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EXCLUSIVE: IAA’s Inaugural Manufacturing Conference Review Oct/Nov 2014
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Oct/Nov 2014
MCI (P) 018/07/2014 | ISSN 0219/5615 | PPS 1561/06/2013 (022960)
Factory Automation | Security | Renewable Energy | Automotive & Transportation
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ADVERTORIAL
RÖHM - Solutions for discerning customers Founded in 1909, RÖHM is now one of the leading chucking tool manufacturers with a wide and powerful product range. Drill Chucks, live centres, lathe chucks and vices, gripping technology, power chucks, cylinders and mandrels, tool clamping systems and a major potential of special designs. Numerous renowned users in a wide variety of sectors have been placing their confidence in us for decades. One sector on which Röhm concentrates is the oil and gas industry. Production of these fossil fuel energy media is presenting the industry with ever more challenging tasks. The increasing difficulty
of reaching oil and gas reserves calls for new approaches, as even reserves lying at considerable depth seem capable of yielding profits. Different versions of the LVE pneumatic front end chuck are thus being used to clamp pipes of large diameter for the production and transport of the raw materials. As an alternative solution, customers can also opt for the HVE hydraulic front end chuck. The new range of indexing chucks is ideally suited for the clamping of sleeves. Sleeves and connecting pieces can be processed from both sides in a single clamping operation. The ring indexing chucks give maximum axial precision while minimising setup times.
Last but not least, clamping equipment for drill heads makes Röhm an all-round supplier, offering what is needed for all processing steps in the oil and gas industry. The special demands in the area of drill head clamping are met with the help of special solutions. So for example the fixed centre drive chuck makes it possible to insert the tapering inner thread of sleeves on both sides simultaneously. Röhm has been successful in developing all-round solutions for all tasks faced in the industry, once again providing a basis for the creation of specially customised clamping solutions.
e-Quipment - How to save energy and money With a comprehensive product range of electrical clamping and gripping systems, Röhm is positioned in the market as a system supplier for electrical machine tools. As a result, the company is making a decisive contribution to the successful implementation of non-hydraulic machine tools. The e-Quipment products by Röhm are real energy savers. 13.800 kWh per year can be saved in a 3-shift operation when compared to hydraulic systems. This is equivalent to the electrical energy consumption of three small family homes. But it is not the energy savings alone; machine time can also
be saved with Röhm‘s electrical cylinders. Using the machine control unit, stroke and force of the e-cylinder can be optimally adjusted in minutes to the work piece. This reduces the workpiece change times to a minimum. Valuable seconds add up to several days when totaled after a year. Maintenance savings can also be achieved. Oil changes and leakages are yesterday‘s issues. The control unit of the e-clamp identifies the requirement for maintenance prophylactically and therefore prevents expensive downtimes. In addition to the savings potential, Röhm‘s electrical cylinder offers additional advantages: By sensibly controlling the tensile/compressive
force, sensitive workpieces can also be machined precisely. Force changes are possible during rotation, which means that – for example – the force can be reduced during the finishing process to avoid deformations. In addition, thermal impacts on the spindle are significantly lower than for hydraulic components.
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CAPTIS Clamping system for internal and external clamping The collet chuck system is made particularly interesting by its diverse combination and conversion options. In less than a minute, it can be converted from external to internal clamping through the innovative quick change function that has been registered for a patent. In addition, the CAPTIS clamping system is captivating due to the
high repeatability and run-out value as well as good power transmission without deforming the workpiece. The power-operated, rotating CAPTIS collet chuck is suitable for use in turning machines and ensures the greatest flexibility. The compact structure creates more working room in the machine. The CAPTIS-D, which is equipped with axial tightening for machining bars can be easily converted to the CAPTIS-A – and vice versa. This makes it possible to install a workpiece stop that can be clamped on the flange-type components with a keep-down effect.
The CAPTIS-AF with an axially fixed collet and optional workpiece stop is ideally suited for delicate workpieces, short clamping surfaces and use in counter spindles. The stationary CAPTIS-MS collet chuck is suitable for use in drilling, milling and machining centres and for manual machining. It is operated manually with hydraulic power intensification. It is extremely easy to use. It is enough to turn the key a maximum of 180 degrees to clamp the collet. The CAPTIS-MS can be clamped on three sides and can be optionally equipped with a front or internal stop. Thanks to the quick change device, the collet can be changed quickly and easily in just 15 seconds.
RRMP synthetic gripper makes special standard
No matter whether round stock, prismatic workpieces or free-form surfaces: The Röhm synthetic gripper RRMP is produced for the customer within a short time - new manufacturing processes make it possible. In practice, the RRMP is convincing by its extremely low weight and tested endurance strength. Thus, the synthetic gripper from Röhm, for example, is tested on the drill chuck
assembly line Extra-RV, in daily use. Here too, absolute reliability and durability is important. The failure of any single component would result in stoppage of the entire assembly process. Joachim Hander, production expert drill chuck assembly: “In our plant, the RRMP moves roughly 16,000 drill chucks daily. Where in the past maintenance was needed after two million strokes, the synthetic gripper continues to run without any problem. In the meantime, it has performed more than 7 million maintenance-free gripping cycles and no signs of wear.“ For unlimited, multiple turning the RRMP can also be used in combination with a triple air distributor. The limit switch signal
can be transmitted via a rotary feedthrough.
RÖHM ASIA PACIFIC Pte Ltd Mr. Roberto Bencina Cell +65 9625 5123 info@sg.roehm.biz www.roehm.biz
ENQUIRY NO. 779
The clamping and gripping technology expert Röhm launches a synthetic gripper with customizable jaws on the market. For the exact production of the gripper only a 3D model of the workpiece is required.
Oct/Nov 2014 | industrial automation asia 3
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ISSUES & INSIGHTS
30
Intelligent Sensor For Factory Automation
34
Rise Of The Machines: The Return Of Robotics In Manufacturing
A sensor that is designed to simplify the automation process by offloading the task of computing the speed and acceleration data from a PLC is now available. By Michael Stingl, Chris Chan and Boerge Wegner, Sick
Asia is automating its workforce at a rapid pace, with China leading the charge. By Ho Kok Koon, Epson Factory Automation Robotics.
34
PROCESS CONTROL
36
IoT And Big Data Combine For Improved Operations
The Internet of Things (IoT) and Big Data are the new buzzwords in the manufacturing and process sectors. They hold great potential for cost reduction and efficiency improvements across industry sectors. By Stuart Carruthers, Advantech Industrial Automation Group
SOFTWARE & NETWORKS
40
Impact Of Oil And Gas Pipeline Simulators
Computer-based simulators are seen by regulatory agencies as an effective tool for operators, and can help expedite regulatory compliance, which is an expensive and critical business issue for oil and gas pipeline operators. By Tony Collins, Schneider Electric
INSTRUMENTATION & MEASUREMENT 40
44
Using Smart Field Devices To Improve Safety System Performance
Many process plants have smart sensors, instruments, and valves installed as part of their safety systems. These smart field devices can provide a host of useful information to the safety system. By Guillermo Pacanins, ACM Facility Safety
48
Protecting Critical Infrastructure By Fuzzing Protocol Implementations
A demonstration will be given of how fuzzing can be used to remediate exploitable vulnerabilities proactively and make ICS networks more robust against cyberattacks. By Sami Petäjäsoja and Anna-Maija Juuso, Codenomicon
ENERGY
52 44
The Good, The Bad And The Ever-Promising: 2014 Renewables Up-Take In Asia-Pacific
An assessment of renewable energy markets across the Asia Pacific region will be given. By Stephen Webb, DLA Piper
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The Trusted Leader
for Any Measurement
NI data acquisition products are the most trusted computer-based measurement devices available, offering superior accuracy and maximum performance. NI CompactDAQ systems feature more than 50 measurement-specific modules and complete breadth and depth of I/O. Coupled with the analysis and signal processing capabilities of NI LabVIEW software, this platform puts the power of graphical system design at your command so you can build any measurement system faster.
LabVIEW offers powerful analysis functions for sensor and signal data, simplifies GUI development, and helps you program the way you think –graphically.
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(65) 6226 5886 Š 2 0 14 Na t ional Ins t r umen t s . A ll r igh t s reser ved. L abV IE W, Na t ional Ins t r umen t s , NI, ni .com, and NI C ompac t DA Q are t rademar ks o f Na t ional Ins t rumen t s . Other product and company names listed are trademarks or trade names of their respective companies. 07926
National Instruments ASEAN ni.com n asean@ni.com Singapore 1800 226 5886 Malaysia 1800 88 7710 Thailand 1800 345 555
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Philippines 1800 1888 3834 Vietnam 1800 585 837 Indonesia (62) 21 2924 191
Other ASEAN Countries (65) 6226 5886
ENQUIRY NO. 783
2/10/14 12:48 pm
Connect with us at www.facebook.com/IAAsia
SECTOR SPOTLIGHT
Vision Technology: The Road To Improved Production
56
Vision technology has its way of enabling automotive manufacturers to take the high road to better products and consumer safety. By Didier Lacroix, Cognex
Addressing The Compliance Complexity Of Safety-Relevant E/E Systems
60
56
An overview will be given on how the automotive industry can address functional safety to help minimise the risks of product liability and ensure continued profitability. By Andreas Bärwald, TÜV SÜD Auto Service
FEATURES
64
Schunk Coming Into Grips With SEA
A German manufacturer of clamping and gripping solutions has recently set up a regional base in Singapore. By Joson Ng
INDUSTRIAL AUTOMATION ASIA (IAA) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: www.iaasiaonline.com Email: iaa@epl.com.sg
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EVENTS
66
IAA Manufacturing Conference 2014
IMPORTANT NOTICE The circulation of this magazine is audited by bpa world wide. The advertisers’ association recommend that advertisers should place their advertisements only in audited publications.
Copyright. Eastern Trade Media Pte Ltd. All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.
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REGULARS
Refer to pg
10
Industry News
28
EtherCAT Technology Group
24
Fieldbus Foundation
68
Products & Services
7 1
Calendar of Events
25 Profibus 26
CAN in Automation
72A Product Enquiry Card
Advertisers’
for Enquiry Numbers
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Asian Manufacturing Awards 2014 The Best Variable Speed Drive Provider
Fuji Electric’s Low Voltage Variable Speed Drives FRENIC Series
Fuji Electric is the pioneer in manufacturing general purpose Variable Speed Drives (VSD) since 1970’s. It has been leading the market in creating more responsive and functional VSD with energy saving characteristics, resulting in its adoption over a wide range of fields. With the new generation VSD, efficiency is further enhanced thereby keeping your buildings competitive in terms of costs and technology. As a specialist in energy, Fuji Electric’s equipment and components provide total energy engineering solutions in the commercial and industrial sectors.
Fuji Electric Asia Pacific Pte. Ltd.
151 Lorong Chuan #02-01A New Tech Park Singapore 556741 Tel : (65) 6533 0014 Fax : (65) 6533 0021 Email : sales@fap.fujielectric.com Website : www.sg.fujielectric.com
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ENQUIRY NO. 780
At Fuji Electric, we believe there are always further miles in Innovating Energy Technology.
2/10/14 2:29 pm
EDITOR’S PAGE
Security For The Era Of ‘Things’
Published By:
EASTERN TRADE MEDIA PTE LTD (A fully owned subsidiary of Eastern Holdings Ltd)
SENIOR EDITOR
Joson Ng josonng@epl.com.sg
ASSISTANT EDITOR
Mark Johnston markjohnston@epl.com.sg
In an age of increasing connectivity, cybersecurity is a key area for
EDITORIAL ASSISTANT
investment and development. With high profile security breaches
Sharifah Zainon sharifah@epl.com.sg
making the headlines, poor security can cost companies millions in GRAPHIC DESIGNER
revenue, but perhaps more importantly customer trust.
Peh Loon Chin pehloonchin@epl.com.sg
As the world becomes increasingly connected, no longer can we think of networks connected to computers in home or office
SENIOR SALES MANAGER
environments. The era of the ‘Internet of Things’ is fast becoming a
derickchia@epl.com.sg
Derick Chia
reality. Although not proven, It was suggested by Dr Sally Leivesley,
ASSISTANT CIRCULATION MANAGER
a former UK Home Office official, who now prepares businesses and
chianghui@epl.com.sg
Chiang Hui
governments for potential terrorist attacks, that the disappearance
CIRCULATION EXECUTIVE
Nurulhuda Binte Suhaimi
of MH370 could be the result of the world's first cyber hijack. The
nurulhuda@epl.com.sg
concern was enough to suggest this possibility, a suggestion that in the past would not have been given the same level of attention. As the world becomes more automated, and we trust technology to perform work for us without human oversight, it is more important
CONTRIBUTORS
Alessandro Figini, Florian Häfele, Michael Stingl, Chris Chan, Boerge Wegner, Ho Kok Koon, Stuart Carruthers, Tony Collins, Guillermo Pacanins, Sami Petäjäsoja, Anna-Maija Juuso, Stephen Webb, Didier Lacroix, Andreas Bärwald,
than ever to stay ahead of cyber criminals who wish to compromise
EDITORIAL CONSULTANTS
Jim Pinto
a systems security.
Industry Analyst
The era of the ‘Internet of Things’ holds many possibilities and
Alastair Ross Director, Codexx Associates Ltd
opportunities for investment, but there are also liabilities. In the automotive space, cars are increasingly becoming connected. On
SUPPORTED BY:
the physical level, cars that can speak to each other, and ultimately coordinate their movements would result in increased safety for passengers. However, for this safety not to be compromised, cars, and the networks they are connected to, need a comprehensive cybersecurity strategy. Investments in car cybersecurity are
EASTERN HOLDINGS LTD EXECUTIVE BOARD
increasing with a recent US$4 million investment seen in a US automotive cyber security firm.
CHAIRMAN
Kenneth Tan EXECUTIVE DIRECTOR
Cybersecurity is a topic discussed in this issue of IAA, as well as automotive, together with content related to the ‘Internet of Things’ and Factory Automation, and renewable energy investment in Asia. As always, we welcome your feedback, and wish you a productive
Lum Kum Kuen
etm
Eastern
Trade Media Pte Ltd an Eastern Holdings Ltd company
Head Office & Mailing Address:
month ahead.
EASTERN TRADE MEDIA PTE LTD
1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: (65) 6379 2888 • Fax: (65) 6379 2805 Website: www.iaasiaonline.com Email: iaa@epl.com.sg
Mark Johnston Assistant Editor
MCI (P) 018/07/2014 ISSN 0219/5615 PPS 1561/06/2013 (022960) Co Reg No. 199908196C Printer: Fabulous Printers Pte Ltd
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industrial automation asia | Oct/Nov 2014
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INDUSTRY NEWS Fanuc Corporation And Rockwell Automation Collaborate On Integrated Manufacturing Solutions Singapore: Fanuc Corporation and Rockwell Automation have entered a collaboration to provide customers with a more seamless and integrated manufacturing solution. The two companies have expanded their initial collaboration, which started four years ago, in the CNC and Logix Programmable Automation Controller (Logix PAC) environments with further integration of robotics, Robomachines and enterprise software products. The effort will have an initial impact on applications in the automotive industry, where customers can experience benefits of a preferred integration plug-and-play automation and information solution.
FCI And Samtec Announces Strategic Partnership Singapore: FCI Electronics and Samtec, two suppliers of high speed connectors and interconnect systems, have announced the signing of a second-source agreement under which Samtec is licensed to manufacture, market and sell FCI’s next generation ExaMAX high speed connector product portfolio. “This second-source agreement pools technology and manufacturing capabilities of both companies to provide for FCI’s new ExaMAX high speed connector solutions” said Alessandro Perrotta, CEO of FCI.
This collaboration between these two companies expands on their initial efforts with further integration of their robotics, robomachines, and enterprise software products.
NEC Asia Pacific Enters Partnership To Develop Smart Energy Solutions In Singapore Singapore: NEC Asia Pacific has partnered with Singapore’s Economic Development Board (EDB) in developing smart energy products and solutions in Singapore. This partnership will focus on product research and solution development in the areas of energy management & control, smart grid, energy storage and renewable energy integration. Through this partnership, the company aims to support Singapore’s vision to be a global leader in sustainable energy management. The company will spearhead research initiatives to create innovative energy solutions through enabling integration of multiple renewable energy sources such as wind and solar photovoltaic with its
existing energy management control and storage capabilities. Through its grid size energy storage technology, the company aims to improve energy quality and consistency from renewable power facilities and lower emissions, maintenance and capital costs of traditional power plants. The initiative also aims to reduce energy loss of utility companies, as well as enhance their effective capacity. The initiative will develop energy management control solutions for both demand and supply side and aims to bring greater stability and reliability as well as reduce operational costs for the enterprises. Completed field trials have shown up to 20 percent reduction in air conditioner energy consumption.
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ATOM
™
Miniaturisation without compromise
New! Miniature optical incremental encoder system Accurate and reliable position feedback is essential when designing complex motion systems. In applications with tight physical envelopes there is the added challenge of finding an encoder that maintains a high level of performance within a small installed package. ATOM’s unique design avoids the compromises traditionally associated with miniaturised encoders. With ATOM there is no compromise! The new ATOM optical encoder is the first to combine miniaturisation with uncompromised accuracy, leading-edge dirt immunity and long-term reliability. •
World first: miniature encoder with filtering optics for excellent signal stability
•
Comprehensive range of linear and rotary scales: 20 μm and 40 μm pitch
•
Ultra-compact readhead: only 6.7 x 12.7 x 20.5 mm for space-critical applications
•
Quick, easy readhead installation: built-in set-up LED and auto CAL routine enable faster optimization
•
Reduce your system cost: ATOM assures high quality, fast delivery and competitive pricing
For more information please visit www.renishaw.com/ATOM Singapore Thailand Malaysia Indonesia
T T T T
+65 +66 +60 +62
6897 5466 2 746 9811 3 5631 4420 21 25504567
F F F F
+65-6897 5467 +66 2 746 9816 +60 3 5631 5407 +62 21 25502555
ENQUIRY NO. 762
E singapore@renishaw.com E thailand@renishaw.com E malaysia@renishaw.com E indonesia@renishaw.com
www.renishaw.com
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Industry News
Eaton Pushes Forward With Environmental Sustainability In Asia Pacific Singapore: Three of power management company Eaton’s Asian facilities are honoured in its zero waste-to-landfill program. The three Asian sites recognised for their contribution to environmental sustainability are located in China. Since 2010, the company’s facilities worldwide have eliminated a combined total of 2,750 metric tonnes of waste sent to landfills, through recycling, reuse, new work processes and other means. In 2013 alone, the company’s global zero wasteto-landfill program reduced its landfilled waste by about 18 percent — an amount equivalent to 4,900 metric tonnes. The company’s zero wasteto-landfill program recognises facilities for consistently achieving a landfill waste diversion rate of 98 percent through either reuse, composting, recycling on incineration — but only if the heat generated by incineration is collected and used in order to create more energy than what was required for the process. All three of the sites in China undergo an intensive audit process that includes verifying that at least 98 percent of a site's waste is diverted consistently for three months. The company currently has 39 sites achieving zero wasteto-landfill across electrical, hydraulics, aerospace and vehicle operations. These sites are located in Europe, Asia Pacific and North America.
Gemalto Unveils Hub Service To Accelerate The Roll-Out Of Mobile Payment Singapore: Gemalto has introduced its Allynis Trusted Services Hub, a turnkey business service that enables financial institutions, enterprises, transport operators and more generally all digital service providers to benefit from a single connection. The intention here is the ability to securely deploy their valueadded and mobile payment services across a portfolio of smartphones and mobile networks around the world. Through the company’s Allynis Trusted Services Hub customers get a one-stop and immediate access to a large user base using NFC smartphones already equipped with Secure Elements.
Over 1.5 billion mobile users worldwide are covered by the company’s contracted Trusted Services Management (TSM) platforms, with over a hundred million ‘multi-tenant’ SIM cards already in place to protect and manage sensitive application credentials. The hub can handle a large number of future configurations, including Embedded Secure Elements (eSE) that are becoming available in some handsets and Trusted Execution Environment (TEE) that will be running inside next-generation mobile devices, as well as the emerging tokenisation standards.
Veolia Water Technologies Contracted To Provide Advanced Water Solutions For Tun Razak Exchange Project In Malaysia Kuala Lumpur, Malaysia: Veolia Water Technologies South-East Asia has announced a 20-year partnership with 1 Malaysia Development Berhad Real Estate (1MDB RE) for the Tun Razak Exchange (TRX) Project. As Malaysia’s new international finance and trading hub, the TRX Project is to designed according to high environmental standards, and a key focus throughout the development will be water reuse. The company aims to recover at least 80 percent of the expected 3.8 million cu m of sewage generated every year, for reuse purposes within the new district, consequently reducing sitewide fresh water demand by more than 50 percent. These targets will be met by leveraging on five of the company’s advanced technologies. These include the Multiflo settler, AnoxKaldnes Moving Bed Biofilm Reactor (MBBR) technology, Hydrotech discfilters, Alizair deodorisation treatment, and Endetec Kapta units.
The signing ceremony between 1 Malaysia Development Berhad Real Estate and Veolia Water Technologies (SEA), for a 20 year partnership on the Tun Razak Exchange project.
The plant will be operated 24 hours a day, 7 days a week, and will offer numerous benefits to the TRX Project in terms of environmental sustainability and water reuse. Five key technologies from the company's advanced water solutions will be featured in the plant, which is custom designed for the TRX project to treat 13,300 cu m of wastewater every day, with peak loads of 555 cu m per hour.
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ENQUIRY NO. 776
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Industry News
Singapore Logistics Group Boosts South Korean Automotive Sector Gimpo, South Korea: YCH Group, an integrated end-to-end supply chain management and logistics partner in Asia Pacific, has officially opened its YCH DistriCentre in Gimpo, South Korea. The warehouse facility in the Yangchon industrial zone was primarily established to service automotive parts management and logistics for Volvo, the Swedish carmaker. The DistriCentre also serves as a hub for other customers across a diverse representation of industry sectors including Kodak and its distributors, Carestream, Alstom, Alcatel Lucent and JS Medical. The opening ceremony was attended by Singapore’s Ambassador to South Korea, Peter Tan, and
YCH Korea celebrates a milestone with the grand opening of its Gimpo DistriCentre, officiated by H E Ambassador of Singapore to South Korea Peter Tan (centre), chairman & CEO of YCH Group Dr Robert Yap (4th from right), president of YCH Korea Stanley Hwang (4th from left) and key customers.
attended by various customers and partners. Ambassador Tan congratulated the company and said: “I am proud to be a part of the celebrations in YCH’s official opening of its Gimpo DistriCentre today. As Singapore’s home-grown leader in the logistic sector, the YCH Group is yet another shining example of how Singapore companies are contributing to the progress of Korean industries and economy. I am confident YCH will become an outstanding model for Singapore companies’ contribution to Korea’s
economic development through direct investments and engagement of local manpower — as such strengthening the robust economic ties between both countries.” Apart from offering end-toend supply chain as well as global freight and forwarding solutions, the Gimpo DistriCentre specialises in various returns logistics, aftersales and LOgistics Value-Added (LOVA) services, such as the raw materials kitting, management of scrap materials, as well as automotive parts certification.
Mitsubishi Electric To Strengthen Factory Automation Product Services In Ahmedabad, India Tokyo, Japan: Mitsubishi Electric Corporation has announced that Mitsubishi Electric India has begun operating, effective immediately, a new centre to provide Factory-Automation (FA) services in Ahmedabad within the Indian state of Gujarat, where a large number of Japanese manufacturing companies in need of FA services are operating. The Ahmedabad FA Centre will support the ongoing expansion of the company’s FA business in India, which is targeting sales of 8.9 billion INR, or US$146 million, by the fiscal year ending in March 2016.
Visit us on our website at
The Centre will offer FA product training, technical consultation, solutions and training support for the engineering personnel of its customers. FA product servicing operations in the Gujarat area had been handled by the Pune FA Centre, which was established in January 2012, and by local partners. The Ahmedabad FA Centre, one of five such centres that the company now has in India, will provide faster, higher quality local services than ever before. Ahmedabad, which has a robust economy and substantial infrastructure, is aggressively attracting outside
India Ahmedabad FA Centre office for Mitsubishi Electric India.
investment. The area’s increasing number of Japanese manufacturers and automotive companies in general are envisioned stimulating demand for FA products and a wide range of related services.
www.iaasiaonline.com
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15 767 MDS.pdf
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Static Analysis Tool for C/C++ Bugs Free Codes
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Buffer Overrun Buffer Underrun Division by Zero Null-Pointer Dereference Free Non-Heap Variable Uninitialized Variable Dead-Lock Null Test after Dereference Format String Problem
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- Performance Measurement - 1 Month Real-time Trace - Multi-core/Multi-process Debugging
ENQUIRY NO. 767
• Long Term Traceability (around 1 Month) • Support Code Coverage Analysis • Software Performance Measurement (10 ns Time Resolution) • Functions & Tasks Flow Analysis • Support Simulator Mode (File Save Mode) without Dynamic Tracer H/W • Support Various I/F such as UART, Ethernet, SPI, SD, GPIO etc. • Support C/C++/C#/Android JAVA
Industry News
Yokogawa Receives Order To Provide Control System For Ultra-Low-Sulfur Diesel Fuel Plant Japan: Yokogawa Electric Corporation has announced that its subsidiary Yokogawa de Mexico, has received an order from Cobra Instalaciones Mexico, a subsidiary of the Spanish EPC firm ACS, to supply an integrated control and safety instrumented system solution. This solution is for an ultra-lowsulfur diesel fuel plant that is being built for Pemex Refinación, a subsidiary of Mexico’s national oil company, Pemex. To reduce air pollution caused by emissions of sulfur oxide, nitrogen oxide, and particulate matter, Pemex is promoting the use of low-sulfur diesel fuel and gasoline. This project involves the construction of an ultra-
low-sulfur diesel fuel plant at the Pemex Cadereyta refinery complex, which is located in Nuevo León state in northeastern Mexico. The new plant will produce ultra-low-sulfur diesel fuel from naphtha purified at the Cadereyta refinery. This facility will have the capacity to produce 35,000 barrels per day of this desulfurised fuel, and is scheduled to come online in the first half of 2017. For the monitoring and control of this plant’s hydrodesulfurisation unit and sulfur recovery unit, the company will deliver the Centum VP integrated production control system, the Stardom network-based control system, the
ProSafe-RS safety instrumented system for shutting down the plant under abnormal conditions, the Exaquantum plant information management system and other solution-based software packages, the GC8000 process gas chromatograph for analysing gas composition, and a variety of field instruments for flow measurement. Yokogawa de Mexico will be responsible for installation and engineering, and will also provide support with commissioning and the training of plant operators. Installation of these systems and products is scheduled to be completed by the first half of 2015.
ABB Awarded US$103 Million Order For World’s Largest Iron Mine In Brazil London/Zurich: ABB has won a US$103 million contract from Brazilian mining company Vale to install electrical and automation systems at a modern iron ore mine in the Carajás mountains of northern Brazil as part of a major capacity expansion. This order follows a previous US$140 million contract won by the company to complete the first phase of the S11D project, supplying and installing automation and electrical equipment for the process plant that separates the ore from the spoil material. With this order, the company will supply a 230 kilovolt in-feed substation to connect the mine to the electricity grid as well as 42 secondary substations. These secondary substations will be contained in the company’s ehouses, prefabricated, walk-in, modular, outdoor enclosures designed to house a range of electrical and automation equipment. The
ABB to install electrical and automation systems at a modern iron ore mine in the Carajás mountains of northern Brazil as part of a major capacity expansion.
company will also supply the motors driving the mine’s conveyor belts. Vale is developing a sustainable mine of the future in the Amazon. The S11D will still represent an industry vanguard in 20 to 30 years. To achieve this, the company has developed customised solutions and has the capability to successfully deploy these solutions on a massive scale.
The company’s first contract for S11D, announced in September 2012, required the installation and successful commissioning of the primary transmission substation, the first of its kind in Brazil. With this next phase, the company has now been asked to extend the electrification system to the excavators, stackers, reclaimers and conveyor-belt system at the mine itself.
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Industry News
BT Extends Partnership With Glencore To Harmonise Global Communications Infrastructure
The consolidated infrastructure will allow all employees to work together more effectively by improving access to critical business applications for the marketing and mining of natural resources.
UK: British Telecom (BT) has announced a contract with Glencore to build and manage the latter’s global core network across Europe, the Americas, Africa, the Middle East and Asia-Pacific. The consolidated infrastructure will allow all employees to work together more effectively in more than 50 countries by improving access to critical business applications for the marketing and mining of natural resources. BT will also provide a range of collaboration services, including voice, audio conferencing and contact centre services. Cyril Reol, global chief information officer, Glencore, said: “We operate globally and deploy critical activities in very remote areas. As a result, we need reliable communications to bring our employees together in real-time, from our trading offices to our mining sites. The recent merger of Glencore and Xstrata presented us with considerable challenges, including those related to the standardisation and management of the network infrastructure and the reliable provision of communication services between our employees.”
B&R Opens Subsidiary In Japan Austria: B&R, a provider of automation technology, has announced the opening of its 24th subsidiary — B&R Japan, headquartered in Yokohama and led by Masashi Ono. "Japan is one of the toughest markets in the world, but we are ready," said Mr Ono. The company’s considers one of its strengths as being its strong local presence. The company will start with a full team of sales, application and support engineers to care for Japanese customers at their locations and in their own language.
Masashi Ono, MD, leads the new B&R subsidiary in Japan.
Bosch To Acquire Siemens’ Stake In BSH Bosch And Siemens Hausgeräte Stuttgart/Munich, German: Bosch and Siemens have agreed that Robert Bosch will acquire Siemens’ 50 percent stake in the joint venture BSH Bosch und Siemens Hausgeräte (BSH). The transaction has been approved by the board of management and supervisory board of Bosch and the managing board and supervisory board of Siemens. The purchase price will total €3 billion (US$3.86 billion). In addition, Siemens and Bosch will each receive from BSH an additional distribution of €250 million before the transaction is completed. The transaction, which still requires regulatory approval, will probably be completed in the first half of calendar year 2015. BSH will then become a wholly owned subsidiary of the Bosch Group. Under the terms of the agreement, BSH will also be allowed to produce
and market household appliances under the Siemens brand over the long term. “BSH has been a successful and profitable company for many years. Strategically and technologically, it is a perfect match for the Bosch Group,” said Dr Volkmar Denner, chairman of the board of management of Robert Bosch. Technologically, there are also opportunities for intensified cooperation between Bosch and BSH in the future oriented field of the Internet of Things and Services. “Employing Smart Home concepts, the use of household appliances can be made even more energy-efficient in the future, while user-friendliness will further increase,” said Uwe Raschke, the member of the board of management of Robert Bosch who is responsible for the Consumer Goods business sector to which BSH currently belongs.
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Allied Vision Technologies Expands Production Capacity With Investment In Stadtroda, Germany Stadtroda, Germany: Allied Vision Technologies (AVT) has expressed its intention to expand its headquarters’ facilities in Stadtroda, Germany. A new building will be erected on the company’s premises and is expected to be completed in 2015. The additional floor space is needed to expand the manufacturing capacity to meet the growing demand for AVT’s machine vision cameras. The new building will be an extension of the current administration building and will provide 820 sqm of additional office space on three stories. This space will be used to relocate administrative offices currently housed
in the manufacturing building. This will free floor space there for manufacturing and order fulfillment. The construction plan includes a bridge to connect the administration and manufacturing buildings with each other. The expansion is part of a multimillion Euro investment plan to build a manufacturing centre of excellence for the company in Stadtroda, Germany. The Thuringian site will specialise on the production of large volume camera models and be the pilot for companywide manufacturing standards and processes. Besides Stadtroda, the company produces its cameras at two other locations: Osnabrück (Germany)
A new building will be erected on the company’s premises and is expected to be completed in 2015.
and Burnaby, BC (Canada). The facilities in Osnabrück were modernised at the end of 2012 and the Burnaby site will also be expanded.
Endress+Hauser Inaugurates US Customer Centre US: Endress+Hauser has inaugurated an 80,000 sq f (7,432 sqm) Customer Centre in Greenwood, Indiana, US This US$16 million investment in infrastructure helps to optimise customer support and further u n d e r s c o re s t h e c o m p a n y ’s commitment to the US market. Over the past few years, the company has continued to grow its market share in the US and around the world. In the last five years, it will have invested approximately US$150 million into its US operations alone in order to expand its flow, level, pressure, analytical and temperature manufacturing capabilities as well as investments in support structures, projects, services and training organisations. This figure does not include expenses related to the acquisitions of SpectraSensors and Kaiser Optical Systems, both specialised in advanced analyser technology.
Customers can send operators, maintenance personnel, engineers and other process people to the company’s new Customer Centre to get hands-on, real-world application expertise.
The Customer Centre is a certified training facility with multiple classrooms. It allows the company to provide additional, tailored service and support to its customers, for example with factory acceptance testing. Training, repair, and calibration are now stationed
under one roof for faster, more accurate and efficient customer service and turnaround — with additional space for increased customer technical support with technicians available around-theclock to answer customer questions, needs and concerns.
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PaR Systems Opens Subsidiary In Toulouse, France Minnesota, US: PaR Systems, an aerospace manufacturing, material handling, automation, and robotic solutions company, has opened a facility in Toulouse, France. The new facility, PaR Robotique opened on July 1, 2014. The facility will serve a number of growing industries and product lines including Aerospace, Nuclear, Defense, Material Handling, Specialty Cranes and Industrial Automation. This office will focus on the coordination of support activities for its European customers. In addition, the office will also serve as the European base for project management, research and development, and collaboration with European partners.
Frost & Sullivan: More Metrology Equipment In The Automotive Industry Due To Automation Mountain View, US: Rapid automation of automotive manufacturing plants is one of the key factors driving the demand for inline metrology solutions in the automotive industry, says a consulting firm. According to Frost & Sullivan, several powertrain and body-in-white manufacturers will replace traditional, manual measurement solutions — such as CMMs — with inline metrology solutions. Moving forward, as companies strive to gain a competitive edge by robotising their manufacturing plants, end-to-end automated inline metrology will be a key solution demanded by leading automotive manufacturers. The consulting firm also states that the market earned revenue of US$949.2 million in 2013 and estimates this to reach approximately US$1.23 billion in 2018. Finally, with growing interest in
Inline metrology solutions are gaining ground in the automotive industry
concepts such as ‘Industry 4.0’, smart factories and zero defects, the trend toward automation is undeniable and continues to gain momentum. The inline metrology segment in the automotive industry is likely to grow at a Compound Annual Growth Rate (CAGR) of 12.2 percent till 2018. Dimensional metrology manufacturers will need to adapt its product development strategies to keep pace with the requirements of its automotive customers.
Technology An Underused Tool In Emerging Market Supply Chains, Finds Accenture Study New York, US: Despite the vital role that technology plays in helping companies manage the complexity and volatility in global operations, only 48 percent of the more than 1,000 global companies surveyed for a new Accenture study use technology extensively in their emerging market supply chains. Furthermore, 45 percent of the companies from 10 industry sectors sampled for the study, ‘Supply Chain Success Factors in Emerging Markets,’ make only moderate use of technology, automating some essential activities but supporting them with manual processes. The Accenture research also identified ‘supply chain leaders’ from the sample and found that 73 percent of them use technology extensively in the supply chains that support their emerging
market presence, versus only 31 percent of lower performers. In fact, nearly three-quarters of the leaders said they had made heavy investments in such automation tools as manufacturing systems, ERP and supply chain systems. The commitment to technology by supply chain leaders is significant as the study revealed that companies with leading supply chains are more likely to generate stronger growth in emerging markets than those with average or low-performing supply chains. They are more than twice as likely as other respondents (58 percent versus 22 percent) to have achieved growth of 20 percent or more in their priority emerging markets in the past two years. “Volatile conditions continue to
complicate growth and production in emerging markets and the strategic use of digital technologies in supply chains, particularly big data analytics, can be instrumental in providing the up-to-date information needed to make decisions and respond rapidly,” said Mark Pearson, senior MD, Accenture. “Supply chain leaders make extensive use of technology in their operations and show that enhanced agility turns uncertain market conditions into a source of competitive advantage,” he added. Of the industry sectors that were studied, electronics and high tech companies appear to be the most aggressive in using technology within their supply chain organisation to support their emerging market strategies. Oct/Nov 2014 | industrial automation asia 19
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Etherios Joins Salesforce Wear Initiative, Accelerating The Adoption Of Wearables In The Enterprise Chicago, US: Etherios, an Internet of Things (IoT) solutions provider and a division of Digi International, has announced it has joined the Salesforce Wear initiative, creating the first ecosystem dedicated to accelerating the adoption of wearables in the enterprise. As part of the initiative, the company is focused on creating mobile-ready applications that help people lead a healthier lifestyle and improve their quality of life by leveraging an open solution that enables individuals to connect any
wearable device to the Salesforce1 Platform through their AppExchange application, The Social Machine. From remote patient monitoring to fitness tracking applications, the provider is transforming wearable device data into actionable information. In one example, a patient's health is monitored remotely from the comfort of their own home by hospital staff through connected scales, blood pressure cuffs and pulse oximeters that relay real-time information into the Salesforce1
Platform through The Social Machine. Family members can also take comfort as they receive updates on the status of their loved ones from their mobile device. Further, the company is enabling fitness tracking devices to encourage a more active lifestyle by creating ‘gamification’ apps built on the Salesforce1 Platform. Companies are expanding their corporate wellness programs to include these apps and wearable devices to lower overall health insurance premiums for their employees.
Texas, US: Canada’s North West Redwater Partnership has selected Emerson Process Management to provide automation services and technology for the first phase of the Sturgeon refinery northeast of Edmonton, Alberta. Expected value of the contract to the company is approximately US$86 million. The Sturgeon facility will capture carbon dioxide emissions and sell them to traditional oil extraction operations, which will inject the carbon dioxide into wells under pressure to enhance extraction before permanently storing the gas in the wells. This approach is expected to reduce emissions by 1.2 million tonnes per year from the first phase of the refinery while also generating income for North West Redwater. The new facility will also use technologies designed for cleaner
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refining, including elimination of petroleum coke, a waste product typical of traditional refining. North West Redwater chose the company to automate the Sturgeon refinery based on its experience in similar refining processes, as well as its technologies and expertise that can help reduce project costs, reduce schedule risk, and increase process availability. As the main automation contractor, the company will manage the automation of the refinery including providing engineering, configuration, start-up, training, commissioning support, and other services. The company’s automation solution for the project will include its DeltaV distributed control system and DeltaV SIS safety instrumented system to control and monitor operations. Both systems include its Electronic Marshalling technology with Characterisation
Gary Scott, Elmira, Ontario, Canada
Emerson To Help North West Redwater Reduce Emissions At Advanced, Low-Carbon Refinery
The facility will capture carbon dioxide emissions and sell them to traditional oil extraction operations, which will inject the carbon dioxide into wells under pressure to enhance extraction before permanently storing the gas in the wells.
Modules (CHARMs), which simplifies connections between the control system and the thousands of instruments throughout the plant. The automation solution will also include the company’s Rosemount transmitters, Fisher control valves, and Micro Motion flowmeters to carry out essential measurement and control functions.
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Keep your business’ gears moving into the future. From heavy loads and extreme temperature variations to design and capability changes, industrial gearboxes operate under very challenging conditions. And with equipment performance and reliability so crucial to your bottom line, you need technologically advanced lubricants to help keep your business going forward. Introducing Mobil SHC 600 Series next-generation optimum-performance circulating and gear oils. Reengineered and upgraded with a balanced formulation to meet the changing demands of your industrial machinery. Protecting your gears and bearings with long oil life, improved viscosity, and low-temperature properties and substantial energy efficiency benefits. Making forward-thinking Mobil SHC 600 Series an investment in your future profitability. For more on how enhanced Mobil SHC 600 Series can unleash the next generation of productivity, go to mobilindustrial.com.
*The energy efficiency design is a trademark of Exxon Mobil Corporation. Energy efficiency relates solely to the fluid performance when compared to conventional (mineral) reference oils of the same viscosity grade in circulating and gear applications. The technology used allows up to 3.6 percent efficiency compared to the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based onoperating conditions and application.
Copyright Š 2014 Exxon Mobil Corporation. All rights reserved. All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries unless otherwise noted.
ENQUIRY NO. 781
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Industry News
BCG Projects US$67 Billion Market For Robots By 2025 Boston, US: Spending on robots worldwide is expected to more than quadruple from just over US$15 billion four years ago to about US$67 billion by 2025 — a 10.4 percent compound annual growth rate since 2010 — according to Boston Consulting Group’s (BCG) study. The personal segment — robots used for entertainment, cleaning, education, security, and household applications — is projected to grow the fastest, at a compound annual rate of 15.8 percent, ballooning from US$1 billion in 2010 to US$9.0 billion in 2025. The commercial segment — robots used for medical and surgical purposes, agriculture, and construction, among other applications — is expected to grow at a compound growth rate of 11.8 percent from US$3.2 billion to US$17.0 billion, overtaking spending on military applications. The industrial segment — robots used in applications such as welding,
assembly, painting, and material handling — will continue to be the largest, growing at a compound growth rate of 10.1 percent from US$5.8 billion to US$24.4 billion. “The fact that robotics and automation are crossing price, performance, and adoption thresholds is a clear sign that the robotic megatrend is growing in relevance and a tipping point may be near,” said Alison Sander, head of BCG’s Centre for Sensing & Mining the Future. Asian Countries Top Demand Demand for robots is currently highest in South Korea and Japan. Roughly 40 percent of the industrial robots used today are in the automotive sector, in which ‘robot density’ (a metric indicating the number of robots per 10,000 manufacturing workers) already tops 1,000 in five countries —Japan, France, Germany, the US, and Italy. China is the
China is the fastest-growing market for imported industrial robots, according to the group.
fastest-growing market for imported industrial robots, according to the group. “Countries with a greater number of robotic programmers and robotic infrastructure could become more attractive to manufacturers than countries with cheap labour,” said Mel Wolfgang, a senior partner in the group’s Industrial Goods practice. “This rise and expanding reach of robots will fundamentally alter the competitive dynamics of the global economy.”
Huntsville, US: NASA has successfully tested the most complex rocket engine parts ever designed by the agency and printed with additive manufacturing, or 3D printing, on a test stand at NASA's Marshall Space Flight Centre in Huntsville, Alabama. NASA engineers pushed the limits of technology by designing a rocket engine injector — a highly complex part that sends propellant into the engine — with design features that took advantage of 3D printing. To make the parts, the design was entered into the 3D printer's computer. The printer then built each part by layering metal powder and fusing it together with a laser, a process known as selective laser melting. The additive manufacturing process allowed rocket designers to create an injector with 40 individual spray elements, all printed as a single component rather than manufactured
NASA photo, David Olive
NASA Pushes The Limits Of 3D Printing Technology
NASA engineers pushed the limits of technology by designing a rocket engine injector — a highly complex part that sends propellant into the engine — with design features that took advantage of 3D printing.
individually. The part was similar in size to injectors that power small rocket engines and similar in design to injectors for large engines, such as the RS-25 engine that will power NASA's Space Launch System (SLS) rocket, the heavy-lift, exploration class rocket under development to take humans beyond Earth orbit and to Mars. Using traditional manufacturing methods, 163 individual parts would be made and then assembled. But with 3D printing technology, only two parts were
required, saving time and money and allowing engineers to build parts that enhance rocket engine performance and are less prone to failure. Two rocket injectors were tested for five seconds each, producing 20,000 pounds of thrust. Designers created complex geometric flow patterns that allowed oxygen and hydrogen to swirl together before combusting at 1,400 pounds per square inch and temperatures up to 6,000 degrees Fahrenheit.
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Apacer IAA AD-May2014-205x275mm-Revised-2.pdf Apacer Apacer Apacer IAA IAA IAA AD-Aug2014.pdf AD-Aug2014.pdf AD-Aug2014.pdf 2014/7/14 2014/7/14 2014/7/14 下午 下午 下午 02:44:55 02:44:55 02:44:552014/4/16 上午 11:51:35
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Formation Of FieldComm Group Approved
Organisation Appointment The board has appointed Ted Masters as president and CEO of the Group. He currently serves in the same capacity with the HART Communication Foundation. Mr Masters has many years of experience in instrumentation and controls in addition to a deep understanding of the use of data analytics in enterprise systems.
He believes the creation of the Group is an opportunity to build upon existing technologies and develop a single future vision toward harmonisation of standards for the process automation industry worldwide. He said: “I am excited about the opportunity to work together with distinguished leaders and technologies around the globe to integrate valuable process intelligence from devices to improve the operations of our users.” During the transition and integration of the two organisations, Richard Timoney will serve as executive VP of FieldComm Group. Mr Timoney currently is president and CEO of the Fieldbus Foundation. He commented: “The joining of Fieldbus Foundation and HART Communication Foundation will realise the automation industry’s goal of a single, unified body to support advanced digital technology. The efforts of countless individuals and companies have helped us reach this milestone.” FieldComm Group will consolidate offices in Austin, Texas, and function as a single entity beginning January 1, 2015. Until that time, the HART Communication Foundation and Fieldbus Foundation will continue to operate independently. ENQUIRY NO. 7101
Svilen Milev, Bulgaria
THE final step in constructing a single organisation to lead process automation communications and integration technologies was completed when the members of both the HART Communication Foundation and Fieldbus Foundation approved the merger proposed by their respective boards through a voting process that concluded on August 30, 2014. This completes a yearlong study and diligence period by a team of volunteers representing each of the foundations. This single organisation, called FieldComm Group, will be led by a board of directors composed of representatives of the collective companies from the current boards of each foundation. Hans-Georg Kumpfmueller has been elected as the inaugural chairman of the board. Mr Kumpfmueller will lead the direction of this Group and oversee the addition of FDI Corporation in mid-2015. Mr Kumpfmueller has served as a leader in setting the course of device integration in his role as chairman of the FDI Corporation board and as CEO of Sensors and Communication at Siemens. He is convinced the formation of FieldComm Group is ‘a major step forward for the process industries by leveraging the strengths of each protocol and adding the value of the next-generation integration strategy.’
A single organisation to lead process automation communications and integration technologies was completed when the members of both the HART Communication Foundation and Fieldbus Foundation approved the merger proposed by their respective boards through a voting process.
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PI Thailand 2014
Full house at the Thailand seminar.
THE Profibus/Profinet Association South East Asia has conducted another Profibus/Profinet Seminar in 2014. The seminar was conducted in Bangkok, Thailand at Marriott Hotel Sukhumvit 57 on September 4, 2014. A total of 125 people from various industries, distributors, system integrators and universities attended. The seminar was supported by ABB, Leoni Kerpen, Link Vue Systems, Pepperl + Fuchs, Phoenix Contact, Siemens and Turck. These companies provided live demonstrations of their products and solutions at a Microfair, giving seminar participants the chance to discuss face to face with the experts.
Demonstrations The Profibus/Profinet multivendor demo was introduced. This showed the wireless integration of Profibus-DP/PA into Profinet, also the integration of different products and protocols. The live engineering of an IO-System was demonstrated along with Profinet’s web diagnostic functions and remote services. The seminar had three parts; news and market updates on Profibus/Profinet; a Profibus Block, with presentations on installations and best practices; and a Profinet Block with presentations on innovative Industrial Ethernet solutions as well as the new features available. These presentations were done in the Thai language which also proved the local competency in the market of Thailand.
PI Growth Bernd Lieberth, president of the regional Profibus/ Profinet Association, presented the latest news, including the world sales figures. Profibus increased
Multivendor demo with wireless integration of Profibus into a Profinet System.
its installed base by 3.6 Mio nodes in 2014, which means the total installed base is now in excess of 47.4 Mio nodes. Profinet also grew, from 5.8 Mio nodes last year in 2013 to 7.6 Mio nodes in 2014. Mr Lieberth also introduced a reference story out of Mexico in the Automotive industry that showed the strength and advantages of Profinet with an installed system of 10.000 nodes on a Profinet network. Mr Suwichai (Link Vue Systems) presented best practice and regulations for setting up a Profibus network based on his many years of experience with real installations, this presentation was done in the Thai language. The day ended with presentations on Profinet from Annop Kijpilankornkul (Siemens, Thai language) and Rockel Babagay (Phoenix Contact). With Profinet, PI has developed a comprehensive Industrial Ethernet networking standard from the experience gained from Profibus. The result is open and manufacturer-neutral. Profinet meets all of the requirements for using Ethernet at all levels, and in all automation applications. It is flexible, reliable and robust in any industrial environment. The technology also offers new possibilities too, such as redundancy, shared device, intelligent devices, and wireless connectivity. The seminar in Bangkok is part of a continuing seminar series in ASEAN countries. Mr Lieberth said: “We achieved a high participation rate thanks to the support of our local Thai members, who helped us with the organisation and with professional translation during the event. We will continue our seminar series this year with the last seminar being in the Philippines.” ENQUIRY NO. 7102 Oct/Nov 2014 | industrial automation asia
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Mechanical Assistants With Embedded CAN Networks FOR farmers the day usually starts at three or four o’clock in the morning. They have to look after their cattle, feeding and milking them. However, thanks to a milking robot, the cows can now milk and feed themselves. This means a more comfortable life for farmers. They are able to go back to bed on a rainy day or can do other things such as cooking dinner or managing other tasks, because the cows now decide when it is milking time. Machines do not complain about getting up early. The robots feed and milk the cows without the help of a human, such as no one has to move the cows into the milking box. The animals go there on their own because they know there is food in the form of a measured amount of grain in the box. Robotics In Agriculture Service robots are revolutionising the agricultural sector. They sow, weed, fertilise, and feed animals with increasing autonomy. Netherlands-based company Lely, a manufacturer of robotic milking systems, offers an entire line of products, from stall cleaning systems to automatic feeding systems. One such product is the CAN-featuring Lely Astronaut A4 milking robot for about US$250,000 including a mechanical arm and teat-cleaning equipment. According to the company, an increase in labour productivity is desired to ensure a healthy dairy business in the future. Achieving more litres of milk per worker in an animal-friendly way is what the company is aiming for. They think only one man can milk two million litres per year. On conventional dairy farms where milking is done twice a day now, production increases of 10 percent to 15 percent can be realised by means of their milking robot. It can handle about 180 milkings a day. A robotic milking system offers the most reliable employee imaginable. This robot employee is there
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A farm may be the last place someone would expect to find a robot but actually, they have long been used to milk cows.
to milk for the owner 24/7 for years to come. It is trained to prepare the cow for milking, to attach the teat cups and to reattach them if required, to detach after milking, and to carry out post-treatment. Due to the robotic milking system, many factors can be monitored for each individual cow, factors that cannot be provided in a conventionally milked herd. Robot milking decisions are transferred from the farmer to the cow, making early signals important. Owners can now treat their cows individually again, which results in improved health of the cows, shorter calving intervals, and reduction of feed costs. In the so-called cow traffic, the cow decides when she wants to eat, get milked or lie down, thereby improving the well-being of the cow. This influences the cow’s behaviour when it comes to visiting the robot. Robotic milking is different from conventional milking in many ways. One of the main differences is that cows can be milked more in tune with their natural behaviour. A main feature of the Astronaut A4 cow box is the walkthrough design called the I-flow concept. Because of it the cow walks straight in and out of the unit without making turns. This makes the process easier for the cow, which shortens the
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After going in the box the stainless-steel robotic arm moves under the cow, scans it with lasers to find the teats, and attaches four teat cups.
learning curve, increases the throughput, and as a result the capacity of the robot. The Teat Detection System (TDS) of the company features a three-level scanning technology, which provides detection of the teats. Above the cow is a mounted video camera that measures the animal’s position, which means if the cow moves, the robotic arm moves with her. Quality Control The Milk Quality Control (MQC) is a tool for measuring milk quality. It is located inside the arm of the robot just beside the udder. During milking, the milk is continuously monitored per quarter. This provides the user with vital information on mastitis, fat and protein, and lactose for managing milk quality and the cow’s health. Mastitis is the inflammation of breast tissue. To prevent it, the optional MQC-C somatic cell count measurement system monitors the SCC per milking per cow. Alarming deviations are noticed and reported. The Milk Quality Control - Somatic Cell Count Indicator (MQC-C) is an optional part of the milking robot and is used to measure the class of the somatic cell count per cow per quarter. This is done in an automated process and can be set in the company’s management system called T4C (time for cows) to carry out the test per cow, group of cows, or the whole herd. The test is based on the drain time of a mixture of the milk and Astri-Cell (a fluid needed for measuring the somatic cell count in the milk). The test also indicates the udder health. The MQC-C gets its input (when to test) from the MQC and sends its output (test results, number of visitations) to the MQC. Results and class attentions of the test can be found in the T4C software. Hardware-related alarm messages can be found
on the X-Link. The visitation lists generated by T4C can be found on the X-Link. The MQC-C can be built into the Astronaut A3 ex-factory but also installed on an existing Astronaut A3 milking robot. Depending on the production date, it is possible some other modifications must be done to install the MQC-C on existing milking robots. It has three primary parts: the sampler, the processor and the wall socket. The sampler is installed on the support between the MQC and the milk jar. The function of the sampler is to separate a small quantity of the milk for the test when a test must be done. The sampler gets input from the processor and sends output to it. The processor is a box (a base and a cover) with pumps, valves, chambers and electronics. It is installed on the milking robot frame behind the intermediate panel and is attached to the processor installation bracket. The processor has the following main functions: to transport, mix, test, and drain the mixture. The processor pumps the milk from the sampler to the processor and adds Astri-Cell to the milk. When the test is done, the processor pumps the mixture to the sewer. The processor gets its input from the sampler (electronic and milk samples), the wall socket (AstriCell, water and compressed air), and the MQC (via the CAN connector). The processor sends output to the sampler and the MQC. The wall socket is installed behind the intermediate panel on the right side of the machine room above the pumps. The wall socket joins the input of the water, Astri-Cell, and compressed air supply with the tube bundle that leads to the processor. It is provided with pressure reducers for the water and the air supply. The CAN Network The CAN network of the milking robot supplies the electrical power to the MQC-C. According to Peter Meyer, product manager dairy, Lely, they use standard CAN network components with a CANopen protocol, the internationally standardised (EN 503254) CAN-based higher-layer protocol for embedded control system. The CAN components of the robot are well supplied with 27.2 VDC / 4 mA to 20 mA. The CAN network works via a two-wire connection (CAN high / CAN low). Saving energy also leads to saving costs. Here, the key to saving energy lies in the few movements for the connection and removal of teat cups as well as using only one pneumatic system for all milking robots and related equipment in the barn, such as selection gates. ENQUIRY NO. 7103
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Diagnostics And Error Localisation With EtherCAT Diagnostic characteristics play a major role in determining a machine’s availability and commissioning time. In addition to error detection, exact error localisation is important. EtherCAT has various different diagnostic features inherent to its system. By Alessandro Figini, technical support and test; and Florian Häfele, technical support and test, EtherCAT Technology Group. IN EtherCAT networks the slave devices process the Ethernet frames according to the topology determined by the hardware using a dedicated real-time component, the so called EtherCAT Slave Controller (ESC). The slave devices come with diagnostic mechanisms on all layers of the ISO/OSI stack specified in the fieldbus standards. Diagnostics On Physical Layer Level The Physical layer includes cables and connectors for building up the infrastructure of the network. Each ESC port monitors the communication on the hardware level by processing relevant information to the user. In addition to different other errors, ESC ports detect link lost occurrences and increment an according link lost counter. Such errors can be caused by loose contacts, insufficient connections or broken cables. By reading out the appropriate registers the disturbance of the physical medium can be localised precisely. Another diagnostic feature is the CRC check (checksum) of the incoming frames: In case of failure the corrupted frame is marked as damaged, the data contained therein is ignored and the CRC error counter is incremented. Following devices ignore the data of this frame, too, and increment a forwarded CRC error counter instead. CRC errors are typically caused by EMC disturbances as they occur in energised cables which run near to the communication cable. By reading out the register of both error counters the user can detect the location where possible EMC disturbances have interrupted the communication. Diagnostics On Data Link Layer Level The data link layer guarantees the data exchange between the EtherCAT frame and the EtherCAT 28
The logical procession of the Ethernet frames is carried out via the EtherCAT Slave Controller.
participants in the network. This exchange can be both acyclic and cyclic. The latter can also be controlled cycle synchronously between several distributed participants. In the slave devices interrupts or watchdogs monitor the data exchange and synchronisation. A powerful diagnostic mechanism on the data link layer level is the ‘working counter’, which is transferred with each read and write command. This counter increments after successful data exchange in each passed slave. By comparing the actual with the expected figures the master checks within the same cycle if all slaves work with consistent data or if individual datagrams have not been transmitted. The ‘working counter’ informs about different possible errors, eg: if a slave cannot exchange data due to missing connectivity or internal hardware interrupts. Also problems with parameterisation which include the configuration of process data or the communication timing are detected that way.
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Status changes are required by the master and confirmed or denied by the particular slaves. In case of configuration errors during startup or internal runtime errors the slave denies the status change or changes to a lower status internally, sets an error bit and provides an error code. An example for this diagnostic function is given when the process data configuration between master and slave differs: the slave will deny a status change to SafeOperational with the error code ‘Invalid Input Configuration’. Another example is given when the slave does not receive valid process data for a specific amount of time: it then With a ‘working counter’ the EtherCAT master can check the application for errors simply changes its status to SafeOperational and cycle synchronously. and reports the error ‘Process Data Watchdog’. The application layer status Working counter errors are processed to an register can be read out cyclically by the master with a single broadcast command to monitor the complete overlaid application, eg: a PLC program, so the network status. applicator can code a suitable response in the Besides the central diagnostic ability via the software. EtherCAT State Machine, EtherCAT devices can In applications which require a high grade of report specific internal application errors. Those synchronicity of their components the mechanism of are dependent on the individual function of the Distributed Clocks (DC) is used within the EtherCAT slave: this can be an overvoltage for an analogue network. For this data link layer functionality there are different diagnostic mechanisms, too. Each slave input terminal, which exceeds the maximum torque includes a system time difference register which limit for a drive, or an internal overheating alarm. contains the difference between the local clock in CAN application protocol over EtherCAT (CoE), the the slave and the global network time. By reading standard EtherCAT protocol for the acyclic parameter out this register value from all slaves which use DCs, access, defines the Diagnosis History Object which the master can monitor how precisely the network works like an error register. Within this object devices is synchronised and inform the user in case of can record and save up to 250 application specific irregularities. diagnostic messages which can be read by the master Since EtherCAT uses standard Ethernet frames and reported by the user. the network status can be monitored via free-ofcharge software tools, eg: Wireshark. That way, whole Conclusion EtherCAT frames as well as all datagrams within them Distinctive EtherCAT diagnostic functionalities are can be reported, displayed and analysed. existent on all levels of EtherCAT communication and as such provide a full and detailed overview about Diagnostics On Application Layer Level the network status. Those functionalities are inherent The application layer applies to the individual to the EtherCAT protocol and can be centralised functionality of each slave: for example, reading a by the master with a short number of additional temperature signal, controlling pneumatic servo commands. The diagnostic mechanisms of EtherCAT valves or driving a motor. Here, one significant are implemented in hardware or defined in the basic diagnostic information is based on the EtherCAT State specification of EtherCAT, as such, the support of Machine which organises the behaviour between all related functions is guaranteed for all EtherCAT master and slaves. Each status corresponds with a devices similarly. number of available communication functionalities. ENQUIRY NO. 7104 September Oct/Nov 2014 | industrial automation asia 29
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ISSUES & INSIGHTS
Intelligent Sensor For Factory Automation A sensor that is designed to simplify the automation process by offloading the task of computing the speed and acceleration data from a PLC is now available. By Michael Stingl, product manager; Chris Chan, product manager; and Boerge Wegner, product manager, Sick
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roximity sensors are the eyes and ears in factory automation processes. They can be the photoelectric type, inductive type, magnetic type or capacitive type. Of all, inductive proximity sensors are one of the most popular choices among designers. They come in many shapes and sizes to fit different applications, and are distinguished by a long operating life and extreme robustness in harsh industrial environments. Inductive proximity sensors are non-contactless switch triggered by the presence of a metal object. The output signal is mostly an ON-OFF type, connected to digital inputs of either a Programmable Logic Controller (PLC) or the distributed Input-Output (IO) units. The inductive proximity sensor is used either to (a) detect unidirectional motion, or (b) detect rotational motion.
Inductive sensors for detecting unidirectional motion.
In automation tasks, the PLC will poll the IO or sensor periodically. For unidirectional motion detection, an automated task will trigger mechanical movements of the metal target towards the sensor, and activate this sensor. For rotational motion detection, the inductive sensor generates ON-OFF pulses due to the rotating movement of the target object. The PLC counts the pulses to determine the speed and acceleration data, and decides on the next automation task. Rotational motion detection normally requires more PLC processing bandwidth. Typically there can be several hundred or several thousand inductive sensors in a factory automation line. Each sensor may demand bandwidth from a PLC. Hence, the PLC has to have enough MIPS to liaise with all equipment including sensors at the same time. Unfortunately, as the automation line
Inductive sensors for detecting rotational motion.
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gets more advanced where more equipment are demanding PLC bandwidth, as such, it may not be able to cope.
Demands For Intelligent Sensors
can trigger the PLC when some abnormal conditions are detected.
Introducing SAM
The Speed-Acceleration Monitor (SAM) inductive sensor is designed to simplify the automation In many factory automation processes, such as process, by offloading the tedious task of computing steel cable stranding machines, textile weaving, the speed and acceleration data from the PLC. certain conveyor systems, and so on, the workBriefly, the SAM is a 4-pin inductive sensor, housed piece quality is highly dependent on shaft rotary speed and acceleration. Any small deviation can affect end product quality which can result in higher scraps. For tighter control, each motor on the machine needs a sensor to capture rotational pulse information, and feed them to the PLC. The classical method is to FAULHABER Drive Electronics. use a simple inductive ON-OFF proximity sensor to measure the rotation of the toothed fly-wheel. The angular speed, for flexible Automation acceleration-deceleration computation is dedicated to the PLC. The PLC ‘MIPS’ has to be high enough to compute all the data simultaneously, and control the process tightly. Unfortunately this classic method hogs a lot of PLC resources. A typical steel cable stranding machine uses around forty motors and therefore re q u i re s f o r t y i n d u c t i v e sensors. The PLC has to poll all the sensors and analyse the total number of pulses to determine the angular parameters. This is taxing to the PLC, which may not be fast enough to handle such tasks. A PC-based controller may have to be Motion controller with canopen interface used instead. Alternatively, IO With the new interface, FAULHABER offers its complete Motion modules such as programmable Control product range with the preferred field bus for multi-axis counters attached to the applications in automation technology. In addition to the standalone inductive sensor, can be used version, complete systems are also available. With a diameter of just to offload the controller, but 22 mm, FAULHABER presents the world’s smallest integrated CANopen this can result in escalating motion controller. info@faulhaber.com.sg system cost. A more intelligent sensor is required, whereby the PLC can dedicate the task of computing We create Motion www.faulhaber.com the angular speed-acceleration data to this intelligent sensor. It
ENQUIRY NO. 782
Integrated Communication
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ISSUES & INSIGHTS
The SAM inductive sensor is designed to simplify the automation process, by offloading the tedious task of computing the speed and acceleration data from the PLC. How It Works?
An intelligent inductive sensor being used in an automation process.
in cylindrical threaded housing. Two housing types are available, the 18 diameter type which has a sensing range of 7mm, and the 30 diameter type whose sensing range is 10mm. The sensor’s output is a simple discrete ON-OFF signal like any other inductive sensor. The sensor can be programmed using an IO-Linkenabled programming box and a laptop-based user interface software. It is connected to the programming box. On the user-interface program, designers can set up a few threshold values to monitor. Once the sensor is setup, it is ready to go, where they can operate either as a stand-alone sensor, or operate as one unit in a IO-link environment. Application wise, it is straightforward. One SAM inductive sensor is mounted on each motor. Instead of transferring every single pulse to the PLC, the computation of the speed is directly done in the sensor itself. The SAM will output a single ONOFF signal to the PLC once the motor speed or acceleration gets above the pre-set threshold values. This reduces the traffic and computing time of a PLC dramatically therefore saving cost.
This inductive sensor offers two main functions: (a) speed monitoring, and (b) acceleration monitoring. In the speed monitoring mode, the SAM checks if the speed of the rotating target reached the upper threshold, and to activate the output if this is true. The upper threshold and a lower threshold can be set from 6 pulses to 12,000 pulses per min. Application-wise, the upper threshold can emulate the MUST_NOT_EXCEED speed of the motor, while the lower threshold as the desired operating speed. In acceleration monitoring mode, the sensor can check for a deceleration of the system between the range of 0,1…2 pulses/sec2. At constant rotating speed, there is no change in acceleration and the output remains. If deceleration is detected, the output is toggled immediately. Application-wise, the acceleration monitoring mode is perfect for monitoring any machines with regular speed changes eg: due to format changes in the production process. When using standard speed monitors, the designers have to adjust the thresholds in accordance with the speed after every format change, in order to detect motor breakdowns immediately. With the SAMs acceleration monitoring mode, this is not needed anymore. The acceleration is independent of the absolute speed value. By monitoring the acceleration ON-OFF data from the sensor, the designer can check for motor breakdown in the automation process.
Cylindrical Φ18mm and Φ30mm SAM inductive sensors.
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SAM Benefits Simpler Process And Lower Cost Of System SAM inductive sensors can simplify the whole automation process design. An example would be an automated process with many cascading motors, whose rotation speed and acceleration are coordinated closely to ensure a smooth process flow. Should one motor breakdown, while all the other motors are still running, crumpling of the work-piece can happen. To safeguard this, the sensor can be used to monitor speed and acceleration characteristics of mission critical motors, and triggers an ON-OFF command to the PLC who then executes recovery sequences. With SAM inductives, the system does not need a high-end PLC or PC-based controllers. The result is a simplified control system which is now cheaper.
Conclusion The SAM inductive sensor is designed to simplify factory automation processes. With this sensor, the bandwidth consuming task of computing angular speed and acceleration data can be offloaded by a system PLC to this sensor. This results in a simpler control system, which drives cost down. In addition, system commission and calibration is also made easier. ENQUIRY NO. 7201
ENQUIRY NO. 754
Simplifies Commissioning & Calibration Lastly, these sensors shortens commissioning time and effort. During process commissioning, the engineers need to teach the system when and how to react. When using the classic
method, the engineers need to measure the system characteristics. Next, they need to write a comparison algorithm and lookup table for the controller. With SAM, commissioning the system is much simpler. The engineers just setup the sensor’s threshold trigger via IO-Link. No physical information is required on shaft speed and acceleration. The sensor will process all data and interrupt the system controller should the actual shaft speed or acceleration falls out of the sensor’s pre-set threshold. This saves a lot of commissioning time and resources.
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ISSUES & INSIGHTS
Rise Of The Machines:
The Return Of Robotics In Manufacturing Asia is automating its workforce at a rapid pace, with China leading the charge. By Ho Kok Koon, regional sales manager, Epson Factory Automation Robotics
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ince its resurgence from the global financial crisis in 2010, the robotics industry has been going from strength to strength as more manufacturers see the benefits of investing in automated systems. To say that the manufacturing industry is changing is something akin to saying that the sun rises every day. The manufacturing industry is an ever-changing landscape and the reason for that is the constant search for a greater return-on-investment. How do manufacturers reduce their costs, increase their productivity and the ever important bottom line? The key element in this would be the streamlining of operations. Regardless of industry, when manufacturers find a method to make their operations smoother and more seamless, it is inevitably found that their overheads begin to decrease and their productivity and efficiency increase. All of this, of course, has a roll-on effect to their revenues. This is one explanation as to why robotics has enjoyed a swelling popularity among manufacturers, especially, manufacturers in Asia who, as a result of being developing markets, are more agile and flexible when it comes to implementing change.
Growth Of Robotics Ever since the early 90’s, the use of robots has been on the rise, especially in Asia. The growth of this industry was only derailed twice (during the 1997 and 2008 financial crises) and both times, through no fault of its own. The most recent resurgence, in 2010 saw a 132 percent rise in robot sales globally and it should come as no surprise considering that manufacturers
who have adopted robotic systems have seen a rise in productivity, safety and consistency in product quality as well as greater flexibility in manufacturing ever changing product models. The growth has not stopped there, however. According to Fuji Keizai, a provider of information on industrialised and emerging economies around the world, sales of small robots (less than 20kg payload) is predicted to grow 160 percent from 2012 to 2016 and global growth from 2013 to 2014 will be around 10 percent.
China Rising So where is the majority of this growth coming from? One does not have to look far to find the answer, nor should it be any surprise. When considering annual sales, the top prize undoubtedly goes to China, who also happens to be the fastest growing market worldwide. According to the International Federation of Robotics, almost 37,000 industrial robots were sold in 2013 in China. The China Robot Industry Alliance also reports that of this, almost 25 percent were installed by local suppliers, making their sales volume three times higher than the previous year and they are not alone. Foreign robot suppliers increased sales by approximately 20 percent and in total, between 2008 and 2013, the supply of industrial robots increased by about 36 percent per year on average. This means that by 2013, every fifth robot sold in the world was installed in China.
ASEAN’s Shining Star Another market, this time within the ASEAN region,
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that has been conspicuous on the manufacturing growth radar is Indonesia. A recent article in a prominent Jakarta daily, the vice chairman of the Indonesian Chamber of Commerce and Industry (KADIN) & president director of PT Gobel International, Rachmat Gobel, stated that Indonesia needs a strong manufacturing sector — one that can compete globally — if it is to provide enough jobs with adequate incomes for its rapidly growing workforce and that it is now time to get Indonesia on track to becoming the manufacturing powerhouse it can be. That seems to be exactly what is happening in this burgeoning market. According to the Oxford Business Group, growth in Indonesia’s manufacturing sector continues to outstrip the rest of the economy, with gains in most industries well above that of the national average. The strongest performers are the food, beverage and tobacco segments, which are registering 9.3 percent growth but in general, non-hydrocarbons industries are ramping up production by 5.5 percent year-on-year for the first half of 2014, which is above the overall 5.2 percent expansion of the country’s GDP for the first six months. The importance of the manufacturing sector in Indonesia is not lost on the powers that be, who announced in late July that it would establish 36 new industrial hubs over the coming 20 years on islands other than Java. The aim of the government is to lift the ratio of manufacturers operating outside of Java to 40 percent by 2025, from its present level of 27 percent. Plans for this are moving along steadily, with the launch of two industrial estates in Morwali, in Central Sulawesi and Kuala Tanjung in North Sumatra, along with two special economic zones in Palu, Central Sulawesi and Bitung, North Sulawesi marking the completion of the initial stage.
Compared to Cartesian robot systems, SCARA’s are generally faster and cleaner, and occupy a smaller footprint.
What this all means is that Indonesia is rapidly becoming a crucial market for industrial automation. With the strong emphasis being placed on the growth of the manufacturing sector, it is inevitable that the robot industry will grow right alongside it and from the perspective of a robotics supplier, there is a great deal of potential in Indonesia, perhaps one of the strongest potential markets in ASEAN.
Why Robotics? As a supplier of Selective Compliant Assembly Robot Arms (SCARA), we have come to understand the ASEAN market very intimately, which is why we are placing a great deal of importance on Indonesia, so much so that we are actually launching a new Robot Evaluation Centre in Jakarta, Indonesia in the fourth quarter of 2014. Our goal is simply to convey the benefits for manufacturers in investing in robotic systems. Firstly, investing in robotics means creating more energy efficient operations, reducing both carbon footprint and overhead costs. Furthermore, the reduction in overhead costs does not come from the reduction in staff, as many fear is the result of automation. In fact, a report by the International Federation of Robots actually quashed the commonly held belief that robots are the nemesis of employment generation. The study, which was carried out in 2011, found that three million jobs are enabled by the use of one million robots and that over the next five years, increasing adoption of robotics technology in areas such as electronics and alternative energy will result in the creation of up to another one million, high quality positions. Another argument for automation comes from the growing global competitiveness that requires increased productivity and a higher standard of quality. The fact is that the markets are growing and the manufacturers in Indonesia who can provide quality products at an increased and consistent rate will be the ones who thrive. Beyond the monetary benefits come the benefits in safety. Workers can avoid harsh, hot and toxic environments and abstain from handling hot and toxic materials and get relief from mundane and repetitive tasks, which in turn leads to a general improvement in process and product quality. There is no doubt that the robot industry is growing, manufacturing is becoming smarter and more efficient and the only question that manufacturers should be asking is how soon they can automate their facilities.
ENQUIRY NO. 7202
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Mario Alberto Magallanes Trejo, Saltillo, Coahuila, Mexico
PROCESS CONTROL
IoT And Big Data
Combine For Improved Operations The Internet of Things (IoT) and Big Data are the new buzzwords in the manufacturing and process sectors. They hold great potential for cost reduction and efficiency improvements across industry sectors. By Stuart Carruthers, marketing writer and editor, Advantech Industrial Automation Group
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he Internet of Things (IoT) and big data are two hot topics for industrial applications. The term ‘IoT’ was coined in 1999 and refers to a world of devices connected to the Internet, in which big data is collected, concentrated and curated. As Commercial Off-The-Shelf (COTS) technologies, such as PCs and their operating systems, have been migrating to industrial automation applications, the IoT and big data underpin the implementation of these concepts.
Why Implement The IoT And Big Data? Commercial and government sectors are showing how the IoT and big data can be used to improve operations, and how they can be profitability extended into manufacturing and other industrial sectors. Originally done manually, most data today is automatically generated by smarter more numerous sensors with reporting capabilities. Once the data has been collected, it needs to be concentrated and curated. The curated data must then be visualised and analysed to improve operations. There are many reasons for manufacturing to implement IoT and big data eg: predictive health monitoring, less downtime, lower rejection rates, improved quality, higher throughput, improved safety, more efficient use of labour, mass customisation. Industrial equipment is automated with embedded controllers or Programmable Logic Controllers
(PLCs), and both types of controllers are commonly available with Ethernet connectivity. Individual sensors, analysers, Radio Frequency IDentification (RFID) hardware, vision systems, and other devices are becoming ‘smarter’ and are offering network connectivity therefore providing more data than ever from the factory floor and process plants. On top of this, automation components have more memory, processing power, and standard functionality on-board. This combination of information and capabilities can be harnessed by a top-level predictive health monitoring system. Tracking metrics can be configured to alert users when equipment requires servicing and more detailed diagnostics such as temperature and vibration monitoring can trigger warnings. For manufacturing industries, uptime is crucial. Enhanced diagnostic capabilities lead to reduced downtime as problems can be identified quickly or even before they emerge. For less severe problems it is possible for systems to proactively and automatically adjust themselves or take corrective action, without human interaction. Such systems result in lower rejection rates, improved product quality and higher throughput. The ever expanding availability of sensed information means there is a reduced need for operators to go into the field, especially in hazardous environments such as refineries.
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Collection Of Data Following on from consumer products with a plethora of incorporated sensors, industrial automation is developing sensors to measure: position, angle, displacement, distance, proximity, speed and acceleration. For electrically driven equipment, sensing devices instantaneously report the current and voltage values and other related power parameters. Even more esoteric is the use of vision sensing systems to track produced parts, verify quality, or simply read tags. Vision systems in particular can generate huge amounts of image data. Sensors’ signals must all be transduced from the raw measurement into a useful signal format for transmission. The latest ‘Smart’ transducers/sensors can not only monitor the primary sensor signal, but can also monitor additional process values including device status, alarms and events. Sensors and transducers are networked via serial or Ethernet links to provide simplified installation, particularly for wireless variants and their collected data, must then be concentrated.
of device makes it practical and economical to extend data logging to remote locations and then storing it using removable memory cards or USB sticks or connecting via Ethernet. Embedded controllers are often used to automate equipment. Although primarily tasked with costeffective machine control, these controllers often have sufficient memory and processing capabilities to perform data logging. Similarly, embedded PCs have more than enough power to perform automation and data logging tasks, and are often configured with rotating or solid state hard drives that can provide significant data storage capacity. PLCs are used in many of the same applications as embedded controllers. A PLC’s strong suit is their reliability, flexibility, and high-speed control of machinery and the latest PLCs offer non-volatile storage capabilities, and historian modules that plug into the PLC chassis: making them a viable option for concentrating data. Just as there are myriad options for collecting data, there are many more options for concentrating this information. Data concentration can be scaled from smaller field devices to large centralised or distributed PC-based systems. It is becoming more straightforward to reduce the amount of manual human intervention required to obtain useful data, which in turn drives up the quantity and quality of data available for curation, and eventually interpretation.
Curation Of Data Once data has been harvested from sensors, and concentrated onto some type of storage system, the information is organised in a manner that helps users make sense of it. Curating this data involves the use Patrick Hajzler, Seine et Marne, France
Self-diagnosing systems mean that maintenance technicians spend less time troubleshooting dead ends and more time performing hands-on repairs. Predictive health monitoring allows repair events to be scheduled in a coordinated manner to minimise production impact, and reduce labour. While speed is important in harvesting big data from the IoT, it is important to point out that determinism is the real goal. Determinism implies that each action can reliably predict another action. The more information we have, the more deterministic we can become since we can correlate more inputs to derive more accurate output predictions. More accurate predictions improve prognostics and health management and other predictive technologies. This ever-improving automated sense/ predict cycle leads to increased productivity due to reduced manual data collection and interaction ensuring better quality products and lower reject rates and higher throughput. But all these benefits cannot be realised until data is first collected, which starts at the sensor level.
Data Concentration Data typically journeys from networked sensors to some form of data storage or concentration device such as a large PC server. Solid state data loggers can accept large quantities of input channels, capturing values at defined sampling intervals with the capacity to store tens of thousands of data values in volatile or nonvolatile memory. This type
IoT and Big Data find many applications in the process and energy sectors.
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Svilen Milev, Bulgaria
PROCESS CONTROL
Most visualisation software products offer mobile modules that enable portable devices to connect to the host system over the Internet or an intranet.
of database software and is usually done at the PC server level. When we look at the manufacturing world, we find that a large amount of the information obtained from sensors consists of time-series information where each sample is the value of a sensor with a timestamp. This real-time data is sampled repeatedly. Process data may also include alarm values and discrete process events. Manufacturing data must be stored and accessed in real-time, and uptime is critical. With so much information available, it is critical to capture what is most important. Without informed analysis, full value is not received from the effort and expense spent in collecting, concentrating and curating data. Curated data is available within an organisation over the facility or company network, which is often referred to as an ‘intranet’ or a ‘private cloud’. The Ethernet is considered a ‘public cloud’, but there are secure methods to link multiple facilities or data sources using it. Easy access to historical database information and the ability to retrieve it in a variety of useful ways ie: raw value, average value over a given period, and graphs of values over a given period, powers higher level analysis of big data.
Visualisation And Analysis Data collection, concentration, and curation activities occur in the background and must be in place in order to visualise and analyse information. However, simply presenting users with large tables of values will not help most people to understand the data, since it is easier to read graphical representations of data such as charts, graphs and other symbols. Fortunately, more options than ever are available to display quantities of information and help users make sense of it. At the field level, many analysers and data loggers offer local displays or come with
associated operator interfaces. These devices often allow users to view trends of data, alarms and events. For data coming from an embedded controller or a PLC, a local operator interface terminal, which is a dedicated device as opposed to a PC, is a good choice for displaying data and alarms for the related equipment or area. Useful local indications, data logging/trending, and alarming capabilities will also be built-in and as such readily available. These products can be configured to offer desired reports and readouts, or can be dynamically operated by users on the fly. Some modules allow users to develop advanced equations using process data in order to solve a problem or optimise an operation. This empowers researchers, scientists, and manufacturing personnel to optimise their operations. Data analytics, defined as using statistics to monitor an industrial process, has many aspects. and is used for early fault detection and employs statistics to explain if the process is within control limits and the end-of-batch quality. Another development is the proliferation of webbased visualisation products. The latest SCADA software offers rich graphics and animation, a library of objects with connectivity to a variety of data sources, and reporting features browser access to these types of web servers ensures simplified deployment throughout an organisation. This opens up the field of data analytics to everyday users, allowing them to ‘tell stories with data’. This type of innovation enables a wider audience to exploit the IoT and big data productively. Finally let us look at the expanding role that smartphones and tablets play in connecting to automation software. Most visualisation software products offer mobile modules that enable portable devices to connect to the host system over the Internet or an intranet. Mobile applications offer much of the same functionality as their big brother PC-based applications, but in a format appropriate to the device size. In some cases, users may find that their preferred operator interface experience is to use their own portable device wherever they go instead of booting up their laptop or seeking out a public PC. A popular method of summarising the results of collection, concentration, and curation is to create a simplified visual ‘dashboard’. A graphical dashboard shows the essential operating parameters of the system and warns of critical problems. There is much more information beneath the surface, but the dashboard distills the key elements to show the most important facts about what is happening, allowing users to quickly interpret conditions and make smart decisions.
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Conclusion The IoT and big data are empowering extensive changes in the manufacturing and automation world. Typical automation system designs have previously incorporated a top-down approach, with relatively limited control actions to maintain specific process variables. As the IoT and big data allows sensed information to become richer and more readily available, and as the capability has increased to capture and analyse that information, the ability to control processes becomes far more powerful and far-reaching. A traditional synchronous manufacturing process consists of all items moving down the production line and being handled identically. However, consider an alternate scenario where the item being produced boasts an IoT smart tag with memory, embedded with the requirements of that item. This would enable asynchronous manufacturing, where the part/subassembly/batch carries its own information and drives the manufacturing process. In fact, German government agencies are working to formalise an object structure to facilitate exactly this
type of ‘smart’ manufacturing, and the IoT and big data are two of the most important tools for enabling this bottom-up interactive manufacturing approach. IoT and big data are reworking the relationship of machines-to-machines as well as people-to-machines. Many new hardware and software technologies have been developed to bring field sensor information from the very edge of the process, to collect it in a distributed or centralised manner, and to curate it through databases and historians. Each of these data harvesting tasks is becoming more automated, which removes the elements of delay and error associated with manual readings and data entry. Improving and automating data collection, concentration and curation enables end users to take full advantage of visualisation and analysis software to make their operations more efficient. As key components of these activities, the IoT and big data are forces ready to be harnessed with today’s products and systems to improve the efficiency, safety and profitability of manufacturers worldwide. ENQUIRY NO. 7301
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SOFTWARE & NETWORKS
Computer-based simulators are seen by regulatory agencies as an effective tool for operators, and can help expedite regulatory compliance, which is an expensive and critical business issue for oil and gas pipeline operators. By Tony Collins, simulation specialist, Schneider Electric
O
ver time, government agencies that regulate oil and gas pipeline operational practices have developed a strong preference for computer-based simulation as an operator training and evaluation tool. Simulator tools vary in scope and function. A proper analysis needs to be made to verify how they can help meet operator and regulator safety and compliance goals. A key factor is the ability of the simulator in question to provide a realistic replication of actual pipeline control. As a result, selection of the right simulation tool can impact not only controller effectiveness but the speed with which regulators grant compliance. In addition, regulators can prevent or stop pipeline operation if they feel requirements are not being met. For this reason, controllers need to be well trained by the pipeline operator. Proper training is critical for the safe delivery of oil and gas to consumers. About 2.6 million miles of propane, gas and oil pipelines crisscross the US alone. According to The Manhattan Institute for Policy Research, America has 175,000 miles of onshore and offshore petroleum pipeline and 321,000 miles of natural gas transmission and gathering pipeline.
Kevin Abbott, US
Impact Of Oil And Gas Pipeline Simulators
In addition, over two million miles of natural gas distribution pipeline send natural gas to businesses and consumers. A full 70 percent of crude oil and petroleum products are shipped by pipeline on a tonne-mile basis and nearly all natural gas is shipped via pipeline. Regulators, pipeline operators, and consumers all want to make sure that pipeline controllers are offered the best training possible in order to avoid improper actions or accidents. Regulators expect that the pipeline controllers who are being trained can perform standard operating tasks such as opening and closing valves and starting and stopping pumps. In addition, pipeline controllers will also be expected to handle abnormal operating conditions such as events that may represent a condition exceeding design limits or resulting in hazards to people, property or the environment.
Controller Evaluation Methods In some countries like the US, controller evaluation is determined by the pipeline operator and reported to the regulatory agency. The evaluation can take any of the following forms:
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Regulators are becoming focused on simulation (see Figure 1) as the primary training and evaluation tool for two reasons:
for leak detection training. In contrast, they found on-the-job training for leak detection to be difficult because such events are rare and may not occur during training.” In essence, computer-based simulator trainers are increasingly viewed by regulators and pipeline operators as essential tools in their controller evaluation process. As a result, utilising these tools can offer an expedited path to regulatory compliance.
1 Written
Regulatory Compliance Criteria
• • • •
Written examinations Oral examinations Work performance reviews Observations of performance on the job or during on the job training • Simulations
and oral examinations do not allow evaluators the ability to observe how controllers execute the identification of and reaction to abnormal operating conditions in real-time. A controller can be trained to know the answer to a question but actual performance under realistic operating conditions is an entirely different situation.
2
While tasks performed under abnormal operating conditions will be infrequent, the training and evaluation of controllers’ ability under these conditions must be extensive and repetitive. Such situations represent the highest risk (and highest cost) to all pipeline stakeholders. Crisis situations cannot be recreated in a safe or efficient manner through any on-the-job evaluation. In addition, deploying observers and trainers for on the job evaluations is an expensive option for operators, requiring significant staff resources.
The National Transportation Safety Board (NTSB), the chief US pipeline regulator, has stated: “Pipeline training coordinators who used simulators for training reported that the simulators were invaluable
Regulators consider several key elements when assessing the value of a simulator: Ability To Replicate A Full Range Of Relevant Tasks A simulation trainer and evaluation program is not effective if it can only simulate a portion of the tasks controllers will need to perform. A simulator that will pass regulatory review has to be able to provide simulation for each relevant task as outlined in the regulators qualification program. Examples of covered tasks include: • Changing operation set points, such as delivery flows and / or pressures, or station discharge pressures. • Normal valve operations, such as batch cutting, shutting down delivery stations, or station bypass operations. • Pump starting and stopping. • Emergency shutdown.
Adequate Replication Of Pipeline Character The simulator needs to replicate the physical characteristics of the pipeline, such as the type o f p ro d u c t / s u b s t a n c e flowing through the pipeline, geographic and climate influences (eg: elevation changes), temperatures, and flow direction for example. All of these factors affect the dynamics of pipeline operation. The simulation should also replicate the nature of the equipment and devices that act on the pipeline. This includes pumps, valves and even monitoring devices. These devices, and the way they interact with the pipeline, are essential to replicating the Figure 1: Sample crude pipeline from controller qualification system (operator trainer simulator solution). pipeline character. Oct/Nov 2014 | industrial automation asia 41
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SOFTWARE & NETWORKS
of the pipelines managed by the operator and the level of qualification needed to match the overall risk threshold. Three main types of simulator trainers exist: generic, full scope and partial scope.
Figure 2: Sample screen from full scope simulator solution.
Record Of Evaluations / Qualifications Accurate and thorough record keeping is also a key consideration for the regulator. A complete up-to-date record of qualified individuals must be kept including results from their latest evaluations. Regulators require this information and this data should also be accessible should an incident investigation occur. These records should include: • Identification of all qualified individuals and the specific tasks they are qualified to perform. • Dates of all current qualifications. • Description of methods used to qualify individuals. Simulators can provide high accuracy electronic records in each of these areas, as well as information regarding how controllers were qualified. They also demonstrate that controllers have received updates regarding changes to pipelines that might affect their assigned tasks. While written exam evaluations can provide a clear record of how and when a controller qualified for a specific task, they cannot provide any context that simulates realistic operation of the pipeline. Evaluations like demonstration tables or on-thejob observation can provide more of a realistic replication of pipeline operation. However, under these circumstances it is more difficult to establish a clear record on how the controller was qualified. It is also more difficult to demonstrate repeatable qualifying performances under abnormal conditions.
Types Of Simulators How do pipeline operators select the right simulation model? The scope of functionality of the simulator may differ based on the needs of the specific operator. The differences depend on the characteristics
Generic Simulators These simulators provide a realistic representation of key controller tasks through a set of common pipeline models. By design, these simulators do not incorporate the exact elements of the actual pipeline that controllers will manage. Therefore, generic simulators are one of the least expensive solutions for operators. They may be cost-efficient option for operators with straightforward and simple pipeline networks that do not require any unique requirements. Full Scope Simulators Full scope simulators are custom-built simulators that exactly replicate a pipeline model and configuration, as well as the Supervisory Control And Data Acquisition (SCADA) functionality and controller interface. These simulators (see Figure 2) provide the most realistic recreation of controlling an actual pipeline scenario. They also provide the operator with the flexibility to utilise the platform for other functions such as validation of production leak detection systems. Other functions include verification of anticipated changes in the physical pipeline system, in control logic or operating components, and in SCADA configurations. If trained in all these areas with a full scope simulator, controllers are better equipped to respond to these changes when they become a reality on their pipeline systems. As a result of customisation, full scope trainers are significantly more expensive. However these tools are better suited for operators with complex pipeline operations and low risk thresholds, or for operators who are faced with rigorous regulatory compliance standards. Partial Scope Simulators This category of simulator incorporates elements of both the generic and full scope simulators. These systems offer the flexibility and core elements of customisation but at a lower price point than full scope trainers. Most partial scope trainers build in key elements of the operator’s pipeline, such as unique topography or particular flow conditions.
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However these simulators do not represent a full end-to-end replica of the pipeline network. They may also incorporate the pipeline model into a full-scope SCADA interface without building a full replica of the operator’s Human Machine Interface (HMI). Partial scope simulators also offer a set of different scenarios that can be played out through simulation with a configurable scenario builder. Partial scope trainers are useful as a universal option because they provide a realistic simulation without the full price of full scope simulators.
Conclusion Regulatory compliance is an expensive and critical business element for pipeline operators. Any solution that expedites compliance efforts in a cost-effective way is a great boon to operators. Computer-based simulators for training and evaluation of pipeline controllers are key tools that help to improve operational safety and to meet regulatory requirements. Regulators have seen the value that simulators can provide above all other forms of evaluations and now consider them as the
preferred training and evaluation tool. Therefore, choosing the right simulator can result in both more effective training and faster regulatory compliance. The right simulator incorporates all the major elements regulators look for in an evaluation system, including replication of pipeline characteristics, replication of key troubleshooting tasks, and an accurate record of controller performance evaluations. It is also prudent for operators to go beyond the simple replication of a pipeline flow model. Enabling the most realistic training experience is essential for both fast regulatory compliance and peace of mind. An advanced training includes creating a realistic HMI experience and incorporating elements of the equipment process logic which offers critical layers of detail to the simulation model. Whether choosing a generic, partial scope or full scope computer -based simulator, operators need to select a method that not only supports and satisfies regulatory requirements, but also accommodates business goals and addresses the risk threshold they are willing to tolerate. ENQUIRY NO. 7401
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INSTRUMENTATION & MEASUREMENT
Many process plants have smart sensors, instruments, and valves installed as part of their safety systems. These smart field devices can provide a host of useful information to the safety system. By Guillermo Pacanins, safety lifecycle leader/educator, ACM Facility Safety
Using Smart Field Devices To Improve Safety System Performance
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ny process plant that handles products, feedstock, or fuels that are the least bit hazardous (flammable, toxic, or otherwise environmentally dangerous) has safety concerns. Operating in compliance with regulations and standards is a way of life for oil, gas, petrochemical, biofuel, and many commodity chemical producers. But beyond compliance, companies want and need to protect their people, equipment, and the surrounding environment. Applicable standards include ANSI/ISA-84.00.012004 Parts 1–3 (IEC 61511 Mod) and IEC 61508, along with facility-recognised best procedures and practices. Compliance with these standards ensures that the plant is not simply within the letter of the law; it helps the plant operate with minimal potential for incidents and injuries. Undertaking this effort begins with plant hazard and operability studies and the Layer Of Protection Analysis (LOPA) methodology. Some situations may call for a quantitative risk analysis, as provided by the Centre for Chemical Process Safety and indicated by ANSI/ISA-84.00.01-2004 Part 3, Appendix F. Performing a LOPA helps identify which identified hazards require Safety Instrumented Functions (SIFs) and the required probability of failure on demand for each to lower the risk to a tolerable level. Performing a LOPA is a main step toward ensuring
that requirements under ANSI/ISA-84.00.01-2004 Parts 1–3 (IEC 61511 Mod) are met. Once the Safety Instrumented System (SIS) is designed and implemented according to the safety requirement specification, its operation must be maintained and monitored to ensure integrity of the SIF, and to ensure ongoing compliance with standards. Any changes to the hardware, such as new equipment, new field devices, different products, or different specified operations and processes must be taken into account using a management of change procedure. Any malfunctions or other process issues must also be accounted for, typically by proof testing and monitoring the SIS along with its associated field devices, such as sensors, instruments, valves, and logic solvers. Real-time safety monitoring software improves the integrity of process safety systems and ensures compliance and safe operation. Companies can enhance the results generated by the software with the information supplied by SISs, plant automation systems, and their associated smart field devices. All these systems and their associated components must be maintained, a task that can be eased by using smart field devices.
Safety Systems Need Maintenance Too In a process plant that runs well, the safety system can fade into the background, because it has a
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an SIS that is capable of gathering more diagnostic information from each field device greatly improves the quality of data available from these systems, and ultimately makes life easier for the process automation professionals responsible for the SIS. However, even if all needed data is available, users must still make sense of the information. Volumes of raw diagnostic data must be transformed into useful information that guides maintenance efforts
ENQUIRY NO. 769
low daily demand rate. Nonetheless, field devices connected to an SIS still need maintenance. Many plant accidents have been caused by a neglected safety system field device not working properly when called upon in an emergency. The reality of thinly staffed process plants is that the operations and maintenance professionals charged with this time-consuming and complex task also have to watch over the other plant assets that support regular production. They are responsible for availability, productivity, and so on. Since the SIS does not affect these areas under normal circumstances, it can become a secondary concern, or slide even further down the list of priorities. To make matters worse, field devices that are part of the SIS do not always employ the latest technologies. They often do not have the capability to provide information to the main plant automation system, an asset management platform, a computerised maintenance management, or other related systems. There may be no alternative to sending an individual to a given field device and inspecting it where it is installed, a task that is often postponed. All SISs depend on field devices for their information, many of which are discrete (on/ off), plain 4–20 mA analogue, 24 VDC, or some other analogue signal type. Each device provides its primary variable and nothing more. This does not have to be the case, because smart field devices can produce extensive diagnostic and other information. Many field sensors, instruments, and valve actuator positioners installed in the past 10 or even 15 years have some diagnostic capability built in. In other cases, dumb field devices can be upgraded to smart ones, either through retrofit or replacement. In either case,
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INSTRUMENTATION & MEASUREMENT
and promotes correct operation of the SIS and other related systems. This is not an easy task, as the relatively small number of plants that operate effective asset management programs indicates. Still, there is a way to improve safety system operation without unduly burdening plant personnel, and it starts with smart field devices.
Advantages Of Smart Field Devices When applied effectively, using diagnostics from smart field devices has a variety of benefits, which are detailed below: 1
2
3
4
5
Diagnostics can indicate out-of-spec instrument operation. Many field devices used in an SIS are more complex than a simple level, pressure, or temperature switch. As a result, there are ways they can malfunction or drift out of the normal range. Diagnostics can indicate these safe failures where a device has malfunctioned without causing an alarm or an incident. This allows operators to compensate until the device can be repaired or replaced. Diagnostics can indicate failure of communication links. A field device that is functioning properly but cannot communicate due to a network failure is still a failed device. However, with the right diagnostic information, operators can isolate the problem as a network issue more quickly and save time troubleshooting. In some cases, a workaround can be created, such as reverting to a 4–20 mA signal. Diagnostics can predict incipient failure. Smart field devices have powerful capabilities to diagnose their own internal systems, to the extent that many can determine when their own circuits are beginning to show signs of degradation. This information can be sent to the asset management system, so operators have the maximum amount of time to correct the problem before an outright failure. Smart field devices can ease the task of redundant system design. Many new smart field devices incorporate capabilities for what is essentially internal redundancy and diagnostics. Clever designs that include voting schemes and redundant circuitry provide the kinds of functions that otherwise would have to be built into the safety system. Moving that kind of capability into the field reduces the complexity of the centralised processing. These features include fail-safe, fail-tolerant with redundancy one out of two voting with diagnostics (1oo2D), and 2oo3D — which allow single smart devices to achieve higher safety integrity level values. Process data in addition to the primary process variable can improve safety system performance. Many smart instruments are multivariable devices
Figure 1: Diagram showing smart instruments connected to a control or safety system, which is in turn connected to a PC running safety monitoring software.
that make measurements in addition to the main variable. For example, a pressure instrument usually requires an internal temperature measurement to correct the pressure reading. While that temperature reading would not ever be used for a safety function, this ‘free’ data can be helpful in troubleshooting or diagnosing process problems. 6 Smart field devices have the ability to automate some testing protocols. Partial-Stroke Testing (PST) of Emergency ShutDown (ESD) valves is now a regular practice in many plants. PST and fullstroke tests follow very strict schedules to fulfill the requirements of relevant standards. Smart valves can digitally connect their actuators and positioners to sophisticated asset management platforms that can be programmed to carry out these tests and record necessary performance data with little or no operator intervention. 7 Smart field devices can feed information to the Basic Process Control System (BPCS) in appropriate situations. Traditionally, most field devices in safety systems were simply discrete: they went from off to on when a liquid level, pressure, or temperature rose too high or dropped too low. As those devices are replaced with smart counterparts that provide scalar digital data, the BPCS can productively use that information. As long as the basic safety function is not compromised, there is no reason that the safety level instrument in a tank cannot report its information to the BPCS, eliminating the need for another field device. Smart field devices can provide a host of useful information, but are most effective when supported by safety monitoring software.
Converting Raw Data Into Useful Information Without a plan supported by the right analytical
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operator making the wrong decisions in a crisis. Many studies have shown that people are often the weakest link in a safety chain. Safety monitoring software can have embedded elements that guide operators through difficult situations, reducing the likelihood of incorrect responses. This is important, as even an experienced operator may make a wrong choice in a new situation, which is often the case with a safety-related incident.
Figure 2: Safety monitoring software provides many benefits, including turning raw data into graphs, charts, and diagrams that show overall safety system performance at a glance, while also allowing operators to drill down to reveal details.
tools, the flood of data from smart field devices can quickly overwhelm users, causing them to neglect useful information. Fortunately, safety monitoring software tools that can turn this data into actionable information are available. A safety monitoring software platform is typically PC-based and receives information from existing control or safety systems via a digital data link (figure 1). A safety monitoring system can fulfill several critical functions. It provides visualisation of real-time risk exposure based on actual operating conditions. Once the SIS moves beyond simple safety switches, safety monitoring software can draw more information from the larger group of smart field devices and watch for changes in the risk landscape. Even if no devices have actually tripped, the system can detect a changing situation that is building toward a higher risk level. 2 It monitors changes in risk levels over time. As the safety monitoring software gathers data over time, it can determine the characteristic operating levels. If those levels begin to move or if changes in production or recipes generate new conditions, the safety monitoring software evaluates the evolving risk profile and determines if the underlying assumptions in the original design still apply. Many process manufacturing environments are dynamic due to changes in manufacturing techniques, sources of feedstock, production levels, and so forth. These variations can also change the specifications of the SIS, and safety monitoring software can guide continuous evaluation to ensure that the SIS is working as originally designed. 3 It provides contingency plans for safety incidents. Few things can make a bad situation worse than a poorly trained, overwhelmed, or panicked 1
Safety monitoring software provides the benefits outlined above by supplying information to operators in easy-to-understand formats. It turns raw data into graphs, charts, and diagrams that show overall safety system performance at a glance, while also allowing operators to drill down to reveal details (figure 2). Although smart field devices and safety monitoring software can greatly improve safety system performance and operation, there is an art to applying these tools to optimise plant operations.
A Delicate Balance Safety systems can fail in two ways: they may be unable to respond as planned during a crisis, allowing a critical situation to escalate. Or, a system may create a spurious trip and shut down the operation when no actual threat exists. Even though this is called a safe failure, it is disruptive to production and costly. There is also a temptation for operators to manually override or bypass these safe failures, which can create very dangerous situations. An effective safety system depends on a chain of events and devices. Field devices feed data to the SIS and to the BPCS, which in turn supplies information to the safety monitoring software. But like any other systems, the devices and software tools that monitor real-time risk exposure are only as good as their users, who must possess the required level of expertise to understand the risk in the process, the SIS automation, and the safety requirements of the process. Those responsible for maintaining the system must walk a fine line between having mechanisms that truly protect the plant, its people, and the environment — against having mechanisms that are too sensitive and trip unnecessarily. Adding a higher level of hardware sophistication can contribute to a safer plant, but at the risk of excessive complexity if intelligent design is not employed. The best solution in many cases is to use safety monitoring software to distill the data from smart field devices and other sources into easily understood and actionable information that can improve the operation of the safety system. ENQUIRY NO. 7501
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INSTRUMENTATION & MEASUREMENT
The Changing Security Landscape
Protecting Critical Infrastructure By
Fuzzing Protocol Implementations Martin Simonis, The Hague, Zuid-Holland, Netherlands
I
ndustrial Control System (ICS) networks are no longer isolated: the integration into corporate networks and the introduction of IP-based communications have exposed these networks to cyberattacks. As a result, vulnerabilities in SCADA and other ICS protocol implementations can be exploited with Internet hacking tools. Fuzzing is a blackbox testing technique originally used by Blackhat hackers to find exploitable vulnerabilities.
The move to IP-based communications has led to a sharp rise in the amount of external attacks against industrial control system networks. Between 1982 and 2000, only 30 percent of such attacks were external, and the rest, 70 percent, were internal, either accidents or deliberate attacks made by disgruntled employees. By 2003, things had changed: between 2000 and 2003, 70 percent attacks were external and only 30 percent internal. In the past 10 years, the connectivity of ICS networks has increased significantly, which implies that the share of external attacks in ICS networks has also grown. During the first half of the fiscal A demonstration of how fuzzing can be used to remediate year 2013 (Oct 2012-May 2013), the exploitable vulnerabilities proactively and make ICS ICS Cyber Emergency Response networks more robust against cyberattacks will be Team (ICS-CERT ) working under presented. By Sami Pet채j채soja, VP, Asia Pacific, and the Department of Homeland Security in the US, had already Anna-Maija Juuso, security analyst, Codenomicon reported over 200 attacks across all critical infrastructure sectors. The amount of attacks against ICS systems already Designed To Be Isolated surpasses the total amount of attacks reported ICS networks used to be electronically isolated from during the fiscal year 2012. other computer systems and the cyber threats that Some external attacks are unintentional, meaning these systems faced. In these isolated networks, all that the malware has not been intended for the targeted devices were deployed over serial analogue circuits ICS, but targeted cyberattacks are on the rise. Several and an attacker would have needed to gain physical power outages have been attributed cyberextortion. access to the analogue circuit to carry out an attack. Electric utilities are also the target of constant Therefore, until recently, the focus was on ensuring probing. Probing is a part of cyber-reconnaissance the physical security of industrial control networks. and it is used to map network infrastructure and locate Similarly, many ICS protocols were designed for vulnerabilities for future attacks. communication between trusted devices in a closed 48
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widespread use of online resources, like WebHMI, and wireless connections expose the production network to both internal and external attacks. The challenge with these new interfaces is that traditional malicious software prevention and patch management processes are difficult to implement. The critical nature of industrial control systems requires that they are available 24 hours a day, 7 days a week. As such, regular patching is inconvenient and often dangerous. Patching can introduce new unknowns and cause failures, whereas, anti-virus software and firewalls can slow systems down, causing performance issues. Connectivity within ICS networks.
network with no connection to the outside world. As a result, ICS protocols contain very little security features, such as encryption. More worryingly, these protocols have never been hardened and, in the rush to improve connectivity of ICS networks, many were simply encapsulated in IP wrappers.
Increased Connectivity Over time, more components of industrial control systems became interconnected with the outside world using IP-based communications and control networks were integrated into larger corporate networks. The convergence of these once separate networks has helped reduce costs and improve efficiency, but it has also exposed ICS networks to external attacks. With IP-based communication used throughout the ICS network, packets can be routed into field devices from external networks. Field devices such as PLCs, RTUs, Smart Instrumentation and other embedded devices are the most critical elements of an ICS network because they control physical equipment like pumps, valves, boilers, compressors, safety systems, and so on. It is important to note that using analogue connections does not guarantee security. The devices within your production network might communicate over analogue connections, but they also communicate with devices that are connected to the corporate network and the Internet. Almost all ICS devices are either directly or indirectly connected to the Internet.
New Attack Surfaces The need to separate the corporate and production network is well known, but other equally critical interfaces are ignored. Trusted third parties like vendors, system integrators and control engineers have direct access to ICS networks. Moreover, the
Proactive Cyberdefense ICS networks form the backbone of many critical infrastructure networks and are used to control everything from waterworks, chemical plants and food and drug production facilities to transportation systems, satellites and power grids. Due to the importance of these networks ad hoc responses are not enough. The focus should be on trying to prevent attacks. The best way to prevent attacks is to identify exploitable vulnerabilities and resolve the issues proactively. Vulnerabilities Enable Attacks There are numerous types of malware, including viruses, trojans, keystroke loggers, rootkits and spyware. What they all have in common is that the initial introduction and access to the system are enabled by a vulnerability in the code. Vulnerabilities are design and implementation errors that are introduced into the code during development. The errors become vulnerabilities once the software is released and is exposed to outside attacks. Zero-Day Vulnerabilities Zero-day vulnerabilities are the biggest threat to an organisation’s security. Their existence is unknown, and there are no defenses against attacks exploiting them: an attack can go completely unnoticed. Advanced attacks, like Stuxnet, can utilise multiple zero-days making them extremely difficult to defend against. Even on a smaller scale, such attacks can cause service disruptions. Detecting Vulnerabilities By Fuzzing Fuzzing is the most efficient technique for finding previously unknown vulnerabilities. In fuzzing, unexpected data in the form of modified protocol messages is fed to the inputs of a system, and the behaviour of the system is monitored. If the system fails (eg: by crashing or by failing built-in code assertions) then there is a potentially exploitable Oct/Nov 2014 | industrial automation asia  49
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INSTRUMENTATION & MEASUREMENT
vulnerability in the software. There are no false positives in fuzzing. Generation- And Mutation-Based Fuzzing There are two popular ways to automate fuzzing: mutation based and generation-based fuzzing. In mutation-based fuzzing real-life inputs, like network traffic and files, are used to generate test cases by modifying the samples either randomly or based on the sample structure. In generation-based fuzzing, the process of data element identification is automated by using protocol models, which are built, for example, from protocol and file format specifications.
Case Study: Fuzzing A PLC Device In this study, we used generation-based fuzzers to test the robustness of a Programmable Logic Controller (PLC) manufactured by an ICS device manufacturer. We tested a number of SCADA and standard Internet protocol interfaces. Tested Protocols We tested both SCADA (MODBUS, ISO-TSA P and ICMP) protocols and standard internet protocols (IPv4, HTT P, SMNP and TLS). Internet protocols have long been fuzz tested successfully. In this case study, we wanted to demonstrate that fuzzing can also be used to find vulnerabilities in SCADA protocols. Therefore, the test runs were stopped once the first vulnerability was discovered. Test Tools All the tests were carried out using generation-based Defensics fuzzers. The test tools were based on protocol specifications. The specifications provide the fuzzers with protocol specific information (eg: on the boundary limits of the data elements). This inbuilt semantic and syntactic knowledge is used to guide the process of generating test cases and test case execution. As a result, the fuzzers can achieve high-level coverage with excellent efficiency. Results We found vulnerabilities in all the tested protocol interfaces. The most frequent failure-mode was DoS, but we also triggered other abnormal behaviour from the test target: the tested PLC started flashing its lights. Both DoS and abnormal behaviour indicate that there are vulnerabilities in the tested protocol interfaces. With more extensive fuzzing more vulnerabilities could be revealed.
Fuzzing Best Practices The majority of critical infrastructure is privately owned, and it is the private companies that need
Actors in the Critical Infrastructure.
to make sure that their networks are robust and secure. However, due to the importance of these networks the protection of critical infrastructure cannot be left to the private sector. An effective cybersecurity strategy is based on partnership between government and the private sector, including both private companies and industry organisations, as well as international partners.
Company Level Complex supply chains are typical for industrial control systems. Systems purchased by critical infrastructure operators, such as power utilities, are typically compiled by system integrators from devices and software they purchase from a variety of device manufacturers. These device manufacturers, in turn, purchase parts of their software from third-party software developers. The ICS devices they produce often contain a Software Development Kit (SDK), which can be used to modify the software to better meet the needs of the critical infrastructure operator. Additionally, open-source software is widely used in critical infrastructure.
Software Developers If a company is developing its own software, the best way to ensure the security and robustness of the software they purchase is to identify and eliminate vulnerabilities during software development. Large software houses already include fuzzing as a part of their secure development lifecycles: Cisco’s CSDL, Microsoft’s SDLC and the Adobe Product lifecycles are good examples of this. Giants like IBM and Google also promote fuzzing. ICS software development would benefit greatly from the same approach. The earlier the vulnerabilities are found, the easier and cheaper
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it is to fix them. Indeed, by building security into your software you can avoid costly, critical, and embarrassing software blunders.
Software Buyers Many vendors are in a hurry to push software onto the market, and often times it is the user who ends up doing the testing. By insisting on using fuzzing as an acceptance condition, you can make vendors claim responsibility over the quality and security of their products. Why not use fuzzing to ensure that all equipment you accept into your ICS network is robust and secure? In ICS networks, patching can be difficult. The more vulnerabilities you can fix prior to implementation, the less patching you will need to do later on.
Industry Level Industry organisations play a key role in motivating the private sector and ensuring that all industry players put enough effort into cybersecurity. The North American Electric Reliability Corporation (NERC) introduced a set of eight Critical
Infrastructure Protection (CIP) standards (CIP-002 to CIP-009). These standards are mandatory in the US and Canada, and NERC has the authority to audit energy producers and distributors and fine them up to US$1 million per day per violation. The challenge with standards is keeping them up-to-date.
National Level The mandate for cybersecurity must come from a high level. Protection must be implemented by the network owners because only they have access to their own networks, but governments must use their authority to make cybersecurity a national priority. The role of the government is to build partnerships with the private sector and to get the private sector to understand that cybersecurity is not only a means of insuring against malicious compromise, but also a necessary component of business continuity. The private sector will only commit to the cybersecurity effort if they can see the benefits (ie: if the efforts also make sense at a business level). ENQUIRY NO. 7502
The comprehensive and modular monitoring solution for PV plants and efficient Energy Management VMU-C and VMU-W: the integrated wired or wireless Web-server A combination of modules performing the monitoring of a roof-top photovoltaic installation or a ground small to medium size plant. Micro PC with web-server and web service capability (VMU-C) and compact mobile modem (VMU-W). DC and AC: V, A, kW, kWh Sun-irradiation, cell/air-temp., wind speed Inverter data, alarms and error messages String, BOS efficiency and control Performance ratio and Yield indices 12 to 28 VDC power supply
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ENERGY
The Good, The Bad And The Ever-Promising:
2014 Renewables Up-Take In Asia-Pacific
I
t is rare to find a government in the Asia Pacific region that is not willing to promote their nation’s ‘push for renewables’ amidst an increasingly carbon constrained world. Behind closed doors, governments are well aware of the geopolitical uncertainties over fossil fuel supplies and prices as well as the self-sufficiency that comes with a strong renewables capacity. However, in 2014, only a few countries in the region have managed to marry sufficient government incentives and strong investor-inducing regulatory environments with the actual realisation of individual projects coming to market in the volumes initially contemplated.
China — The Powerhouse, But A Largely Closed Market China remains the global leader in renewable energy in almost every respect. Nationally, it added an estimated 100GW of new power generation capacity in 2013, comprised of coal (39.7GW), hydropower (30.5GW), wind (14.1GW) and solar (12GW). Throughout this period, it is estimated China spent US$54 billion on renewables. The 2013 data underlies the sheer scale of China’s 52
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An assessment of renewable energy markets across the Asia Pacific region will be given. By Stephen Webb, Partner and Head of Energy (Asia), DLA Piper. energy development and that even with an investment of US$54 billion, new renewables capacity was only marginally higher than new coal capacity. The renewables surge was heavily reliant on large-scale damming of river systems in China’s south, however there continues to be significant gains in solar and wind capacity too. With pressing air pollution concerns and a push to diversify energy supply (with oil and gas pipelines to Russia and the Bay of Bengal through Myanmar indicative of this), renewables investment is expected to amount to US$1.54 trillion from 2011 to 2026. Nonetheless, foreign investors have largely struggled to infiltrate the renewables boom in China and Chinese companies are dominant in the US$100 billion solar PV cells manufacture market. As such, the Chinese market remains largely closed to foreign players.
Opportunities In The Philippines And Japan By contrast, the Philippines and Japan have offered more opportunities for foreign renewables developers but under very different pricing structures. While the size and expected growth of their renewables markets are largely dwarfed by China’s booming
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Hyoung-Il So, Iksan-Si, Jeonbuk, South Korea
appetite, a large number of opportunities have arisen for domestic and international developers, particularly in the solar sector. In 2008, in an effort to diversify its renewables base, the Philippines Government moved to stimulate renewable energy through the Wind energy has been a Renewable Energy Act surprisingly big contributor to Thailand’s renewables capacity. of 2008. It was not until February 2014 though, when the final guidelines on the collection of the Feed-In Tariff (FiT) allowance and disbursement of the FiT allowance fund were (finally) released, that the full make-up of the FiT scheme became known (FiT schemes are a common mechanism used by governments to accelerate renewable energy investment by offering generation incentives for renewables developers to counter the high start-up costs vis-à-vis fossil fuel developers). Even without the FiT scheme being finalised, between 2008 and 2014, the Philippines Department of Energy approved 325 renewables facilities. Under the final guidelines, the Department of Energy has set installation caps for each type of renewable energy and has also adopted a ‘first come-first served’ policy. As a result, developers are effectively racing against each other to achieve FiT eligibility. If they ‘arrive’ too late (when the FiT capacity has already been filled), the developer will not be eligible for the FiT, which has led to an ultracompetitive market. President Aquino’s administration has overseen strong economic growth and appears committed to renewable energy despite the political sensitivity over electricity prices in the Philippines. Booming demand has placed great strain on existing facilities and encouraged fast-tracking or expansion of electricity plants (both renewable and fossil-fuelled). Reports suggest President Aquino may even invoke his emergency powers to address booming demand with the Government estimating it needs an additional 5GW of generating capacity by 2017 just to maintain current economic growth levels of six percent and to overcome blackout issues experienced recently. Hydropower and geothermal have been the historically dominant renewable fuels in the Philippines, but it is the solar sector that stands to benefit most from foreign investors/developers. In 2014 for instance, the Sacosol solar power plant became the country’s first large-scale, commercially
financed solar plant. The 22MW plant is being developed by Bronzeoak Philippines and foreign investor ThomasLloyd. Nonetheless, the solar sector currently has a very marginal contribution to the Philippines overall generating capacity. Japan arguably has the most generous renewables incentive package in the region, with FiT rates sometimes double that of the Philippines. Three years on from the Fukushima nuclear meltdown and despite grand plans for large offshore wind farms, Japan’s solar PV sector has accounted for the majority of renewables investment. However, wavering political commitments at different levels of government and questions over the longevity of Japan’s generous FiT regime has meant that the country has not fully realised what seemed to be an ‘extreme renewables revolution’ even as late as 12 months ago. As it has been since Fukushima, the country’s nuclear future remains uncertain and any government move to promote or discontinue nuclear energy will no doubt impact on the attractiveness of renewables. In the meantime though, banks are competing for a share of the solar PV market, following the market entry of backers such as Goldman Sachs Japan and IBM Japan. Key local players include Mizuho Corporate Bank and Sumitomo Mitsui Banking Corporation. Mizuho is acting as project financier for the 70MW Kagoshima Nanatsujima Mega Solar Power Plant, which went live on November 1, 2013. As at that date, it was the largest operating solar plant in Japan. The project is being operated by a six-member SPV, and involves an investment of approximately JPY 27 billion (approximately US$275.5 million). Sumitomo Mitsui announced in April 2014 that it and four other banks will provide a JPY6.6 billion (approximately US$60.6 million) syndicated loan for a 20MW solar power station in the Iwate prefecture in northern Japan. The project is part of reconstruction efforts following the 2011 Tohoku earthquake and tsunami.
Next Best? Thailand And Malaysia Thailand is seeking a 25 percent renewables contribution to overall electricity demand by 2021 (a target that is relatively common in the region). Wind energy has been a surprisingly big contributor to Thailand’s renewables capacity. Wind Energy Holding’s wind farms have taken particular advantage of government subsidies and feed-in tariffs, currently set above US$0.11 for wind-sourced power. In July 2014, Thailand celebrated the completion of the last of 36 solar PV projects built by Kyocera, (a solar PV manufacturer) and SPCG (Thailand’s largest Oct/Nov 2014 | industrial automation asia 53
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Australia, much like South Korea, seems destined to be reliant on fossil fuels for the foreseeable future.
power utility provider). The pair have also agreed to construct a US$31 million solar panel production plant in Thailand. Like the economy in general though, Thailand’s renewables sector was hit hard by foreign investor concerns in the wake of the military coup in May 2014. The solar sector may be the vehicle to re-engage with foreign investors, but much work is needed to be done to meet the 2021 target and to continue the solid momentum that the solar sector had built up. The solar FiT (currently US$0.20) may be reformed to attract more investment, but is considered competitive by regional standards. Malaysia’s renewables industry was buoyed by the commissioning in June of the country’s largest solar power plant, operated by Malaysia-based Amcorp Group. Indicative of China’s renewables role in the region, Chinese manufacturer Yingli Energy was awarded the contract to produce the plant’s solar panels. A lot of Malaysia’s renewables capacity remains off-grid, mostly from private palm oil millers and through solar hybrid systems. Yet, with a number of other large projects scheduled to come online (and take advantage of the country’s well-established FIT scheme), Malaysia is moving towards a delivery stage.
The Ever-Promising Markets A number of Asia-Pacific nations have been sluggish in project delivery and remain in a prolonged ‘promising and planning stage’. Indonesia has plans to build hydropower plants at 239 government-owned dams to complement its ample geothermal resources, however the overall contribution of renewable energy has not increased significantly in recent years, let alone in 2014. India’s new government has added even more ambition to existing renewable energy goals, notably with the country’s Energy Minister proposing that
Petr Kovar, Prague, Czech Republic
sbhattac, Germany
ENERGY
Indonesia has plans to build hydropower plants at 239 governmentowned dams to complement its ample geothermal resources, however the overall contribution of renewable energy has not increased significantly in recent years, let alone in 2014.
India add 10GW of wind power capacity annually, including a new offshore wind initiative targeting 1GW of offshore wind generation capacity by 2020. Minister Piyush Goyal has also promised to go ‘far beyond’ the previous government’s solar power goal of installing 20GW of solar energy capacity by 2022 with Coal India currently in talks with the Ministry of New and Renewable Energy to construct 1GW of solar projects. Nonetheless, mega-projects, like the Thar Desert solar power plant (4GW), have stalled. Like India, Vietnam has also been big on promises and has received significant funding from the World Bank and other national development banks, however renewables development is expected to be slower than in other nations, with estimates that just six percent of electricity will be produced from renewables in 2020. Vietnam’s hydropower sector is more developed than its other natural energy resources. In recent months, Alstom was awarded a contract from Electricity of Vietnam to add 75MW of capacity to the existing 150MW capacity of the Thac Mo hydropower plant, while geothermal developments have hit legal roadblocks due to the lack of regulatory framework and the perceived unattractiveness of the country’s FiT offerings. Further north, the developed economy of South Korea seems destined to continue relying on fossil fuels and nuclear power. The recent ‘Second Basic Energy Plan’ (covering energy policy until 2035) emphasised the importance of reducing reliance on nuclear power, but at the same time reinforced the need to expand imports from LNG hubs like the US.
The Bad - Australia Australia has been a case study in how to effectively diminish a renewable energy market. A prolonged and legislatively-mandated review of its chief renewable energy driver — the 20 percent 2020 renewable energy target — has killed-off any remaining confidence in
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long-term government commitment to renewable energy. Citing cost concerns, the report’s review, which was handed down in August, recommended that the renewable energy target be scaled back or closed to new entrants (the Government is yet to respond to the report’s recommendations). Despite the success of various small-scale, residential rooftop solar schemes and the efforts of the South Australian State Government and Australian Capital Territory Government which are following through with positive initiatives to create renewable energy opportunities, Australia, much like South Korea, seems destined to be reliant on fossil fuels for the foreseeable future. Australia’s plight is in stark contrast to its near neighbour, New Zealand, which is a regional renewables powerhouse, particularly in the geothermal space, and already enjoys over 75 percent renewables contribution to energy supply.
Next Twelve Months A ‘gap’ appears to be opening between the nonChina renewable energy markets of the Asia-
Pacific. Twelve months ago, it seemed that the majority of nations in the region would enjoy a strong uptake in renewables. What has emerged though, is perhaps the beginnings of a ‘two-track’ renewables economy with some governments willing to commit to renewables through strong FiTs and foreign investment incentives, and others more reticent to reform the traditional energy mix due to short term market barriers and the requirement for initial government regulatory support and financial incentives to promote renewables over fossil fuels. China’s boom will likely continue to cast a shadow over the region, but there are no signs that its renewables sector will become as open as the other emerging renewables economies like the Philippines and Japan. The group of other nations who have been big on plans and promises, might finally begin their charge in the next few years, although it is perhaps more realistic to expect only a few to make the leap into the delivery stage, and likely with solar the most lucrative fuel of choice for foreign investors. ENQUIRY NO. 7601
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The EPC-2000 series supports to EtherCAT Master Stack and Real-Time OS. This series is a PC-based motion controller using high-performance Intel’s processor which realizes simultaneous operations such as user interface and image processing. Expansion slot models are available.
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SECTOR SPOTLIGHT
Vision Technology:
The Road To Improved Production Vision technology has its way of enabling automotive manufacturers to take the high road to better products and consumer safety. By Didier Lacroix, senior VP, International Sales & Services, Cognex
S
hifting landscapes in the political scene usually play a major role in shaping the business environment. Continued unrest in Thailand has affected profitability in many industries; and the months leading up to presidential elections in Indonesia also created a degree of uncertainty in commercial activities. At the same time, government decisions to support or cut back on subsidies can have an impact on the growth direction and spending in a particular sector.
Country Developments In Thailand, the sales of commercial vehicles fell by 37.5 percent year-on-year (y-o-y) in March 2014, according to Business Monitor International (BMI). Due to the default in payment by the government to farmers under the rice subsidy scheme, the pickup truck segment is expected to be sluggish. As such, sales of pick-ups are expected to decline 20.8 percent this year. Security risks have also caused a drop in tourism levels. For this reason, demand for buses and coaches are also likely to decline. Down south in Malaysia, automotives production growth in both commercial vehicles and passenger cars are expected to be at 4.9 percent. Statistics provided by the Malaysian Automotive Association (MAA) also indicated vehicle sales rising 2.3 percent y-o-y in March 2014. This brings sales for the first three months of 2014 to 159,910 units, which is an increase of 1.4 percent y-o-y. BMI forecasts passenger car sales growth at four percent. The National Automotive Policy (NAP) has incentives that encourage EnergyEfficient Vehicles (EEVs) production. This segment is expected to become popular in Southeast Asia, since governments in various countries choose to reduce their fiscal burdens by cutting back on fuel subsidies, which results in higher pump prices. In neighbouring Indonesia, the Association of Indonesian Automotive Industries (Gaikindo) reported an increase of 17.8 percent y-o-y in domestic vehicle sales in March 2014. According to the BMI, sales were helped by the Low-Cost Green Car (LCGC) segment. For 2014, BMI predicts auto sales to rise 7.1 percent. The availability of fuel-efficient LCGC cars will give consumers an alternative in the face of higher petrol prices; and these eco-car models should continue to sustain passenger car sales in 2014. According to BMI, the passenger car segment is expected to continue to outperform the commercial vehicle segment. Another possible driver of private consumption is greater spending by political parties in the form of cash handouts, prior to the July 2014 elections. Politics aside, quality and production efficiency
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are equally important aspects that every automotive manufacturer needs to focus on. This is especially true when there are strong competitive pressures to reduce cost and waste, while driving to improve profit margins.
Raising The Bar
Lifting The Burden In vehicle parts production today, manufacturing first-rate precision components is only half the picture. Many of these components also have to be tracked to ensure complete reliability in the traceability process. The manufacturing of automobile disc brakes can be a physically demanding and challenging process that has sophisticated tracking requirements. In a particular facility, operators typically had to repeatedly lift the heavy discs — weighing between 12 and 20 kg — out of a stainless steel box and
ENQUIRY NO. 772
An engine manufacturer has to put together approximately 3,000 units of automotive engines every day. Previously, the assembly and inspection for each unit was carried out manually. This curtailed production efficiency and affected the quality of inspections. To curb these problems, the facility installed 18 In-Sight vision systems to perform accurate inspections and to facilitate production automation. The vision systems perform inspections for accessories feeding and assembly, as well as for final product defect detection. Vision tools check and verify aspects such as accessories types, vacancy, mixture and size measurements. One of the tasks of the system is to inspect an engine cylinder assembly line. After the system has inspected the components,
a robot on the production line picks up and installs the parts as needed. Although each inspection task is different, the vision system is able to meet the multiple precision inspection requirements of the production line, while achieving top inspection rates. In this manner, the need for human-eye inspections has been eliminated, which has effectively improved production efficiency and product quality. The inspection precision achieved is 99.5 percent.
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SECTOR SPOTLIGHT
Quality is achieved by implementing vision technology for inspections on the production line.
place them on different stations. Needless to say, performing this heavy work posed health risks to people on the production line. A fully automated disc brake finishing and testing process was therefore needed to ensure quality products — for the turning and milling processes of downstream finishing and inspection work. Such a setup has also helped to take over manually intensive physical work from employees. By using integrated machine vision, the handling process is given ‘eyes’ that can reliably read alphanumeric characters by using Optical Character Recognition (OCR). The system reads the codes on rotating discs brakes, which not only increases safety in the process but also relieves employees of performing the strenuous task. To make this possible, an In-Sight vision system was installed directly on a robot gripper’s head. With its automatic focus, quick image acquisition and built-in lighting, the fully-integrated smart camera recognises the location of disc brakes delivered onto a conveyor belt. The camera aligns itself to the inside diameter before image data is transmitted to the robot control in less than a second. This allows high-performing magnets to quickly grip the discs. After picking up the disc brake, the next step is to read the alphanumeric characters. This is accomplished by the robot that puts the disc brake on a rotary disc. Another vision system reads the alphanumeric characters with the aid of integrated red Light-Emitting Diode (LED) lights. These lights help to create an environment that allow the vision system to have a better focus on the characters. The high-speed 1K In-Sight line scan imager captures images of the pixelated embossed characters as the disc brake makes two rotations.
Manufacturing facilities are turning to vision systems to perform accurate inspections and to facilitate production automation.
One of the challenging tasks was the reliable reading of different embossed characters. This is because the embossing can differ between different product lots. The issue was overcome by using a stepby-step teach-in procedure of all possible variants. The process was facilitated by the OCRMax image processing tool that is used for OCR applications. After reading the alphanumeric characters, the finishing and inspection processes are carried out, which includes balancing and sound testing. Finally, the robot creates stacks of six discs each in a stainless steel box and places a wooden cover on top.
Eliminating Errors Another company produces plastic components for the automobile industry. One of its requirements is to ensure zero-faults in the manufactured items. To fulfil this, the company’s management decided to implement an In-Sight line vision system. The job of the vision system is to accurately check the quality of each item produced and to reject any that are faulty. This means that the system needs to be able to intercept parts that show imperfections of any kind, eg: geometrical defects, excess or lack of plastic material, and the presence of oil or other impurities on the plastic body. The vision system was installed on equipment that are dedicated to monitoring the operation. These equipment consist of: • a vibrating unit that sends through the parts to undergo inspection; • a conveyor belt, which moves the parts under the camera and; • a pneumatic discharge system, which removes faulty parts.
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The entire system is controlled by a Programmable Logic Controller (PLC). As for the vision sensor, the In-Sight 5100 model was selected due to its efficiency and processing power. The unit also has a rugged and sturdy structure, which allows it to be used in a harsh production environment. A software tool that is particularly useful for the operation is PatFind. It is a function that enables the vision system to reliably locate the objects being inspected. Even despite changes in lighting and angle of view, each individual part is recognised and picked up by the tool. Two geometric options provided are angle and reference position. These make it possible to carry out a detailed in-depth analysis of the geometric characteristics of the object by using the Edge and Blob Finding tools. The vision system runs inspections at a speed of 120 parts/minute and is able to keep up with the production line. Faulty components are reliably identified and removed while the approved components rejection rate has fallen below 0.5 percent.
ceramic filters onto the conveyor belt before they are forwarded to the packaging phase. It is also possible to perform additional control tasks such as packing of the soot filters. By using a colour vision sensor, it is possible to: 1) verify the presence of a green quality label on each filter and 2) determine whether the cardboard box contains the prescribed number of parts. By continuously checking the number of packed parts and comparing the number actually produced, it is possible to determine the number of rejects/ losses. The user-friendly working platform is based on the Windows environment and enables a timesaving, application-specific solution for vision tasks to be completed. By enforcing quality before rubber hits the road, manufacturers can help to ensure consumer safety and the efficient operation of vehicles. Such goals can be achieved by implementing vision technology to inspection and guidance systems on the production line — giving reliability to rides for many years to come. ENQUIRY NO. 7701
A manufacturer of soot particle filters uses vision systems to improve efficiency on its production lines, where robots are deployed to handle materials. Immediately after firing, the ceramic filters are automatically sent to a conveyor, before they go into a robot cell. The soot filter product variants differ only very slightly from each other, and need to be reliably handled by the vision system. The vision system used in the robot cell must recognise each individual shape among the 25 different filter variants, while determining the object’s exact position. These angles are provided to the robot in the form of data. The latter has to be accurate as the reading of the 2D codes takes place at the same point. The PatMax software operates using geometr yoriented object recognition. This allows a target of 99.9 percent accuracy to be set. The position data supplied by the vision system guides the robot, which places the selected
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Relying On Sight
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Solving application challenges with engineered solutions.
SENSORS | NETWORKS | RFID | CONNECTIVITY | INTRINSIC SAFETY
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SECTOR SPOTLIGHT
Addressing The Compliance Complexity Of
Safety-Relevant E/E Systems An overview will be given on how the automotive industry can address functional safety to help minimise the risks of product liability and ensure continued profitability. By Andreas Bärwald, business line manager Safety and Electronics, TÜV SÜD Auto Service
Bernhard Possenig, Innsbruck, Kematen, Austria
A
n increasing number of high profile recalls have proved that even industry leaders in automotive technology are not immune to functional safety issues. ISO 26262 provides an automotive safety lifecycle that covers management, development, production, operation, service and decommissioning. Automotive Original Equipment Manufacturers (OEMs) and their suppliers risk losing their competitive advantage if they fail to implement the requirements of ISO 26262. They also often approach functional safety as an afterthought following product development, rather than as an integral part of the design process, spending millions of dollars rectifying issues, rather than avoiding them from the start. The standard was published in 2011 to address the increasing complexity of safety-relevant electrical and electronic systems, and is now recognised as the state-of-the-art functional safety requirement. The standard covers safety-related systems that are installed in series production passenger cars, and include one or more electrical and/or electronic (E/E) systems.
The standard’s framework deals with product related requirements that define properties which can be observed as specific safety features in the final product, as well as process related requirements that reduce the probability of systematic faults (but cannot directly be observed as a feature of the product). Following a number of functional safety related issues that have put lives at risk and cost the industry dear, few automotive
OEMs and suppliers will dispute the importance of the standard. However, while the necessity to improve functional safety in the automotive industry has become widely accepted, many will agree ISO 26262 is a challenging s t a n d a rd t o i n t e r p re t a n d implement due to its complexity and the lack of functional safety experts within the industry. While it is a complex standard, it will help OEMs to improve the safety of their product, minimise
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risks of product liability and help them remain competitive. It will also enhance a business’s reputation as a premium quality manufacturer with a commitment to safety, thereby improving attractiveness to both consumer and corporate customers. The standard contains 10 sections, which provide a system of stages to manage the development process:
Overview Of ISO 26262 In general, ISO 26262: • P ro v i d e s a n a u t o m o t i v e safety lifecycle (management, development, production, operation, service, decommissioning) and supports tailoring the necessary activities during these lifecycle phases.
The 10 sections of ISO 26262:
• P ro v i d e s a n a u t o m o t i v e specific risk-based approach for determining risk classes (Automotive Safety Integrity Levels, ASILs).
1. Vocabulary — a glossary of terms and abbreviations for application across all parts of the standard.
• Uses ASILs for specifying the item’s necessary safety requirements for achieving an acceptable residual risk.
2. Management of functional safety — outlines organisational aspects of functional safety management. 3. Concept phase — a risk evaluation and safety concept. 4. Product development at the system level — safety aspects of the system development. 5. Product development at the hardware level — safety aspects of hardware development. 6. Product development at the software Level — safety aspects of software development. 7. Production and operation — safety aspects after Start of Production (SOP). 8. Supporting processes — quality ensuring processes. 9. ASIL-oriented and safety oriented analyses — safety analysis. 10. Guidelines on ISO 26262.
• Provides requirements for validation, verification and confirmation measures to ensure a sufficient and acceptable level of safety being achieved. While it is not demanded by the standard, it would be best practice to initially perform a gap analysis. This is an assessment of your existing processes and products against the requirements of the standard. Typically the process involves the internal and independent third party functional safety experts investigating key issues of the development process and/ or technical product or system. These processes are outlined within ISO 26262 and include documentation, management processes, technical functions and risk analysis. Stages within the ISO 26262 safety life cycle identify and assess hazards (safety risks), establish specific safety requirements to reduce those risks to acceptable levels, and manage and track those safety requirements.
The definition of the item is the first of these stages, which means identifying when it is necessary to achieve functional safety and what the required safety functions are. A risk assessment process, carried out according to accepted principles of risk assessment, is the best way of achieving this. This approach, for example, defines which actions of a product are defined as safety-relevant and which are not safety-relevant. A safety goal can then be determined for every hazard identified. For example if one of the safety requirements identified is an airbag, a potential hazard may be the airbag initiating unintentionally and the safety goal would be to prevent this. The result of the risk assessment is the ASIL, which is a measure of the potential risk and determines the activities and methods required to address the risk in an appropriate manner. The ASIL is defined by the level of risk based on a combination of the probability of exposure, the possible controllability by a driver, and the possible severity if a critical event occurs. The ASIL is defined in four steps, from ASIL A (the lowest amount of risk reduction) to ASIL D (the highest amount of risk reduction), with the standard detailing the minimum re q u i re m e n t s a c c o rd i n g t o the assigned ASIL. This is a key component for ISO 26262 compliance, as the ASIL, and therefore the hazard level, is determined at the beginning of the development process, and the intended functions of the safety system are then analysed with respect to those possible hazards (Figure 1). The next stage is to ensure that the defined safety requirement performs as its design intended, which must include accounting for failures of the underlying Oct/Nov 2014 | industrial automation asia 61
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SECTOR SPOTLIGHT
hardware and the prevention of systematic faults. The identified safety goals, which define the safety requirements, must also be implemented as specified by the appropriate ASIL, with suitable processes and methods implemented. This is achieved by defining a functional safety concept, with the technical aspects detailed in a technical safety concept, together with a safety design (or safety architecture), that determines the hardware and software safety requirements. Using the airbag example, a safety architecture could be defined that stops the airbag inflating unintentionally, but ensures it protects the driver in a crash. It is also necessar y to formulate a plan that closes any conformity gaps. Should, for example, the hardware layout of a safety relevant electronic system leave a high risk of malfunction when there is a short circuit, the plan would outline how the layout
(design) needs to be changed to prevent this. It would also describe how the design will be technically modified, the still safe interaction of the modification with other systems and the supporting documentation required. This will ensure all activity is documented correctly so, if there is an incident, it can be re-assessed at a later date. This is also required even if no change to the layout or concept was necessary. It is crucial for such measures to be taken early in the process as changes become more costly and time-consuming in later stages. Verification that the system meets the assigned ASIL is also a vital stage. This is achieved by a specialist, either in-house or a qualified third-party, running appropriate tests and analysis to determine the safety function’s mean time between failures. Many that have experienced the implementation of ISO 26262 fully understand the value of
obtaining an external assessment, as well as certification. This final step involves attaining a technical report or certificate from an independent assessor as a proof of conformity to the latest standard.
Staff Competence While ISO 26262 sets out the complex ‘functional’ steps that must be taken towards compliance, you must first ensure that your business has the exper tise required to understand how ISO 26262 relates to your products and, if required, how to implement any changes towards conformity. This can either be achieved through training existing staff, hiring functional safety specialists to become part of your staff, or outsourcing the work to an independent third-party. It is vital that relevant staff fully understand the content of ISO 26262, the required documentation and the key issues in each of its 10 sections.
Figure 1: Approach to hazard analysis
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Figure 2: Three key task profiles for successful functional safety management.
Within larger organisations there are often three key task personnel profiles that could support successful functional safety management within the organisation: 1 2 3
Company Safety Manager Business Unit Safety Manager Project Safety Manager — the only role required by the standard
This hierarchy is shown in Figure 2. The Company Safety Manager is the custodian of an organisation’s safety culture, ensuring consistent communication amongst all staff, the company’s management team and external service providers. They are also responsible for the further development of functional safety within the business, ensuring that company specific guidelines and staff training are updated according to compliance changes. They should also instigate regular audits of departments to ensure consistent compliance with company wide guidelines for functional safety, including regular adjustment meetings with the safety managers of each separate business unit. The Business Unit Safety
Manager is not a role specified within the standard, but is common within larger organisations. They are the central point of contact within the business unit for all questions relating to functional safety, and should also be responsible for the maintenance of basic data and ensure the appropriate training of staff. The Project Safety Manager is the most important role, and the only one that is required by the standard. They work with the Business Unit Safety Manager to coordinate specific functional safety projects. The Project Safety Manager typically has the responsibility for the creation and maintenance of a project safety plan, which includes the execution of assessments, the application of measures to avoid systematic faults, as well as the execution of verification and validation measures. They also have responsibility for the coordination of all internal and external interfaces (business units, suppliers, customers, and so on).
Creating A Culture Of Functional Safety Achieving functional safety requires more than just an understanding of the technical
requirements of ISO 26262. For successful implementation there must be a culture where employees at all levels ‘live and breathe’ its mantra. Functional safety is an extension of quality management that can only work if all employees adhere to high standards. For example, a major safety issue can be caused if just one out of the hundreds of engineers involved in the development process misses an activity or uses the wrong method. To help OEMs and suppliers achieve this cultural consistency, appropriate management processes must be in place, including the strict execution of safety rules and tools.
Conclusion While ISO 26262 is complex, it is imperative for OEMs and suppliers as it helps them to improve product safety and minimise liability risks. However, not only does ISO 26262 help to ensure vehicles, systems and components are safe, it will also enhance your reputation as a premium quality OEM or supplier, improving the appeal of your products and helping you to remain competitive. ENQUIRY NO. 7702
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FEATURES
Schunk Coming Into Grips With SEA A German manufacturer of clamping and gripping solutions has recently set up a regional base in Singapore. By Joson Ng Mr Koh believes the distributor network is crucial to the success of the company in this region.
I
n order to establish a stronger presence here in Southeast Asia, Schunk has set up an office and distribution centre at the German centre in Singapore. The company began operations on July 1, 2014 and Industrial Automation Asia (IAA) paid Koh Keng Lim, regional sales manager in charge of Southeast Asia, a visit to gain a better understanding of the company’s plans for the region. IAA understands that the 170 sq m office in Singapore is the company’s fifth in the Asia Pacific region. Apart from the office, the company also has an 80 sq m warehouse to house critical stock. With the initial startup investment of S$800,000 (US$638,000), the company is looking to expand their headcount in 2015 from the current three. The operation here may not be the largest compared to other locations in Asia Pacific (a region that is responsible for roughly 10 percent of the company’s total revenue in 2013), but there is potential for growth. “We see strong potential for growth. We are looking at a 30 to 40 percent growth in total revenue from existing revenue across Southeast Asia,” said Mr Koh. The reasons for this optimism stem from a few factors, but namely the company’s distribution network in the region.
awareness of our products in Southeast Asia. Another reason is to support the distributors over here,” he said, before telling IAA that he has distributors in Singapore, Malaysia, Thailand, Indonesia and the Philippines. Balluff and Eureka Tools represent the company in Singapore while SKTec and Precisetech cover the Malaysian market for him. Brainworks, PT Metaltech and Bon Industrial take care of business in Thailand, Indonesia and the Philippines respectively. For Mr Koh, the distribution network is crucial to the success of the company in this region and it is very much an arrangement that is mutually beneficial. “We need our distributors to increase our network across Southeast Asia. The synergy between the distributor and our office here will be getting stronger.
Local Presence Mr Koh revealed that the main functions of his office are to give a stronger support to the distributors as well as establish a direct relationship with key strategic customers. “We set up an office here to increase the 64
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“We see strong potential for growth. We are looking at a 30 to 40 percent growth in total revenue from existing revenue across Southeast Asia.” – Koh Keng Lim
The company’s solutions fall under clamping and gripping devices.
Market Outlook & Future Plans Southeast Asia is a region with a high level of diversity. While language is one such area, the fabrics that make up each economy are very different from country to country. As a result, it is important to consider each country individually rather than treat them as a whole. “While dealing with five different countries, the type of investment might be slightly different. Thailand and Indonesia focus on the clamping portion (work and toolholding), they belong to the end user market along with the Philippines. Singapore and Malaysia on the other hand, have more machine integrators and makers. As such, we see more automation there,” he said. Although each country has its own idiosyncrasy, they all have one common trait according to him, ie: they all have room for growth. Having said that, Mr Koh picked out Indonesia as the country with the largest potential. “Among the five (nations), the revenues are pretty even. However, Indonesia is the fourth most populous country in the world and they just got the election out of the way. As such, the economy will pick up soon and we will see a brighter 2015,” he said. The year 2015 will be a very important one for the company’s unit in Southeast Asia. As such, Mr
Koh has plans to accelerate his company’s footprint across this region. He revealed that the company will conduct technical seminars, first for their employees and distributors before organising one for their customers sometime in the first half of the year, possibly in Singapore. This is in line with his company’s ethos in providing good before and after sales services. ENQUIRY NO. 7801 SG-1001-triflex TRCF 83x110_SG-1001-triflex TRCF 83x110 22.09.14 1
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ENQUIRY NO. 774
We want to work closely with them, not forgetting that we also want to have more knowledge of new markets,” he said. This thirst for knowledge also extends to Vietnam, where Mr Koh hopes to break into sooner rather than later. “We went to MTA Vietnam in July as we wanted to create our presence over there. We want to be there as early as possible. We are looking for suitable candidates over there and we are targeting the first quarter of 2015 (to get distributors in Vietnam),” he said.
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EVENT REVIEW
IAA Manufacturing Conference 2014 Industrial Automation Asia’s inaugural Manufacturing Conference was held on August 29, 2014, at Concorde Hotel Singapore. The event was well attended and received positive feedback from attendees. A major theme of the conference was Industry 4.0 and the increasing digitisation and automation of the production process to improve productivity. Reporting for IAA was Wong Tsz Hin. INDUSTRY 4.0 has been a buzzword in the manufacturing industry for several years now, but its implementation has been slow moving. Introduced by the Germans in 2011 at the Hanover Fair, the concept will provide a platform for the strong customisation of products under the conditions of highly flexible mass production, and introduce self-optimisation, self-configuration, self-diagnosis, as well as cognition and intelligent support into automation technology. In recognition of the importance of this vital next step for the industry, Industrial Automation Asia (IAA) organised a manufacturing conference on August 29, 2014, at Concorde Hotel Singapore to provide a platform for knowledge exchange and dialogue between stakeholders. The 50 over attendees at the event shared the same question in their minds, how should the industry move forward? According to a white paper from IHS Technology, “the challenge for the fourth industrial revolution is the development of software and analytical systems that can turn the deluge of data products by intelligent factories into useful and valuable information.” This entails big data, another enigmatic concept that seems feasible, but has proven to be very difficult to achieve in practice. However, the infrastructure is very much in place to make it a reality. As we move into the 21st century, connectivity
has become a prominent feature of our lives and this has also infiltrated into business practices, with cloud technology and data links between different work stations. “Wireless is going to be a big thing for manufacturing,” Satish Lele, VP for Automation and Electronics Practice of Frost & Sullivan, shared during the opening session. The only issue is that not many companies are fully embracing the benefits offered by the technology.
Better Together With the formation of the ASEAN Economic Community by 2015, the Southeast Asia region with a combined population of 602 million and combined trade volume of US$2 trillion, will have huge growth potential for its manufacturing industry. The GDP of the top six countries in the ASEAN was US$2.306 trillion in 2012 and the figure is expected to rise to US$3.251 trillion in 2018. By 2030, the region will be the fourth largest single market in the world. “Foreign Direct Investment (FDI) in ASEAN-5 exceeded China’s for the first time in 2013.” Mr Lele believed that China’s FDI advantage in manufacturing is eroding in favour of the ASEAN as the region continues to have a strong structural foundation for further investments in the future. The manufacturing
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The Smart Factory
The Conference inspired much discussion, with some of our speakers exhibiting their products during the event.
The Conference consisted of two panel discussions, which gave an opportunity for attendees to ask any questions. (l-r) Chris Lee, Autodesk and David Chia, Beckhoff Automation.
sector of the top five ASEAN countries constitutes more than 20 percent of the country’s GDP. Of all the ASEAN countries, Indonesia has the greatest prospect to break out. Autodesk, a 3D design software provider, is another company that has realised the impact of connectivity. “34 percent of the world’s population is online,” Chris Lee, manufacturing sales lead of Autodesk ASEAN, said. The company has taken major steps by providing its software solutions on the cloud so that designers can access the plans anytime, anywhere. “Teams are now global and increasingly involve stakeholders from different industries and with different needs. The design process and the tools that support it need to support open collaboration and invite into the process voices that were once impossible to access.” By designing a prototype using the cloud-based technology, members of the team will be informed of its status and can give comment or make amendments when necessary. According to Mr Lee, amongst the challenges faced by manufacturers are short time-to-market, increasing speed of innovation, product complexity, rising standards for design, accelerating technological development, global competition and uncertain economic conditions.
Kenny Lee, director of high tech industry value engineering at SAP (Asia Pacific and Japan), Industry 4.0 is focused on creating smart products, procedures and processes and Cyber Physical Systems (CPS) can be used to create smart factories. “Its interfaces with smart mobility, smart logistics and smart grids will make the smart factory a key component of tomorrow’s smart infrastructures,” he remarked. He added that the key enablers that will drive the fourth industrial revolution will be mobile networked computing that provides affordable access to information, social media that facilitates knowledge sharing in communities, the Internet of Things, machine-to-machine self-regulation and big data and predictive analytics. Beckhoff Automation, a provider of PC-based control, envisions that the fourth industrial revolution will be achieved through the use of cyber-physical systems. Citing the Google Glass as an example, plant operators in the future will be able to access data from the virtual space anywhere they need. “In an ‘Internet of Things’ scenario, both the pick-and-place XTS system and the processing systems are internet users. They communicate openly with each other over the internet and use cloud services, for example, in the evaluation of their energy consumptions,” David Chia, MD of the company’s Singapore office, explained. Rounding up the conference, Pedro Henrique Furtado, project director at Efacec (Singapore), demonstrated how automated storage and retrieval systems can be implemented at logistic operations to lower operation costs and raise profit margins.
In Conclusion To some, the session may seem non-conclusive on what exactly Industry 4.0 entails, but it is this constantly exploration of new technology and practice that will help drive the industry forward and closer to this vital evolutionary next step in manufacturing. Instead of expecting a wholesale makeover, perhaps what manufacturers really need is to be ready to embrace new advances and focus on enhancing the smaller elements across the entire value chain, which will naturally revitalise the overall process. August 29, 2014 Concorde Hotel Singapore Singapore
ENQUIRY NO. 7901
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PRODUCTS & SERVICES Aspen Technology: Manufacturing & Supply Chain Software
Banner Engineering: Vision And Barcode Sensors
The aspenONE Manufacturing and Supply Chain V8.7 software from Aspen Technology has been released. This software addresses Oil, Gas, and Chemicals companies’ challenge to maximise continuously the operational performance of plants, and to optimise the supply chain with increased visibility for better decision making. This software includes the ability to: modify controller behaviour, expand refinery pipeline scheduling, and create the optimal refinery plan. It includes updates to the Aspen DMC3, Aspen Petroleum Scheduler, and Aspen PIMS-AO software.
A new generation of vision and barcode sensors offering multiple tools and resolution options in each unit has been introduced by Banner Engineering. The iVu Plus Gen2 line includes integral and remote screen models for use in a wide range of inspection, machine vision and quality control applications. These vision sensors are designed to solve applications that would typically require multiple photoelectric or proximity sensors. They now include a full resolution option to detect small features, and capability to use multiple sensor tools in the same inspection.
ENQUIRY NO. 7902
Autocrib: Object Recognition Capabilities For Automated Inventory Control
Beckhoff Automation: Compact I/O Modules
AutoCrib’s Vertical Lift Modules (VLM) can reach a height of up to 40 feet with the option to ascend in 6-inch increments. Within the elevated racking systems, the automated inventory control system offers lifting and storage capacity of parts, equipment and supplies up to 500 pounds per tray. The storage system’s three standard VLM models are said to deliver the industry’s first object recognition capabilities integrated into a vertical lift system. The optional real-time tracking of objects works to record items as they are issued or returned to the storage tray. The module occupies a minimal footprint (5 feet 9 inches wide and 8 feet 3 inches deep) and the control system allows the operator to retrieve parts by tray, part number or description.
With the introduction of the ER series, Beckhoff Automation is extending the range of applications that can be served by the EtherCAT Box product line. These robust ER series I/O modules in die-cast zinc housings are designed for harsh environmental conditions, for example, in the heavy-duty and automotive industries as well as in robotics. Together with the EP and EQ module series, the EtherCAT Box I/O system covers a wide range of signals for all industrial applications and is intended for use outside of control cabinets. Utilising die-cast zinc as the housing material, the IP 67 rated I/O modules from the ER series can be used in harsh industrial and process environments.
ENQUIRY NO. 7903
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ENQUIRY NO. 7904
ENQUIRY NO. 7905
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PRODUCTS & SERVICES
Delcam: Inspection Software Enhanced Delcam’s PowerInspect inspection software has a new interface with new icons that make the software more intuitive and easier to use. Other enhancements in this version include the ability to create compound items, and so speed up and simplify repetitive measurements. There are also enhancements to the measurement dialogs and a further increase in the range of geometric features that can be inspected. In addition, the software program now has the ability for users to create custom toolbars, which allow frequently-used commands to be grouped together in one convenient place, and so improve speed and ease of use. It is possible to export and import toolbars, so users can transfer their set-up to a different PC or share their toolbars with other operators. Finally, the product now includes improved support for the Renishaw PH20 probe. ENQUIRY NO. 7906
Hirschmann: Mobile App
The HiMobile app, from Hirschmann, makes it possible for immediate response to error messages by network administrators using smartphones or tablets. This app allows access to status information about network devices from almost any location. A specially formatted QR code can be scanned to direct to the correct device and view its status information immediately on the display. Used together with the Industrial HiVision network management software, this app is suitable for mobile monitoring of network devices, and for practically all missioncritical applications that depend on seamless processes and hence effective data communication. The app is available for mobile devices running on the Apple, Android or Windows Phone operating systems. ENQUIRY NO. 7908
Eplan: Automation Software
Igus: Modular System
The 2.4 release of the Eplan Platform is now available for download and, for the first time, also as a 64-bit version. The Computer-Aided Engineering (CAE) system provides additional opportunities to increase efficiency during the engineering process. The simplified representation of the PLC communication networks makes the documentation and management of PLC structures clearer and also simpler. The sub-project management also enhances the overview. Specific sections can be extracted from a project, individually edited and merged back into a final project. As a result, complete and high-quality documentation is created and users can concentrate specifically on their required tasks.
Moving small scale capillary tubes reliably and safely often poses major problems for design engineers, especially in the medical industry. Igus has now developed the e-cord micro system to address this. The modular system of straight, curved and mounting parts, means that even the smallest tubes can be fitted into moving equipment with confidence. The system ensures the hoses do not fall within a predefined minimum bend radius of 45mm, and are also given some physical protection. The modular nature of the system and the elasticity of the material allows machine designers lots of flexibility when designing moving capillary tubes into the smallest of spaces.
ENQUIRY NO. 7907
ENQUIRY NO. 7909
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PRODUCTS & SERVICES
MDS Pacific: Dynamic Testing Tool
Röhm: Clamping Device
DT10, from MDS Pacific, allows developers to grasp the realistic movement of a whole system exactly by analysing the underlying source code before starting the development. Developers can input design values such as execution time, period time, arguments and variables on this products software and compare them with the measured values. In addition, developers can improve efficiency of debugging because they can get and analyse task transition, function period, execution time, coverage, and variable transition at the same time. Therefore, this product will be able to be utilised for gray box test. It also supports C/C++/Java languages and is independent of CPU (x86, ARM, MIPS, etc.) and OS (Windows, Linux, Android, RTOS, etc.), which is beneficial for developers.
The use of palletising and clamping devices from a single source has many advantages. The prefabricated pallets can be combined in a modular system with a multitude of standard clamping devices. Here, the Röhm provides standard pallets for vices and chucks. Thanks to its sturdy construction and corrosion-resistance, the Power-Grip zero-point clamping system fits during the whole process, from machining through Electrical Discharge Machining (EDM) right up to the measuring machines. Due to cushioned, conical centring with a levelling system, accuracy of +/- 0.002 mm is achieved in permanent use. Even with thermal changes, zero point clamping is ensured throughout.
ENQUIRY NO. 7910
Opto 22: Analogue I/O Modules
The SNAP-AIMA-iH and SNAP-AOA-23-iH twochannel analogue input and output modules has been release from Opto 22, each with HART communications. Both SNAP I/O modules use the HART communications protocol to extract status, diagnostics, and other information from smart devices such as field-mounted process transmitters and analysers. This information can be used by the automation system and/or the asset management system to increase uptime, improve productivity and enhance safety. Both analogue modules are transformer isolated as well as optically isolated from all other modules and from the I/O processor. Transformer isolation prevents ground loop currents from flowing between field devices and causing noise that produces erroneous readings. ENQUIRY NO. 7911
ENQUIRY NO. 7912
Schunk: Electric 2-Finger Parallel Gripper With the Safely Limited Speed (SLS), Safe Operating Stop (SOS), and Safe Torque Off (STO) functionalities, the Schunk EGN gripping system is the first certified safety gripping system, certified in accordance with DIN EN ISO 13849, which enables safe human/machine collaboration. If the production process is interrupted by an emergency shut-off, this gripping system goes into either an SLS mode or a safe stop mode depending on the activated protection zone. In contrast to other solutions available in the market, this safety gripping system is continuously powered even in the SOS so that the gripped parts are reliably held even without mechanical maintenance of gripping force. ENQUIRY NO. 7913
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Calendar Of Events 2014/15 oct 14 – 16 BuildTech Asia 2014 Singapore Expo Halls 3 & 4 Sphere Exhibits Pte Ltd Email: buildtechasia@sph.com.sg Web: www.buildtechasia.com
16 – 19 IGEM 2014 Kuala Lumpur Convention Centre, Kuala Lumpur, Malaysia Expomal International Sdn Bhd Web: www.igem.com.my
22 – 24 Electrical Power Automation & Smart Grid 2014 China International Exhibition Centre Beijing, China China Electrical Council, Adsale Exhibition Services Email: power@adsale.com.hk Web: http://www.epchinashow.com/epa
22 – 24 EP China & Electrical China 2014 China International Exhibition Centre Beijing, China China Electrical Council, Adsale Exhibition Services Email: power@adsale.com.hk Web: http://www.epchinashow.com/
nov 4 – 6 China International Industry Fair 2014
9 – 11 SIAF Guangzhou 2015
Shanghai New International Expo Centre Shanghai, China Shanghai Eastbest International (Group) Email: office@shanghaiexpogroup.com Web: http://www.ciif-expo.com/
China Import and Export Fair Complex Guangzhou, China Guangzhou Guangya Messe Frankfurt Email: sps@china.messefrankfurt.com Web: http://www.siaf-china.com/
4 – 8 Industrial Automation Show 2014
18 – 20 Korea Machine Vision Show 2015
Shanghai New International Expo Centre Shanghai, China Hannover Milano Fairs Shanghai Email: ias@hmf-china.com Web: http://www.industrial-automation-show.com/
Coex Seoul, South Korea Korea Machine Vision Industrial Association Email: gemma0707@coex.co.kr Web: http://automationworld.biz/
19 – 21 BioMalaysia & Bioeconomy Asia Pacific 2014
31 – Apr 2 Propak Vietnam
Kuala Lumpur Convention Centre (KLCC) Kuala Lumpur, Malaysia Protemp Exhibitions Email: BioMalaysiaExhibition@protempgroup.com Web: http://www.biomalaysia.com.my/
dec
27 – 31 Singapore International Energy Week Sands Expo & Convention Centre Singapore Energy Market Authority Email: ema_siew@ema.gov.sg Web: http://www.siew.sg/
28 – 30 HVACR Indonesia 2014 Jakarta International Expo Informa Exhibitions Email: hvacrps.marketing@informa.com Web: www.hvacrseries.com/indonesia
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Saigon Exhibition & Convention Centre (SECC) Ho Chi Minh City, Vietnam Singapore Exhibition Services Email: events@sesallworld.com Web: http://propakvietnam.com/
apr 13 – 17 Hannover Messe 2015
3 – 5 Semicon Japan Tokyo Big Sight Tokyo, Japan SEMI Email: jeventinfo@semi.org Web: http://www.semiconjapan.org/
3 – 6 Manufacturing Indonesia 2014 The Jakarta International Expo Jakarta, Indonesia Pamerindo Indonesia Email: maysia@pamerindo.com Web: www.pamerindo.com
22 – 24 Oil & Gas Vietnam 2014 Indoor Sports Complex Vung Tau City, Vietnam Fireworks Vietnam Email: viet@asiafireworks.com Web: http://www.oilgasvietnam.com/
mar
Hannover Exhibition Grounds Hannover, Germany Deutsche Messe Email: info@messe.de Web: http://www.hannovermesse.de/
21 – 23 Nepcon China 2015 Shanghai World Expo Exhibition & Convention Centre Shanghai, China Reed Exhibitions Email: tim.wang@reedexpo.com.cn Web: http://www.nepconchina.com/
22 – 23 RFID World Asia 2015
feb 4 – 6 Semicon Korea Coex Seoul, South Korea SEMI Email: jcho@semi.org Web: http://www.semiconkorea.org/
26 – 28 India Automation Technology Fair 2015 Bombay Exhibition Centre Mumbai, India MMI India Email: tarun.marwah@mmi-india.in Web: http://www.iatf.in/
Suntec Singapore Convention & Exhibition Centre Singapore Terrapinn Email: Christine.lee@terrapinn.com Web: http://www.terrapinn.com/2015/ rfid-world-asia/
To be considered for inclusion in the Calendar of Events, send details of event (name, date, venue, organiser contact) to: The Editor IAA Eastern Trade Media Pte Ltd. 1100 Lower Delta Road, EPL Building, #02-05, Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2805 Email: iaa@epl.com.sg
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