Elektor industry productronica 2019 sample by Elektor

www.elektormagazine.com � Edition 3/2019 � € 9.75

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Coverstory:

6 Are We Really Equipped for Industry 4.0 ? The beginning of the fourth generation of the industrial revolution

34 Interview with Barbara Müller on productronica 2019

16 Lighthouse project “Go Beyond 4.0”

Foreword

Bringing high-quality electronic products to market is a difficult task for start-ups and long-established companies alike. Challenges abound. Design issues, manufacturing delays, budget constraints, and logistics problems should be anticipated. They’re all part of the game, right? Fortunately, the more you prepare, the better you’ll fare. And Elektor is here to help. The final 2019 edition of Elektor Industry covers the topics of electronics development and production, which are also the focus of the upcoming productronica trade fair in Munich, Germany (November 12-15, 2019). We dive into many of the subjects and technologies that will be highlighted at the 2019 productronica event, including the future of Industry 4.0, realtime spectrum analysis, SiC power supplies, high-performance electronics measurement tools, and much more. If you are planning to attend productronica 2019, visit Elektor at Hall B2 Booth 472. Here’s what you can expect:

• productronica Fast Forward - the start-up platform powered by Elektor: Startup competition finalists will have an opportunity to pitch their companies and products for a chance to win valuable media packages and international recognition. Award winners will be announced at the event. • Tech talks, presentations, and discussions: Attendees can listen to technical presentations, meet electronics industry thought leaders, and network. Come learn and share! • Meet with Elektor: Visitors can chat with Elektor engineers and editors, learn about our newest products, and grab copies of our magazines, including ElektorLabs, MagPi (Dutch or French editions), and Make (Dutch edition)! I’m confident this edition of Elektor Industry will inspire you take your products and companies to the next level. Enjoy the journey and keep us informed about your progress! Elektor Industry

C.J. Abate, Editor-in-Chief 191114-01

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Production Methods and Components

Contents Elektor Industry Edition 3/2019,

Focus:

productronica 2019

Regulars 32 Infographics Facts and figures.

62 Wall of Fame Elektor’s partners in the electronics Industry.

Are We Really Equipped for Industry

4.0

64 Elektor Industry Store Selected products for innovators, makers, and start-ups.

66 Index of Advertisers | Our Contributors | Next Edition

News pages 9, 14, 15, 19, 25, 29, 36, 37, 59, 60, 61

Lowering the Costs of Applying Pressure Sensors by Mitigating the Risks

Articles 6 Are We Really Equipped for Industry 4.0? 10 Lowering the Costs of Applying Pressure Sensors by Mitigating the Risks 16 Lighthouse project „Go Beyond 4.0“„

26 Sensing for safety brings comfort and convenience

Industrie 4.0 and then some

20 R&S RTP high-performance oscilloscope from Rohde & Schwarz doubles maximum bandwidth to 16 GHz

30 Why Open Source PLCs Are Here To Stay From small DIY projects to large industrial applications

34 Interview with Barbara Müller 22 How to Simplify Power Supplies and Save Cost with SiC

Elektor Industry 3/2019

Messe München

38 Elektor Review OWON XDS3064E 4-channel Oscilloscope with Touch Screen

44 Elektor Review Seek ShotPro and Seek Compact Thermal Imaging Cameras

46 Interview with Markus Strecker Teiimo

Colophon Elektor Industry Issue 3/2019 productronica Special Edition

Printers Pijper Media, Groningen

Reader Notices Elektor Industry contains contributed/sponsored content. www.elektormagazine.com The Publishers acknowledge all trademarks that may exist Elektor Industry, English edition, in connection with products, is published four times a year by services, materials and company Elektor International Media names that appear in this PO Box 11 publication. NL-6114-ZG Susteren The views expressed in Elektor The Netherlands Industry are not necessarily Phone: +31 46 4389444 those of the Publisher or the Fax: +31 46 4370161 Editor. © 2019

Editor-in-Chief C.J. Abate Email: newsdesk@elektor.com Deputy Editor Robert van der Zwan Email: robert.vanderzwan@ eimworld.com Advertising Margriet Debeij Tel. +49 241 955 09-174 Email: m.debeij@elektor.com

50 Fast-Forward Startups @ productronica 2019

54 The Origin of IoT OSes Most IoT OSes originate from embedded OSes, whose kernels most likely come from RTOSes. Of course, there are IoT OSes that are original, like Android Things, Microsoft Windows 10 IoT Core, and others. Here we present a “A Brief History of RTOS”!

Layout Jack Jamar Publisher Don Akkermans Email: don.akkermans@elektor.com Mission Elektor Industry offers to electronics engineers, innovators, and start-up companies, essential information and insights into the latest products, research and intelligence from the industry. Distribution and Supply Elektor Industry appears synchronously in English and German and is supplied free to selected Elektor Magazine Gold members in print, and to Elektor Green members as a pdf download. The magazine is also on free distribution at selected trade fairs including Productronica (Munich), electronica (Munich), and embedded world (Nuremberg).

Copyright Notice The content of this magazine is for educational use only. All drawings, photographs, printed circuit board layouts, and article texts published in this magazine (other than third-party advertisements) are copyright Elektor International Media b.v. and may not be reproduced or transmitted in any form or by any means, including photocopying, scanning and recording, in whole or in part without prior written permission from the Publisher. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Patent protection may exist in respect of circuits, devices, components etc. described in this magazine. The Publisher does not accept responsibility for failing to identify such patent(s) or other protection. The Publisher disclaims any responsibility for the safe and proper function of reader-assembled projects based upon or from schematics, descriptions or information published in or in relation with Elektor Industry.

Production Methods and Components

Are We Really Equipped for ? Industry

4.0

Mark Patrick, Mouser Electronics

The beginning of the fourth generation of the industrial revolution is now upon us. It has been conceived through the combining of information technology (IT) with operational technology (OT) to enable a far higher degree of automation than was previously possible. Industry 4.0 is based on the deep-rooted principle of creating smart infrastructure that optimizes the manufacturing process and significantly boosts throughput. This infrastructure will be heavily dependent on Internet of Things (IoT) devices, which are powered and controlled through cyber-physical systems (CPS) and artificial intelligence (AI) algorithms. Smart manufacturing systems are going to be capable of delivering a clear com-

Elektor Industry 3/2019

petitive edge over traditional manufacturing systems, resulting in commercial advantages for early adopters. As well as increasing productivity levels, they can enable the interconnection of various cross-functional operations. They can also enable the benefits of predictive maintenance – monitoring system health, highlighting potential issues, thus prolonging the working lifespan of equipment and reducing the risk of downtime. The advent of the Industrial IoT (IIoT) means that machine-to-machine communication can be implemented right down to a granular level. In this way continuous data capture and analyt-

ics can be supported, and appropriate actions taken in real time – leading to safer and more efficient production/processing facilities. However, the biggest challenge today is to gather the prerequisites of the IIoT (in particular its networking requirements) into some form of consensus that will reduce complexity, drive standardisation, and make deployment more straightforward.

Why So Many Protocols? A single machine in a factory is usually connected to many networks for different functions or use cases. Each of these works on its own specific protocol. Over the years, many different communication protocols have evolved. Some sup-

Go Beyond 4.0 Industrie 4.0 and then some While many companies are busy putting Industrie 4.0 concepts into practice in their factories, new challenges are already knocking at the door. For example, demand for customized products is on the rise. Fraunhofer researchers have set out to develop technologies to meet these emerging requirements and take Industrie 4.0 to the next level in a lighthouse project called Go Beyond 4.0.

The basics of customized mass production are easily explained with a visit to the pizzeria around the corner. It is nothing unusual for a diner to order a Pizza Napoli base and then pile on the special requests – hold the olives, add some mushrooms, how about some extra capers. Ten minutes later, a steaming hot pizza pie replete with the diner’s favorite toppings arrives on a plate. What has long been the norm in catering – a standard product tailored to the buyer’s taste – is now sweeping the manufacturing industry. The challenge for manufacturers is to find a way of customizing on the fly in highly flexible, connected Industrie 4.0 factories. This is akin to asking for bespoke products off the rack, delivered with assembly-line speed and reliability.

Components like these are used in the additive inkjet printing process, for example, for lab-on-achip systems.© Fraunhofer IOF

Digital printing and laser sintering for Industrie 4.0 plants

ers of these technologies to add functions to any component during production. This initiative was sparked by an idea that Prof. Reinhard Baumann and Dr. Ralf Zichner had at the Fraunhofer Institute for Electronic Nano Systems ENAS in 2014. Now they are pursuing that notion with their research in the eponymous lighthouse project.

The Go Beyond 4.0 initiative aims to make that happen with two technologies not normally associated with industrial-scale manufacturing – the first using digital inkjet, dispensing and aerosol jet printing techniques, and the second by means of laser sintering. Fraunhofer researchers want to harness the pow-

At first, it sounds paradoxical to produce unique products in mass production lines. However, if the digital manufacturing technologies of inkjet printing and laser processing are clever integrated into mass production environments, the respective products can be individual-

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ized in-line«, explains Prof. Reinhard Baumann of Fraunhofer ENAS, project coordinator of the Fraunhofer lighthouse project Go Beyond 4.0. Prof. Thomas Otto, acting director of Fraunhofer ENAS, heads up the Go Beyond 4.0 lighthouse project. It is a joint effort of six institutes, the Fraunhofer Institutes for Laser Technology ILT, for Applied Optics and Precision Engineering IOF, for Silicate Research ISC, for Machine Tools and Forming Technology IWU, and for Manufacturing Technology and Applied Materials Research IFAM.

How to Simplify Power Supplies and Save Cost with

SiC

Silicon carbide technology can offer many advantages besides greater efficiency, enabling designers to increase power density, enhance reliability, and economise on the overall bill of materials, even in a relatively simple circuit such as By Aly Mashaly, ROHM Semiconductor GmbH

a flyback converter

More Accessible Than You Might Think Silicon carbide (SiC) power semiconductors are understood to enable greater efficiency in power-conversion applications where energy is extremely precious, such as solar generators and electric vehicles. In fact, they have many more advantages to offer, including increasing power density and reliability due to their increased temperature capability, simplifying circuit design, reducing reliance on external components, and allowing smaller and lower-cost passive components. We can see how these benefits can be unleashed in ordinary applications by comparing several designs for the flyback converter of an auxiliary power supply using both SiC and silicon technologies.

Recap: The Root of SiC’s Advantage In the form used for fabricating power semiconductors, SiC has a bandgap of

Elektor Industry 3/2019

3.2 eV between the valence and conduction bands, which is about three times that of ordinary silicon. In addition, its dielectric breakdown field strength is about 10 times that of silicon. Together, these two characteristics endow SiC devices with superior properties, including faster switching, higher efficiency, greater stability over temperature, and higher maximum operating temperature. For equipment designers, this can relieve demand for thermal management without compromising device reliability. SiC’s higher breakdown field strength allows MOSFETs to be designed with a much thinner drift layer, resulting in lower on-resistance, RDS(ON) relative to the die area, for a given breakdown voltage. To achieve high breakdown voltage in ordinary silicon, the MOSFET has higher RDS(ON) leading to greater conduction losses. SiC also permits lower MOSFET gate charge, Qg, enabling faster switching with lower energy loss, concurrently with low RDS(ON) and high breakdown voltage.

Auxiliary Power Supply Design Challenges Equipment such as solar inverters, industrial DC/DC converters, battery chargers, and others often contain an auxiliary power unit running off the main input to supply subsystems such as sensor modules, a display, and other control units or drivers (figure 1). For simplicity a flyback converter is typically used. The main power switch must be able to withstand the worst-case drain-source voltage due to the reflected voltage from the secondary side, maximum turn-off overshoot, and DC input voltage (figure 2). The sum of these voltages can exceed 1300 V. A variety of design approaches can be considered to ensure the power transistor is able to withstand worst-case voltage applied across the drain and source terminals. Each has its own advantages and disadvantages. One approach is to choose a power tran-

Where Do the Printed Circuit Boards (Still) Come From? When combining the markets for PCB manufacturing and PCB assembly, the figures are very telling: 50% of all PCBs manufactured and assembled come from China. That is not all: two other APAC countries account for a further 24.2% of global PCB and PCBA output (PCBA = Printed Circuit Board Assembly). These are Taiwan with 12.6% and South Korea with 11.6%. What’s more: in total 90% of all PCB and PCBA output comes from APAC countries, leaving the rest of the world a meagre 10%. It is not all doom and gloom for North America and Europe though. Both are bouncing back somewhat, mainly due to a lowering of the production costs in these regions. (Source: Beroe)

PCB and PCBA markets combined Taiwan

12.6%

South Korea

China

11.6%

50% Rest of APAC countries

Rest of World

15.8%

10%

By Robert van der Zwan

What New Kind of PCBs Will be Around? Formaspace is a vendor known for manufacturing advanced industrial furniture to fabricate, assemble and test PCBs. The American company, listening to its customers over the past years, has developed its own take on the future of PCBs. According to Formaspace, there are 5 trends that will define the future of PCBs. Trend 1. PCB substrates that have built-in Electrostatic Discharge Protection in order to prevent ESD problems during assembly and testing. Trend 2. PCBs that are protected against hacking, for example, by embedding cryptographic keys into the substrate of PCBs. Trend 3. PCBs that can endure higher voltages, if only because fully electric cars bring with them a much higher voltage standard (48 V, not 12 V). Trend 4. PCBs with unconventional substrates so that you can fold them, roll them or bend them (“Despite the apparent lack of progress […], they are becoming big business behind the scenes”). Trend 5. More sustainable PCBs, not only in terms of material use (doing away with lead), but also in terms of contributing to a lower power consumption of its components.

Elektor Industry 3/2019

Interview with Barbara Müller Exhibition Group Director electronica – productronica

Automation, digitization and customer orienting are driving electronics manufacturing

productronica 2017 was a very successful fair with more than 1,500 exhibitors from 43 countries. Your trade fair – which attracted approximately 45,000 visitors from 96 countries – focused on the IoT, big data, and smart technologies. What trends can we expect to see this year at productronica? Barbara Müller: The dominant topic at this year’s productronica is not a classic industry phenomenon or a special technological development. The focus will be on the demand for young staff and skilled employees. This is currently also a problem in many other industries, which is why we decided to create a separate exhibition area at productronica that we have named “Accelerating Talents.” This platform will encourage communication between exhibitors and the skilled employees of the future, in other words, students, graduates, and young professionals. However, this does not mean that we are losing sight of current trends. The other focuses at productronica 2019 are smart factory and smart maintenance. Elektor: Tell us more about your Accelerating Talents program. Barbara Müller: The concept in Hall B2 includes various things, such as the Talent Gateway – a recruiting platform. This consists of three main building blocks: First, a trail with entertaining features such as an escape truck to raise awareness of electronics production. Second, a career café for meetings between the exhibitors’ HR staff and visitors. Third, the Accelerating Talents Stage, where companies will present a brief description of what they do – but there will also be specialist presentations and tech slams. Other components include Hackathon@productronica, which will take place for the first time this year, the Career Center, and the Education Path.

Elektor Industry 3/2019

Elektor: By organizing this globally leading trade fair, you come into direct contact with global decision makers and opinion leaders who revolutionize electronics production. Based on your interaction and research, where was the electronics manufacturing industry a decade ago? Barbara Müller: Around ten years ago, automation and digitization were still in their infancy in electronics production. To realize this, all you have to do is take a look at the changes that have taken place in our private lives. In 2009, smartphones, tablets, and other digital devices were not so widespread. Social developments over the last years have also been largely responsible for many of the changes that have taken place in electronics production. Elektor: What do you think will be the trends of the future? In which direction is the electronics manufacturing industry heading? What technologies do you believe will play a major role in the electronics manufacturing industry in 2020?

Smart Garments Improve People’s Quality of Life In 2018 Teiimo, a Munich based start-up, won the prestigious Elektor “FastForward”-Award at electronica 2018. The company’s products improve people‘s quality of life. Teiimo designs conformable textile-integrated solutions for capturing and transmitting biometric data in real-time and via Cloud. The novel technology is fully compatible with standard textile manufacturing techniques. After a start in sport, the company expanded in B2B market segments during last year. Elektor Industry Magazine spoke with CEO & Founder Markus Strecker about his strategy and technology as well as opportunities.

EIM: Markus, please be so kind and introduce your company. MS: Teiimo improves the people’s quality of Life. We develop conformable systems which can be integrated into textiles to capture biometric data. We bridge the gap between research and production. Our focus is on an active second skin that captures valuable biometric data. The wearer barely feels the difference between the new garment and his normal underwear. The company was founded end of 2014 and we are today a small but powerful team with a great track record. For ambitious sports athletes we developed the „iinMotion“ sports shirt. The integrated system provides athletes important data, e.g. heart rate, heart rate variability, speed as well as balance and motion information and many more parameters. Based on the data, athletes optimize their training program, align themselves for the competition schedule and take care of their body to stay healthy and fit. During last year we strengthened our technology and expanded into B2B market segments, focused on Healthcare, Active Assisted Living (AAL) and Work Safety. We have strong customers in these fields and thus set the course for growth.

EIM: Before focusing on opportunities for the Industry sector, please explain your technology in greater detail and exactly what you are offering to customers?

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MS: Our conformable systems consists sensors, conductors and electronic units. Today we have a suite of technology blocks that enable us to place sensor freely in a garment and even in a base layer. We can respond to diverse needs for electro-

Fast-Forward Startups

@ productronica 2019

The short and firm byline of this year’s productronica trade exhibition in Munich is “Accelerating Innovation”, so apart from the Bierstuben there’s no better place to go than the Elektor / productronica

Touchless Automation GmbH

2019 Fast Forward Award (FFA, Hall B2 Booth 472)

Producers of innovative industrial equipment that can manipulate parts of any material, without touching them.

event. Start-ups are true innovators, explorer, out-of-the-box thinkers, disrupters … whatever you call them, the ones you can meet and interview at the 2019 FFA show floor are the best of the crop. All passed a lengthy selection process and are now ready to pitch their innovations and enthusiasm to the ever critical productronica audience, a threeheaded monster called The Jury, and the odd camera. FFA is part of the fantastic Accelerating Talents platform organized by Messe München, which Elektor is grateful to exploit for putting seven fantastic start-ups in the spotlight. Give them a warm welcome, critical feedback and a warm cheer — they deserve it.

Elektor Industry 3/2019

Arkite The Human Interface Mate provides the employee with realtime picking and assembly instructions through Augmented Reality and warns in case of any error in a forwardlooking manner. The smart sensor validates correct execution of picking and assembly tasks and ensures qualitative performance by preventing human errors.

robodev GmbH Makers of a modular automation solution you can set up and program in a simple way. It enables your employees in production or assembly to implement applications, even for small batch sizes or short product life cycles

Meta Smart Factory In anytime, anywhere you can monitor and manage your factory with Meta Smart Factory in your hands.

Production Methods and Components

WAL NOVEMBER

Elektor International Media is proud to present its 2019 Wall of Fame! We partner with top electronics companies – from global parts suppliers to device manufacturers – to promote exciting products and services that power high-tech innovation. The companies listed on this month‘s Wall of Fame offer electrical engineers, makers, and students a wide range of indispensable tools and solutions for developing next-generation electronics projects and products.

www.arrow.com

www.honeywell.com

www.pcbcart.com

www.kurtzersa.com

www.trinamic.com

www.ems-proto.com

www.microchip.com

www.keysight.com

www.labcenter.com

www.eurocircuits.com

www.baslerweb.com

www.mouser.com

www.buerklin.com

www.hammondmfg.com

www.picotech.com

www.konrad-technologies.com

www.weller-tools.com

www.bernstein-werkzeuge.de/en/

www.ebv.com

www.comsol.com

Elektor Industry 3/2019

LL OF FAME 2019

www.infratec.eu

www.rohde-schwarz.com

www.congatec.com

www.controllino.biz

www.microchip.com

www.infineon.com

www.peak-system.com

www.reichelt.com

www.tme.eu

www.distrelec.com

www.konrad-technologies.com

www.hammondmfg.com

www.we-online.com

www.schurter.com

www.multi-circuit-boards.eu

www.almit.de

Your logo could be here. Please call +49 (0)241 955 09 186 www.rohm.com

www.rs-online.com

www.peaktech.de/

Production Methods and Components