercial vehicle models in excess of 3.5 tonnes will have to be equipped with Advanced Emergency Braking Systems (AEBS) and Lane Departure Warning Systems (LDWS) effective from November 2013. These assistance functions support drivers during emergency braking and warn them if they unintentionally drift out of lane. The 77 GHz sensor provides object separation up to three times more

Conference In Seoul Organised By Vector Korea Vector Korea celebrated its 5th anniversary with a conference in the Hilton Hotel in Seoul, South Korea. More than 230 engineers followed the invitation to this event. The event took place September 25, 2012. In three parallel sessions, the companyâ&#x20AC;&#x2122;s experts informed about

industrial automation asia | Oct/Nov May 20092012

accurate, and can measure speed and distance three to five times more accurately than a 24 GHz version. It uses a frequency band, which has been permanently allocated to automotive applications worldwide. In addition, the measurement data from the sensor can be used to inform drivers how close they are to the vehicle in front. The silicon-germanium sensor can be concealed in the bumper or mounted unobtrusively in the vehicleâ&#x20AC;&#x2122;s radiator grille. It is smaller and more cost-effective than the conventional 24 GHz sensors. For use at the rear of the vehicle, a 12 V version is also available for light commercial vehicles. This allows drivers to be warned of vehicles that are in their blind spot, and that are approaching at speed from the rear. It also makes it easier to reverse out of parking spaces where vision is restricted, as approaching vehicles can be reliably detected. ENQUIRY NO. 7102

ECU testing, measurement and calibration, embedded software, and process management. Most of the presentations were technical and provided detailed information. The fourth session comprised several presentations by CiA discussing CANopen developments, and the future of CAN base technologies including CAN-FD protocol and partial networking. ENQUIRY NO. 7103

Following the launch of the CAN-based Electronic Stability Program (ESP) 9 in passenger cars, Bosch (Germany) is introducing the ESP 9TE for light commercial vehicles. The already manufactured ESP 9LE has been optimised for the types of van commonly found in Europe, which have high pressures in their main brake cylinders. With ESP 9TE, a number of additional ESP Functions WITH ESP 9TE, will be available for the weightier segment of light commercial vehicles weighing up to eight tonnes. These functions include brake prefill by bringing the brake pads into position, automatic braking in hazardous situations, and safety interventions on steep gradients. The company is planning to start series production in 2014. Vans, sport utility vehicles, and pickup trucks place greater demands on the brake system due to features such as gross vehicle weight, wheel base, and larger brake calipers. Both the ESP 9TE and ESP 9LE have been optimised to meet those demands. Both allow the kind of additional functions, including comfort functions, that are common in the passenger-car segment. In addition, automakers can offer the kind of stability support required specifically for vans. The load adaptive control function, for example, adapts the interventions by the ABS, TCS, and ESP active safety systems to the respective load status, while roll-over mitigation acts to check roll-over by braking the individual wheels appropriately and reducing torque. ENQUIRY NO. 7104

A Decade Of Success 2001

2005

Industrial Automation Asia (IAA) was established. The magazine started with 6 issues a year and 4,000+ readers in Southeast Asia.

2002

Endorsements poured in as the magazine grew, including Fieldbus Foundation and Profibus. IAA introduced a new classified section, IAA Market Place.

2007

IAA was officially endorsed by Singapore Industrial Automation Association, and supported by Profibus while its circulation climbed to 10,500.

2004

The magazine was officially audited by BPA. It became the only magazine in its sector to be awarded the BPA certificate.

With growing demand, 2 more issues were added making IAA available 8 times a year. Endorsements from International organisations included CAN in Automation (CiA) & EtherCAT Technology Group. In 2007, there was a record 40 percent increase in enquiry responses from readers to advertisements and editorials.

2010

Book

IAA established its ebook enabling us to reach out to readers and clients in Europe and America. We increased our participation in regional exhibitions, with SIWW and OSEA among our new target industry focus.

2012

400% The publication experiences a 400 percent increase in product enquiries and boasts 27,000 combined registered professionals via our print and ebook editions.

2011 2013 IAA celebrated its 10th year anniversary and embraced new media by going into Facebook. The website was also enhanced with a dictionary.

IAA will include two new supplements targeting the water and energy sectors. We will also include new initiatives, such as video hosting to allow better exposure to new media advertising.

We understand, make the right choice. Email : salesiaa@epl.com.sg Tel: (65) 6379 2888 Fax: (65) 6379 2805

www.iaasiaonline.com

connect with us

Fieldbus Foundation

Updates HSE Interoperability Test Kit With Foundation for Remote Operations Management (ROM), industrial operations can implement a true predictive and proactive maintenance strategy for remote assets that could not previously support one. The High Speed Ethernet Interoperability Test Kit (HSE ITK) has been updated by the Fieldbus Foundation, including the addition of transducer block test profiles for both wired and WirelessHART devices. The transducer blocks bring information from both wired and WirelessHART devices into the Foundation fieldbus infrastructure, and are a key element of Foundation for Remote Operations Management (ROM) technology. Updated to Version 6.1, the HSE ITK is used for interoperability testing of HSE capable field devices. The kit will verify the functionality of a device and its conformity to the Foundation fieldbus function block specifications, before it is submitted to the Fieldbus Foundation for official registration and testing. The Benefits HSE ITK Version 6.1 is beneficial for automation equipment manufacturers looking to develop Foundation for ROM devices due to its added support for wired and WirelessHART 22 industrial automation asia | Oct/Nov 2012

device specifications. Other test kit updates include: Pressure Transducer Block 2, Temperature Tr a n s d u c e r B l o c k 2 , F l o w Transducer Block and Flow Totaliser Transducer Block. The Fieldbus Foundation’s Foundation for ROM solution offers a unified digital infrastructure for asset management in a range of remote applications, ranging from oil and gas pipelines to tank farms and offshore platforms, and even Original Equipment Manufacturer (OEM) skid-mounted equipment. Single Environment Foundation for ROM is the first example of the capability of integrating ISA100.11a, WirelessHART, wired HART, and wired H1 protocols into a single standard environment, without sacrificing the diagnostic capabilities of the existing wireless devices. Those capabilities are mapped into the block structure to provide a standard environment for data management, quality, and more, eliminating today’s solutions, which are highly customised and much more costly to maintain

throughout the plant lifecycle. With Foundation for ROM, industrial operations can implement a true predictive and proactive maintenance strategy for remote assets that could not previously support one. All-Digital Communication Infrastructure Foundation fieldbus provides an all-digital communication i n f r a s t r u c t u re f o r p ro c e s s automation, with multivariable measurement capabilities, device diagnostics, and the ability to integrate wireless devices across multiple networks. The block structure of Foundation fieldbus is unique, and provides true distributed functionality for implementing control in the field, improved data management, and alarm and alert management. The Architecture Within the Foundation automation architecture, the H1 (31.25 kbit/s) and HSE (100 Mbit/s) fieldbus networks provide a distributed function block capability with HSE serving as a larger pipeline with increased speed and throughput. The Foundation for ROM solution expands these capabilities by establishing open, nonproprietary specifications for an interface to wireless field device networks, a wired HSE backhaul, and a wireless HSE backhaul integrating various wireless sensor networks such as WiFi, satellite, cellular, and so on. ENQUIRY NO. 7105

ENQUIRY NO. 494

ETG Roadshow In China The Industrial Ethernet seminar series held by the EtherCAT Technology Group (ETG) in China in September marked a new attendance record: more than 600 representatives from machine builders, automation vendors, design institutes and system integrators took part in the seminars, located in Beijing, Chengdu, Guangzhou and Shanghai. “We are thrilled by the interest in EtherCAT in China. The response to the seminars was overwhelming and clearly shows the high potential for EtherCAT in the Chinese market,” commented Martin Rostan, executive director of the ETG. Based on the success of this roadshow and the continuing demand, the ETG has plans to organise further seminars in China already by next year. Mr Rostan added: “The support of our Chinese members during the

preparation phase as well as the feedback during the event encourages us to extend our Industrial Ethernet seminars to further cities in China.” The ETG seminars have a focus on the EtherCAT technology itself as well as its use, although product presentations are not accepted during these events. Kicked off by a detailed technology introduction, the seminars then focus on user benefits: It is shown how EtherCAT lowers costs and improves throughput and efficiency of machines and plants. The agenda contains application presentations, which inform about the practical use of EtherCAT as well as the user-oriented changeover from traditional fieldbus systems to EtherCAT.

ENQUIRY NO. 7106

Impressions of the Ethernet Seminar Series in China 2012.

ETG Semiconductor Working Group In The Home Stretch Immediately after its kick-off in October 2011 the ETG Semiconductor Technical Working Group (TWG) gained momentum, mirroring the strong position of EtherCAT in the semiconductor industry: 7 out of the 10 largest semiconductor manufacturing equipment makers are ETG members, and most of them actively contribute to the TWG. Within less than a year 12 detailed profile documents have already reached the review stage. There is, of course, also the profile work ‘at home,’ web meetings and telephone conferences. The working group meetings take place in California’s 24

industrial automation asia | Oct/Nov June/July 2012 2012

Silicon Valley in the US, usually at one of the large manufacturers of semiconductor manufacturing equipment, the end users of EtherCAT technology. In regards to the composition of the working groups, users in addition to fieldbus experts from companies that often offer specialised devices for the semiconductor industry are represented. Participants come from North America, Europe and Asia, as such representing the worldwide market for semiconductor production. The working group is headed by Daniel Judd of Arlington Laboratories, who already played a key role in shaping the previous fieldbus standard in

The recent Semiconductor Technical Working Group meeting was hosted by Lam Research in Fremont, California, US.

the semiconductor industry. Technical and organisational support for these activities is provided by the experts in EtherCAT from the ETG offices in the US and Germany, who ensure that the results match the existing EtherCAT specification and tools. ENQUIRY NO. 7107

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ENQUIRY NO. 459

issues & insights

Machine Vision:

Making A Quality Statement

he manufacture of medical implants requires accuracy and a keen eye. Very often, the difference between an acceptable product and a rejected product is only a few thousandths of a millimetre. This makes precision an important factor in the machining of miniature parts and components. A laser-cutting line is used in a facility that builds miniature medical components. Laser cutting is especially suited for thin-walled parts such as small tubes. It is a virtually zero-force machining method that can create various shapes â&#x20AC;&#x201D; including complex geometric structures â&#x20AC;&#x201D; in a matter of seconds. These products are made of nitinol (an alloy of nickel and titanium), and range from stents that are used in the stabilisation of blood vessels, to holders for artificial heart valves. Cutting On Target The machine that is used for cutting the parts is the result of combining laser technology know-how with vision system knowledge. Using the PatMax pattern matching vision software tool, precision cutting control is possible with image processing algorithms. A highenergy laser beam source is placed at the top section of the unit and a mirror diverts the laser beam downward vertically. The beam is finely focused in the cutting die, and is able to form an ultra-precise, ultra-thin metal structure from the basic metal tube. One key factor of the cutting operation is in ensuring the precise positioning and orientation of the tube that is being processed. The In-Sight Micro 1403 vision system has an image resolution of 1,600 x 1,200 pixels, and ensures that the tube coordinates are correctly registered prior to the cutting operation. The machine then continually adjusts the object to the required position by using

26â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

the clamping jaws chuck that is mounted on a linear axis. This process is accurately carried out to a few thousandths of a millimetre. The vision system follows a distinct tube contour formed in an upstream processing stage. The system is aligned to the side of the object and is assisted by a telecentric light source on the opposite side. The system detects the characteristic contour. Both the telecentric light source and the vision system are mounted in the same solid framework. This special layout ensures that the pair is always correctly aligned to each other, even despite the large clearance of about 80mm on both sides of the object. In detailed imaging testing, the system determines the optimum mean value for the depth of focus

and resolution of the components. When the stainless steel tube has been correctly positioned, the laser cuts the desired contour out of the rotating object at an accuracy of +/- 3µm. Finding Fault Elastomeric bands are manufactured and used in medical devices, making it critically important to reject any bands that carry defects such as thin spots, pinholes and embedded particles. In general, defective areas are those that are darker or lighter than the surrounding material. The facility that manufactures these bands previously employed operators to perform manual inspections. The inspections were performed by backlighting the band and rotating it on two spindles, while the operator

checked for discrepancies. The problem with this approach was that standards became subjective to what each operator defined as defective. It was especially confusing when it came to deciding whether minor ﬂaws or variations constituted a defect. It was also common for an inspector to give approval for a part that had a certain minor ﬂaw on one day and then reject the same part on the next. This made inspections of the four inch wide, eight inch circumference elastomeric band challenging as there was no objective way for a human inspector to consistently maintain standards, much less for inspectors to find agreement amongst themselves. The decision was eventually made to install a machine that could

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Oct/Nov 2012 | industrial automation asia 27

issues & insights

The manufacture of medical instruments/devices is made possible by vision sensors and precise quality control.

produce consistent and repeatable inspection results. A specification was developed that takes into consideration both the size of a light or dark area and also the degree to which it contrasts with the surrounding material. In this manner, an objective specification for defects was created based on machine vision parameters. During the prototyping phase, it was necessary to mathematically define each type of defect and to develop the lighting and vision tools that would consistently identify defects. It was concluded that multiple inspection processes were required to characterise the product. When checking for field defects such as inclusions or thin spots, two histograms are applied by the system to look for areas of high contrast. One histogram checks for dark areas while the other looks for light areas. In the event that such areas cannot be found, it is then assumed that the region is free of defects. Where either a light or dark area is found (ie: an area of high contrast), a regional blob tool is used to locate the potential defect. The blob tool makes use of information from the histogram to better classify the size of the defect. 28â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

Defect Detection Once the regional blob tool localises the suspect area, another histogram tool and a defect specific blob tool are applied directly to the potential defect. The outputs of the final two tools are contrast level, defect size, and defect location. These three values are then checked against the preset thresholds that define a reject. For checking edge defects, the camera applies ten edge tools perpendicular to the edge of the membrane in a small region. Each of these tools produces a numerical reading that pertains to the position of the edge. When the membrane passes under the camera, the latter calculates the average of these readings to find the edge. When locating edge defects, each of the individual readings is compared to the average. If there is a variance that exceeds the preset limit, the area is considered a defect. A red backlight is used to illuminate the membrane for imaging. This light generates 0.550mw/cm 2 in the 660nm wavelength and creates good contrast with the pigment in the band. Two vision systems provide the necessary inspection resolution while imaging the full width of the band. The first offers a resolution

of 1,600 pixels by 1,200 pixels, making it possible to accurately inspect about 60 percent of the width of the membrane. A second vision system covers the full width of the membrane when used in combination with the first. The systems capture several images of each section of the band. The first few images are used to adjust the gain to compensate for possible thickness variations caused by stretching of the band as it is rotated in front of the cameras. Using In-Sight vision systems, a band can now be inspected in 16 seconds. Quality Injection Moving on to syringe production, manufacturers are required to ensure that high levels of quality are adhered to. This to meet the goals of patient safety and regulatory requirements, while ensuring profitability for the manufacturer. Customised machine vision inspection stations are used for the syringe assembly process and are coupled with a packaging system. The vision system performs a series of inspection operations, such as ensuring the presence and location of components, within a timeframe of 50 milliseconds. In a particular facility, syringe production is performed by two machines and 17 individual stations. The workings of stations one through five are described here. The first machine indexes every two seconds and processes 16 syringes during each cycle, achieving a total production rate of 480 syringes per minute. The needles, or cannulas, are loaded into the first station of the machine before being picked up from a hopper via a vacuum gripper. After this, the pointed ends of the needles are inserted into a wheel. At the bottom of the wheel, needles are transferred to a belt before being presented to a vacuum pickup head.

VisionPro software are employed to perform the inspection. Interpreting Objects The PatMax pattern-matching tool is used to locate the part and to report its orientation to the machine control system. During setup, programmers provided examples of good needles for training models used by the software. The software uses geometric information in place of pixel grid-based correlation. For example, a square is interpreted as four line segments and a football is seen as two arcs. This is achieved by applying a three-step geometric measurement process to an object. The key individual features within an object image are identified and isolated by the software, which then measures characteristics such as shape, dimensions, angle,

arcs, and shading. The spatial relationships between the key features of the trained image are then correlated to the runtime image, encompassing both distance and relative angle. It is by analysing the geometric information from both the features and spatial relationships that the software is able to determine the object’s position without regard to the object’s angle, size, or appearance — with precision and repeatability. Due to the level of precision that is required for producing medical devices, manufacturing can be a challenge. In many situations however, vision-based technology can provide a robust solution that is both accurate and affordable. ENQUIRY NO. 7201

ENQUIRY NO. 444

At the second station, the needles are collected and rotated 90 degrees before being inserted into plastic hubs. Each hub includes a protector (applied to the needle after use, to prevent accidents). Adhesive is applied to each hub-needle assembly in station three and ultraviolet light is used to perform curing in station four. It is possible for the needles to appear in the pallet at the first station at any random angle. A vision system at station five determines the angle of the needle. This operation takes place during the indexing of the machine, taking up 660 milliseconds of the cycle, leaving only 41 milliseconds for each needle to be inspected. A custom lens light coupled with a Sony XC-HR50 camera and

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Oct/Nov 2012 | industrial automation asia 29

process control

Towards A More Open HMI

Kristian Stokholm, Hinnerup, Denmark

HTML5:

trictly, HTML5 is the latest, and as yet incomplete edition of the HTML standard for presenting content. However, in common usage HTML5 usually refers to the HTML5 standard itself, plus ancillary standards and technologies: CSS3 (Cascading Style Sheets), the JavaScript scripting language and associated standards, such as AJAX (Asynchronous JavaScript And XML) and JSON (JavaScript Object Notation), Document Object Model (DOM), and other nonproprietary standards, including XML. It is 30 industrial automation asia | Oct/Nov 2012

this, broader, definition of HTML5 that interests us here. Second, we can simplify the discussion by grouping into three areas the number of new features, capabilities and improvements HTML5 brings over its predecessors: • Applications: HTML5 now supports enough capability to construct applications either inside or outside of a browser, with all the expected capabilities; eg: databases, threading, input from the

device hardware, and so on. • R e n d e r i n g : u s i n g C S S 3 animations, the <canvas> element, WebGL, and SVG graphics, HTML5 provides control over the HMI rendering that is precise enough for games and flexible enough for applications. • I m p r o v e d a p p l i c a t i o n development model: the influx of application developers (as opposed to web page designers) adopting HTML5 t o b u i l d c ro s s - p l a t f o r m applications, is re-orienting the HMI development community, which is increasingly following traditional design patterns in its applications, separating the model (HTML/DOM), view (CSS), and controller (JavaScript) in a more maintainable architecture. Finally, we should note that with these changes, HTML5 reaches beyond the traditional domain of HTML. It is no longer just the standard for presenting web content, but a viable technology for HMIs for all sorts of applications — connected and not connected, using traditional browsers or chromeless browsers (rendering engines minus all the browser widgets: navigation, history bookmarking, and so on). HTML5 Applications HTML5 introduces features that give an HTML page many of the capabilities typically associated with an application. One of the key benefits of these capabilities is that with HTML5, HMI designers do not need to choose between a downloaded app running on the device, and a service hosted in the cloud. They can support both use cases from the same code base. For example, ideally, an invehicle navigation app is always connected, receiving traffic and weather data, updating the vehicle

location, and so on. In practice, however, connectivity can not always be guaranteed. Cars travel outside network coverage areas, down urban canyons, and through tunnels. A hybrid navigation app that stores data locally could continue without a blink in any of these situations, synchronising its locally-stored information with updates when connectivity was re-established. Local Data Storage A key requirement for many off-line apps is local data storage. With previous versions of HTML, local storage was limited, unreliable and restrictive: cookies, (small, hence very limited capacity), plug-ins (annoying, often out of date, blocked by firewalls), or custom browser features (which Half Page Ad_Final_High Res.pdf

created browser lockin). HTML5 offers designers Web Storage and Indexed DB. Web Storage Web storage supersedes the old cookies local storage model, and is: • Faster — every server request does not require a new data transmission • More secure — stored data is accessible only to the web page that stored it • More useful — data size is not severely limited as it is with cookies Web Storage comes in two flavours: Local Storage (data is persistent; it remains on the local device until it is expressly removed) and Session Storage (data is not 9/18/12

persistent; it is removed when the browser window with which it is associated is closed). All Web Storage data is stored in key/value pairs. The catches with Web Storage, are that it does not support: • Indexing — searches on large amounts of data can hurt performance • L o c k i n g f o r d a t a b a s e transactions — apps in multiple tabs can overwrite each other’s data, so applications must manage their own database transactions to ensure data integrity Indexed DB Indexed DB offers faster searches and transaction locking. It is less complex than Web SQL Database,

5:05:53 PM

CMY

ENQUIRY NO. 504

Oct/Nov 2012 | industrial automation asia 31

process control

Ilker, Izmir, Turkey

engine. This interface supports both speech recognition and synthesised speech output, and is designed to allow a ‘web application author to add speech to a web application’ using familiar methods. As such, assuming that the underlying system supports a speech engine, a designer building an HMI that includes speech recognition and output only needs to know the HTML5 interface. Internet technologies allow many applications to run on servers, rather than locally.

which W3C dropped, perhaps due to neither Microsoft nor Mozilla supporting it. As its name suggests, Indexed DB supports indexing of specified fields, which speeds searches; and locking of the entire database, tables or individual rows, which ensures data integrity when more than one app accesses the database. Using Indexed DB requires a bit more knowledge than does using Web Storage, but applications can do a lot more with the stored data. Threading According to one web site designer, threading support is worth pretty much every other improvement in HTML5. Threading is handled with JavaScript improvements, which provide a pseudo-threading implementation with the newly added Web Workers. A Web Worker is ‘a single JavaScript file loaded and executed in the background’. Web Workers do not have access to all JavaScript features; for instance, they can not access the DOM or any global variables or JavaScript functions. Despite these limitations, threading means that complex HTML5 applications can be designed much more naturally. Multimedia HTML5 establishes nonproprietary specifications that 32 industrial automation asia | Oct/Nov 2012

all content-creation tools and browsers are supposed to respect, as such doing away with most of today’s requirements for plugins. With new HTML tags such as <audio> and <video>, developers can drop multimedia content into an HTML page just like an image, and users should no longer be ambushed by required updates for the likes of Flash Player, QuickTime and Silverlight. Anything inside these tags should simply run, providing the system provides the appropriate codec support at the native code level. Although the expectation is that most audio processing will continue to be handled by lower-level code, such as C or C++, the HTML5 standard allows for JavaScript to perform audio processing and synthesis directly. Giving the top level developers direct access to audio simplifies HMI development and greatly increases developer efficiency. Performance in JavaScript will never be equal to that in native processing; however, depending on the platform, audio file and complexity of the processing, for some use cases it may very well be a viable alternative. Speech Interface The HTML5 Speech Incubator Group has proposed a standardised interface that allows JavaScript to talk to an underlying speech

Device Interaction In a nod to the migration of HTML implementations onto mobile platforms—from smartphones to in-vehicle systems, HTML5 offers APIs that provide access to device information such as orientation and geo-location. This information can be used to adjust HMIs based on screen orientation, and for anything from tracking a taxi through its navigation system, to adjusting the time zone on a mobile phone — provided the device has GPS or accelerometer chips, of course. Rendering Control One of the advantages of HTML pages and browsers is their forgiving nature. Browsers were originally designed to do their best to display what they are served, and ignore what they did not understand. If a specified font is missing, the browser substitutes another; if an element or attribute is unknown, it is omitted, and so on. The downside of this tolerance is that no two browsers display content exactly the same way. This is rarely a significant issue with traditional web content: text, images, forms, the occasional embedded video or audio. However, it is a serious impediment to using HTML for displays where precision is required. The location of a ball or brick or whatever being thrown in a video game must be exactly controlled. It can not be left up

Canvas The HTML5 <canvas> element sets aside one or more screen areas where JavaScript can be used for precise rendering of shapes and images. With this element, no special code in required to detect the browser, and serve up the appropriate code for that particular browser flavor and edition, so there are no unpleasant surprises. As long as the browser conforms to the HTML5 standard, inside the area specified by the <canvas> height and width attributes, bitmap images render exactly as specified. It is important to note that the <canvas> element also imposes design demands. If the application output moves to a different device (for example, from a tablet to an in-vehicle infotainment system) the browser will not automatically adjust a display drawn on a canvas to a new aspect ratio — this means that the application developer must consider it and implement it if required. WebGL And SVG Scalable Vector Graphics (SVG) offer relatively light-weight 2D graphics rendering. And designers can now use JavaScript with WebGL to access OpenGL ES 2.0 rendering to display 3D images.

HTML5 and JavaScript can as such be used to present any sort of image or animation called for by the application. Sandbox (Nested Browsing) Composite screens — screens made up of frames from different sources — have usually been

something to avoid. Allowing the browser to render content from multiple sources left the door ajar for security breaches. HTML5 lets HMI developers bring content from different sources onto a single HTML page and, critically, manage permissions for this content. In

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ENQUIRY NO. 481

to the browser to do its best and place the object more or less where the game designer intended it to go. Similarly, maps must be precise, as must medical imaging such as, say, a 3D rendering of a mammogram. H T M L 5 i n t ro d u c e s n e w features that allow HMI designers to do things such as render images and control displays down to the individual pixel, as well as to safely bring together content from different sources. In addition to offering precision, these features can often take advantage of hardware acceleration.

13/02/2012 19:25 13/02/2012 19:25

Oct/Nov 2012 | industrial automation asia 33

Chaleerat Ng, Leuver, Belgium

process control

HTML5 and complementary technologies will allow a range of touch, speech, and visual inputs to internet applications.

particular, the <iframe> element now has a sandbox attribute that controls content permissions. Settings allow the frame content a range of permissions, from only display content, to do everything the containing document is allowed to do, including executing scripts and submitting forms. The default is the most restrictive and safest: display only. An HTML5 HMI can therefore bring together onto a single display page, say, a map, navigation instructions, the weather report, points of interest, and even content provided by the point of interest. With the external, unverified content restricted to a sandbox, there is no concern about malicious content. Better Programming Model Despite the large number of new and useful features it introduces, arguably the most important change with HTML5 is not part of the specification, but the way that the development community i s re a c t i n g t o a p p l i c a t i o n development using HTML5. Since HTML5 is becoming a more popular choice for application development outside of traditional web browsers, the tendency to keep application logic and display styles out of the DOM is becoming increasingly popular, bringing over the heavily used Model, View, Controller (MVC) design pattern into the HTML world. 34â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

Semantics Tags Like earlier editions of HTML, HTML5 is inspired by SGML and has inherited some of its syntactic features; for example, it maintains the <!doctype> element. However, HTML5 no longer refers to an SGML Document Type Definition (DTD) and it incorporates into its own syntax new elements (<section>, <header>, <article>, <aside>, <time>, and so on) that, like SGML elements, define the content type rather than its presentation, which is left to the CSS. Anyone who has tried to mark up documents using <div> tags will appreciate the change. HTML5 is not attempting to replace SGML or XML for document content management; rather, by adding a limited set of elements identifying content type, it simplifies page markup and content manipulation. Document Object Model (DOM) Document Object models are a mechanism HTML5 offers for controlling the HMI by controlling, not the specific page but how it is defined. The best definition of the DOM comes from the W3C itself: The DOM is a platform- and language-neutral interface that will allow programs and scripts to dynamically access and update the content, structure and style of documents. The document can be further processed and the results of that processing can be incorporated back into the presented page. JavaScript is used to manipulate the DOM and control pages. Scripts change the DOM based on what the user is doing; these changes are picked up by the webrendering engine, which displays or hides parts of these pages, as defined by the altered DOM. The HTML5 improvements allow much easier and consistent manipulation of the DOM. This means that application code becomes simpler to write,

and identical across multiple platforms. Cascading Style Sheets (CSS3) Cascading Style Sheets have been part of HTML design for a long time. With HTML5 they are confirmed as the primary method for defining how the HTML page is displayed. The HTML determines what is displayed, and the style sheets determine how it is displayed. As long as the devices have appropriate style sheets, applications can be designed once and move easily between devices. The style sheets ensure that applications display correctly on each device, even branding them, or filtering out content such as animations or other distractions when the application moves, say, to an in-vehicle system in which driver distraction is a consideration. None of this is entirely new to CSS3. However, CSS3 adds, literally, another dimension to cascading style sheets: time. It introduces new, dynamic capabilities, such as 2D and 3D transforms, and transitions, which cause an object to gradually change from one style to another. In keeping with the HTML5 philosophy of keeping the details of how something should be displayed separate from the actual content, these styles permit generalised manipulations, rather than requiring special code for each instance. Conclusion HTML5 is rapidly becoming, not just a standard, but the standard, not just for web pages, but for all types of rich user interfaces. Offering simplicity of use in a familiar environment and capabilities previously supported by disparate and incompatible, proprietar y technologies, HTML5 appears to be delivering on its promise. ENQUIRY NO. 7301

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ENQUIRY NO. 507

process control

System redundancy extends the capabilities of automation control systems. In the case of safety-related applications or Safety Instrumented Systems (SIS), it is diverse redundancy technology that drives and delivers increased safety integrity. Contributed by Vineet Kumar Gupta, Tüv Certified Functional Safety Engineer, ABB

Elevate Safety Integrity To New Heights P

rocess efficiency and productivity are key metrics of performance in a plant. However, given today’s globally competitive yet socially responsible marketplace, a company cannot work to attain simply these. They must ensure that these goals are achieved sustainably and, more importantly, safely. There is continuous pressure to protect people, property, t h e e n v i ro n m e n t , a n d t h e surrounding community from harm. Within the automation and control space, the International Electrotechnical Commission (IEC) has set standards and requirements for the integrity control of safety applications. Diverse redundancy is one of 36 industrial automation asia | Oct/Nov 2012

the mechanisms recommended in the IEC 61508 standards to increase safety integrity of programmable electronic systems. Diverse redundancy technology refers to the use of two or more different technologies or systems that are built using different components and design methodology to perform the same task. Diverse redundancy has proven to be a more effective way to reduce common mode and systematic failures such as those caused by design flaws and that is one of its key benefits. The use of diversity is an effective defense against hidden dangerous faults in logic solver or programmable electronic systems.

Achieving Safety Integrity Through Diverse Redundancy Over the years, the process industries have applied Hardware Fault Tolerant (HFT) architecture such as 1oo2, 2oo3 and 2oo4 to achieve safety integrity. These have become accepted in the market and are still appearing in requirement specifications and supplier brochures. ABB, refers to these systems as first generation safety systems. Historically, safety integrity has been equal to Safety Integrity Level (SIL) capability. ‘Safety Integrity’ is now welldefined and has resulted in the development of a better generation of safety systems. T h e c o m p a n y a d d re s s e s safety integrity by employing

diverse redundancy in the safety system of its 800xA Extended Automation System. Addressing Safety Integrity The 800xA High Integrity (HI) system, from ABB, utilises diverse technology to perform active diagnostics for discrepancy checking between signal paths. Embedded diversity in the controller hardware and software is achieved by the use of different processor boards and by the use of different system compilers and different programmatic implementations. The I/O modules also use two signal paths with embedded diverse technology to achieve SIL3 safety capability. By using diverse technology, which is a diagnostic method, 800xA HI is therefore classified as 1oo2D — where ‘d’ stands for ‘diagnostic capability’ — the best SIL architecture qualification among safety capabilities. This technology is employed as 1oo2D and 2oo4D formats, depending on whether it is a single or redundant configuration. The system achieves redundancy with two controllers performing the logic functions in parallel, keeping its operation in step. If a failure occurs, there is a switchover and one of the controllers takes over in a seamless manner without degrading system integrity — avoiding the potential of unwanted shutdowns. Also, by virtue of the diverse

Safe Failure Fraction (SFF)

structure, the 800xA HI product has an HFT of one for the simplex controller and the simplex I/O. Table 1 shows that 800xA HI effectively meets the Probability of Failure on Demand (PFD) and Safe Failure Fraction (SFF) requirements for SIL4. Certification, Compliance And Availability ABB’s Safety Execution Center is certified by Tüv for implementing the recognised Functional Safety Management System (FSMS), including the IEC 61511 standards for integration and implementation of SIS. System 800xA HI is fully compliant and certified in accordance with international safety standards IEC 61508, ISA S84.01, ISO 10418 (API RP), EN 954 (ISO 13849-1), NFPA 72, NFPA 79 and NFPA 85. The systems controller is certified up to SIL3 in a single configuration. Redundancy is not required for achieving or maintaining safety integrity; however, redundancy can be arranged by using two controllers in a quadruple structure to achieve better system availability. The Benefits The use of diverse technology to implement SIS, as recommended by the IEC 61508 standard, can contribute to improvements in the performance of safetyrelated systems.

< 60%

Hardware fault tolerance (see note) 0 1 2 Not allowed SIL 1 SIL 2

60% - < 90%

SIL 1

SIL 2

SIL 3

90% - < 99%

SIL 2

SIL 3

SIL 4

≥ 99%

SIL 3

SIL 4

Note 2: A hardware fault tolerance of N means that N + 1 undetected faults could cause a loss of the safety function Table 1: Hardware safety integrity: architectural constraints on complex electronics/ programmable safety-related subsystems (source: IEC61508-2 Table 3)

Diverse technology in SIS can contribute to improvements in the performance of safety-related systems.

To b e p r e c i s e , d i v e r s e redundancy results in increased safety integrity by providing: • Increase in SFF due to unmasking of undetected dangerous failures • Prevention of common mode failures • Reduction of systematic failures System 800xA HI can also increase system availability through the allocation of redundant hot stand-by components that independently meet the required SIL. Furthermore, the system is able to run both SIL3 certified and basic process control applications in the same controller either in simplex or redundant configuration due to the system’s diverse technology design and the use of secure firewall technology. These benefits result in better cost efficiencies because maintenance and total cost of ownership are kept to a minimum. But just as impor tantly, diverse technology helps reduce risks, common mode failures and unwanted shutdown. As such, companies can maintain operations and achieve higher safety integrity of the safetyrelated systems for a profitable and sustainable business. ENQUIRY NO. 7302 Oct/Nov 2012 | industrial automation asia 37

software & Networks

Over the past few years, promotional material for new versions of CAM software has been full of claims about the ability to support the latest hardware developments, such as parallel processing and multithreading. This article will explain why these developments are important and the benefits that they can give to the user. By Peter Dickin, marketing manager, Delcam

CAM:

A Clear Path To Better Performance

he key change in computer hardware has been the move from single-processor computers to multi-processor equipment. After many years of steadily increasing processor speeds, there has been a step change in processing power through the much wider introduction of multi-processor equipment. Many laptops for home use now come with dual processors, while equipment for commercial use will often include four, eight or even more processors. As with all computer developments, the increased number of processors has come alongside continuing falls in the price of the equipment. Computing power that would have been impossibly expensive 10 years ago is now very affordable even for smaller companies. Benefits Of Multiple Processors There are two main benefits from multi-processor 38â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

computers; background processing and parallel processing (also called multi-threading). Background processing allows the user to prepare, simulate or edit one tool path in the foreground, while simultaneously calculating other tool paths in the background. In fact, this technology can work on any hardware but the benefits are only really apparent on multi-processor equipment. The ability to prepare data in the foreground while calculating tool paths in the background eliminates the need for the user to wait for each calculation to be completed before preparation work can start on the next operation. For example, it is no longer necessary to wait for a complete roughing path to be produced before work starts on programming the rest-roughing operation. Similarly, the user can be setting the parameters needed to machine one area of a part, while tool paths

different processors. This process becomes more complex, and so takes more capacity, as the number of processors increases. The optimum number of processors for most machining calculations will be eight. Coping With Complexity There are, of course, obvious benefits in being able to reduce calculation times and waiting times. User

ENQUIRY NO. 498

are being calculated in the background for machining a second area with a different strategy. Productivity is also increased because the computer can continue with a series of calculations during the user’s breaks or even overnight. Calculations can be queued by the operator and the software will automatically start the next operation as soon as each tool path is generated. This approach can be also used with single-processor equipment but the benefits are again much greater with computers having two or more processors. With parallel processing, the computer can perform different par ts of a single complex calculation at the same time. Essentially, this divides the processing of this operation over all of the processors in the CPU chip. Clearly, this ‘spreading the load’ between multiple processors allows calculation times to be reduced significantly. The extent of the savings will depend on the size and complexity of the part being machined and on the programming strategies being used. Tests at Delcam indicate that a dual core computer will perform raster machining calculations in around 55 percent of the time taken by a single core machine. A quad core machine will complete the calculation in around 35 percent of the time and an eight core machine in around 25 percent of the time. The ultimate benefit comes from applying both these technologies at the same time, with parallel processing being used for both the foreground and background operations. It might be expected that the benefits would continue to increase exponentially as more and more processors are added to the computer but this is not the case. This is because the computer must use some of its capacity to manage the allocation of the different parts of the calculation between the

Oct/Nov 2012 | industrial automation asia 39

software & Networks

PowerMill 2011 5-axis simulation

productivity can be increased significantly, reducing any down-time where machine tools are waiting for Numerical Control (NC) data and minimising lead times. These benefits are most important for companies that are using the latest generation of machine tools, like five-axis machines and mill-turn equipment. For both types of equipment, the main advantage is the ability to complete the manufacture of more complex parts in a single operation. With a five-axis machine, this is possible because of the ability to change the angle of approach of the cutting tool, for example, when machining undercuts or drilling holes at a series of different angles. With a turn-mill machine, operations can be carried out on a single piece of equipment that would otherwise needs a series of lathes and mills. The ability to produce parts in one operation obviously saves time compared to performing the job in a series of setups. Labour costs can be reduced because there is no need to relocate the part on the machine or to transfer it between different machines. In many cases, multiple setups means multiple fixtures so moving to a single setup reduces the time and cost of making fixtures. Furthermore, with multiple setups, there is always a possibility of incorrect alignment each time the part is moved. By machining parts in a single setup, there are fewer opportunities for error, so quality and consistency should improve. The problem with this more advanced equipment is that calculating tool paths for their operation is more complicated than for simple lathes or threeaxis machines. Not only are there more options to 40â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

Mill-turn simulation

consider but the software will need to undertake more comprehensive checking to ensure that collisions will not occur. For example, many CAM systems now include some sort of automatic collision avoidance during five-axis machining. The software will change the tool axis automatically when collisions might occur, tilting the cutter away from the obstacle by the specified tolerance and then returning the cutting angle to the value set for the overall tool path once the obstacle has been cleared. More sophisticated systems will even incorporate a look-ahead distance as part of this capability in order to ensure a smooth transition when tool-axis changes are required. This all involves extra calculation and checking, making the extra speed of modern hardware an even bigger benefit. Stock Models Another intensive computation involves the production of stock models during the overall machining process. Of course, all CAM systems require the user to describe the shape of the stock at the start of the operation and most allow arbitrary shapes to be used, for example when finish machining a casting. The latest CAM software produces a model of the material still remaining on the part as each machining stage is completed. They can be used by the system to ensure that the cutter is never asked to remove more material than it can safely cut. At the same time, the stock models also ensure that tool paths are not produced where there is no material remaining so the machine tool is never left cutting air.

The options to optimise tool loading will help overcome a constant conﬂict for programmers. On the one hand, they want to maximise productivity by setting feed-rates as fast as their machines will allow; on the other hand, they need to ensure safe speeds that will not break the tool. The need for safe machining has, of course, become more critical as a growing number of companies are introducing lights-out, unmanned operation overnight or during weekends.

In Conclusion As mentioned, despite the improved capabilities, computer hardware is still becoming cheaper than ever. An investment of a few thousand dollars in a better CAM system and the hardware to allow it to operate at its peak efficiency can give huge benefits to companies, especially those using more sophisticated machine tools. With those machines costing hundreds of thousands of dollars, it seems very short-sighted not to provide the best supporting systems for a small additional investment. ENQUIRY NO. 7401

Your networks are evolving. Choose the right Industrial Ethernet partner. The demand for increased productivity, multiple applications and seamless data communication is driving the convergence of automation systems and enterprise IT networks under a single Ethernet platform. To support the proliferation of these mission-critical applications, Belden offers a high quality, high availability line of Industrial Ethernet network devices and systems from our globally known brands - Belden, GarrettCom, Hirschmann and Lumberg Automation. From the factory floor to the control room to the data center and everywhere in between – Belden is your trusted partner to support all your network needs of availability, performance, integrity and security. Who will you trust to transform your network? You can Be Certain with Belden.

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ENQUIRY NO. 435

Simulation As mentioned above, the ability to undertake background processing means that tasks that might have been considered too time-consuming can now be completed in the background, simultaneous with other programming work. An important aspect of this capability is the ability to undertake more simulation of the machining process. This aspect of programming has also benefited from the better quality of the graphics that can be provided in the latest computer hardware. These improvements have made it possible for software developers to generate accurate, three-dimensional models of a wide range of machine tools and to then simulate the complete machining process. It is even possible to give an indication of the surface quality of the part. Being able to prove out the program on the computer gives a very high confidence that it will work successfully on the machine tool. Warnings are displayed whenever there is any possibility of a collision, either between the machine and the job or between any parts of the machine itself. Any potential problems can be eliminated before the program is issued to the shop ﬂoor so minimising the chance of collisions during machining. It is, of course, much cheaper to find mistakes on the computer than on the machine tool, where there is a risk of scrapping the part, breaking the cutter or damaging the machine.

Oct/Nov 2012 | industrial automation asia 41

software & Networks

CAD has evolved from its traditional design role to a sustainability driver in production. By VR Srivatsan, ASEAN MD, Autodesk

Using

CAD Optimising Tool As An

he business world is undergoing a permanent change, and this is especially evident in the manufacturing industry. The cost of materials like tin, copper, and steel are increasing, energy prices continue to escalate regardless of type and source and the global problem of waste is becoming more acute. Sustainability In The Manufacturing Context In today’s competitive climate, large manufacturers are often faced with the choice of acting early with less reliable environmental data, or to wait for more trusted information to minimise the risk of altering their business operations inappropriately. Two factors help to reduce the risk of updating a production process to improve its sustainability — one is using a proven methodology and the other, a proven technology. Lean Manufacturing and SixSigma are well-known process improvement methodologies that target and eliminate waste to drive profitability; they usually improve the environmental performance of a process at the same time. The other way to reduce risk is to take advantage of the latest software technology. Businesses that use a Computer-Aided Design (CAD) platform with digital prototyping capabilities can develop a single 3D model that evolves from concept through manufacturing. The model allows the designer to evaluate 42 industrial automation asia | Oct/Nov 2012

opportunities to reduce environmental impact throughout the manufacturing process — for example, by reducing weld energy through optimisation of material thicknesses in an assembly. Optimising For Outcomes Before Production With CAD Today, CAD software helps designers understand the impact of material choices and production processes on the product’s overall sustainability and outcomes that advance their top business priorities, such as lowering operating expenses or taking market share from a competitor. Once the desired outcome is selected (such as lowering energy use during production by 20 percent), the design team can pick a strategy (reduce the number of heat-treating operations) and make use of the software tools to analyse the inputs and process steps to understand the impact of each of the outcome. The team can then integrate all design data into a single digital model, streamlining the design process and improving communication. As the model develops it becomes a more accurate digital prototype of the product, reflecting the material attributes such as weight, strength and recycled content, and process attributes such as energy intensity and water consumption.

• Facilitating quick disassembly and recycling by using a single bolt to assemble the back to an office chair frame; • Substituting recycled metal and plastic for virgin lumber in playground equipment; • Lowering energy use by 50 percent and eliminating the need for oil and lubricants by creating a gearless elevator hoist, and • Enabling fast, cost-effective remanufacturing by using only standard, interchangeable parts. Regardless of the specific sustainable outcome and strategy selected, a digital prototype will save the design team time and money as it analyses and tests alternative options. In many cases, the digital prototype created with CAD software can help predict the impact of the proposed change on the product’s characteristics and the energy consumed during its manufacture, even before it goes into production. Armed with such data, the design team can quickly and cost-effectively experiment with different material and process variables until it discovers the optimal combination. Multiple options for the same product can be saved at any stage, from concept through manufacturing, allowing the team to pursue multiple strategies in parallel. If the market or regulatory environment changes, the product can quickly be optimised to meet the latest conditions. The CAD model reduces risk by allowing the design team to incorporate changes much later in the process, increasing design decision flexibility to support sustainable product strategies. Rather than building physical prototypes, the real-world performance of a product can be digitally simulated with CAD, saving time and money required to build multiple physical prototypes. The optimised design can be tested and broken virtually before spending a single dollar on materials or labour.

If a manufacturer chooses to design its product for disassembly, CAD simplifies the analysis. After the product is in production, the CAD can assist with accurate documentation of material and design data important for compliance with environmental regulations. CAD and digital prototyping offer even greater promise for the future, and design software will become an increasingly important tool in efforts to improve the sustainability of manufacturers. By allowing designers to make better decisions in the early stages of product development, when they are most effective, future product capabilities may make it even easier and faster for manufacturers to design products that are resource-efficient, carbon neutral, healthy and safe. Conclusion Sustainability is still a differentiator, but not for long — it is quickly becoming an expected part of doing business in the global economy. A sustainable design methodology and CAD software are both essential tools to help designers develop products meeting one or more businessoriented, environmental outcomes. ENQUIRY NO. 7402 SG_Catalog_chains-cables_Layout 1 19.06.12 11:39 Seite 1

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ENQUIRY NO. 461

The team can experiment with alternatives that might achieve the desired goal. In this example, the team might consider using designs that can take advantage of selective induction hardening processes rather than bulk heat-treating. Experimenting with different scenarios will reveal the feasible and costeffective options. As the product design evolves from concept through engineering and on to production, it can be tested, modified and optimised digitally to achieve the desired outcome, before the first prototype goes into production. Product outcomes and strategies will vary widely according to the type of business, constraints and market opportunities. Examples might include:

Oct/Nov 2012 | industrial automation asia 43

instrumentation & Measurement

‘to provide a practical safe working area for employees relative to the hazards arising from the use of electricity’ (NFPA 70E 90.1). However, many industry professionals may not be fully aware either of how the changes in this standard are likely to impact their operations, or of the types of identification and safety solutions available to help them achieve compliance with both old and new elements of NFPA 70E. This article highlights the changes to the 2012 edition of NFPA 70E, which will require customers to update their compliance to include these latest developments. It also defines the risks associated with arc flash hazards and identifies solutions available to help prevent arc flash incidents and optimise worker safety.

Asif Akbar, Hungary

Arc Flash And Electrical Safety

he continuing modernisation of industrial/ manufacturing facilities, including significant upgrades to electrical systems, present considerable shock and arc flash hazard exposures to workers. In response, the National Fire Protection Association (NFPA) released a 2012 update to standard 70E, Standard for Electrical Safety in the Workplace, in order to address these and other industry developments. Originally developed at Occupational Safety and Health Standards (OSHA) request, the 2012 edition of NFPA 70E, an extension of the National Electric Code, NFPA 70E Electrical Safety in the Workplace responds to new information about the effects of arc flash, arc blast, and Data Centre hazards, as well as recent developments in electrical design and Personal Protective Equipment (PPE). OSHA utilises NFPA 70E to address the inspection of electrical hazards in the workplace. It was written 44 industrial automation asia | Oct/Nov 2012

What Is ‘Arc Flash’? An arc flash occurs as a result of an electrical fault generating an arc that ionises the air leading to combustion. The usual causes of electrical hazards can be mechanical (such as accidental touching, dropping of tools or metal parts, or closing into faulted lines and loose connections) or environmental (such as water, dust, impurities and corrosion at contact surfaces or failure of insulating materials). Arc Flash is the most common electrical event in the workplace today and the resulting explosion generates the following hazards capable of severe injury or death: • High temperature • Pressure waves • Shrapnel (from components contained within electrical enclosure) • Electric shock • Sound waves The amount of energy released during this Arc Flash event is dependent on three primary factors: 1 Arcing Time — The duration of the arcing fault 2 Arcing Fault Current Magnitude — The quantity of

fault current available in a system

3 Distance to the Arcing Fault — The distance an

individual is from an arc

Typically, as much as 80 percent of hospital admissions from electrical incidents are a result of burns resulting from an arc flash and ignition of flammable clothing rather than electrical shock. Regulatory Compliance — What Does NFPA 70E Compliance Require? The purpose of NFPA 70E is to establish an electrically safe workplace by outlining specific practices and

standards that must be followed in order to protect the workplace from electrical hazards such as arc flash that can cause injury and death. In order for a work environment to be electrically safe, the energy that workers are exposed to must be minimised while work is being performed. NFPA 70E is the recognised standard that addresses electrical safety requirements for employees. It provides multiple methods by which the employer can calculate or estimate the hazard or risk. It covers electrical safety issues like safety-related work practices, maintenance of electrical equipments/ installations, and the requirement of special equipment for electrical installation. The following sections will discuss regulatory compliance as it relates to work involving electrical hazards, preventive measures, training, and establishing an electrical safety program.

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ENQUIRY NO. 500

Work Involving Electrical Hazards The proper precautions must always be taken in all circumstances, whether normal, (eg: working on electrical circuit parts or equipment), or special circumstances (eg: confined spaces or vision or access to equipment is obstructed). In most cases, work on electrical equipment greater than or equal to 50 VAC or 100 VDC is conducted in a de-energised state using approved Lockout/ Tagout (LOTO) procedures, which is the preferred state to perform work safely. Energised work is only permitted when the employer can demonstrate that de-energising introduces additional hazards or is not feasible due to equipment design or operational limitations. If energised work is absolutely necessary, an Energised Electrical Work Permit must be used. For tasks such as voltage measuring, testing, or troubleshooting, an energised work permit is not

required. For de-energised work, the conductors are considered to be energised until a tester is used to verify the conductors are de-energised. Therefore, Personal Protective Equipment (PPE) shall be worn by employees until de-energising verification is complete. It is important to understand that whether performing energised or de-energised work, mitigating the risk of electrical hazards begins with an analysis

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Diagram of specific boundaries and what type of personnel (qualified or unqualified) is authorised for each specific area. Q=Qualified Personnel, U= Unqualified Personnel.

to determine the incident energy available at the specific area of work on the electrical power system. The incident energy or hazard category level may be determined utilising several methods including: • Software analysis (examples: etap, SKM, EasyPower) • IEEE1584 Guide for Performing Arc Flash Hazard Calculations • Information tables contained within NFPA 70E Table 130.7 (C)(15) The NFPA 70E is a guide toward establishing electrical safety in the workplace by mitigating risk of injury or death. This article focuses on electrically safe work practices as explained in the 2012 edition of the NFPA 70E, specifically the importance of training and establishing an electrical safety program. Preventive Measures: Training Training is critical for workers who are exposed to safety hazards. They need to thoroughly understand the requirements of the electrical safety program, which is required by NFPA 70E and OSHA 29 CFR 1910.147 for all industrial locations and shall include safety principles, controls used to measure and monitor, and specific procedures regarding how to work within the safety boundaries. • NFPA 70 requires training which is divided into two groups: Qualified and Unqualified employees. A qualified person has skills and knowledge relating to the construction and operation of electrical equipment and installations. This 46 industrial automation asia | Oct/Nov 2012

person is typically the electrician who is working on energised conductors. Unqualified personnel are neither trained nor familiar with determining exposed energised conductors or how to determine nominal system voltage and the apparent hazard. • The content of the ‘authorised’ training includes the identification of specific electrical hazards and the potential risk for injury. It shall also d i s c u s s e m e rg e n c y p ro c e d u re s n e e d e d in the event of an incident and first aid care, including resuscitation. ‘Affected’ or ‘unqualified’ employee training only includes training on electrical safety practices necessary to avoid injury. Retraining or additional training is required when new technology or job roles change or on an interval not to exceed three years. It is important that the employer documents employee training which shall include the content of the training, employee’s name and dates of training. Preventive Measures: Electrical Safety Program It is the responsibility of the employer to establish an electrical safety program and training. The employee is responsible for implementing the safety work procedures. In the case of outside contractors, a documented meeting between the host employer and the contractor is required. This meeting should include a discussion of the potential hazards in the workplace and the established safety program. Annex E of the NFPA 70E standard provides

Arc Flash Protection Boundary The Arc Flash Protection Boundary is the distance where the incident energy is equal to 5 J/cm² (1.2 cal/cm²) which is the energy level that unprotected skin will sustain a 2nd degree burn. Therefore PPE is required within the Arc Flash Boundary and unqualified personnel must be continuously escorted by qualified workers. The Arc Flash Protection Boundary mitigates the arc flash hazard. This boundary is relevant to systems 50 V and greater and should be updated when a significant modification or renovation involving the electrical distribution system occurs or it should be reviewed at least every five years. The Arc Flash PPE is selected from either the incident energy calculation or the hazard risk category determined from NFPA 70E Table 130.7(15). Labeling The previous edition of the NFPA 70E was the 2009 release where the arc flash labeling requirements

1 At least one of the following:

a. Calculated available incident energy and corresponding working distance b. Minimum arc rating of clothing c. Required PPE d. Highest Risk Category (HRC) for the equipment 2 Nominal system voltage 3 Arc Flash Boundary It is also good practice to include the date of analysis for determining when the next review is required. Note: Labels applied prior to September 30th, 2011 are acceptable if they contain the available incident energy or required level of PPE.

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ENQUIRY NO. 390

Shock Hazard Approach Boundaries S h o c k H a z a rd A p p ro a c h B o u n d a r i e s a re requirements developed by the NFPA 70E to minimise the risk of injury to workers as a result of shock and arc flash hazards. These boundaries to energised conductors mitigate the shock hazard. There are three types of Approach Boundaries: Prohibited, Restricted, and Limited. The Prohibited Approach Boundary is the area where one should consider any work in this space to be the same as making direct contact with the energized conductor. Unqualified personnel are not authorized within this boundary. Qualified personnel must wear proper PPE. The Limited Approach Boundary is the space where a shock hazard exists and therefore requires shock PPE. Unqualified personnel are only allowed within the Limited Approach Boundary if they are continuously escorted by a qualified person and wearing the proper PPE. The Restricted Approach Boundary is the area that contains an increase in the shock hazard and does not allow for the presence of unqualified personnel. Qualified personnel must wear proper PPE.

addressed only the available incident energy or the required level of PPE. The 2012 edition added several new labeling requirements which are described below. The NFPA 70E 2012 edition specifies the labeling requirements in section 130.5 (C) for electrical equipment likely to require maintenance and servicing while energised. The NFPA 2012 70E edition requires that equipment labels applied September 30, 2011 to present contain the following information:

Asif Akbar, India

a general outline of recommended topics for an electrical safety program, which shall also provide a procedure for identifying hazards and determining a risk assessment before work is initiated, job briefing methods, and the audit scope and interval. It is specified that an audit of the overall safety program shall be conducted and documented at least every three years.

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Safety Solutions The company offers a safety solution to customers c o n s i s t i n g o f re l e v a n t products and services to mitigate risk created by hazards in the workplace. It Hazard Risk Avoidance provides a system of reliable UNAUTHORIZED PERSONNEL A key strategy for solutions, and ongoing protecting personnel from support for customers to Arc Flash is reducing the comply with regulator y e x p o s u re t o e l e c t r i c a l standards and ensure the Clear signs and markings are necessary for hazards by removing safety of employees and a safer workplace. the need to enter areas property that are exposed where electrical hazards to hazardous energy. exist. Door solutions such as data access The company provides identification solutions ports for network connections, infrared sight for indoor and outdoor/harsh environments glass portals, and bulkhead connectors limit including pre-printed, print on demand (do-itthe need for entering live cabinets, reducing yourself) software/printer systems, or custom employee risk. printed solutions. It also has a range of secure and Trending recently is the ability to install network compliant lockout devices for electrical and other equipment like Ethernet switches in control and types of hazardous energy. power panels, where there can be an increased In terms of hazard risk avoidance, it has a range hazard risk for ser vice and configuration. of solutions for increasing safety by removing the Zone architecture solutions that provide separate need to access networks employed in electrical zone enclosures to house networking assets, and power equipment, such as data access ports, physically remove the hazard of exposure to higher IP67 rated bulkhead connectors for network energy circuits. connections, NEMA rated network zone enclosures, and physical barriers for power circuits internal to Personal Protective Equipment (PPE) network zone enclosures. PPE includes specialised clothing or equipment worn by employees to protect the body including the head, Conclusion face, eyes, and hands. The level of PPE is determined Mitigating workplace hazards and protecting by the degree of the shock and arc flash hazard. The employees are crucial toward maintaining Hazard Risk Category determined by the NFPA 70E a successful and growing operation. This is a 130.7(C) (15) or the incident energy calculation is challenge considering the continual release of then used to decide the required PPE for the task. new technologies into the market and the internal For example, the Hazard Risk Category for toggling changes taking place within most facilities. As a a circuit breaker with the enclosure doors open result, the complexity of the supporting power for a 600 V class motor control centre (MCCs) systems and demand for electrical power are is a Hazard/Risk Category (HRC) 1 according to increasing. Consequently, the NFPA 70E is evolving Table 130.7 (C) (15) (a). According to Table 130.7 to address the technology/market trends and further (C) (16), for HRC 1, the PPE required is a hard mitigate electrical hazards in the workplace. hat, safety glasses or goggles, hearing protection, Unfortunately, it is estimated that only 20 heavy duty leather gloves, and leather work percent of the industrial sector is compliant to the shoes. Additionally, insulated tools and equipment required elements within the NFPA 70E. Over the (and/or handling equipment) are used when working next five years, it is expected that the percentage within the limited approach boundary. of compliant facilities will climb as the industry The PPE is listed in Table 130.7 (C) (16) by becomes more aware of the severity of the Arc Hazard Risk Categories 0 through 4. Above 40 cal/ Flash hazard and effective methods to mitigate this cm² is considered HRC Dangerous because PPE is risk. Implementing electrical safety programs as not able to sufficiently protect employees which outlined in NFPA 70E will benefit both the employee means energised work is prohibited. NFPA 70E and employer, resulting in a safer and an overall Table 130.7 (C) (14) lists the standards relevant to lower cost operation. protective equipment. ENQUIRY NO. 7501 Other alerting techniques such as safety signs, symbols, or prevention tags are recommended to warn employees of potential workplace hazards.

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48 industrial automation asia | Oct/Nov 2012

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ENQUIRY NO. 426

instrumentation & Measurement

Personal Safety By Object Detection A

camera system, integrated into a rectangular shaped housing, results in a ‘vision sensor’ technology platform which provides quick solutions for two different tasks: The ‘Safety Camera Sensor’ for safeguarding semi-automated workplaces, and the ‘Automation Camera Sensor’ for improving processes of industrial automation. Independent of the different tasks, the camera sensor always works together with a flexible reflective tape. This tape defines the protective field of the safety system. The different paint finishes of the two devices points to their differing characteristics. The automation camera sensor remains in a classic blue, while the safety camera sensor takes on the colour yellow, as is the standard in safety technology. Core Technology Both devices have an image processing system consisting 50 industrial automation asia | Oct/Nov 2012

of a camera chip and intelligent programming. The sensor’s sender, receiver, and electronics are integrated into a single housing. A special reflector strip mounted in the sensor’s field of vision defines the protective field. The sensor emits infrared light that is sent back by the reflector. The resulting image is displayed on the receiver chip and evaluated within just a few milliseconds. This means that any changes in the protective field, such as entry with hands into hazardous points or an overhanging pallet on a conveyor system, can be detected quickly, with a response time of 20 ms. Installation Without Alignment The self-adhesive reflector strip is usually attached on a profile frame or on a machine wall in order to define the protective field. The camera sensor is placed opposite so that the reflector strip is in its field of vision. One press on the teach button and the camera

automatically searches for its reflector, without the need for lengthy fine-tuning. The optical aperture angle measures approximately 110 deg lengthwise. Sideways, the camera sensor is able to ‘squint’ about 10 deg to the left and right. With this wide field of view, the camera sensor can be positioned in variable locations and still see the entire protective field. This provides a number of options for positioning the device and the reflector at the best possible place in the machine. C o n s e q u e n t l y, t h e c a m e r a sensor can be protected against mechanical damage, for example, or even just discreetly integrated into a machine design. Active From The Corner, Without Blind Zone The triangular housing design allows the integration of the camera sensor into the corners of profile frames. From there, the sensor faces opposite the reflector strip,

Flexible Protective Field Conﬁguration The reflector strip can also follow unusual contours. This enables curves or steps to be integrated into the protective field. The protective field no longer has to be a square. This means that for example annoying cable channels can be easily bypassed. Also round shapes like the edge of a rotary table can be achieved.

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Permanent Reliability The camera sensor and the reflector strip together form a reliable unit. The strip’s adhesion is so strong that it will not detach even under severe industrial conditions. The surface of the reflector strip is also resistant to scraping movements. This has been proven by endurance tests in which, for example, a loaded crate was shoved over the reflector 10,000 times. If scratches do occur on the reflector strip, the camera system is intelligent enough to ignore these and can distinguish between scratches and a human body part or an object to be detected. Eye On Safety The safety camera system is

suitable for hand protection in applications with a required Performance Level (PL) ‘d’ or lower. It allows the protection of work windows, for example, on assembly and handling machines or on test stations. Also, it can protect industrial robot movements. Basically, semi-automated workstations, used routinely or sporadically, can be protected without barriers with the use of this sensor. In many cases, this relates to applications for which category 3 and PL ‘d’ according to ISO 13849-1, or SIL 2 according to IEC 61508 is required. Due to a lack of alternatives, light curtains from the higher safety levels (Cat 4, PL ‘e’, SIL 3) previously had to be used

ENQUIRY NO. 508

which specifies the protective field. The strip can be precisely cut to the required length. Dead zones or device overhangs, as sometimes unavoidable for light curtains, are a thing of the past. The resulting protective field ends precisely there where the reflector ends.

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One vision technology, integrated in two types of camera sensors, results in two product families with fundamentally identical technologies, but for different fields of applications.

Vision sensor for safeguarding semi-automated workplaces, and for improving processes of industrial automation.

for such applications. The safety camera sensor with the appropriate safety design and the single housing concept is a more favourable solution in this case. I t c a n p ro t e c t w i n d o w s up to a size of 1.5 m x 1.5 m. If two devices are synchronised 52â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

and used simultaneously, the protective field size can even be doubled to 3 m x 1.5 m. An ergonomically optimised, barrier-free workplace can also be designed with two V300 cameras installed across in the corners. Both camera systems synchronise automatically.

Gaze Towards Automation Demand for 2D sensors is widespread in the area of industrial automation. Intralogistics alone provides a multitude of application possibilities. For example, when transferring palettes from one unit to another, it must be ensured that the clearance between the approaching and the fixed unit is free from top to bottom. The load must not shift, and the palette must not become jammed such that it can no longer be removed during the transfer of the load from one side to another. The clearance must be reliably monitored in order to prevent a collision and subsequent damage. The precision requirements are in the range of 15 mm. In comparison with the safety camera system, the â&#x20AC;&#x2DC;non-safeâ&#x20AC;&#x2122; automation camera makes it possible to secure much larger areas. The maximum possible field dimensions are 2 m x 2 m. Before the introduction of the automation camera sensor, this type of clearance monitoring was previously only possible with conventional light curtains. However, it was not always possible to install the right light curtain sender and receiver lengths for the application. Development For The Future O n e v i s i o n t e c h n o l o g y, integrated in two types of camera sensors, results in two product families with fundamentally identical technologies, but for different fields of applications. Wi t h t h i s s e n s o r s o l u t i o n , an alternative for common light curtains is created. The integration of sender and receiver into one device opens up new opportunities for customers in the design of their machines. With this, a trend for the future is set. ENQUIRY NO. 7502

energy

Energy Sector:

A Smooth Path To Efficiency IAA spoke with Yan Côté, global business development advisor, Mobil Industrial Lubricants on the company’s presence in the Asia Pacific region and their involvement in the wind energy sector. By Mark Johnston

IAA: What are the major industries for Mobil Industrial Lubricants in the Asia Pacific region? Yan Côté (YC): Today, Mobil Industrial Lubricants are used throughout the Asia-Pacific region in many industrial market sectors — such as in power generation, general manufacturing, metalworking, food and beverage processing, pulp and paper, cement, construction, metals and mining. IAA: In the energy sector, particularly wind energy, what is your market share, and how do you plan on increasing market share in this area? YC: As published in ExxonMobil’s Outlook for Energy: A View to 2040, renewable energy sources, such as wind, continue to grow as contributors to the global energy demand. We will continue to support our wind energy customers’ safety, productivity, and environmental care objectives. Increasing productivity through improved efficiency, both in design and operation, remains a key element of our offer in support of the wind sector. China is a key growth market for wind industry, earmarking more than US$10 billion a year toward wind-energy initiatives through 2020.

IAA: Do you have any new products that are specific to the wind energy sector, if so, what are the unique variables in wind turbines that you need in order to develop a targeted product for this area? YC: For wind turbine operators, the impor tance of effective lubrication cannot be overstated. Wind turbines are highly engineered and sophisticated pieces of machinery. Whether they are located onshore or offshore, they are often subjected to some of the most demanding operating conditions. To best protect critical wind turbine components, such as the main gearbox, lubricants such as Mobilgear SHC XMP 320 are recommended. This lubricant has been formulated to help increase productivity and reduce unscheduled downtime. It provides oxidative stability and water tolerance as well as long term filterability, gear and bearing protection. In addition to this product, our company also offers a range of lubricants that are formulated to deliver protection for all parts of a wind turbine, including greases to lubricate bearings and hydraulic oils that help pitch rotor blades.

IAA: A client uses Mobil Industrial Lubricants for their wind turbine. How much efficiency savings can they expect compared to not using at all, or by using a competitor's products? YC: The Mobil SHC 600 Series, used in wind turbine pitch and yaw gear applications, have demonstrated reduced energy consumption up to 3.6 percent compared to conventional mineral oils. Low traction (internal friction) and high-viscosity index combine to reduce power consumption compared with mineral oils in gearboxes and circulating oil systems. This lubricants characteristic helps reduce energy costs and therefore, lowers customers’ operating costs. IAA: What are your expansions plans in the region, in terms of new offices, new people, and what percentage of annual revenue do you invest in R&D? YC: We will continue to invest in lubrication technology, though we do not publish investment figures, the company has a long history in serving the Asia-Pacific region and it will continue to invest in this region. ENQUIRY NO. 7601 Oct/Nov 2012 | industrial automation asia 53

energy

any challenges exist for the wind turbine manufacturer growing and expanding in new markets. They include establishing and managing an effective supply chain, identifying and complying with relevant standards, improving the safety of workers and equipment and remaining competitive as customers demand shorter timeto-market cycles. Another challenge is remaining competitive against other power generation sources. Levelised Cost Of Electricity (LCOE) is the total lifecycle cost to build and operate a plant over a period of time, divided by the total electricity produced by that plant. Wind turbine manufacturers can use LCOE as a metric to compare the cost of generating wind power with other technologies. Continuously

i m p ro v i n g t h e d e s i g n a n d performance of wind turbines can help lower the cost of electricity generated from wind. Wind turbine manufacturers building turbines for offshore applications face an additional set of unique supply chain and safety challenges associated with the extreme, unpredictable environment. 1 Establish A Global Supply Chain

With Regional Experience Wind Turbine Generator (WTG) manufacturers expanding operations in new markets may encounter several supply chain challenges, including how to manage costs, inventory and vendor relationships. When working with a reliable supply chain partner that can provide

value add ser vices, such as electrical engineering, design and manufacturing, manufacturers benefit from one local point of contact for supply chain considerations, freeing up internal resources to focus on their core competencies and lowering the total cost to design, develop and deliver new turbines. A global supplier with broad industry experience also can help the WTG manufacturer implement a successful production management system based on industry best practices and can help weather economic downturns and boom/ bust cycles that can be detrimental to smaller suppliers that only focus on one or two industries. WTG manufacturers partnering with a global supplier can leverage the supplierâ&#x20AC;&#x2122;s worldwide

Building Cost-Effective Wind Turbine Generators A wind turbine manufacturerâ&#x20AC;&#x2122;s path for growth and expansion in new markets is not without obstacles. Todayâ&#x20AC;&#x2122;s challenges include establishing and managing many variables. By Dave Schaetz, industry technical consultant, Alternative Energy and Steve Ludwig, safety programs manager, Rockwell Automation

2 Outsource Electrical

Control Panels Engineering the control panel is time-consuming and can have a significant impact on system cost for the WTG design and development process. One alternative to building control panels in house is for WTG manufacturers to retain the design and documentation responsibilities, but work with thirdparty panel builders to streamline the process. As business grows in new markets, working with multiple panel builders can become quite arduous, often resulting in the need for increased engineering and supply chain staff resources to coordinate and monitor multiple sources of supply. A more efficient alternative is for WTG manufacturers to work

with a single automation supplier that can design and build the entire panel — including all the control and power components — and help standardise component selection and panel design across many locations worldwide. This single point of contact through design, prototyping and ongoing deliveries can help a WTG manufacturer increase production capacity without increasing its internal workforce, freeing up existing resources that would be needed for e n g i n e e r i n g , p ro c u re m e n t , inventory management, testing, s t a n d a rd s c o m p l i a n c e a n d troubleshooting support. A supplier with a testing/ validation lab for environmental cycling and accelerated life testing gives a WTG manufacturer the opportunity during the design phase to achieve the best possible control panel design. This may lead to additional benefits such as reducing the panel size, selecting components that generate less heat, and/or designing an integrated safety system to help provide safe access to panels during operation. No matter which design strategies are employed, a testing/validation lab can help a WTG manufacturer optimise the panel layout and minimise troubleshooting. 3 Design For High Availability

And Reliability WTGs are used in extreme onshore and offshore environments. WTGs and their equipment must be reliable when deployed in onshore and offshore environments, and spare parts should be readily available in the event of failure. In addition, lowering the Operating and Maintenance (O&M) costs during and after the warranty period is important. Utilising offthe-shelf components with long life cycles and leveraging a large network of global support with

ENQUIRY NO. 501

manufacturing facilities, providing one point of contact for design, documentation management, global coordination of assembly, and consistent quality of wiring, assembly and testing. Most importantly, a global supplier’s distributor network helps ensure product availability and support. The WTG manufacturer also can standardise component selection and panel design across all locations worldwide, simplifying spare parts inventory, procurement methods, training and staffing practices. Reducing the number of control platforms also helps ensure that there is always a knowledgeable technician available because the manufacturer’s staff only needs training and familiarity with one platform. Finally, partnering with an outside vendor for supply chain management allows a WTG manufacturer to effectively increase its production capacity without increasing its internal workforce, allowing existing staff and resources to remain focused on the company’s core expertise — designing the best WTG.

Oct/Nov 2012 | industrial automation asia 55

energy

access to spare parts inventory can help reduce system downtime if a problem occurs. Offshore wind turbines are increasingly used in a number of countries because offshore winds tend to flow at higher speeds than onshore winds, allowing turbines in offshore environments to produce more electricity. Much of this potential energy is near highly populated areas and energy load centres where energy costs are high and land-based wind development opportunities are limited. Offshore turbines have unique technical needs because weather conditions in offshore environments can be extreme and fluctuate more often than on land. Many WTG manufacturers supplying offshore equipment try to meet design challenges by engineering their own solutions. These solutions can be susceptible to moisture and contaminants resulting in short circuits and corrosion of conductors and solder joints. A better alternative, however, is to invest in components specifically designed for these extreme environments and include them as part of a complete control and information architecture, helping improve product longevity while reducing integration and installation costs. 4 Conduct A Standards

And Safety Audit Safety is a critical element in WTG design and operation. Protecting people is most important, and WTG manufacturers must also consider protecting the large capital investment in a WTG. The diameter of wind turbine blades has become significantly larger in recent years, and is now larger than the wingspan of a Boeing 747 jumbo jet, increasing the potential amount of wind energy each WTG is capable of producing. In turn, protecting assets becomes 56â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

WTG Safety Architecture Example

increasingly important for wind turbine manufacturers. Personnel must be protected against rotating parts in the nacelle and hub, and WTG designers may need to use physical guarding or special access requirements to stop the WTG from rotating prior to personnel entering the area. Automation suppliers will continue to validate and test solutions for mitigating arc flash hazards through new wind turbine power cabinet designs. Continuing to develop arc flash resistant solutions by leveraging control components will help WTG manufacturers more effectively mitigate the risks associated with arc flash energy in the future. Performing a safety audit before control system design helps engineers chart the course for an effective safety solution and evaluate risks early in the development process. This saves critical time and helps machine builders get their equipment to market faster. Where hazards cannot be removed through design, machine builders typically will install a fixed physical barrier that helps protect users from the hazard. When

frequent access to the hazardous area is required, non-fixed guards are used, such as removable, swinging or sliding doors. In areas where non-fixed guards are impractical, guarding solutions that monitor the presence of the operator rather than the status of the gate can be used. 5 Provide Compliance To

Regional Electrical And Safety Standards As WTG manufacturers expand operations globally, they must adhere to local and regional standards to help ensure the safety of workers and equipment in those regions. By following appropriate international standards, WTG manufacturers can streamline production processes globally, and gain access to customers all over the world. As an added bonus, incorporating standards into the wind turbine design process can increase productivity and profitability for both manufacturers and operators of wind turbines. The international standards add two very important elements to the reliability of the machineâ&#x20AC;&#x2122;s safety function: time and risk. These two elements help machine

builders take advantage of a more methodical approach to safety system design. Electromagnetic Compatibility (EMC) Directives: EMC management has emerged as a critical means of improving the reliability and operating life of electronic equipment employed in WTGs. EMC directives aim to help ensure that all electrical devices in one electrical environment work properly and safely together. Product Directives: Many product directives have been issued in Europe as part of an effort to create a unified European market. Limited to ‘essential requirements,’ which are general in nature and primarily focus on health protection, these directives are compulsory for any product put into circulation and so apply to wind turbines and their sub-assemblies. GL Guideline for the Certification of Wind Turbines ( E d i t i o n 2 0 1 0 ) : The latest edition of this guideline makes specific references to the EN ISO 13849-1: 2006 Functional Safety Standard and requires that WTG manufacturers conduct a risk assessment to determine the maximum permitted probability of failure. By providing numerical

evidence of the probability of failure, WTG manufacturers can help justify a customer’s investment in new safety systems. WTG manufacturers must follow ISO 13849-1: 2006 and IEC 602041 to gain GL certification of a WTG. GL publishes guidelines for certifying WTGs. Tackling the many, often complex, standards can be daunting. WTG manufacturers should leverage the expertise of certified safety consultants from a global supplier to navigate requirements and design an acceptable safety system. 6 Integrate WTG Safety Into

The Control System Design To Reduce Complexity The evolution of safety standards and economic factors are driving the evolution of safety systems from hardwired to contemporary, highly integrated configurations. Using an integrated platform for safety and standard control eliminates the need for electromechanical or hardwired controls. The more designers integrate the standard and safety control functions of a system, the better the opportunity to reduce equipment redundancies, improve

Tough Love

Allied Vision Technologies Asia Pte Ltd

82 Playfair Road #07-02 D'Lithium Singapore 368001

Tel : +65 6634 9027 Email : info-asia@alliedvisiontec.com

Superior choice takes superior engineering.

Consider the Prosilica GX series, with a sustained data of 240 MB/s, or the all new Guppy F-503, which runs up to 6.5 fps. The modular Stingray will meet even your trickiest OEM requirements,

Interaction of Standard and Safety Control Functions in a WTG Std. Control System Monitoring Examples ➢ Rotational Speed ➢ Electrical Power ➢ Frequencies & Voltage Measurements ➢ Wind Direction & Speed ➢ Temperature Monitoring ➢ Grid Failure ➢ Component Diagnostics ➢ Status of Braking System

Safety System Monitoring Examples ➢ Activation Speed ➢ Activation Power ➢ Short Circuit Detection ➢ Shock ➢ Cable Twisting (Nacelle to Tower) ➢ Yaw Drive ➢ ESTOP ➢ Status of Control System

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Tel : +65 6634 9027 Email : info-asia@alliedvisiontec.com Allied Vision Technologies Ltd 82 Playfair Road #07-02 D'Lithium Singapore lied Vision Technologies AsiaAsia Pte Pte Ltd 368001 82Tel Playfair Road #07-02 Singapore 368001 : +65 6634 9027 Email D'Lithium : info-asia@alliedvisiontec.com

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GL Guideline for the Certification of Wind Turbines

Tel : +65 6634 9027 Email : info-asia@alliedvisiontec.com

Oct/Nov 2012 | industrial automation asia 57

ENQUIRY NO. 503

Standard Control System

and our speedy Pike series now includes 11 and

energy

can simplify designs and reduce integration costs. On The Horizon Wi t h t h e a d v a n c e m e n t s i n technology and globalisation o f s a f e t y s t a n d a rd s , W T G manufacturers can expand to new markets and help customers improve worker safety and protect equipment and assets. By enlisting the help of global suppliers, WTG manufacturers can provide a smooth expansion to new markets and continue growing as the wind energy industry expands. ENQUIRY NO. 7602 Standard and safety control are implemented in a single controller, as shown in the diagram.

productivity and minimise costs. T h i s i n t e g r a t e d c o n t ro l functionality reduces the number of unique components in use as part of the WTG control system, which in turn reduces inventory costs, as well as maintenance team training requirements. End users also benefit from less waste with fewer parts to maintain and replace throughout the WTG life cycle. In addition, integrated control systems, having broader intelligence regarding machine operation and status, reduce nuisance shutdowns and prolonged restarts, further improving machine efficiency and productivity. Safety controllers provide this integrated control functionality and offer benefits in multistep shutdown or ramp-down sequences because they provide the necessar y logic through software rather than the hardwired logic of relays. An integrated safety controller is an solution for any application requiring functionality, such as zone control. Being able to monitor and control access to what is active on each level of the WTG is critical due to the size and height of the 58â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

decks within a WTG tower design. With properly designed safety controls and guarding, designers reduce access time, helping make machines safe and efficient. Along with eliminating the need for a separate safety controller, integrated safety systems also use a single programming software package. This can eliminate the need to write and coordinate multiple programs on different controllers, which in turn can simplify application programming and help reduce training and support costs. Networking offers another way to integrate safety and standard c o n t ro l s . T h e i n t ro d u c t i o n of networks to industrial environments helps increase productivity, reduce wiring and installation, improve diagnostics and ease access to facility data. Using an existing network to include safety information extends those same benefits, allowing communication of the complete automation process on one standard network with one set of hardware and wiring. Diagnostics from smart devices that are networked together also

Rockwell Automation Helps WTG Manufacturer Manage Its Supply Chain Rockwell Automation helped WTG manufacturers get through the economic recession by managing panel shipments. Outsourcing this activity reduced WTG manufacturersâ&#x20AC;&#x2122; financial risk and eliminated the need to have a dedicated assembly team for the project. The company also helped WTG manufacturers manage their supply chain to keep pace with production demands, especially as manufacturing ramps up again. For example, when a global WTG manufacturer enlisted Rockwell Automation to build its control panels and help manage its supply chain and production worldwide, it reached out leveraging its best production practices when building panels. These include using detailed and standardised work instructions, identifying and labeling raw material, colour coding air screwdrivers to match the colour coding of screws for proper torque settings, using safety and metrics boards and effective lockout/tagout procedures. ENQUIRY NO. 7603

ENQUIRY NO. 428

sector spotlight

Smaller Scale,

Bigger Potential IAA speaks with Russell Tham, president, Applied Materials (Southeast Asia), and David Wilhoit, president and CEO, Siltronic Samsung, on the major industry trends they are facing, and the challenges, in the semiconductor industry. By Mark Johnston

he semiconductor industry is adapting to changing conditions in major industries, such as computing. With an increasing number of mobile computing devices and changes in the way we handle information, it is important the industry adapts and innovates to lower the cost of production, but also to develop technology which achieves greater processing potential, at a small scale, while draining less power.

Design Matters, 3D-IC And Beyond I A A : W h a t a re s o m e of the most promising technologies available today that could transform the industry in the next five to ten years if commercialised? Russell Tham (RT): Wafer level packaging, which is one of the key focus areas Russell Tham of research in this joint lab is obviously one of them. This technology enables low power consumption in data centres, and enables products, like iPad, iPhone to get even slimmer, with less power consumption, and so on. A few other big trends, technology inflection points as we call them, that are occurring over the next two to four years as demand for higher performance at a lower power consumption becomes a market requirement, are things like 3D structures within the IC device, making 3D memory structures and 3D finFET structures, and new materials beyond your normal material that you use inside the IC chips. These are all key technology inflection points. As you make things even smaller, another area is extreme

60â&#x20AC;&#x192; industrial automation asia | Oct/Nov 2012

UV wavelength for printing on wafers, called EUV technology. The last trend would probably be transitioning to larger wafer sizes, 450 mm, with todayâ&#x20AC;&#x2122;s industry based on 300 mm wafer sizes. IAA: What are some of the biggest challenges facing the semiconductor industry, particularly with the commercialisation of research? RT: For an equipment making company, I think it would be making sure you have a good grasp of what the technology inflection points are. Another would be making sure you spend your R&D money wisely, because we anticipate that in the next five years the amount of technology inflection points across the industry will be greater than the total submission of what transpired over the past 15 years. R&D capacity, how you make it more efficient, and choosing the right products â&#x20AC;&#x201D; I think these points would be a representation of the industry challenges from an equipment standpoint, but our customers would have to go through these transitions themselves. IAA: What trends do you see playing out over the next five years? RT: We typically look at the end markets, what is happening

IAA: Do you notice changing consumer patterns because of emerging trends, like cloud computing? RT: There is an increasing amount of information being stored in the cloud and with the amount of content going around, the number of devices existing within the whole ecosystem is probably phenomenal. Every year it is increasing and a lot more consumers are entering the middle class consumer space and they are driving this demand. ENQUIRY NO. 7701

The Potential Of Mobility IAA: What will some of the most promising technologies be in the semiconductor space over the next five to ten years? David Wilhoit (DW): If you look at technologies, and this would be mostly the technologies for our customers, you are going to see a bigger drive towards cost optimisation and leading design rules. If you make it smaller, then it is faster and David Wilhoit uses less energy and it is more portable, these are the main mantras that we push. So, for us as a wafer manufacturer, we just have to make things cleaner and flatter. To take advantage of these technologies you need to invest in leading edge, this could be EUV, or going to bigger wafer sizes (ie: 450 mm). All of this takes a lot of money and so a wafer fab that costs maybe US$2 billion to build right now, probably will cost US$5-10 billion in the future. This enables the end products, the newer phones, the newer iPads and such. IAA: What are some of the biggest challenges in the semiconductor industry specific to Singapore? DW: The main challenges in Singapore are attracting talent, and holding on to talent, so what we do is we hire predominantly from within, so we have opportunities for individuals. Over 90 percent of our indirect workforce are Singaporean or Singapore Permanent Residents. We also try and engage them early in the process with awards, etc, where we make sure our employees understand their

ideas are important to our success. In addition, one of the big challenges for us is energy right now, it is a problem around the world, but if you compare Singapore to other semiconductor hubs the cost of energy in Singapore is significantly higher, by 75 to 100 percent higher. What we need to do is work more efficiently, we worked with the government where we introduced high efficient lighting, and Photovoltaics to try and reduce our consumption, but the cost is continuing to go up, and that is a focus for us. IAA: What trends do you see in your industry? DW: As a consumer I would say the trends are towards mobility. The exciting thing for me is that this means more silicon. People get concerned that consumers will buy these mobile deviced and not PCs. Actually the data does not show that, what the data says is that 90 percent of people who have tablets, also own a PC or a notebook, 75 percent of people who own a tablet have a smartphone, and this is a good trend for us because it is duplicate devices. As these devices evolve, an increasing amount of silicon goes into them. For example, for a 32GB iPhone, more NAND, is needed, and actually in 2012, NAND will overtake DRAM in regard to total consumption, so for us as a wafer supplier, our wafers are going into either NAND or DRAM. So, for us, we just want to see demand, we do not care where it is going into. ENQUIRY NO. 7702

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ENQUIRY NO. 366

there, and what it means to us. Mobility is a huge trend, with mobile phones, and cloud computing being the dominant driver of semiconductor growth over the next five years to 10 years. If you look at the market commentary, we are in the very early phase of this whole cycle. The mobile industry is probably what the PC industry was to the whole industry in the 1990s, now we are in a phase where Asia mobility will drive the semiconductor industry for quite a period of time.

Oct/Nov 2012 | industrial automation asia 61

EVENT REVIEW

Away from its noble aspirations, Medtech is big business particularly in Singapore, where its manufacturing output nearly tripled over a short span of 11 years. By Joson Ng

Singapore Posting

High Growth In Medtech Medical device manufacturing is a lucrative trade these days, especially in Singapore. Often overshadowed by their bigger neighbours like Thailand, Indonesia and Vietnam in recent years, particularly in areas of automotive and mould and die manufacturing, Singapore and Malaysia have displayed good competency in the area of Medtech. It is evident in the Medical Manufacturing Asia (MMA) and Medical Fair Asia s h o w s h e l d re c e n t l y f ro m September 12 - 14, 2012. Apart from the two Southeast Asian countries, China, Taiwan, South Korea, France and Germany, along with other nations were also out in full force, exhibiting medical 62 industrial automation asia | Oct/Nov 2012

products from ambulances to surgical drills and artificial joints. T h e b u rg e o n i n g m e d i c a l industry in Singapore hardly comes as a surprise. Minister of State for Health Dr Amy Khor said at the opening of MMA: “The global medtech industry has been growing rapidly over the last decade and is expected to grow at a rate of some 10 percent per annum. Singapore’s Medtech sector has similarly witnessed significant growth over the past decade. In the year 2000, manufacturing output stood at only S$1.5 billion (US$1.2 billion). In 2011, this almost tripled to S$4.3 billion.” This sentiment was echoed by Dr Ricky Souw, chairman of

Singapore Precision Engineering and Tooling Association (SPETA). Also speaking at the opening of MMA, he said: “Singapore plays a leading role as one of Asia’s fastest growing medical device and equipment market. We are currently home to 30 global medical technology companies.” He also pointed out that the country has about 2,800 precision engineering companies that can support the world’s medical technology OEMs and ODMs. The core competency showed by Singapore can partly be attributed to government policies as highlighted by Dr Souw. He mentioned the support shown by SPRING Singapore and IE

The Technologies & Solutions In Medtech IAA zooms into the ‘Tech’ in Medtech Dr Souw said that Singapore is playing a leading role as one of Asia’s fastest growing medical device and equipment market.

Be careful what you put into your body — this phrase is no longer only applicable to what you eat. In today’s world, people need to be mindful of the medical products they choose to use because products like artificial hip joints, surgical implants, dental implants and various internal fixation products are introduced to the body, often permanently. The stakes are understandably high, and so are the engineering requirements. With stringent tolerances and unique performance issues to consider, materials, machining processes and metrological competency are placed under the microscope.

Exotic Materials Often Required In Medtech

Dr Khor expects the Medtech industry to increase in size in the future.

Singapore that have both helped local PE companies upgrade their business capabilities and venture beyond Singapore. It is therefore not surprising that some home grown companies took part in the show. Racer, a SME based in Singapore specialising in contract manufacturing of precision parts was singled out by Dr Khor for their products, which have helped in lowering production cost. In addition to developing home grown companies, Dr Khor also mentioned that the Medtech industry is set to get even bigger in the future. She said: “Singapore’s position as the next hotspot for medtech innovation creation is beginning to take shape. The new Medtech Park, when fully developed, will occupy 185,000 sq m.” September 12-14, 2012 Suntec International Convention & Exhibition Centre Singapore ENQUIRY NO. 7801

The human body is a unique entity that sometimes baffles modern science and engineering. In Medtech, before any real engineering work is done, the base material to be used is under intense scrutiny due to compatibility issues. As the best possible solution is often required in healthcare, materials need to be optimised as well, leading to the usage of composites materials because they often display unique properties that hail from its constituent materials. Ricky Chua, sales and marketing manager of Morgan Ceramics (Singapore) spoke about ceramics’ place in the medical industry and innovations in materials technology. The company has developed a biocompatible metal to ceramic assembly that allows more flexibility in product development. For instance, this results in implantable feedthrus with smaller dimensions. The company also developed the Ultinex Brazing solutions, which utilises tightly toleranced alloys to improve repeatability. This results in lower WIP and lead-times. The technology can join metals like titanium, kovar and ceramics like zirconia and silicon carbide.

Machines For Medtech Machine tool manufacturers Makino and GF AgieCharmilles were also at the show to showcase their medical solutions. According to Makino, Asia Pacific is expected to account for some 25 percent of the global market share for the medical device market. Worth up to US$62.3 billion, this lucrative market looks set to grow. The company pointed out that although milling is commonly used to produce medical parts, EDM are slowly becoming popular as well because they are suitable for titanium, a material that sometimes poses difficulties for conventional milling. To illustrate the point, the company’s U3 wire EDM is said to be used for production of spinal plate and femoral hip stem, which are manufactured from titanium. Difficult-to-machined materials are also high on GF AgieCharmilles’ agenda. Their Mikron HSM 400U LP is touted to be suitable for titanium grade two and five and other materials like CrCo steel and ZrO2. The machine can be used in the dental arena to make abutment, overdenture framework, crowns and bridges. ENQUIRY NO. 7802

Oct/Nov 2012 | industrial automation asia 63

EVENT REVIEW

based to the manufacturing and service-oriented economy it is today. WSH Initiatives The Singapore WSH Conference witnessed the launch of two key initiatives, namely the CultureSafe progamme, and the ergo@work mobile app.

Workplace Safety And Health Conference 2012

Suntec Singapore International Convention and Exhibition Centre was the host of the second Singapore Workplace Safety and Health (WSH) Conference 2012 held from September 12-13, 2012. The theme of the 2012 edition was ‘Changing Landscapes, Shaping a Progressive WSH Culture’. The show opened to over 750 leaders, experts, and delegates from around the world. Opening Address The opening address was given by Tharman Shanmugaratnam, deputy PM and minister of finance, Singapore. Mr Shanmugaratnam touched on three key points during his speech that affect how we look at workplace safety and health, namely, the evolution in 64 industrial automation asia | Oct/Nov 2012

the structure of economic activity, the increasing proportion and participation of older workers, and the continuing advance of technology. Why Now? The event is timely and critical g i v e n t h e u rg e n t n e e d f o r businesses around the world to address pressing WSH challenges. It will draw focus to a wide range of issues, including striving for strong WSH performance in an increasingly challenging operational landscape; ageing workforce; recognising WSH as a core business consideration; and new workplace risks emerging from fast-pace technological developments and the evolution of the global economy from agrarian

CultureSafe Programme By WSH Council The CultureSafe is a programme that provides organisations with a roadmap to advance their WSH culture through a five step cycle. The programme will help companies progress from a reactive to a proactive culture. The Council has also prepared a set of diagnostic tools that measure a company’s WSH culture maturity or CultureSafe index. Through the programme, companies will also be able to identify WSH cultural gaps and develop implementation plans. Ergo@Work Mobile App By WSH Institute The WSH Institute’s new mobile application, ergo@work, will enable smartphone users in the increasingly tech-savvy workforce to download the free app from both the iPhone and Android market. The app takes photographs of sitting postures, evaluates and suggests possible areas for improvement as well as provides tips on how to improve postures and carry out simple stretching exercises. The app aims to raise awareness on good ergonomics in an office environment and help prevent work-related health issues due to poor postures. The third Singapore WSH Conference will be held in 2014. September 12-13, 2012 Suntec Singapore International Convention & Exhibition Centre Singapore

ENQUIRY NO. 7803

ENQUIRY NO. 499

EVENT REVIEW

National Energy Efficiency Conference 2012 power plant thermodynamic performance monitoring, developing Singapore’s energy efficient capabilities, and driving energy efficiency in industry: public and private sector perspectives.

The National Energy Efficiency Conference (NEEC) 2012 took place at the Mandarin Orchard S i n g a p o re f ro m S e p t e m b e r 18 to 20, 2012. The objective of the conference is to provide thought leadership in energy efficiency, bringing together experts in the field of energy efficiency to share best practices and success stories. The theme of the 2012 edition was ‘Energy Efficiency as a Business Opportunity’, aiming to provide insight into controlling and managing operating expense by way of energy efficiency. Focused On Energy The first evening of the event saw the opening, with the events proceedings beginning on day two and three. The second day opened with keynote presentations by Jim Kelly, group VP, head of energy efficiency, ABB, and Juan Aguiriano, worldwide MD, sustainable operations, DuPont, Sustainable Solutions. The focus of the presentations was on 66 industrial automation asia | Oct/Nov 2012

energy efficiency as a business opportunity and how being energy efficient increases productivity and reduces cost. A plenary session followed the opening keynote presentations, titled ‘Driving Energy Efficiency: Public and private sector perspectives’. Various speakers participated, including speakers from the EDB, Texas Instruments, GSK, and Accenture. The session was moderated by Tang Tuck Weng, from the NCCS. On the final day a morning plenary session was held, titled ‘Developing Singapore’s Energy Efficiency Capabilities’, with key speakers including representatives from across the professional and academic fields. Some of the highlights and topics covered over the course of NEEC 2012, include: Industry benchmarking and optimisation, integrative design for energy efficiency, implementing an online energy management system for ISO50001 compliance, direct current distribution for data centre,

Reducing Emissions Mr Kelly, from ABB, one of the keynote presenters, spoke about how energy efficiency can add to productivity and achieve cost savings. He shared how effective energy management systems can contribute to energy efficiency. “Improving energy efficiency is the fastest and cheapest way to reduce energy use and emissions while mitigating the need for power generation and resource acquisition to support economic growth,” said Mr Kelly. Industries account for about one-third of the world’s energy demand. Mr Kelly mentioned key industrial players in Singapore can successfully reduce their carbon emissions, as successful case studies presented in the conference show that the return on investment is clear, and the economic benefits can be reaped quickly. For Singapore, leading in the energy efficiency space will reinforce Singapore’s attraction as a destination for industrial capital investments. September 18-20, 2012 Mandarin Orchard Singapore Singapore ENQUIRY NO. 7804

products & Services

Agilent: Analyser/Curve

Cognex: Barcode Readers

The Agilent B1505A covers up to 1,500 A and 10 kV. Power devices/power modules, including IGBT, Diode, power MOSFETs and power management ICs are a growing device category that requires both high-power and high-accuracy test capabilities. It is an integrated solution that provides researchers and device/process development engineers of these power devices with high-voltage and high-current source and measurement capabilities. This all-in-one analyser/curve tracer unit is designed to characterise all current, emerging and evolving power devices from sub-pA to 1500A/10kV with μΩ and 10μs pulse capability.

Cognex Corporation has integrated the 2DMax+ code reading software technology into the compact DataMan 100 and 200 fixed-mount barcode readers. The readers can now identify and decode severely damaged or poorly marked 2-D matrix codes. Most importantly, the barcode readers are unaffected by variations in lighting, marking method, code quality or surface finish. Although Data Matrix codes have built-in error correction, ‘no-reads’ can still occur when codes are incomplete. The software can read Data Matrix codes even when critical elements are missing. It can also locate and decode Data Matrix codes that are overexposed or underexposed, without requiring multiple retries. This improves throughput, speed and overall reliability.

Tracer Unit

Enquiry no. 7901

Enquiry no. 7903

Banner Engineering: Wireless

Contec: Media Converter

The SureCross Q45 Remote Device (RD) model by Banner Engineering is the latest addition to the company’s line of wireless sensors. The Q45 RD model is capable of interfacing with isolated dry contacts or PNP outputs, allowing the RD to interface with almost any digital sensor. It also features a mode where it interfaces directly with NAMUR inductive proximity sensors. In addition to flexibility, the RD model delivers the longest lifetime of all Q45 sensors. The device operates on less than 100uA of current, allowing the battery to last up to five or more years depending on the application.

The IEEE802.11n-compliant media converter, the FXR2000-G, part of the Flexlan 2000 series from Contec, is a small embedded device embedded device that can convert from RS-232C interface to wireless or wired LAN. Its wireless LAN is compliant with four standards such as IEEE802.11n/a/b/g. Setting the device to IEEE802.11n, allows it to support data speeds of 300 Mbps (theoretical value) communication. It also resists irregular reflection (multi-pas). The result is more speedy and stable communication than the conventional model. The RS-232C converter function of this product implements TCP/IP protocol.

Q45 Sensor

Enquiry no. 7902

Enquiry no. 7904 Oct/Nov 2012 | industrial automation asia 67

products & services

Delcam: Software For

Faulhaber: Product Integration

Delcam has released the 2012 R2 version of its PowerInspect software for inspection and reverse engineering. This includes enhancements to the inspection capabilities and also continues the development of the reverse engineering capabilities introduced earlier this year. The main enhancement in this area has been an expansion of the digitised curves capabilities to create a powerful reengineering and modelling tool. Improvements to the inspection functionality include a simplified procedure enabling users to calibrate the probe assembly by probing a single point anywhere within the measuring envelope.

Faulhaber has extended its linear DC-Servomotor product range with versions aimed at facilitating product integration. The linear servomotors integrate an axial type connection to satisfy constrained space requirements in applications where performance and size cannot be compromised. The axial coupling also improves the mechanical robustness of the connection to electronic controllers. LM 2070 and LM 1247 respectively provide a peak force of up to 27,6 N and 10,7 N. They are available with different stroke lengths ranging from 20 to 120 mm for LM 1247 and up to 220 mm for LM 2070.

Inspection & Reverse Engineering

Enquiry no. 7905

Denso: Robots With

Fuji Electric: UPS

Using its open resources interfacing network, Denso robots can be controlled by C#, C++ and VB. This helps reduce the time requirement for programmers who are proficient in the common language in designing robotics systems. The robot manufacturer has also made its proprietary software Wincaps 3 available to conventional robotics programmers. The software program allows virtual simulation and program testing.

Fuji Electricâ&#x20AC;&#x2122;s UPS and power solutions are available in the 72 VA to 2,000 kVA range, for single modules. For higher ratings, these can be paralleled to deliver 12,000 kVA. The companyâ&#x20AC;&#x2122;s high efficiency UPS helps in reducing costs, weight, footprint and heat. The company has launched a new product line, a Mediumcapacity UPS, the 5000CF series. This series is designed for the Industrial environment, has a IGBT Inverter type and has an included output isolation transformer as standard.

Control Options

Enquiry no. 7906 68

Enquiry no. 7907

industrial automation asia | Oct/Nov 2012

Enquiry no. 7908

products & Services

Harting: Connector Modules

HMS Industrial Networks:

The Ha-VIS preLink technology from Harting is taking further components on board. A connector module can be fitted into the universal M12 housing. Possible connection types include a D-coded version for 4-core data cables with transfer rates of up to 100 Mbit or a variant with X-coding for 8-core data cables, suitable for 10 Gbit. Among the features of preLink connection technology is a termination block, which is connected to the individual cores of the data cable via internal, insulation displacement terminations, which remain stable over time and are vibration-proof.

Anybus CompactCom modules, from HMS Industrial Networks, now come equipped with M12 connectors. This enables network connectivity for machinery which operates in wet, dusty, or otherwise demanding industrial environments. Networks are initially Profibus, Profinet, DeviceNet, EtherNet/IP, Modbus TCP and EtherCAT. Just as the standard CompactCom modules, the M12 versions will be available with and without housing. The M12 version without housing makes it possible to achieve a protection rating of IP67. The CompactCom M12 versions with housing are IP20 rated, just as the standard CompactCom modules with the default fieldbus connectors.

Enquiry no. 7909

Communication Modules

Enquiry no. 7911

Hioki: Power Analyser

IFM: Point Level Sensor

The Power Analyser 3390 and 3390-10, from Hioki, are designed primarily for the testing and evaluation of inverters and motors made for new energy applications. The 3390 and 3390-10 come with a maximum accuracy of ±0.16 percent and ±0.1 percent respectively achieved with the company’s current clamp sensors. Both models are equipped with four fully isolated voltage and current channels allowing measurement of the primary and secondary sides of inverters simultaneously. Harmonics analysis of up to the 100th order and inverter noise analysis by FFT are included as standard functions.

The LMT121, from IFM electronic is an hygienic point level sensor designed to be maintenance free and insensitive to foam and deposits and can be integrated into almost every pipe or tank due to its small compact sensor tip. It can be adjusted to virtually any liquid and viscous medium as well as to bulk materials. Via IOLink it can identify different media by two independently adjustable switch points. Parameters are set by means of IO-Link or the USB interface E30396. The sensor is preset for sugary, sticky media such as honey, sugar syrup or nougat spread. The high protection rating IP 68 / IP 69K also ensures that the sensor is resistant to cleaning processes.

Enquiry no. 7910

Enquiry no. 7912 Oct/Nov 2012 | industrial automation asia 69

products & Services

Igus: Knife Edge Rolls

Nord Drivesystems: Distributed

Igus has knife-edge conveyor belt rollers that were developed in-house for use by the conveyor industry for deflecting conveyor belts. Use of these belts can be found in packaging, conveyor technology, automation, and food technology industries. The thin igus knife edge rollers allow narrow deflection radii for optimal use of available space and a smooth delivery of goods that are especially difficult to handle. The lower driving power required because of rolling instead of sliding knife edges is another advantage. Other advantages are freedom from lubrication and a increased lifetime as well as a higher service life of the conveyor belt.

The SK 200E inverter series from Nord Drivesystems provides certified safety technology for applications up to SIL3. Economic efficiency requires quick restarts after safety-related shutdowns. This series of distributed frequency inverters from the company feature several safety functions that enable safe shutdown procedures in high risk applications that comply with Category 4 or Performance Level ‘e’ according to EN 13849-1. Conventional frequency inverters in this performance class prevent motors from restarting by disconnecting the voltage supply or the 24 V control supply. By contrast, SK 21xE and SK 23xE models feature a certified safe pulse blocking device as well as digital inputs for the ‘Disable Voltage’ and ‘Quick Stop’ functions.

Enquiry no. 7913

Frequency Inverters

Enquiry no. 7915

Kranendonk: Robot Welding

SIC Marking: Fibre Laser System

Dutch robot integrator Kranendonk offers a robotic assembly line for beam profiles. The company’s beam assembly line automatically assembles, tacks and welds attachments to steel beams. The combination of assembling (within 1mm accuracy) and welding increases the quality and productivity of manufacturers. The programming of the system is automated, meeting the demand of the construction where beams differ in size and layout. The system is delivered with two ABB robots and ESAB welding equipment.

A range of integrated laser i 103 l-g meets marking needs on plastic or metallic parts which are subjected to close tolerances or very high rates of production. The choice of the fibre laser technology allows it to be more compact. As a result, its integration into production line is easier. The laser is noted for its high speed of execution, due to optic fibre and sources going from 10 to 50 W. It can also guarantee up to 100,000 hours without maintenance fees. Using the laser, SIC Marking has developed a controller, the fibre unit. Pertinent feature of this controller is its stand-alone function, doing away the need for a PC. With the system, all marking types like alphanumeric, datamatrix, logos, deep or superficial are possible.

Enquiry no. 7914 70 industrial automation asia | Oct/Nov 2012

Enquiry no. 7916

Calendar Of Events 2012/13 OCTOBER

3 – 5 Power Gen Asia 2012

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

4 – 6 Metalex Vietnam 2012

Saigon Exhibiton and Convention Center Ho Chi Minh City, Vietnam Reed Tradex Email: rtdx@reedtradex.co.th Web: www.metalexvietnam.com/

10 – 13 IGEM 2012

Kuala Lumpur Convention Centre Malaysia Expomal International Sdn Bhd Email: igem@expomal.com Web: www.igem.com.my/2012/index.html

22 – 25 Singapore International Energy Week Marina Bay Sands Singapore Energy Market Authority Email: ema_siew@ema.gov.sg Web: www.siew.sg/

27 – 30 OSEA 2012

Marina Bay Sands Singapore Singapore Exhibition Services Pte Ltd Email: es@sesallworld.com Web: www.osea-asia.com/

28 – 2 Mar IIC China Conference & Exhibition 2013 Shenzhen Convention & Exhibition Center Shenzhen, China Email: dgu@globalsources.com Web: www.english.iic-china.com/

MARCH

DECEMBER 4 – 7 ConBuild Mining Vietnam 2012

Vietnam Exhibition Fair Centre (VEFAC) Vietnam MMI Asia Pte Ltd Email: info@conbuild-vietnam.com Web: www.conbuild-vietnam.com

4 – 6 SIAF Guangzhou 2013

China Import and Export Fair Complex Guangzhou, China Guangzhou Guangya Messe Frankfurt Co Ltd. Email: sps@china.messefrankfurt.com Web: http://www.siaf-china.com/english/

13 – 16 Automation World 2013

5 – 7 Semicon Japan 2012

Makuhari Messe Japan Semi North America Email: jstandards@semi.org Web: www.semiconjapan.org/en

5 – 8 Manufacturing Indonesia 2012

Jakarta International Expo Kemayoran Indonesia PT. Pamerindo Buana Abadi Email: info@pamerindo.com Web: www.pamerindo.com

Coex Center Seoul, South Korea Coex Co Ltd Email: mintkiss@coex.co.kr Web: http://automationworld.biz/

20 – 23 Industrial Automation 2013

Kuala Lumpur Covention Centre Kuala Lumpur, Malaysia Malaysian Exhibition Services Sdn Bhd Email: enquiry@mesallworld.com Web: http://www.asean-ia.com/

20 – 23 Propak Vietnam 2013

NOVEMBER 6 – 10 China International Industry Fair 2012 Shanghai New International Expo Centre China Shanghai World Expo (Group) Co., Ltd. Email: ciif@shanghaiexpogroup.com Web: www.ciif-expo.com/

6 – 10 Industrial Automation Show 2012

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

21 – 24 All Industrial Expo 2012

Jakarta International Expo Jakarta, Indonesia Krista Exhibitions Email: info@kristamedia.com Web: www.allindustrialexpo.com

JANUARY 30 – 1 Feb Semicon Korea 2013

Coex Center Seoul, South Korea Email: semiconkorea@semi.org Web: http://www.semiconkorea.org

FEBRUARY

Saigon Exhibition Center Ho Chi Minh City, Vietnam Bangkok Exhibition Services Ltd Email: arayabhorn@besallworld.com Web: www.propakvietnam.com

26 – 29 Inatronics Jakarta 2013

Jakarta International Expo Jakarta, Indonesia PT Global Expo Management (GEM Indonesia) Email: info@gem-indonesia.com Web: http://www.inatronics-exhibition.net/

1 – 3 India Automation Technology Fair Bombay Exhibition Center Mumbai, India Email: tarun.marwah@mmi-india.in Web: www.iatf.in

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

IndustrialAutomationAsia

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ABB PTE LTD

IFC

454

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504

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503

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IBC

496

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435

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481

EXXON MOBIL

494

FLIR SYSTEMS CO., LTD

442

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498

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484

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500

HONEYWELL PTE LTD

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ICP DAS CO LTD

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43/47

461/390

426

OBC

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505

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495

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430

SICK PTE LTD

497

SIEMENS PTE LTD

502

SPECTRIS PTE LTD – RED LION CONTROLS

508

SINGAPORE EXHIBITION SERVICES PTE LTD – OSEA 2012

428

SINGAPORE EXHIBITION SERVICES PTE LTD – MTA 2013

499

IGUS SINGAPORE PTE LTD INGERSOLL-RAND SOUTH EAST ASIA (PTE) LTD MITSUBISHI ELECTRIC ASIA PTE LTD

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| EK11-04E |

Universal high-speed Ethernet. PC- and EtherCAT-based control technology from Beckhoff.

PC-based Control Bus connected directly to Ethernet port software instead of hardware: PLC and Motion Control on one PC

EtherCAT I/Os real-time Ethernet down to every I/O module large selection for all signal types

EtherCAT Drives highly dynamic Servo Drives integrated, fast control technology

www.beckhoff.com.sg/EtherCAT-System Beckhoff EtherCAT components: fast, ﬂexible and cost-optimised. Industrial PC: PCs in various form factors EtherCAT Terminals: IP 20 I/Os for all signal types EtherCAT Box: IP 67 I/Os directly in the ﬁeld TwinCAT: automation software for multi PLC, NC, CNC TwinSAFE: Safety PLC in a Bus Terminal IPC I/O Motion Automation

ENQUIRY NO. 496

Beckhoff Automation Pte. Ltd. Phone: + 65 6635 5000 info@beckhoff.com.sg Beckhoff Automation Sdn. Bhd. (889044-H). Phone: + 60 (3) 7731 8388 info@beckhoff.com.my

ENQUIRY NO. 397