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Š 2016 SCHUNK GmbH & Co. KG
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SCHUNK grippers. Proven since 1983 With more than 4,000 standard components, the most extensive line of robust and durable small component and universal grippers sets worldwide standards in all industries.
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Analysis (OptiStruct, RADIOSS & MotionSolve)
CFD Contest (AcuSolve)
This section of the contest is open to students and will constitute the This section of the contest is open to students & will test their skill Analysis and Optimisation stream, student will need to solve a combination with regards to CFD simulation using Altair AcuSolve of Altair provided analysis (CAE/MBD) and Optimisation contest problems and student contribution using Altair’s industry leading Analysis and Optimisation solution - OptiStruct, RADIOSS, and MotionSolve
Design (Inspire) This section of the contest is open to students and will constitute the Design stream, student will need to solve a combination of Altair provided design contest problems and student contribution using Altair’s industry leading design optimisation solution - solidThinking Inspire
Manufacturing Simulation This section of the contest is open to students undergoing tool/die design diploma/graduate/post-graduate courses and will test their skill for Stamping Simulation using Altair HyperForm
Faculty CAE Expert* This section of the contest is open to Faculty from Engineering Colleges & will test their skill with regards to CAE using Altair HyperWorks
igus has been manufacturing chainflex cables for e-chains for 25 years ... ®
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E D I TO R I A L
Future-ready factories The future of manufacturing is smart. Smart manufacturing will transform industry in a similar way to how the strategic use of information technology transformed the business model and consumer shopping behaviour, for example, at Amazon.com. Smart manufacturing, with automation as the key driver, will deliver a similar, extraordinary shift in the competitive landscape of the global industry. It will reverse the flow of the 100-year-old industrial supply chains that forced consumers to accept whatever was mass produced. Flexible factories and demand-driven supply chains will change manufacturing processes to allow manufacturers to customise products to individual needs. These will be gamechanging, market-disruptive innovations in products and processes. What change will this bring in the Indian industry? Is India ready for this? Today, although China is still the manufacturing leader in Asia as well as the world, I feel that India is in a unique position. The software services sector is the key knowledge component in India, and since Industry 4.0 combines traditional manufacturing with IT and IoT, India can become the major industrial hub in Asia if it plays its cards right. In this context, the recently held Symposium on Smart Manufacturing, organised by Indian Machine Tool Manufacturers’ Association, with A&D India as the Media Partner, discussed a range of technology trends, opportunities, real-time benefits and challenges in making the factories in India future-ready. Almost everyone in the discussion was of the opinion that we have to first concentrate on making Indian factories present-ready and then develop a roadmap for making them future-ready. I am sure together we can achieve this goal, as soon as possible!
EDITORIAL ADVISORY BOARD
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Vijay Srinivasan Partner, Effectus Consulting LLP Anup Wadhwa Director – AIA (Automation Industry Association) P V Sivaram MD – B&R Automation Member – AIA Anant Maheshwari President Honeywell India
Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Raj Singh Rathee Managing Director Kuka Robotics India
Compact micrometer with integrated controller Non-contact and wear-free Measurement distances up to 2m High resolution and accuracy Set up and configuration via web interface Interfaces: Ethernet / EtherCAT RS422 / analogue
Edge / Position
Diameter
Segment
Centre
Gap
Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant
Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants
Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
A&D India | Feb-Mar 2016
LASERMICROMETER
Phone +91 20 267 410 09 www.micro-epsilon.in/odc 5
CONTENTS
Market
Management
Focus
Pharma & Packaging 08
NEWS
14
“AUTOMATION AS A BUSINESS STRATEGY�
24
“GLOBAL STAGE FOR INTEGRATED INDUSTRY�
A pre-event report on HANNOVER MESSE 2016 to be held at Hannover, Germany
PLATFORM-BASED APPROACH FOR IIoT TRENDS
The round-table discusses how IIoT trends help to illustrate on using a platform-based approach to address several challenges across smart machines
FINDING A CURE FOR PHARMA
Pharmaceutical manufacturers implementing enterprise-wide, integrated control systems are better able to achieve regulatory compliance, and reduce costs and time-to-market without sacrificing product quality. The article discusses the best practices and the right approach in this area.
Round-table 26
58
30
Interview with Martin Rostan, Executive Director, EtherCAT Technology Group
Interview with Vikas Chadha, Managing Director, Honeywell Automation India Ltd, Leader, HPS India
Event Preview
“PROVIDING THE BEST OF BOTH WORLDS�
36
MAXIMISING SLIP RING LIFECYCLE
A read on simple design tips that will help engineers to ensure the longest possible life and lowest possible maintenance for the slip rings used on packaging and other industrial machines
Cover Story 16
BIG DATA ANALYTICS
A read on the fundamentals of the ‘Information Driven Enterprise for the Connected World’ and its specific manifestations in NTPC as it stands today, while discussing the application of Big Data analytics in the power sector from a holistic perspective.
CONTENTS
Advt
Technology
Drives & Components 40
ENERGY EFFICIENCY WITH HYBRID DESIGN
Safety & Integration 52
An application story on how the hybrid machine increases the production rate and provides energy efficiency up to 35-40% compared to the competition
44
FOCUS ON OPTICS
The article explains how B&R’s Automation Studio helped TMS to handle everything from communication and HMI to CNC and machine control with a single software package
SAFELY INCREASING FLEXIBILITY
The article briefs on how the packaging machines from BVM Brunner enhance flexibility and availability with the help of automation solutions
Software & Engg tools
New Products 61
Line monitoring system; Machine vision systems; RFID transponders; Brushless DC motors;
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Temperature monitoring system; Modules for data transfer; Solar powered pumps; Braking torque control module;
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Diagnostic handheld device; Configurable control systems; Brush DC motors; Safety gripping system
Safety & Security 55
MANAGED INDUSTRIAL CYBER SECURITY
A read on managed security and effort of industrial cyber security off the task list and how it puts into the hands of process control security experts
Manufacturing IT 48
ADDRESSING IIoT CHALLENGES
The article explains how protocol conversion addresses challenges in connecting legacy equipment to the IIoT
Columns 05 06 64 64
Editorial Contents Highlights - Next issue Company index
Advt
! " # $ % # & " ! ' ( ) ! * " " # + & " # (
MARKET | NEWS
Automation trends unveiled at B&R Innovation Day 2016 B&R has unveiled new trend setting automation technologies for the application development that too with a higher quality; HTML web industries in its 2016 edition of focussed technology for a platform independent conference, Innovation Day. The HMI development that transforms the conference revolved around the theme way automation engineers develop ‘Adding SMART to your factories’ visualisation and APROL process highlighting on solutions for smart control that offers a scalable and machines and smart factories. It flexible solution which caters to all the witnessed the launch of various solutions stakeholders of a factory operating in a in software and hardware, which were global market. According to PV Sivaram, well received by the audience. MD, B&R Automation, the company Chief Guest for the conference was brings one innovation per day. Atul Modi, Global Lead—Automation and “Innovations are not just new products, Controls, Unilever. In his keynote speech but also refinements in already ‘Smart Factories: A visionary perspective,’ available products and processes. We he addressed the gathering comprising Innovation Day 2016 gave diverse perspective on building smarter call them silent innovations. This manufacturers, machine builders, factories from guest speakers shows our commitment as well as integrators and technology providers strength to give the value and with insights on trends in manufacturing such as flexibility and sustainability competitive edge to our customers, thereby, bringing enormous benefits,” driven by changing consumer demands, key technologies, which enable to he stated. achieve a balance and expectations from technology providers. Congregation of guest speakers from companies like Unilever, The host of products exhibited include secure remote maintenance Accenture, IMA PG, Alfa Laval and Future Formats gave diverse perspective solution; System Diagnostic Manager—a web-based diagnostics tool; on building smarter factories from the viewpoint of end users as well as mapp, a revolutionary software technology that promises 67% faster equipment suppliers.
Entrepreneurial Heart award to Henrik A Schunk
Increasing demand for embedded solutions from HARTING
Henrik A Schunk, Managing Partner, SCHUNK GmbH & Co KG from Lauffen am Neckar, was recently presented with the ‘Entrepreneurial Heart’ award at the summit of the global market leaders in Schwäbisch Hall. The awards are an initiative of WirtschaftsWoche magazine and Adolf Würth GmbH & Co KG company. With the Kaywald school cooperation project, a school for children and young people with physical and mental disabilities in Lauffen Germany, SCHUNK showed that social engagement and entrepreneurial thinking can go hand-in-hand. The company has cooperated with the school for over Schunk accepting the ‘Entrepreneur with Heart’ ten years. “The focus of award at the event our cooperation with the Kaywald school is not charity, but the desire to give disabled people the chance of true participation and to develop a special kind of team spirit within the workforce”, said Henrik A Schunk. Some previous students of the Kaywald school have made the leap to a full-time position at SCHUNK. With 11,000 standard components, SCHUNK offers the largest range of clamping technology and gripping systems in the world.
HARTING Technology Group’s embedded solutions are important components in the implementation of Industry 4.0. The demand for these solutions is growing steadily. “The developments we saw in a few months were a pleasant surprise. Business developments to date give us good reason for optimism,” explained Holger Heidenblut, Sales and Application Support, HIS & Robert Pulman, European Products Applications Manager. HARTING integrated solutions brings high “Embedded means more transfer rates for signals, data & power to PCBs than just minimise – far more, the incorporation of a very wide range of technologies and engineering competence into one market – or customer-oriented solution is what really matters”, he added. As a part of the HARTING Technology Group, HARTING Integrated Solution (HIS) draws on existing standards and components, but above all, on its know-how. For example, HIS is bringing high transfer rates for signals, data and power onto PCBs and integrating complete solutions for customers. As a member of diverse organisations such as PICMG ® and VITA ®, and also based on the unit’s expertise, the embedded solution team is the first contact point.
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A&D India | Feb-Mar 2016
MARKET | NEWS
HMS and eWON go together to increase IIoT leadership
Honeywell completes acquisition of Seelze
HMS Industrial Networks AB has recently signed an agreement to acquire the Belgium-based company eWON SA – a leading IIoT manufacturer of intelligent internet-based remote access routers. “In the fast growing business of the Industry 4.0 and Industrial IoT market, we see great opportunities to further strengthen our business and our leadership position by gaining access to HMS’s well-established development organisation and sales channels,” said Serge Bassem, CEO & co-founder, eWON. eWON is world-leading, when it comes to
PLC remote access, and joining the two teams and operations will create a strong market position and unique value proposition to our OEM partners and worldwide customer base. According to Staffan Dahlström, CEO, HMS Networks AB, “eWON’s strong position primarily in the market for remote access to PLCs, providing a secure data tunnel between a software application and a remote machine, will complement and reinforce HMS’s existing remote management offer in the form of Netbiter.
Honeywell recently announced that it has completed the acquisition of Seelze, Germany-based laboratory research chemicals business from Sigma-Aldrich, broadening Honeywell’s offerings for high-purity solutions for drug discovery, medical diagnostic testing and other laboratory applications. The offerings are now part of the company’s broader portfolio of offerings for research chemicals, which already includes the Riedel-de Haën® and Burdick & Jackson® brands. “The combined Honeywell business will be able to serve a broader range of customers and applications with global brands for a range of applications including drug synthesis, food, environmental, chemical and forensic testing,” said Qamar Bhatia, President—Specialty Products Business, Honeywell. The Honeywell portfolio now includes six product lines, like Fluka® chemicals and reagents; Hydranal® Karl Fischer titration reagents used to measure moisture content in liquids & solids; Chromasolv® high-purity solvents for chromatography to separate and analyse complex mixtures; Riedel-de Haën® used in pharmaceutical production and bioscience; Burdick & Jackson® high-purity solvents, reagents and chromatography products for laboratories and pharmaceutical production & Sigma-Aldrich® solvents & inorganics sold into the European Economic Area.
ESDM industry scales up for $400B ‘Make in India’
Messung partners with ERFI, Germany
IESA, representing the Indian Electronic System Design and Manufacturing (ESDM) has recently commenced IESA Vision Summit 2016 to evolve the ESDM industry into a $400B ‘Make in India’ opportunity. The summit theme “Indian Semiconductor & ESDM Ecosystem: Scaling up for $400B Make in India Opportunity” recognises the need to elevate focus on the immediate opportunities in the indigenous ESDM landscape. Speaking on the The summit recognises the need occasion, M N Vidyashankar, to elevate focus on immediate President, IESA, said, “Investment opportunities in the indigenous in the electronics manufacturing ESDM landscape sector has jumped over six-fold to reach ` 1.14 lakh crore in 2015, and this has re-established the need for initiating dialogues to seize the $400B ‘Make in India’ opportunity. With aggressive engagement from government, industry bodies and industry, we have witnessed the transition of India as a global manufacturing destination. The involvement of various state governments are noteworthy as they have utilised their edge on natural resources, infrastructure and offered multiple levels of benefits in driving domestic electronics manufacturing to help India in achieving the status of an ESDM powerhouse.”
Messung Group has partnered with Erfi GmbH, the innovators of technical work place systems, measuring & testing devices and test equipment to announce their exclusive distribution agreement for the Indian market. Messung will be an exclusive distributor for the entire range of Erfi products in India. The partnership will focus on providing innovative measuring and testing solutions to diverse electronic industries in the
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Indian market. “Messung is proud to be partnering with Erfi. With this partnership, our vision is to provide technologically advanced products & solutions to our clients, and change the outlook of the testing and measuring industry in India, including work place systems,” said Farook Merchant, Chairman & MD, Messung Group. Speaking on the occasion, Andreas Fischer, MD, ERFI GmbH, said, “We are proud to associate with a credible organisation like Messung in India. Our innovative products and Messung’s legacy are all set to create a revolution in the testing, measuring and work place industry in India.” The partnership will focus on sectors like educational institutes, electronic manufacturing and automobile products.
A&D India | Feb-Mar 2016
MARKET | NEWS
NI releases NI Trend Watch 2016
Delta video walls at NTAMC, Manesar
National Instruments has recently announced the release of NI TrendWatch 2016. The third annual report examines a range of topics focused on the IoT and its impact on how we manage data from the consumerisation of software to prototyping 5G to make it a reality. Speaking on the occasion, Eric Starkloff, VP—Global sales and marketing, NI, said, “As the world becomes more connected, the incredible amount of real-world data available today promises engineers and scientists great insight, but getting that insight can be a challenge. We strive to help our customers stay ahead of the deluge of analog data by investigating the trends The Trendwatch 2016 report that will help them handle the increasingly talks about the technology complex amount of information they’re trends having a major acquiring to make the right decisions at impact on engineering and the right time.” Adding further, Jayaram scientific community Pillai, MD, National Instruments India, Russia & Arabia, said, “The Trendwatch 2016 report talks about the technology trends which will have major impact on the engineering and scientific community globally.”
Power Grid Corporation of India (PGCIL) Limited is among the leading electric utilities that have always equipped their control rooms with the latest equipment. PGCIL recognised that a display wall would enable its operators at National Transmission Asset Management Centre (NTAMC) to have a much clearer view at any given moment. Delta’s recent video wall solution helped NTAMC achieve its visualisation demands ensuring all operations progress Delta’s video wall solution helped effectively and effortlessly. NTAMC achieve its visualisation According to RP Sasmal, Director— demands ensuring effectivity Operations, PGCIL, “We found Delta’s Display solutions meeting our specifications. Delta installed 5 sets of 70” LED-lit video wall. Delta has given their solutions to us in the past, and our experience in 4x3 configurations with them has been good in terms of reliability and post sales inside the control room – one video wall for each regional load support.” The significance of NTAMC is that all the 186 substations across the country are unmanned and have to be monitored from a single location, i.e. at NTAMC Manesar.
Endress+Hauser aims to double India revenue
igus among world’s leading cable manufacturers
Endress+Hauser recently announced that the company is looking to double India’s revenue to ` 800 Cr by 2020 by undertaking smart cities projects. Speaking at the announcement, Sajiv Nath, MD, Endress+Hauser (India), said, “Our entire strategy of doubling the revenue by 2020 hinges on water and energy management projects in smart cities. We have initiated talks with civic bodies for tieups on these projects in the proposed ecological urban spaces. Around 55% of our (L to R) Sajiv Nath, MD, Endress+Hauser revenue focus will be on smart (India); Klaus Endress, President, cities initiative.” The company Endress+Hauser; His Excellency Dr Linus Von is also investing ` 30 crore Castlemur (Ambassador, Switzerland) and approximately on Aurangabad Matthias Altendorf, CEO, Endress+Hauser factory that is expected to be completed by October. Matthias Altendorf, Global CEO, Endress+Hauser, informed, “We are planning to invest 7-8% of global revenue worth € 2.1 billion in research and development globally and our India operations will benefit the most with the technology transfer. We are aiming to achieve exports worth ` 1,000 crore from India operations to Southeast Asia, South Africa and Australia.”
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With 100 million euros of revenue from cable sales over the last year, igus is maintaining its status as a world leader among cable manufacturers for moving applications in energy chains. The company has revolutionised the cable design for moving applications in e-chains 25 years ago and has been offering motor, control and data cables for specialised moving applications in energy chains through the chainflex brand ever since. “As market leader for e-chains, the advantage at igus is igus has revolutionised the cable design for that we develop both moving applications energy chains as well as cables. For this reason, we can test and offer both as a system,” emphasised Frank Blase, CEO, igus GmbH. The chainflex business area exceeded 100 million euros in revenue last year, which made up more than 20% of the total revenue at igus. In the Indian market alone, the company generated ` 250 million, which is an increase of approximately 25% over the revenue from cables in the previous year.
A&D India | Feb-Mar 2016
INDUCTIVE SENSORS
C23 FULL INOX
FLAT, RUGGED, EFFICIENT KEY ADVANTAGES 9 9 9 9
www.contrinex.com
Indestructible sensor Factor 1 on steel and aluminum Long operating distances IO-Link
MARKET | INTERVIEW
“Automation as a business strategy” Vikas Chadha, Managing Director, Honeywell Automation India Ltd, Leader, HPS India, in this interaction with Megha Roy, discusses the emerging trends in automation and how IT plays a vital role in executing a project efficiently in a process industry. Excerpts from the interview… Brief us on the emerging trends in areas like oil & gas, technology which helps optimise industrial performance of power generation, petrochemicals and metals, minerals and the varied size industries. PlantCruise is a solution which mining, from the automation perspective? offers advanced optimisation and batch control technology The overall smartness of all assets implemented on the usually found in larger DCS platforms. field or control room is a trend today, followed by data analysis and big data. Today, everything cannot be done at What role does IT play in driving significant advances in the plant level, however, there are many the industrial automation solution? Brief best practices like remote installation and us on the developments offered by your remote commission, which can be deployed company on this front? at the plant level. Also, the cloud that acts We see a strong growth in the Indian as a collaborative platform helps executing automation industry that provides excellent a project in the process industry. Today, growth opportunities to the entire gamut automation is a business strategy. Good of automation products and systems. automation system with smart remote However, companies need to recognise the devices and data analytics built on it, can full potential of the industry and invest generate a productive environment. heavily in IT & software solutions in order to maintain competitiveness globally. What roadmap should the process In this regard, we offer a latest innovation manufacturing industry adopt to achieve a called - Honeywell Pulse™ that can remotely competitive edge? connect plant managers, supervisors and India is increasingly recognising that in engineering staff using a mobile application the competitive and globalised environment, investing in to customise real-time plant performance notifications intelligent automation and control systems to optimise from Honeywell’s industrial automation software. Experion manufacturing, plant optimisation, and control & process Collaboration Station is a first of its kind in the process monitoring systems is the way forward. At Honeywell, automation world to integrate with the control system and leveraging the right emerging technologies at the right time show information from any available source. It enables plant, is a key differentiator. Industrial Internet of Things (IIoT) business and support personnel to use interactive displays, has been evolving towards the processing industry for several embedded video and other telecommunication capabilities years and Honeywell solutions allow customers to retain their to communicate, collaborate and make decisions. intellectual assets as they take advantage of new functionality. Next is mobility. We recently launched Honeywell Pulse TM What are your expectations on the performance of the Indian that remotely connects plant managers, supervisors & industrial automation market in the upcoming years? engineering staff using a mobile application. There is a strong potential for growth in the Indian industrial automation market. The core vertical where the maximum Can you suggest us some measures required for increasing potential lies is the chemical and petrochemical industry. the adoption rate of advanced automation technology in the In these verticals, technologies like cyber security, critical Indian manufacturing sector as well as in Indian SMEs? infrastructure protection and integrated fire and gas solutions The Indian manufacturing sector’s ability to adopt advanced will see growth due to increasing safety and security threats. technology is quite high, however, SMEs are mostly under The BS4 norms in terms of gasoline output will let users cost pressures and do not opt for automation technologies invest in upgrades and blending. On the gas side, there will unless they see return on investment on doing so. SMEs prefer be huge investments in transportation & distribution. In adopting technologies that are less complex and can be easily addition, we continue to see more investment in the thermal integrated with an existing solution deployed at the plant. For energy sector. The pharmaceutical & chemical sector will example, PlantCruise by Experion is based on Honeywell’s grow too. The ‘Make in India’ campaign should attract award-winning Experion Process Knowledge System (PKS) investments in manufacturing and defence. ☐
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A&D India | Feb-Mar 2016
C O V E R S TO R Y | T E C H N O L O G Y
BIG DATA ANALYTICS
Application in the power sector
With every capacity addition, large amount of real-time process data is generated. This data, along with other strategic business data is used in driving the business processes of the company. But this data needs to be converted into actionable information & here’s where the concept of “Information Driven Enterprise for the Connected World” comes into picture. The feature details on the fundamentals of this concept and its specific manifestations in NTPC as it stands today. It also discusses the power sector challenges and a holistic perspective of application of this concept in the Indian power sector for providing solutions. 16
Arundhati Bhattacharya General Manager (PE-C&I) & CTF (Darlipalli & Muzzafarpur TF) NTPC Ltd arundhatib@ntpc.co.in
A&D India | Feb-Mar 2016
T E C H N O L O G Y | C O V E R S TO R Y
BIG DATA Advanced Connectivity
ADVANCED ANALYTICS
Advanced Storage Advanced Sensing
ADVANCED ACCESS TOOLS
BIG DATA
DOMAIN KNOWLEDGE REPOSITORY
Required information at various locations
Figure 1: Business decision model in an Information Driven Enterprise
Not long ago, industry, whether process or manufacturing, was operated in silos. All functions including engineering, operation & maintenance functioned in isolation. But thanks to advancements in technology, today, most of the systems are connected & there is widespread availability of data everywhere. The reasons for this huge deluge of data are multifold; one is advanced sensing, which has made it possible to get data, which was always relevant for the business, but sensors on a techno economic scale were not developed. Secondly, the advent of data storage technology and also storage techniques has increased the storage period enormously with the result that data at very fine time resolution is available for wishful periods and third, the advanced connectivity makes the data ubiquitous. For instance, ten years back, only a few signals of a power station related to generation was brought to the head office. Today, practically all critical data of each generating unit is brought to the head office. All this translates to the term we call ‘Big Data’. I will use the most prevalent definition of Big Data, i.e. data so big that organisation finds it difficult to extract useful information for its business processes. Its similar to the situation in ‘The Rime of the Ancient Mariner’ by Coleridge–water, water everywhere/not any drop to drink. In order to ‘drink’ the water i.e. to make the data useful, it needs to be leveraged into business triggers to improve operational efficiency; to use unknown correlations and hidden signatures or patterns to improve business processes, ultimately for increasing profits. The difference between having data and acting on it can be a big game changer. This concept is depicted pictorially in Figure1. Some worldwide efforts by governments and corporates in the field of information driven enterprise include Industry 4.0, Industrial Internet, Connected Manufacturing, Smart
A&D India | Feb-Mar 2016
Manufacturing Leadership Coalition. Mainly related to the manufacturing sector, all aim to extend access and visibility throughout the value chain to improve adaptability to dynamic markets, for increasing profitability and customer satisfaction. The availability of data at all corners of the organisation pitches for real-time performance monitoring in order to bridge the gap between vision & realisation. The Steven Covey model for the four disciplines of Execution is presented in Figure 2. A corporate governance model can be based on this concept with KPIs percolating into each functional area of the organisation. For instance, in power plant operation, the lead measure can be heat rate. If the compelling score card indicates a deterioration and if it is due to a spray valve passing, then accountability is fixed on mechanical maintenance. If it is due to improper tuning, it is C&I maintenance. So, the cadence of accountability is there. Identification of the relevant lead measures in other functional areas will also generate pertinent and actionable information.
Power sector challenges Having described the relevance of the concept of Information Driven Enterprise in a connected world to an organisation like NTPC, let us examine some of the challenges of the power sector spanning all stakeholders in the power sector value chain, i.e, generators, transmission companies, distribution companies, consumer and regulator. Figure 3 depicts the basic challenge generators in the power sector are facing today. Fuel uncertainty is one major challenge. The coal source cannot be pre-determined on regular basis & due to this, seldom we get to fire the coal of the desired quality (i.e. the
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C O V E R S TO R Y | T E C H N O L O G Y
quality on which the boiler is designed). Land & water are also major issues, due to which we need to optimise land & water usage. Further, CERC regulations change over time, especially in the tariff fixation, leading to change in operating regime of the power generating business. The latest challenge confronting the power sector is stabilisation of grid due to the huge solar power capacity planned to be added. This is posing tough demands to the existing utilities, especially thermal power plants for keeping spinning reserve for quick start up/shut down, a situation unheard of in earlier days. Overcoming the above challenges requires optimising the resources at hand & here is where technology comes to the rescue. Some technologies which can improve resource utilisation & drive efficiency are ultra supercritical technology, renewables, high voltage transmission and smart grid/smart metering. Smart grid is likely to generate the Big Data in the power sector and many business analytics models can be developed on this Big Data.
NTPC scenario NTPC follows a three phase business process as described in Figure 4. At the engineering phase, many software tools have been developed in house. DREAMs package was conceived way back in 2003 and has now become the backbone of engineering. About 2,00,000 drawings are getting reviewed & approved using this package. ICONS & IDEAL are also two tools developed in-house by our C&I engineers & used in C&I detailed engg. C&I system Factory Acceptance Test was another area where automation using technology has saved many man
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hours & streamlined the entire testing process. The software testing could be separated from the hardware assembly, staging, integration & hardware tests, creating a win-win situation for both suppliers & NTPC. The Construction & O&M phase has many automation areas, which are described in subsequent sections of advanced analytics, advanced sensing and advanced connectivity.
Advanced analytics First, we start with analytics. Real-time data in our generating units has lot of stories in-built in it and we need to harness every bit of it, not by the operators sitting in the control room, but a centralised expert team catering to all the plants. This vision was created as early as 2008 in NTPC & from this vision was created Antariksh, NTPC’s fleet monitoring centre at the Noida office with data brought from each site (PI server) through MPLS line. Data of each unit is analysed & expert advisories are provided to stations. A centralised expertise pool ensures uniform operation and maintenance practices across the organisation. You can take it as an equivalent of cloud computing in NTPC. Also, last but not the least, the experience is captured; the knowledge gained is institutionalised. This is so important for an organisation like NTPC where expert manpower is due to retire in a few years. The main components of this fleet monitoring centre is analysis of each unit startup & shutdown w.r.t. OEM curves, problem diagnosis (through in-house developed fish bones), vibration analysis through remote client set-up, and specialised alerts using PI data (sms & emails). Startup & shutdown of each unit is analysed w.r.t. to the curves given by
A&D India | Feb-Mar 2016
C O V E R S TO R Y | T E C H N O L O G Y
the OEM and each deviation is deliberated and resolved with the aim of improving the process both w.r.t. the time taken, consumption of oil and the life consumption of the boiler & turbine. More important, all this analysis is stored. The experience of the astute operator in diagnosing problems is encapsulated in fish bones. For instance, in case of condenser vacuum problem, if we click on the poor performance indicator, a fish bone diagram opens pointing to the root cause of the condenser vacuum problem. Vibration analysis data, reveals failure signatures hidden in the data, which is used in predictive analytics to get information about impending equipment failures. Similar to vibration analysis on vibration data, advanced pattern recognition tools can detect anomaly on a parameter, which along with drill down diagnostics can point to an impending equipment problem. Addressing this problem will prevent a major forced outage. This type of tool is available commercially in the market and is in the process of procurement. Using PI tools, specialised alerts as e-mails and sms are sent to key operation personnel at Noida office as well as site, e.g. mill-off and outlet temp greater than 60 degree which is a warning for mill fire in advance. NePPS is an in-house development of NTPC’s research wing intended to replace the procured software PADO (Performance Analysis, Diagnostics & Optimisation), being provided for on-line performance improvement of coal fired plants. Another case of business analytics at work at the power station is Merit Order Rating. Given a load schedule for the station or a stage of a station, it gives the best distribution of the station load amongst the units, which will result in lowest cost of generation. This system will be of additional advantage
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to the shift charge engineer to decide the backing down of the units and keep spinning reserve for catering to the varying demand from load dispatch centre through the day.
Advanced sensing Uptil now, cases were presented wherein data was there, rather Big Data was there, but some kind of analytics was needed to extract useful information out of it. But what about the reverse? We know about a technique or algorithm, which can significantly improve the operating efficiency, but we do not have the relevant data. Here is an example of the same. One of the key challenges was the uncertainty in coal source and quality. Many a time, coal is imported and needs to be blended with domestic coal for getting the desired quality. But the coal analysis data based on which we blend the coal is obtained only after two days, due to which we are not able to optimise on the right blending mix. Installing on-line coal analysers (an advanced sensor based on nucleon penetration), which is being specified for all future projects, will give the elemental analysis of coal in real-time and optimise the usage of imported coal. Hence, at times, we need to demand the relevant data for the analytics to work, i.e. in some way the reverse of data mining.
Advanced connectivity The next significant aspect is advanced connectivity. Today sitting on Earth, you are able to control satellites orbiting Mars. So, why not use advancements in data connectivity to remotely operate power stations? Its not just
A&D India | Feb-Mar 2016
C O V E R S TO R Y | T E C H N O L O G Y
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an application of technology, but it’s a need of the hour. Over the years, it will be difficult to get qualified manpower posted in remote locations. At the same time, with the increased degree of automation, local interventions are likely to decrease. With land acquisition an issue, there is a need for construction of power stations on minimum land. More units could be constructed in the space earmarked for staff township. The vision for remote operation for hydro plants was created about ten years ago in NTPC. As a result, this was envisaged in the technical specifications of hydro plants. As an important milestone towards achieving this goal, POC (Proof of Concept) has been carried out by operating drives of Koldam Power station situated in Himachal Pradesh from Engg Office Complex of NTPC at Noida through MPLS line.
The holistic picture So far, we discussed all these cases of advanced analytics and advanced connectivity in the generation area. There will be equal such cases in other areas too. But the information driven enterprise model in a connected world will be truly achieved only when there is connectivity between all the stakeholders in the value chain. For instance, when demand forecasting for the generating stations uses load consumption data from smart grid, it will
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enhance the business value delivered by the power sector as a service to consumers. Similarly, for grid stability, it is imperative that data is shared between grid operator and the utilities for frequency support operation. Similarly, like the online shopping chain for general purpose items; if we have such a portal created by suppliers for spare parts, we do not have to stock the huge quantity of equipment spare parts as we do today. Manufacturers need to adopt the requisite technology to support their customers and optimise their supply chain. Similarly, best practices can also be shared between customers in the power sector.
Conclusion With the new focus on renewables and smart grid / micro grid, there will be greater opportunities in the power sector to leverage each bit of data for driving business decisions. The ‘Organisation Culture’ element is seen as critical in driving this change. An organisation can grow when its old people embrace new technology and its new people assimilate the experience of its old people. To sum up, seamless integration of emerging technologies in the entire value chain of power industry will help percolate the benefits to the society at large and will be instrumental in achieving far reaching goal of Indian power sector, i.e. ‘Smart India’. ☐
A&D India | Feb-Mar 2016
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MANAGEMENT | INTERVIEW
“Providing the best of both worlds” Martin Rostan, Executive Director, EtherCAT Technology Group (ETG), talks about the trends in EtherCAT as an Ethernet-based real-time communication system, comparing it with the conventional fieldbus systems, and also briefs about ETG’s plans for India. Excerpts from his interview with Shekhar Jitkar… ETG has been a 13 years old organisation now. Brief us on its journey so far. How challenging it was to convince the industries to standardise on EtherCAT? When we started we had to face the “what came first, the chicken or the egg” dilemma: to win customers for the technology, you need a choice of products; in order to convince vendors to implement EtherCAT, you need customers that ask for it. Fortunately, this was not a big issue, since there was a large number of “early adopters” on both sides, which understood the benefit of the technology for their products and applications alike. So, one year after kicking off ETG, we already had a joint booth with 28 co-exhibitors showing an EtherCAT product variety – and this has even accelerated ever since. How many members are there in ETG currently and what are the membership profiles? Today, we have over 3600 member companies and institutes
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from 60 countries. About two thirds are makers of EtherCAT devices, and one third are predominantly users. They range from small engineering firms to the large multinationals, such as the major automotive companies or consumer electronics manufacturers. Can you tell us about the advantages of EtherCAT as an Ethernet-based real-time communication system? EtherCAT is known for superior performance: due to the unique functional principle called “processing on the fly”, it is by far the fastest industrial Ethernet Technology. But this principle also leads to other advantages, such as the flexible topology with hardly any restrictions in distance or number or nodes but without the need for switches or hubs. Furthermore, EtherCAT is robust, very easy to use, since there is no need for any IT know-how, no address setting and very little configuration, and it is low cost.
A&D India | Feb-Mar 2016
INTERVIEW | MANAGEMENT
“EtherCAT is a very good fit in India, since it combines low costs with ease of use and superior performance, and there is a lot of very detailed EtherCAT know-how available in India already” Martin Rostan
What are the main differences between EtherCAT and the conventional fieldbus systems? Are you seeing a major shift in the industrial segment from fieldbuses to Ethernet? Well, EtherCAT is several orders of magnitudes faster while being even easier to install, set up, and diagnose. And it provides access to the Internet technologies if needed. So, overall, EtherCAT provides the best of both worlds: the power of Ethernet and the simplicity and low costs of a conventional fieldbus system. Therefore, we do now see that for new designs the classical fieldbus systems are being replaced by EtherCAT. However, since the lifetime of old architectures is longer that one would expect, the classical fieldbus systems will still be around for a long time… Can you tell us about the range of EtherCAT master products currently available? We count almost 200 vendors that support EtherCAT masters – and this does not only show the openness of the technology and its adoption rate, but is also a differentiator to most other fieldbus technologies, which are dominated by the “one” major master maker. The products range from small embedded controllers to extremely powerful multi-core PCs with PLC and motion control software that even supports multiple EtherCAT segments. There is also a wide range of master implementation options supporting over 30 different real-time operating systems: from very lean and free-ofcharge protocol stacks to fully-featured commercial software products – keep in mind that for an EtherCAT master there is no special hardware needed, making EtherCAT the only hard real-time Ethernet technology, which can claim that. This is why – on top of those 200 – there are many more that have implemented EtherCAT masters in their controllers, which they do not sell as products, but use in their own machine or other applications. And, by the way, there are already over 100 I/O device vendors with over 1000 EtherCAT I/O products and over 150 drive vendors with over 500 EtherCAT drives.
A&D India | Feb-Mar 2016
Tell us more about ETG’s partnership with OPC Foundation to develop standards for building a bridge in next-generation factories utilising Industrial IoT. With the “EtherCAT Automation Protocol” (EAP), we have a lean and fast protocol and technology for horizontal, Master/Master type communication via classical switchbased infrastructure. So, EAP enhances the Master/Slave Architecture of the EtherCAT Device Protocol, which is used for I/O, motion control and alike. However, EAP does not provide all the features that are required for vertical communication, such as to ERP systems or into the cloud. Here, OPC UA has its strengths. So, instead of reinventing the wheel and competing with OPC UA, we decided to rather partner with the OPC Foundation – and the OPC Foundation also decided not to compete with the fieldbus level. EtherCAT and OPC complement each other in an ideal way, therefore, both organisations entered into an agreement under which we now develop joint interfaces between our technologies. This provides a seamless communication path from the sensor to the cloud and thus fully meets the communication requirements of Industrial IoT and Industry 4.0 alike. How do you see Indian industry in terms of potential for EtherCAT? What are ETG’s plans for India? Indian industry is very receptive for advanced technology; it is not only “advanced”, but also robust and easy to use. And, Indian industry is very cost sensitive. So, EtherCAT is a very good fit, since it combines low costs with ease of use and superior performance. There is a lot of very detailed EtherCAT know-how available in India already, since many EtherCAT product developments have been done here. And, at our EtherCAT seminar series – we recently had the 3rd one in India since 2009 – we have received a very positive feedback and a lot of interest. So, I am very confident that EtherCAT will continue to make its way into an even wider range of applications. And ETG will continue to accompany both the users and implementers of EtherCAT and support them closely in the deployment of our technology. ☐
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R O U N D - TA B L E | M A N A G E M E N T
Platform-based approach for IIoT trends The idea that the Internet of Things (IoT) and the Industrial Internet of Things (IIoT) are fads is quickly fading. Today, the real challenge is how to implement a solution that can adjust to the volatility of a rapidly changing market. The round-table features how does IIoT trends help to illustrate on using a platform-based approach to address such challenges. Read on… According to a recent research from GE and Accenture, 73% of companies are already investing more than 20% of their overall technology budget on Big Data analytics. With that amount of money being spent on IIoT, it’s no longer a question of if or when the IIoT will become reality, it can easily be said that it’s is a reality today! Currently, whether it’s Apple’s iOS or Android or wearables or online machine condition monitoring, the smart grid, or smart machines within the IIoT, the answer lies in a platformbased design. Speaking on IIoT trends that show how a platform-based approach can be used to address challenges are Raviteja Chivukula, Technical Marketing Engineer, National Instruments India; Brian Rosema, Director of IIoT Strategy, Red Lion Controls and Ninad Deshpande,
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Megha Roy Features Writer megha.roy@publish-industry.net
Specialist–Open Technologies, B&R Automation India.
Flexibility of future design No one can truly predict what the future of the IIoT might bring, yet it’s still critical to be prepared for it. As per Rosema, with the addition of platform, comes the ability to de-couple hardware-specific software and virtualise software in the cloud. “By combining IIoT-ready products from vendors like Red Lion Controls with updateable platforms, customers can reduce risk and overall cost of ownership by extending equipment lifespan, improving process visibility and pushing control to the edge,” he asserts. Since traditional approaches seem to be not enough,
A&D India | Feb-Mar 2016
M A N A G E M E N T | R O U N D - TA B L E
“With the addition of platform, comes the ability to de-couple hardware-specific software and virtualise software in cloud” Brian Rosema Director of IIoT Strategy Red Lion Controls
“A platform suited for IoT should allow the user/ administrator to identify, access, debug and upgrade each of the IoT nodes” Raviteja Chivukula Technical Marketing Engineer National Instruments India
flexibility of future designs can be carried out to address industry risks. Ten years ago, Chivukula avers, developing an application for a phone took a lot of expertise. “Then iPhone with its iOS happened, and Android shortly thereafter. These platforms took the expertise of the phone engineer and focused on the hardware component layout, operating systems (OSs), servicing middleware, software/hardware integration and application programming interface (API). The API and development tools enabled software developers to become phone application designers,” he shares. Deshpande believes that standard & open interfaces are the necessity of successful IIoT implementation. He says, “With the rise of IIoT, intelligence and connectivity are integrated in the same device. Also, the component manufacturers and solution providers are becoming increasingly aware and prefer developing a vendor independent product, providing a multiple platform connectivity aiding integration of future devices and tackling obsolescence at the same time.”
challenges, it is not a sufficient requirement. Focusing on the features to envisage IoT, Chivukula opines that a platform suited for IoT has to have some specific features to enable the scale at which we envisage the Internet of Things. “It should allow the user/administrator to identify, access, debug and upgrade each of the several thousand IoT nodes remotely over the network, while maintaining the necessary security,” he suggests. Furthermore, he explains, “Deployment is only the first step of an IIoT enabled plant. Maintenance & system upgrades for maximising life time is equally important.” Elaborating on the cost component, Deshpande believes that at the field level, when we talk about connectivity to the smallest of device, then the cost is of great significance. “It could be that the cost of adding connectivity to an intelligent device would be twice as much as the cost of the device. This is usually true for the sensors, field devices and actuators. Connectivity in the industrial arena, demands features such as high availability, real-time determinism and usage of standard interfaces,” he believes.
Distribution and systems management
Unification of disparate sensor types
Machine condition monitoring is a prime example of the IIoT in action today. Several factors have prevented companies from adopting and enjoying the benefits of a predictive maintenance strategy. Using a platform-based solution can significantly reduce the cost to improve the ROI of covering more assets. Emplacing this, Rosema says, “Many of our IIoT-ready products include protocol conversion, data logging and device management tools that easily scale to support large deployments. They also offer the ability to manage a wide array of assets through remote monitoring and control functionality.” While a platform is a necessary requirement for tackling
As condition monitoring and smart grid systems become more distributed, the need to unify measurements into a single platform becomes more apparent. According to Rosema, sensor networks are unique in the regard that they are commonly built over a period of time using multiple manufacturers, with each manufacturer requiring specialised protocols for communication. “Our company thrives in these multi-vendor environments by being able to speak & convert native protocols into whatever platform providers require to visualise data. Red Lion’s protocol converters and HMIs help organisations easily connect disparate devices to get legacy systems and equipment to communicate across current IP
A&D India | Feb-Mar 2016
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R O U N D - TA B L E | M A N A G E M E N T
“At the field level, when we talk about connectivity to the smallest of device, then the cost is of great significance” Ninad Deshpande Specialist –Open Technologies B&R Automation India
networks without losing any important data. As part of a platform, this enables the strong unification of data visibility, control, alerting and analytics,” he opines. The problem of unknown is the biggest challenge in IoT. The way technologies are integrated into IIoT applications is constantly evolving over time. Chivukula explains this by citing an example. He says, “Traditionally, condition monitoring takes input mainly from accelerometer sensors that measure vibration signature from heavy equipment. Today, some recent analysis techniques involves continuously monitoring motor current along with motor vibration to better understand the health of the machine. The use of Infrared Thermography is picking up, because it is now possible to implement sophisticated image processing on the IIoT condition monitoring node itself.”
Modularisation of smart machines A platform can simplify development, which helps to modularise the machine into distinct subsystems with tight communication protocols. This approach is continually evolving in terms of communication. As the performance of these machines improves, the communication capabilities also need to improve. Rosema suggests that his company’s IIoT-ready products provide the ability to securely collect, transmit and deliver data across serial, Ethernet, Wi-Fi and cellular communication protocols. “With support for over 300 industrial protocols, this flexibility allows the platform to absorb the data and provide a unified approach that helps improve visibility and control,” he adds. In fact, National Instruments embedded platform allows for system architects to configure systems by choosing from a plethora of modular hardware options for connecting to various sensors. Explaining this, Chivukula opines, “The core computational elements of the platform include a realtime processor for high level processing and an FPGA for more time critical processing. The functionality of the system is defined using high level graphical system design software, LabVIEW. The high level programming language, along with toolkits for signal processing, control, machine vision, motion control, data-logging, etc help the engineers to simplify the process of development. The platform, frees up the system engineers from the hassles of low level
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programming, circuit design, validation and testing and enables them to focus on the market differentiating idea of the application, just like what iOS & Android did.” To satisfy the requirements of users for an efficient IIoT implementation, Deshpande suggests that it’s the need of the hour to embrace openness and standards. It is necessary to use the standard Ethernet interfaces complying with the IEEE 802.3 standards. He further highlights, “On the field level, we need determinism and availability. The first technology, which comes to our mind is Ethernet POWERLINK, which is completely open source and truly hardware and software independent. It couples benefits of standard Ethernet interfaces complying with the IEEE 802.3 as in Internet of Things and the determinism and availability needs of the Industrial IoT. It provides determinism down to 100 µs. Looking at the software platforms, its implementation can be over Windows, Linux, VXWorks, QNX, and any other operating system or without an operating system.”
Simplification of system complexity Finally, platforms enable the proliferation of the IIoT and smart machine by simplifying the system complexity of each modularised subsystem, similar to how a platform consolidates condition monitoring measurements. Rosema believes that system complexity is simplified when devices and processes work together. “Protocol conversion is the first step to making this happen. By connecting & gathering data from both new and legacy devices, organisations can use that data to improve efficiency and gain a competitive advantage,” he adds. Deshpande points out that openSAFETY can handle the SIL 3 safety requirements on the field and process level. “It is the only fieldbus independent SIL 3 safety protocol available in the market. So, openSAFETY can work on top of POWERLINK and OPC UA for satisfying the safety needs,” he opines. He further concludes that Ethernet POWERLINK, OPC UA and openSAFETY can work together in harmony utilising the same physical medium of Ethernet. “Users, thus, can benefit from the real-time, high availability and standard interfaces achieving a seamless connectivity from sensors to the cloud level, keeping the security & safety intact,” he suggests. ☐
A&D India | Feb-Mar 2016
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P H A R M A C E U T I C A L S & PA C K A G I N G | F O C U S
FINDING A CURE FOR PHARMA With pharmaceutical industry facing reduction in sales of drug, the risk aversion is holding the industry back today. Pharmaceutical manufacturers implementing enterprise-wide, integrated control systems are better able to achieve regulatory compliance, and reduce costs and time-to-market without sacrificing product quality. The article discusses the best practices and the right approach in this area.
The pharmaceutical industry is facing significant challenges. From discovery to commercial realisation, the cost of drug development has increased by 18%, from $1,094 million in 2010 to $1,290 million in 2013. At the same time, the forecasted peak sales of a given drug have declined by over 40%, from $816 million in 2010 to $466 million in 2013. And total forecast sales over the lifetime of a product, too, have declined since 2010, estimated to be $4.6 billion in 2013. The following are some of the factors contributing to these reductions: Global healthcare reform: Leading companies are reviewing the way they approach innovation and sales activities in the face of reforms. Some countries are adopting value-based
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pricing structures, while others are combining cost containment with assistance for companies investing in R&D. Regulatory demands: The regulatory landscape for the pharmaceutical sector has evolved significantly in the last decade. As technology and collaboration have the potential to transform commercial and R&D processes, so do new compliance take in issues including government policies and mandates, drug safety, counterfeiting, information security and privacy, intellectual property protection, corruption, and M&A/joint venture and other third-party risks. Competition from generics: Healthcare systems globally have been encouraging greater use of generic drugs. In the United States, generics now account for around 80% of prescriptions.
A&D India | Feb-Mar 2016
Image Courtesy: Shutterstock
F O C U S | P H A R M A C E U T I C A L S & PA C K A G I N G
improved medicines at lower costs, along with the evidence to support this. Whether this means a better outcome for the patient, or the same standard of care but at a much lower cost, there are more risks involved in investing in a product, as these outcomes can be very hard to judge early on in a product’s development. Initiatives including targeted treatments and medicine tailored to specific patient groups are driving changes in strategy from a push-oriented model to the pull model used in other industries. At the same time, many life science companies are faced with islands of automation, aging equipment and manufacturing processes designed for validation, but not efficiency. Any modification to existing manufacturing processes will require change control, long lead time for quality checks and batch record reviews before products are approved for shipment. Meanwhile, baby boomers are departing the workforce every day, leaving gaps in leadership, knowledge and experience, and forcing companies to manage the process and costs of this retirement wave, as well as fill the knowledge and skills gaps it creates.Historically, large-scale, single-product manufacturing has met customer and statutory needs and made business relatively straightforward. However, an output that has remained essentially static for the past decade, and a reliance on existing means of discovering and developing new products isn’t sustainable. New ways of doing business leave traditional models as obsolete as 15-year-old manufacturing equipment – the industry has to create its own momentum. Best-in-class companies are finding that they can use manufacturing as a strategic business asset, investing in automation systems and technologies that help them to meet consumer and stakeholder demand, improve traceability, and reduce costs and cycle times.
Leveraging technology for business advantage Brazil is focusing business on branded generics and proprietary drugs, and in China, reforms have put intense pressure on the prices of all drugs, including generic and over-the-counter medicines. Patent cliff: The patent cliff has come sharply into focus. In 2012, $38 billion of worldwide prescription drug sales were lost as a result of expired patent protection. The risk continues as statutory bodies and private investors intensify efforts to maximise savings from patent expirations through generics.
The changing scenario Healthcare payers are becoming more demanding, wanting
A&D India | Feb-Mar 2016
Visibility of production information will be a key to more efficient pharmaceutical production in the future. In the US, FDA initiatives around Risk-Based Manufacturing and Process Analytical Technology encourage the industry to look at how process control has been used to date, and to explore new ways to address product variability through better process understanding, improved access to information and greater control. Producing and maintaining FDA-mandated audit trails, electronic records and copies, time stamping, and validation puts more emphasis on the need to access information from machines, whether electronic or paper record based. Big data, already being used extensively, is central to the
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P H A R M A C E U T I C A L S & PA C K A G I N G | F O C U S
Image Courtesy: Shutterstock
Visibility of production information will be a key to more efficient pharmaceutical production in the future
machine-level visibility that leads to enhanced performance. The McKinsey Global Institute estimates that applying bigdata strategies to better inform decision-making could generate up to $100 billion in value annually across the US healthcare system, helping to optimise innovation, improve the efficiency of research and clinical trials, and drive a collaborative approach throughout the supply chain. In complex manufacturing environments like pharmaceutical, where data is generated from a number of sources, today’s automation, information and control technologies capture the most relevant production information and make it actionable, leading to improvements in asset utilisation, productivity and system performance.
Lowering validation costs Process validation is defined by the FDA as ‘establishing documented evidence, which provides a high degree of assurance that a specific process will consistently produce a product meeting its predetermined specifications and quality attributes.’ In other words, companies have to be able to prove they are producing a safe, consistent product. Studies have shown that the total cost of compliance for medium-to-large drug manufacturing facilities can reach as high as 25% of the total operating budget and 80% of the cost of implementing a control system, excluding raw materials. In addition, manual sampling is a time-consuming process that significantly delays releasing product to the market. The focus has to be on building quality management into the control system to reduce the need for manual sampling, while keeping validation simple. Lack of adequate changeover capabilities can be a major barrier to maintaining an efficient validation process. To efficiently change over from one product line to the next, manufacturers need well-developed validation methods and agile, robust machines that can support multiple product recipes. Systems that lack modularity or plant-wide integration are more time-consuming for the FDA to review, and inspectors have a difficult time identifying if good manufacturing practices were used.
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By implementing control and information architectures on their machines, companies can reduce validation time and costs by automating the acquisition, storage and retrieval of all manufacturing data. Architectures can also help protect the integrity of system information required for certification with advanced batch control and reporting capabilities. n terms of best practice, companies that want to streamline regulatory compliance and reduce validation costs standardise technology across their operations.
Reducing time-to-market Both generic and brand name manufacturers face continuing pressure to introduce new products and formulations faster, while containing costs and reducing risks. Pharmaceutical companies are often put in the difficult position of trying to balance competing forces – such as the need to achieve regulatory compliance and reduce validation costs – while reducing the time it takes for new drugs to reach consumers. Patent protection for marketing and amortisation typically expire in 8 years, so the day clinical trials are complete should be the day manufacturing begins in order to recoup development costs. Time-to-validation and production rampup time must be minimised – even as manufacturers are using more complex systems and diagnostic data to maximise revenue potential and product margins before patents expire and competition from generics begins.
Optimising production Once production begins, both generic and brand name companies demand speed and accuracy from equipment to maximise manufacturing efficiency, improve agility and ease changeovers with standardised systems that enable functional, repeatable control. Systems that eliminate paperwork and reduce errors while maintaining expected high quality standards, help improve plant throughput and will reduce the time it takes for compounds to reach consumers. The ability to see data and act on production information
A&D India | Feb-Mar 2016
P H A R M A C E U T I C A L S & PA C K A G I N G | F O C U S
Image Courtesy: Shutterstock
Bringing clinical operations and manufacturing together results in more efficient, productive and responsive working practices
generated at all stages of the value chain, from discovery to real-world use after regulatory approval, is vital in performance optimisation. Fully integrated systems provide contextual, real-time information in an actionable format at senior level, for controlling key business drivers including cost of compliance, best practice, reducing total cost of ownership, life cycle optimisation and batch cycle review times.
Promoting a collaborative approach Historically, pharmaceutical R&D has been undertaken in closed environments. Changing working practices and potential drive a more collaborative approach, facilitating input internally and externally, from peers, partners, other pharmaceutical companies and stakeholders, statutory bodies and patients themselves. The configurable technologies available support a collaborative model by linking disparate, manual processes throughout an organisation. The integration of multiple systems helps to streamline new product development and leads to automated formulation and clinical trial management. Bringing clinical operations & manufacturing together results in more efficient, productive & responsive working practices.
Combatting intellectual property theft Enterprise-wide visibility into production data offers significant, long-term benefits to pharmaceutical companies. Some manufacturers, however, view the risks associated with open environments as excessive. By adopting the appropriate measures, not only is security assured as far as is possible, but productivity improved. Security cannot be implemented as an after-thought or bolt-on, but rather should be designed into the devices, the control systems, and the networks that make up the automation environment. Companies need to take a holistic view of industrial security – addressing people, process and technologyrelated risks – to maintain operational integrity and protect the company’s most important operational assets.
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Industrial security requires a ‘defence-in-depth’ strategy based on the premise that any one point of protection or single firewall may be penetrated by the persistent attacker over time. The solution is to adopt multiple layers of defence—physical, electronic, and procedural – where security is designed into the infrastructure and becomes a set of layers within the overall network security. This means that attackers must first penetrate or circumvent each layer of security without detection, and that any point of vulnerability or flaw in one security layer can be backstopped by different variables or capabilities provided by other layers. To combat counterfeiting, best practice manufacturers are putting serialisation processes in place, whereby each item is marked with a unique serial number. Manufacturers and retailers can then identify and track each unit throughout the supply chain, providing greater traceability. Serialisation-ready machines produce an auditable electronic record of every step taken by a retail package of prescription drugs, as it moves from the factory to the final point of sale. This chain-of-custody record can be used to assure the integrity and safety of the drug supply.
Conclusion Pharmaceutical manufacturers implementing enterprisewide, integrated control systems are better able to achieve regulatory compliance, and reduce costs and time-to-market without sacrificing product quality. Greater insight into deliveries and improved communications with suppliers regarding scheduling changes, order increases and other issues help optimise inventory management and drive faster time to market. And connecting manufacturing operations with enterprise information systems connects employees across functions, empowering them to better collaborate and work toward one common goal of better meeting customer demand. An integrated working environment improves planning, heightens production visibility, and enables more assured risk management. The greater risk is in avoiding change, and giving competitors the opportunity to capitalise. ☐ Courtesy: The article is submitted by Rockwell Automation.
A&D India | Feb-Mar 2016
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P H A R M A C E U T I C A L S & PA C K A G I N G | F O C U S
Maximising slip ring lifecycle A read on simple design tips that will help engineers to ensure the longest possible life & lowest possible maintenance for the slip rings used on packaging and other industrial machines Do your slip rings run trouble-free for their expected lifecycle? If the answer is “No,” you are not alone. Many engineers working with rotating machines experience slip ring problems or downtime at some point. The good news is you can easily keep your slip rings running smoothly for the long haul by following just three simple steps. All you need to do is configure, install and maintain the slip rings properly. Unfortunately, even experienced engineers sometimes configure slip rings without paying enough attention to how the device will be installed on the machine. It turns out that different mounting orientations call for different slip ring configurations. And if you get the configuration wrong, the slip ring may suffer from recurring signal loss problems and a shortened working life. Maintenance isn’t always straightforward either. It’s easy to lay the blame for poor maintenance on end-users, but the
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Prashant Raghatwan Product Manager Kuebler Automation India prashant.raghatwan@kuebler.com
truth is some slip ring designs are inherently difficult to maintain. What’s more, engineers do not always consider the actual operating conditions when setting maintenance expectations, causing them to overstate or understate service intervals. Bottomline is that slip ring maintenance starts on the drawing board, not on the factory floor. The article details simple design strategies that will help you ensure the longest possible life and lowest possible maintenance for the slip rings used on packaging and other industrial machines.
Eliminate configuration errors To maximise design flexibility and minimise size, modern slip rings typically have a modular design. Modularity allows users to freely combine power and signal channels to meet
A&D India | Feb-Mar 2016
P H A R M A C E U T I C A L S & PA C K A G I N G | F O C U S
Vertical hanging and standing orientations in particular will need different configurations to ensure that the signal channels remain above the labyrinth seals
their exact application requirements. The SR085 slip ring, Subsequent maintenance intervals should be scheduled every allows configurations up to 20 channels, divided between 100 million revolutions or yearly. The maintenance regimen load and signal any way the application requires. itself is simple: just vacuum out any dust that has accumulated Often, engineers configure a slip ring without regard for on the slip ring load and signal contacts. The slip rings used its mounting orientation. The reason orientation matter is in most packaging or industrial applications don’t even that the signal channels are more susceptible to contamination require any oil on the contacts. from dust or other particles than load channels. Accumulated While it’s true that engineers have little control over dust can degrade the signal integrity, ultimately shorting the whether end-users will ultimately adhere to the recommended maintenance intervals and lifecycle of the slip ring. So it’s maintenance intervals, there are a couple of key upfront important to configure slip rings with the signal channels design factors related to maintenance as follow. above other modules—such as power channels. As long as Duty cycle: Nominal maintenance intervals may not be the signal channels are on top of the slip ring, gravity will enough if you plan on running a slip ring at high rotational work in your favour and minimise the amount of dust that speeds, at elevated temperatures or in contaminated falls onto signal channels. Keeping the signal channels on top environments. These aggressive operating conditions can requires an awareness of the mounting orientation. Vertical lead to signal degradation or even mechanical failures without hanging and standing orientations in particular will need an equally aggressive maintenance regimen. different configurations to ensure that the signal channels Easy access: All slip rings require some routine maintenance, remain above the labyrinth seals. With horizontally mounted but not all slip ring designs make maintenance quick and slip rings, gravity doesn’t help or hurt the dust situation much. easy. It’s important to look for designs that have ready access You can locate the signal and load channels in any order that to the power and signal contacts without requiring disassembly makes sense for your application. of the slip ring. Our designs, for instance, have a removable maintenance window adjacent to the contacts. Slip rings are so common nowadays that engineers tend to take their Follow maintenance instructions performance for granted. And in general, modern slip rings Another threat to smooth slip ring operations is a are reliable enough to tolerate some neglect. However, if you disregard for recommended maintenance intervals. Nominally, really want to get the most out of a slip ring, a little extra we recommend the first maintenance at 50 million revolutions attention to mounting orientation and ease-of-maintenance or after one year of operation, whichever comes first. will go a long way. ☐
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A&D India | Feb-Mar 2016
electronic ifm electronic India Private Limited Plot No. P-39/1, MIDC Gokul Sirgaon, Kolhapur - 416234 Maharashtra Ph: 0231-2672770 E-mail: info@ifm-electronic.in
M OTO R S & D R I V E S | T E C H N O L O G Y
Energy efficiency with hybrid design First in Turkey in the field of plastic injections, Tisse and Kollmorgen have together developed an electric-hydraulic hybrid machine. An application story on how the hybrid machine increases the production rate and provides energy efficiency up to 35-40% compared to the competition. eS-Drive450 Tisse is the result of the cooperation between Kollmorgen engineering and Tisse Plastic Injection Moulding Machines Company. It is the first hybrid plastic injection moulding machine, whose injection part includes an electric system and a hydraulic system comprised of clamping and conveying as well as an ejection unit. The hybrid design provides speed and energy saving in manufacturing. The entire software of the machine was written by Kollmorgen, in house, from scratch. The injection part of the hybrid machine consists of 2 servo motors, whereas clamping, conveying and ejection
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parts form the hydraulic system. However, because the pump of the hydraulic system is driven using servo motor, the machine may be called a full electric hybrid. The reason why servo motors were used in the injection part was to provide crucial acceleration and sensitive pressure balance, making it easy and quick for the liquid plastic to be injected into the mould. Speed is of great importance, especially for moulding thin-walled packaging products. For instance, because products, such as the lids of yoghurt pots cool very quickly, the process is required to be completed immediately.
A&D India | Feb-Mar 2016
T E C H N O L O G Y | M OTO R S & D R I V E S
Improved speed and energy efficiency Seref Karaoglan, Project Manager of Kollmorgen Turkey, while speaking about the machine performance, shared, “We often witness that manufacturers have difficulty in manufacturing such products. We designed the hybrid not only to provide energy efficiency but also to increase speed. People think it is not easy to manufacture such machine because, for instance, we apply 10 different speed stages and 10 different pressure stages in accordance with the type of mould in order to make a movement of 90 mm (P/Q). It is really not easy to do this just with any servo motors, but we used Kollmorgen’s S600 drives and PDMM controllers.” Omer Sengelen, Production Manager of Tisse Machine, summarised their position in the sector: “We are endeavoring to add remarkable features even to typical machines. Actually, we quit manufacturing injection moulding machines in 2000. In 2008, however, we noticed that there was a need for blow moulding machines and we started manufacturing again. With the expertise and high product quality that we developed through our partnership with Elsim Kollmorgen, we have become capable with very highlevel injection moulding machinery.”
A&D India | Feb-Mar 2016
Clamping systems in normal injection moulding machines are usually problematic. The injection moulding might be fast but the clamping is the negative side. The compression ratio is less, but they cause great expenses at high speed. The clamping part in hydraulic injection machines is always as per specifications, but complaints about the injection speed predominate. Their maximum speed is between 100 mm/h and 200 mm/s. This hybrid machine has the best side of those 2 systems. While it enables the clamping and other parts of the machine, which require power to run fast, it is also able to reach a speed of 300 mm/h by getting the injection system to work with servo motors. In addition to these advantages, it provides energy saving in the pump of the hydraulic system by using servo motors. Karaoglan said, “The reason why electric machines are liked is that they are energy efficient unlike AC motors, in the hydraulic part of old machines, that keep cycling even while the machine is off & consume energy even if you do nothing.”
Special valve technology Regeneration is provided through the special valve used in the hydraulic system of the machine. Suppose that the grease
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M OTO R S & D R I V E S | T E C H N O L O G Y
Kollmorgen automation suite machine automation solution
taken from the tank and injected into the system, supplies 100 units of energy in the classical systems. Thanks to this valve, the grease coming out of the system is re-injected into the system, instead of transferring it into the tank. Thus, you obtain extra power up to 60%. According to Karaoglan, you get extra speed as well as extra power, and “It is like the generator of a car charging the accumulator. We could have used standard valves for the clamping parts because we had acceleration in the injection part. But thanks to this special valve, we use the clamping system as if it is electrically operated, and increase the speed thanks to regeneration” he said. Another stellar feature of the machine is that two different motors are used in the injection process, getting parallel power through each other. The motors are connected by very special screws that run synchronously. These screws enable the motors to cycle with high-precision in less than 1/10 mm, and they provide stable running even at high speed.
Efficient communication system The speed doubles because the injection nozzle in the machine is pushed and pulled by twin motors. Karaoglan said, “Kollmorgen communication systems allow the synchronous work of two motors on the same mechanical system but running independently. If one of the motors runs at a speed slower than 1/10 mm, it might damage the screws, which are very special and expensive. The communication time and synchronisation of the motors takes less than 1 m/s. The motors used in the machine are quite heavy and powerful. “We took all kinds of measurements in the event of
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any communication problems between each other. 6.5 kW of braking resistance is used in the system because the flywheel effect comes out while the screws and balls gain acceleration” said Karaoglan. He also points out that it gets really difficult to control the speed and shared, “The products we use here are those developed by Kollmorgen and include plates providing stepped braking. It would have been impossible for me to succeed in this project with standard braking resistances.”
Special pump software There are two important elements in grease-powered systems: speed and pressure. The software developed for this machine, ensures the desired pressure at the desired speed. Karaoglan explained, “We can use 10 different PQ distances. We are also using this advantage on the clamping system. Thanks to the servo motored pump software, we reach the desired speed within 150-200 ms and despite this speed, we provide the desired pressure on an error band of 2 or 3 bars.” Kollmorgen’s machine automation solution brings highly integrated and intuitive software programming platform, top of the range movement components and extraordinary cooperated engineering services in order to create highly differentiated machines and more profitable business organisations. It has been proven that Kollmorgen Automation Suite™ accelerates the development process, raises the machine manufacturing, reduces wastage and increases hardware efficiency (OEE). ☐ Courtesy: Kollmorgen
A&D India | Feb-Mar 2016
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S O F T WA R E & E N G G TO O L S | A P P L I C AT I O N
Focus on optics An application story on how B&R’s Automation Studio helped TMS to handle everything from communication and HMI to CNC and machine control with a single software package
Kay Trumpler and his company TMS are dedicated to the field of precision optics. Well established in the field of servicing and retrofitting optical manufacturing equipment, TMS recently began constructing its own CNC machines for milling, drilling and cutting optical glass. The automation for these new TMS machines like all other automation technology installed by the company since its founding in 2008 comes from B&R. For Kay Trumpler, a trained machinist and industrial foreman with decades of experience in the optics industry, there are clear reasons for choosing a B&R automation solution for his machines, whether retrofit or new constructions. “Particularly in retrofitting jobs, we have to
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F Rossmann Journalist from Gauting, Germany f.rossmann@b2bkommunikation.de
deal with all sorts of unique automation challenges. To cover such a broad spectrum, we need a highly integrated, extremely flexible automation solution. That’s exactly what we get with B&R,” he said. Since retrofitting is generally only a feasible option for relatively simple machinery, the complexity of the task is kept within reasonable limits. Constructing new machines is a whole different story. New machinery has complex automation architectures that integrate safety functions, CNC, motion control and sequential control. “The exceptional scalability and seamless integration of B&R’s solutions have been pivotal in our smooth transition into product-based business,” said Trumpler.
A&D India | Feb-Mar 2016
S O F T WA R E & E N G G TO O L S | A P P L I C AT I O N
One engineering environment for the project As a smaller company, TMS has to be especially careful about how it uses its personnel and resources. “That’s where we really benefit from the universal engineering environment in Automation Studio,” added Trumpler. With Automation Studio, TMS is able to handle everything from communication and HMI to CNC and machine control with a single software package, regardless of which hardware is used. “And we can do all this without constantly having to purchase new licenses and upgrades. That and B&R’s outstanding support make it easy for us to get up to speed on new topics, lower our expenses and complete projects more quickly,” he added. With this support, TMS successfully transitioned into the new construction business with a low-cost centering machine in under a year and with only five employees. Positive feedback from the market inspired TMS to begin development of an entire product family based on a shared machine platform. The first products from this new family are the TGS 300 glass cutter and the TGB 300 glass processing machine.
the servo drives feature B&R’s integrated SafeMOTION technology, which allows the axes to be operated safely at reduced speed. The machine’s safety equipment, such as its E-stop buttons, are all integrated via safe I/O modules from the X20 system. TMS retrofits optical manufacturing equipment for other manufacturers as well as building its own glass processing machinery. The small team of engineers is confronted with a broad spectrum of automation challenges ranging from basic controllers to complex, multi-axis CNC machines with safety functions. That’s why TMS chose to work with Automation Studio, because it allows them to program every aspect of the software – from communication to CNC and HMI – in a single environment.
Real space savings with a virtual safety controller
The safety functions are controlled by a compact SafeLOGIC-X module. “The virtual controller supports all the same SafeMOTION functions as the more powerful safety controllers,” explained Fabian Hölzel, who worked with Trumpler on the design and construction of the machine. He Universal glass milling machine was the one responsible for programming all of the control The TGB 300 allows optics producers to mill workpieces and application software, including the CNC and HMI out of glass blocks measuring up to 300 millimetres in applications, in Automation Studio. “The software is diameter for in-house production of prototypes and small absolutely modular and is identical for both machine types. batches. “This type of task used to require three separate The only adaptation required is to change a few parameter machines,” explained Trumpler. “Now all you need is one settings.” explained Hölzel. Users can also easily adapt the TGB 300,” he said. This is the first processing solution for HMI application to their requirements so that even semioptics production that offers all the functionality of a skilled workers are able to operate the machine. universal milling machine for metalworking, but is designed For its operator interface, TMS selected an operator for the specific requirements of glass. panel from B&R that combines a touch screen display, key For example, TMS completely encapsulated the machining switch, keyboard and E-stop in a single, ergonomic housing. centre and eliminated all guides and metal blinds to provide A powerful Automation PC 910 provides a high-performance immunity for the machine against the abrasive glass-diamond hardware platform for the machine control, CNC and HMI residue created during processing. applications. “The ability to unite CNC, PLC, motion and The TGB 300 is equipped with up to five CNC axes (X, Y, HMI within a single software platform is one of the Z, rotary table and indexing head) controlled by ACOPOSmulti remarkable aspects that sealed the deal for the B&R solution,” servo drives. To keep the machine accessible during setup, concluded Trumpler. ☐
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A&D India | Feb-Mar 2016
M A N U FA C T U R I N G I T | T E C H N O L O G Y
Addressing IIoT challenges Within the industrial sector, connecting disparate devices from multiple manufacturers is a key first step to creating the Industrial Internet of Things (IIoT). The article explains on how protocol conversion addresses these challenges in connecting legacy equipment to the IIoT. The Internet of Things (IoT) is a hot topic in the press today that is stealing many headlines. The reason for all this attention comes from the rapid growth expected in the IoT world. According to Berg Insight, the number of wireless IoT devices in automation networks is now forecast to grow at a compound annual growth rate (CAGR) of 27.2% to reach 43.5 million by 2020. However, the Industrial Internet of Things (IIoT) is more of a near-term reality, and many industrial firms are striving to take advantage of its benefits. There are many different terms for IIoT, including Industry 4.0. and the Connected Factory. Whatever you choose to call it, how can you take steps to ‘get in the game’ with IIoT?
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Jeff Thornton Product Manager Red Lion Controls
The challenge—IIoT readiness One might wonder how to get started with IIoT, especially when you look out at your organisation and see equipment from different manufacturers that is 5, 10 or 20 years old (or more). How can you solve the challenges of being IIoT ‘ready’ when you use legacy devices to operate many of your processes? Replacing equipment is not an option because of cost and integration time. You need to find a way to not only protect your existing investment, but also make it compatible with more modern equipment. This may seem to some like a ‘best of both worlds’ scenario.
A&D India | Feb-Mar 2016
Economical and exible – Solutions for packaging machines
Are you looking for a reliable partner for the automation of your packaging machine? We offer a comprehensive portfolio for the packaging industry, from safe sensor technology to control systems, operation and visualisation, through to drive technology.
Further information: www.pilz.com/packaging
Pilz India Pvt Ltd.
Pune 411009
020 2421399-4/-5
info@pilz.in
www.pilz.in
M A N U FA C T U R I N G I T | T E C H N O L O G Y
The answer—protocol conversion Protocol conversion is a key first step in solving the multivendor and legacy equipment challenge. Wikipedia describes a protocol converter as ‘a device used to convert a standard or proprietary protocol of one device to the protocol suitable for the other device or tools to achieve the interoperability.’ There can be many different devices on a manufacturing floor, with each one having its own protocol, so organisations can have a situation where you need to handle several different protocols in order to gather data. The ability to provide protocol conversion in a Human Machine Interface or other automation products across a multi-vendor environment is a great way to connect several different devices, with different protocols, and be able to aggregate that data collection. Protocol conversion allows you to collect data from different devices and different protocols and ‘translate’ those in a centralised device so that you can collect and compile data from all over the factory floor. Then, you can turn this information and data into useable, trend-related information and reports that help you to make informed decisions and do effective planning of your resources. Some refer to this as the mining and displaying of data for actionable intelligence, which gives you real-time visibility to help make operations more efficient.
Connect—speaking the same language You can benefit from bringing new and legacy equipment together on the same network. Some of the newer equipment on the factory floor may be ‘Ethernet ready’ while older equipment may use a serial connection and a legacy protocol specific to that vendor. By integrating different devices (and getting legacy devices talking with newer devices) you can get disparate equipment to communicate across multi-vendor environments. Industrial environments are embracing newer communication infrastructures such as cellular M2M, Wi-Fi, Gigabit Ethernet, fibre and Power over Ethernet. These
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communication technologies help deliver and enable higherbandwidth applications that bring more information and intelligence to manufacturing environments.
Monitor—using data to visualise processes Protocol conversion is also important for monitoring processes – collecting and analysing data to develop more efficient operations and reduce downtime. In particular, when protocol conversion is implemented in multi-vendor environments, customers can leverage visual management solutions to display Key Performance Indicators (KPIs) that can be used for tracking, assessing and analysing manufacturing processes. These performance measurements are commonly used to evaluate success in relation to goals and objectives. While KPIs tend to vary by organisation, common examples of KPIs in manufacturing include: count (good or bad), reject ratio, rate, target, Takt time, Overall Equipment Effectiveness (OEE) and downtime.
Control—increasing operational efficiencies Protocol conversion can help you integrate PLCs, PCs and SCADA systems to collect and process data in real-time to control devices and applications that directly affect operations. Exercising control over operations could mean such things as having the ability to turn legacy serial-connected equipment on or off, or open or close valves regardless of location. In conclusion, addressing IIoT challenges through protocol conversion enables organisations to improve productivity and increase operational efficiencies through real-time device connection and data processing. With protocol conversion, you can get all of your devices – both legacy and new – communicating to provide a holistic environment view that allows you to plan more effectively and take action. By enabling disparate devices to communicate, you can now connect, monitor and control operations from a single platform. This type of data-driven monitoring and decision-making will get you on your way to IIoT readiness. ☐
A&D India | Feb-Mar 2016
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S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y
Safely increasing flexibility If products are to be packaged in large numbers, automation of the packaging process will play a key role. It is a prerequisite for high cycle counts and consistent quality. The article discusses how the packaging machines from BVM Brunner enhance flexibility and availability with the automation solutions from Pilz. A high level of automation is needed to enable shrink wrapping machines to be flexible and allow high speeds, with over 100 cycles per minute. One of the leading manufacturers of such machines is BVM Brunner GmbH & Co KG. Since 1985, its products have included the shrink wrapping machines responsible for cost-effective packaging of books, CDs, chocolate boxes and many other consumer items. Around 160 machines per year leave the factory in Reutlingen, Swabia. Machines in the ‘Compacta’ series from BVM Brunner can produce up to 9,000 film packagings per hour.
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Protecting workers during loading On these machines, a pusher unit can be used instead of the infeed belt to access the production process manually and load the machine. The pusher unit is mainly used for round products such as cup lids or rolls of adhesive tape, for example, it is installed on the machine’s infeed conveyor. To provide the necessary protection for workers, potential danger zones must first be identified and appropriate safeguards put in place. BVM Brunner turned to Pilz’s expertise to help
A&D India | Feb-Mar 2016
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S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y
them satisfy the legal requirements of EN ISO 13849-1 under the machinery directive. The first task for the Ostfildern-based safe automation solution supplier was to carry out a risk assessment in accordance with EN ISO 14121. The result of such a risk assessment is the foundation for developing the safety concept and producing the safety design, including the selection of appropriate components and safeguards.
Electrosensitive protective equipment Pilz recommended the use of electrosensitive protective equipment, because mechanical safeguards such as gates and covers can adversely affect work processes. Instead of a safety gate, which the operator would have to open and close each time products were placed in the pusher unit, optoelectronic protective devices PSENopt from Pilz provide a safe, efficient option for accessing the machine. With PSENopt light beam devices, light grids and light curtains, the operator has a clear view of the process including free access, provided the machine is in a safe condition. A PSENopt light curtain is used to protect the operator working on the pusher unit. The necessary protected fields and detection capability, enabling objects of a certain size to be detected safely, can be set up to suit the process. Type 4 PSENopt light grids are used in safety-related applications and are approved in accordance with EN/IEC 61496-1/-2. So, the safety level determined in the risk analysis, PL e in accordance with EN ISO 13849-1, is safely met. As the material is fed in, different functions on the light curtain, such as muting, blanking and cascading, enable the optimum solution to be found for each individual production process. Muting means the safe, automatic and temporary suspension of electrosensitive protective equipment, so that material can be transported into and out of a danger zone, for example. Through muting, i.e. the temporary suspension of safety functions, it is possible to distinguish between operator and material. The blanking function allows partial blanking of individual light curtain beams. The safety function will not be triggered as the material that is currently being processed passes through. However, under no circumstances, should anyone be able to reach the danger zone undetected via this
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deactivated section of the protected field. That is why the cascading function is used to provide effective protection against encroachment into and behind the protected area.
Safety via complete solutions At BVM Brunner, the complete safety technology solution comprises sensors, such as optoelectronic protective devices PSENopt and magnetic safety switches PSENmag, in conjunction with the configurable safety relay PNOZmulti Mini from Pilz. PNOZmulti Mini monitors the station, in other words, the light curtains PSENopt, as well as the emergency stop pushbuttons. The base unit PNOZ mm0.1p is designed to evaluate multiple safety functions and operates independently of the operational or standard control system. The base units are able to reconfigure up to 8 of the 20 inputs plus the 4 test pulses into standard outputs. With these configurable contacts, individual information about an operational or standard control system can be communicated directly via the safetyrelated evaluation device, without the user having to invest in a fieldbus or Ethernet interface. As the user is not restricted in his choice of additional automation components, the PNOZmulti Mini can be used as a worldwide safety standard for all machine types. With the PNOZmulti Mini, the safety circuit is generated on the PC using an intuitive configuration tool. This saves time as well as the cost of a complex wiring process.
Combining safety and productivity Despite the high level of automation, packaging machines still require manual access, when loading or setting up the machine, for example, and when things go wrong. The challenge when safeguarding processes such as these is to provide maximum safety for the operator, while not disrupting production unnecessarily. Electrosensitive protective equipment such as PSENopt provides a barrier-free concept, enabling higher productivity, while still safeguarding access to the work process. � Courtesy: Pilz
A&D India | Feb-Mar 2016
TECHNOLOGY | SAFETY & SECURITY
I m a g e C o u r t e s y : Shutterstock
SAFETY & SECURITY | TECHNOLOGY
Managed industrial cyber security Security awareness is on the rise, but translating that awareness into action can be a very daunting experience. A manufacturer can end up stalled because he lacks direction in where to begin or which best practices to follow. This is where managed industrial cyber security services can open the door to a secure environment.
Mark Littlejohn, Global Leader, Cyber Security Managed Services, Honeywell Process Solutions
In this day of targeted attacks that can focus on any for control environments. In addition, they provide a proactive manufacturing enterprise, a solid industrial cyber security defence with continuous monitoring and analysis of the system. program is critical to ensuring availability. A system outage As a result, the manufacturer can focus on keeping the process due to a virus infection or other cyber incident is unacceptable. operational and making more product. On top of that, the direct consequences of an attack could The goal of a managed industrial services program is to result in unplanned downtime, loss of product or impaired deliver services with a secure encrypted connection with twoquality, manipulation of data, unauthorised use of systems, factor authentication; protection management that provides damaged reputation, and harm to personnel and monetary tested & approved patches and anti-malware definitions; damages. Utilising managed security services in an industrial continuous monitoring & alerting, which provides 24/7 environment enables continued uptime because these providers monitoring of system, network and cyber security performance assess, design, implement, and continuously monitor security and automated alerting against thresholds; intelligence
A&D India | Feb-Mar 2016
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SAFETY & SECURITY | TECHNOLOGY
Goal of a managed industrial services program
reporting that delivers insights into the operation and security status of distributed control system (DCS) components and process control network (PCN); Perimeter and intrusion management, which offers firewall support and intrusion protection system (IPS) implementation and management.
reactionary security to a continuous security program – one with an infrastructure and methodology that supports the ISA99/IEC 62443 concepts of zones and conduits, authentication, security logging, input validation and system integrity checks.
Attack vectors all around
Managed change is inevitable
There are plenty of new and sophisticated attacks hitting industry from the outside, like advanced persistent threats (APTs), including malware, viruses and Trojans. These threats are dynamic, ever-changing and the attack code is readily available. In addition, there is the issue of an accidental, or malicious inside attack. For most process control environments, the insider threat is more prevalent and dangerous than the outside attack. Most environments have some type of firewall in place, so attackers must go through the corporate firewall and then the process control firewall to infiltrate. If proper configurations are in place this could be difficult. A more plausible scenario could be someone on the plant floor, such as an employee or contractor, who plugs in an infected USB and that is the beginning of a security problem. Or possibly someone with elevated privileges getting on the system and then accidentally causing a problem—like changing a configuration parameter or the name of a software program resulting in an outage. In the end, a manufacturer needs the defenses to fight off any kind of attack. Thus, the need to transition from a static,
There are engineers and operators that have been doing process control for a long time and in the past their environment has been completely isolated from any, and all, other networks in the company. The reality is at least 90% of manufacturers don’t have that anymore. Whether they realise it or not, the plant floor has connectivity. Either through a firewall, or a gateway to the business networks, there is connectivity because the people in the corporate offices need to monitor what is going on inside those networks. In addition, outside third parties need to enter systems for activities like monitoring for environmental or compliance issues. So, there is plenty of connectivity outside of the process control environment and engineers executing real-time process control often don’t understand that. Clearing up the misconception of internet connectivity and allowing a third-party service centre access to the network can be a challenge. However, a managed industrial security program provides a very secure way for the user to control delivery of software and antivirus updates and patches. Software found on the Internet can have viruses – and who
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A&D India | Feb-Mar 2016
TECHNOLOGY | SAFETY & SECURITY
Managed security services take the uncertainty, complication and effort of industrial cyber security off the task list and puts it into the hands of process control security experts
knows where the laptop has been? Managed industrial services experts will test and verify all updates and then send software updates over a secured connection for the process control network. As a result, it will be free of viruses and it will be the correct version of software for the network. While there is fear about remote connectivity with engineers saying, “Someone from the outside will be able to connect to my environment and do anything they want,� a secure encrypted connection with two-factor authentication can resolve those concerns. A secure connection means it is a dedicated private communication from the process control network to the isolated managed security facility. The user is in complete control of the connection as far as who connects, when they connect, and what traffic is allowed to flow. Having all communication flow through a single, high security channel is much more secure than allowing multiple connection solutions or using portable media or devices.
Cost factor A managed security service is not a new idea. Corporate IT environments have been doing this for a long time and have achieved great cost benefits. Depending on the location of the site, the cost for managed industrial services could be up to 75% lower than the cost of a single onsite engineer. If a company were to employ security services by itself, it would need, depending on the size of the network, two or three people dedicated to the program.
A&D India | Feb-Mar 2016
When you look closely at it, the crown jewel in any organisation is the process control environment. If there is any unplanned downtime, cash can begin draining like water through a sieve. Therefore, the most critical component in their infrastructure requires a secure environment.
Management awareness Awareness is continuing to grow to the point where everyone from the plant floor up to the boardroom recognises an unsecure environment is a clear and present danger. The board might ask questions about the process control environment security regarding compliance and adherence to regulations. The managed industrial services program can provide a plan, answering those questions before they are asked. In addition, in this litigious age, having a solid and cost effective security plan will show the board and stockholders you invested in keeping the organisation secure. It shows a strong level of corporate diligence. However, industrial cyber security is a complex problem that cripples most organisations from the start of planning. With that in mind, C-level executives and board members are beginning to understand that they need to develop stronger, more comprehensive plans for incident response. A managed security service in an industrial environment is a vital move to reduce a breach that will damage the corporate image, or incur losses. A risk-free decision considering the alternative. �
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EVENT | PREVIEW
Global stage for integrated industry The age of integrated industry is standing at the door. At HANNOVER MESSE 2016, all eyes will be on Industry 4.0 (advanced manufacturing). Over five action-packed days, around 5,000 exhibitors will be showcasing the latest technologies for the factories & energy systems. An event preview… With the theme of “Integrated Industry – Discover Solutions!” the world’s leading trade fair for industrial technology—HANNOVER MESSE will be staged from 25 to 29 April 2016, in Hannover, Germany. The United States of America has being designated as the official Partner Country, making its maiden debut at the trade fair. HANNOVER MESSE 2016 is the global hotspot for Industry 4.0 solutions. “This April, the world’s key drivers of industrial digitalisation will all be in Hannover. Among them, German specialists from the fields of mechanical and electrical engineering and the electronics industry, as well as leading US software providers and Asian firms also focused on making industrial digitalisation a tangible reality,” remarked Dr Jochen Köckler, Member of the Managing Board, Deutsche Messe. “This all adds up to promising new partnerships and business models
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on the road to the next industrial revolution”, he added. HANNOVER MESSE will also be a powerful vehicle for next-generation economic policies of global scale. “The US as this year’s Partner Country, German industry and their European partners are all intent on leveraging the fair to promote the TTIP free trade agreement,” emphasised Köckler. “We share the view of Germany’s leading industry associations that the TTIP will promote growth and employment on both sides of the Atlantic in the fields of mechanical and electrical engineering and the electronics industry. With its focus on industrial automation and energy and a strong lineup of around 5,000 exhibitors from 70 different countries, HANNOVER MESSE is the perfect platform for transparent and constructive dialogue in support of the TTIP,” he shared.
A&D India | Feb-Mar 2016
PREVIEW | EVENT
“German specialists as well as leading US software providers and Asian firms also focused on making industrial digitalisation a tangible reality” Dr Jochen Köckler, Member of the Managing Board, Deutsche Messe
“Predictive maintenance is now so important that we have decided to feature it as a new dedicated showcase at HANNOVER MESSE” Marc Siemering, Senior VP, HANNOVER MESSE bei Deutsche Messe AG
Event highlights
Partner Country USA
President of the United States, Barack Obama, will join German Chancellor Angela Merkel to open HANNOVER MESSE 2016. Obama will appear at the fair’s official opening ceremony on Sunday, 24 April, and is also scheduled for the traditional opening tour of the fair with Merkel on Monday morning. The digitalisation of factories and energy systems is the foremost topic at the trade fair. Speaking on the importance of digitilisation, Dr Köckler said, “Integrated Industry is no longer a vision of the future. It is reality. Industry 4.0 is moving into more and more factories. Power grids will evolve into smart grids. To remain competitive, companies must recognise and fully exploit the potential of digitalisation.” He further added, “A world first this year will be over 100 examples of real-world implementations of Industry 4.0. That’s an unparalleled achievement.” The trade fair includes special conferences on niche topics as well as on cross-industry themes with high-caliber speakers from business and government. This year, over 5,000 decision makers will attend Europe’s leading forum, Global Business & Markets in Hall 3 to discuss new global market opportunities. In addition, the Young Tech Enterprises platform has everything that ambitious startups need. The WoMenPower conference is Germany’s most successful event for highpowered women and men in the business, organisational and networking worlds. At job and career at HANNOVER MESSE, specialists from the area of technology get in touch with attractive potential employers. In Tec2You, young technology enthusiasts will find answers to questions like which is the right field for them to start into? And which company can give them a smooth start to a successful career?
Roughly 250 companies from the world’s biggest economy will come to the fair to present their latest solutions for advanced manufacturing. Among them will be General Electric, Eaton, Molex, Microsoft, AT&T and IBM. In addition, the US-based Industrial Internet Consortium (IIC) will be mounting it’s first-ever display at HANNOVER MESSE. “HANNOVER MESSE 2016 is an unparalleled opportunity, and President Obama’s participation illustrates how important this show will be for the US business community,” said US Ambassador to Germany John B Emerson. “Our Department of Commerce team is consulting with each US exhibitor and we believe their unique products, innovations, and investment opportunities are well suited for the global industrial technology market. Foreign attendees and exhibitors will have the chance to connect with some of the leading American companies and organisations at the event,” he noted.
A&D India | Feb-Mar 2016
Industry trends The exhibition will serve as a platform for manufacturing professionals to learn how they can systematically turn their production plants into smart factories, while visitors from the energy industry can find everything they need to take their energy systems to the digital dimension. For several years, now, HANNOVER MESSE has played a major role in paving the way to Industry 4.0. Rarely in history has a technology had such a profound impact in such a short space of time. The new industrial era will gain further momentum at HANNOVER MESSE, not only in terms of the technologies on display, but also the radical new business models stemming from them.
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EVENT | PREVIEW
Image Courtesy: Siemens
From the smallest particles of nanotechnology to giant bionic robots that have adopted nature as their role model, this wide spectrum is made possible by a variety of disciplines joining forces
New showcase: Predictive Maintenance 4.0
Trade fair line-up
Predictive maintenance is a good case in point. Deutsche With the leading trade fairs taking place in parallel, Messe’s HANNOVER MESSE team has been quick to pick up HANNOVER MESSE covers a wider range of themes and on this key trend. Marc Siemering, the company’s Senior Vice exhibits than any other event. President, in-charge of the fair, explains: “Predictive Industrial automation: Located at the focus of Industry 4.0, it maintenance is now so important that we have decided to presents the entire spectrum of factory/process automation, feature it as a new dedicated showcase. To be known as systems solutions and industrial IT. “Predictive Maintenance 4.0,” the showcase will include a Digital factory: What is the digital factory capable of? group pavilion and will be located in the northern section of Intelligent integration allows for the optimisation of processes Hall 17, just across from the North 1 entrance. It will present and the development of new products that conserve resources. real-life examples of predictive maintenance applications.” With technologies such as CAE, MES and PLM, it displays The displays and live demonstrations at the “Predictive integrated processes and IT solutions. Maintenance 4.0” showcase will be supported by guided Energy: The trade fair for intelligent and secure energy and tours that will take participants to the display stands of mobility technologies shows the value-adding chain for a selected providers at various locations throughout complete picture of the energy industry. HANNOVER MESSE. Tour participants will witness Industrial supply: It is unique and presents the entire continuous machine data capture, processing and analysis subcontracting market in all its diversity with new materials & in action and learn how it can give factory operators real, process technologies, more efficient lightweight construction useable information on the condition of their systems, and innovative components and systems. machines and machine components. Research & technology: From the smallest particles of nanotechnology to giant bionic robots that have adopted nature as their role model, this wide spectrum is made possible Flagship fair for energy-related displays by a variety of disciplines joining forces. This results in new Tomorrow’s energy systems will be comprised of many opportunities and possibilities for all sectors. Representatives small, decentralised parts that need to be merged and from all areas of science, industry and politics will be gathering managed by smart, digital technology. “Under the motto at research & technology. ‘Integrated Energy,’ the trade fair will feature a comprehensive The opportunity to develop new sales leads in other sectors, array of solutions for integrating the entire energy unique access to new products and technologies and a huge production and supply chain, covering everything from international presence attract exhibitors and visitors from all generation, transmission, distribution and storage right over the world. “HANNOVER MESSE 2016 will serve as a through to electric vehicle solutions,” explained Köckler. crucible for Industry 4.0 expertise from around the world. The “We will also be presenting a working model of the energy show is soon to deliver major gains for everyone who takes system of the future. Visitors to this brand-new interactive ‘Integrated Industry – Discover Solutions’ as an invitation to display can see how tomorrow’s energy systems can be made find out how digital integration can help them gain & maintain safe, secure and efficient thanks to various technologies a competitive edge,” summarised Köckler. ☐ Courtesy: HANNOVER MESSE working in concert,” he added.
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A&D India | Feb-Mar 2016
NEWS | TECHNOLOGY
Line monitoring system
Machine vision systems
B&R offers easy line control and monitoring based on PackML. With just a few mouse clicks, a convenient line monitoring system can be implemented using the APROL process and factory automation system from the company. The solution is based on OMAC’s PackML standard, which can be applied to virtually any machine. To remain competitive, owners of machinery and equipment must eliminate all sources of inefficiency. A line monitoring system provides the information they Display of line overview need to identify & eliminate problems early on. The increased efficiency in turn boosts production output. The standard PackML machine data interface in APROL contains control modules for machines and lines that provide convenient access to relevant details. From the line overview, details for each machine are just a click away. Faceplates and sub-faceplates display key data and important details. B&R combines state-of-the-art technology with advanced engineering to provide customers in virtually every industry with complete solutions.
Cognex has introduced PatMax RedLine™, a feature-location technology that reinvents the industry-leading PatMax® pattern-matching tool by maximising speed and performance. Available in the latest Cognex® In-Sight Explorer™ software version 5.1, PatMax RedLine technology is optimised to run on the following three new In-Sight® vision systems: In-Sight 5705, the world’s fastest stand-alone 5MP vision system, for reliable In-Sight® vision systems with inspection on high-speed production lines; PatMax RedLine technology In-Sight 8405, the world’s smallest standalone 5MP vision system, ideal in applications that require a lightweight camera or have limited mounting space; and In-Sight 5705C, the world’s only stand-alone 5MP colour vision system, which addresses even the most challenging applications with advanced tools and true 24-bit color image filters. Pattern matching represents the critical first step in most machine vision applications. Because previous tools imposed certain speed limitations, many applications resorted to lower resolution cameras to keep pace with production lines. PatMax RedLine technology performs faster on high-resolution vision systems.
B&R Industrial Automation | Pune
Cognex Sensors India | Pune
Email: shyam.padwal@br-automation.com | Tel: +91-20-4147-8999
Email: vaggu.sunil@cognex.com | Tel: +91-9881466003
RFID transponders
Brushless DC motors
Contrinex offers low frequency all-metal RFID transponders that are resistant to metal chips, dirt, alkaline cleaning agents and hot water. They withstand wash-down processes undamaged and are recommended for use in construction machines, cement works, food industry and aluminium processing. In situations too challenging for standard RFID components, stainless steel RFID transponders come into their own: Lowfrequency all-metal read/write modules and tags have an IP68 protection rating All-metal RFID transponders and can, therefore, be used even under water. Models additionally rated to IP69K, a normal protection type for food industry use, will withstand high-pressure cleaning with hot water and highly chemically active detergents or disinfectants, such as hydrogen peroxide and products with alkaline or chlorine content. For these requirements, transponders are hermetically sealed in one-piece stainlesssteel housing with laser-welded backplate. However, aggressive cleaning agents are not alone in having no influence on low-frequency all-metal transponders. They also work faultlessly in stainless steel environments even when embedded with only the transponder face visible.
InnoVista Sensors offers brushless DC motors with built-in controller as an all-in-one solution to simplify all project requirements. Users can use these motors to simplify the design: simply enter the direction and the speed, and this brushless motor will handle the rest. The company combines Brushless DC motors variable speed drive, encoder and motor all in a single compact and unit. This BLDC motor offer high-performance with constant torque at all speeds, instantaneous start/stop, low level of noise and high service life. In addition to these features, the motor has been designed in a compact package and is easy to install with its wiring on mono block. Users can take advantage of optimum performance levels at an affordable price. With built-in controller, the motor is suitable for packaging, printing, weighing, medical and railway industry applications. InnoVista Sensors is recently re-organised from the company Custom Sensors and Technologies (CST), a specialist in designing and manufacturing sensing, control and motion products.
A&D India | Feb-Mar 2016
Contrinex Automation | Pune
InnoVista Sensors | Bengaluru
Email: info@contrinex.in | Tel: +91-20-66890770
Email: india@innovistasensors.com | Tel: +91-80-4113-2204
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TECHNOLOGY | NEWS
Temperature monitoring system
Modules for data transfer
Fluke Process Instruments launches a new, complete turnkey solution for real-time temperature monitoring and documentation of wallboard manufacturing processes. The TIP900 system is an efficient quality control tool designed to help manufacturers quickly set up their line and improve yield. The infrared temperature measurement system creates highly detailed thermal images of the boards as they leave the dryer. Analysing these, the system software detects moisture and density TIP900 system variations and identifies any faults, such as clumps or voids in the plaster core, paper blows, edge burns, or overlapping boards. The thermal images and any flaws are instantly displayed on a touchscreen, allowing the line operator to adjust the dryer for maximum board quality. Tolerances for rejects, alarm settings, and report generation are user-configurable. The dust-proof and Ethernet-enabled TIP900 system allows for remote access to all thermal images and graphs of all processed boards. The LogViewer database stores all recorded data.
HARTING has extended the Han-Modular ® series by adding new modules for data transfer via Ethernet and PROFINET/Modules for high mating cycles. The latest modules from this series: the US4 switch, enabling data transfer via Ethernet/IP and PROFINET, as well as other data modules have been optimised for frequent mating and demating (for >10,000 mating cycles). Standard industrial connectors are designed Han-Modular® Switch US4 for 500 mating cycles. The HanModular ® series extends well beyond these capabilities and contains an increasing number of modules that have been designed for at least 10,000 mating cycles. This part of the portfolio is called ‘High Mating Cycles (HMC).’ Two shielded data modules have currently joined this group: The Han ® Megabit HMC module is suitable for transferring up to Megabit Ethernet Cat. 5e. The Han ® Gigabit HMC module enables data transfer according to Gigabit Ethernet Cat. 6A. Thanks to the shielding, the two new modules are especially suitable for transferring sensitive (bus) signals.
Fluke Technologies India | Bengaluru Email: info.india@fluke.com | Tel: +91-80-6715-9000
Harting India | Chennai Email: in@HARTING.com | Tel: +91-44-43560415
Solar powered pumps
Braking torque control module
KSB Pumps has launched a new product called KSBSol, which is a submersible pumpset with high energy efficiency and reliability suitable to run using solar power. KSBSol pumpsets are centrifugal pumps in radial and mixed flow type construction coupled with AC motors and are specially designed and matched to the requirements of solar pumping applications like drip irrigation, sprinkler irrigation, water supply etc. Pumpsets are capable to work under low sun intensity. Motors are suitable to work with VFD/MPPT controller. KSBSol These pumpsets are suitable for borewells of sizes 100 mm and above. They are designed using the proven German technology and are manufactured in its ultramodern plant located at Sinnar, near Nashik in Maharashtra. The pumpsets in the first phase are available up to 5 HP motors which can deliver heads up to 65 metres and flow up to 1,26,000 litres per day. Other customised models are also offered from the company’s wide range up to 150 HP.
Mayr has introduced new electronic braking torque regulation for ROBAstop® safety brakes. The new, intelligent braking torque control module makes it possible to decelerate devices and machines evenly and gently. This innovative and economically attractive solution is pre-destined for application in smart, interconnected machines. Using the new system, the brake specialists have succeeded in continuously changing the contact force on the brake linings and, therefore, also the braking torque during operation. In this way, machines can be decelerated ROBO-switch DC gently, adapted to the respective system requirements. Furthermore, the new braking torque regulation makes it possible to compensate for negative influences on the braking torque consistency in applications requiring a constant braking torque within narrow tolerance limits. The new, intelligent switching device, which is operated with 24 V or 48 V DC voltage, can control brakes with a coil nominal current of 10 A or 5 A. The new braking torque control module provides the possibility to build up control circuits and brake movements intelligently.
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KSB Pumps | Pune
Chr Mayr GmbH + Co KG | Germany
Email: rameshwar.sonawane@ksb.com | Tel: +91-20-2710-1000
Email: info@mayr.com | Tel: +49 (0) 8341 804-0
A&D India | Feb-Mar 2016
NEWS | TECHNOLOGY
Diagnostic handheld device
Configurable control systems
Pepperl+Fuchs has developed the new FieldConnex fieldbus diagnostic handheld device (FDH-1) that uses a quick and simple method to display the quality of the fieldbus installation. The handheld has been specifically designed to be easy to operate without the need for expert fieldbus knowledge. To connect the handheld to any fieldbus segment, PC is not required. This connection enables the handheld to show whether or not there are any errors in the physical layer installation prior to commissioning a segment. If there FDH-1 are errors, it will pinpoint what they are, where they are, and how they can be corrected. This saves time and money during installation. The FDH-1 can also be used to check existing cables in order to determine whether they are suitable for a fieldbus installation. Taking this approach can lead to considerable savings in terms of cabling costs and the amount of maintenance work required, ensuring reliable operation of the fieldbus. In existing installations, the FDH-1 can check the short-circuit protection at the spur connections.
Pilz is adding its new base unit PNOZ m B1 to the range of configurable control systems PNOZmulti 2. Not only does it offer higher performance for machines with a larger function range, i.e. for larger projects, but it also provides a connection to all common fieldbus systems via the corresponding expansion modules. For the first time, the new base unit PNOZ m B1 contains no inputs or outputs: expansion modules are used to adapt the system to the application. Two integrated PNOZ m B1 Ethernet interfaces save costs, as there is no need to connect an ETH expansion module. The number of expansion modules that can be connected on the right-hand side has been increased to eight on the new base unit. Short downtimes and high plant availability are guaranteed by connection to common fieldbus systems via the respective expansion modules. The maximum program size of the PNOZ m B1 has been quadrupled: up to 1024 connections can now be inserted between the elements.
Pepperl+Fuchs India | Gurgaon
Pilz lndia | Pune
Email: fa-info@in.pepperl-fuchs.com | Tel: +91-12-4389-4000
Email: info@pilz.in | Tel: +91-20-2421-3994
Brush DC motors
Safety gripping system
Portescap introduces the next generation of Athlonix™ high power density brush DC motors. Athlonix DCP motors offer an optimised price-toperformance solution ideal for a broad spectrum of applications. Available in a 22 mm diameter, the new 22DCP motor will feature an energy efficient coreless design with an optimised self-supporting coil and magnetic circuit. Athlonix 22DCP motors are available in 2 variations, precious metal commutation and graphite commutation with Alnico Athlonix 22DCP motors magnet inside. The unique constant force spring design for carbon brush ensures consistent performance. An REE (Restriction of Electro Erosion) coil is an available option, which ensures extended life of the motor. With maximum continuous torque up to 6.5 mNm and higher stall torque than similar comparative motors. Athlonix 22DCP motors are ideally suited for use in applications such as medical & industrial pumps, gas analyzers and security & access and power tools. Component standardisation and design modularity ensures quick customisation capability for samples across various applications.
SCHUNK now offers the DGUV (German Statutory Accident Insurance Association) certified safety gripping system that ensures personal safety with the functionalities SLS, SOS, and STO up to the level of the actuators. The EGN and EZN SCHUNK gripper modules are certified according to DIN EN ISO 13849, and, thus, enable a safe human-machine interaction in confined spaces. By combining the company’s safety gripping systems with safety mats, door switches, light curtains or 3D cameras for room surveillance, for the first time ever it is possible, to define graded protection zones without having to interrupt the production process by emergency shutdown due to close human-machine contact. Instead, the grippers DGUV certified safety slow down to a save limited speed or safely gripping system stop – according to the activated protection zone. In contrast to the existing solutions on the market, the company’s safety gripper is safely energised during the safe stop and gripped parts are safely held even without a mechanic gripping force maintenance.
Portescap | Mumbai
Schunk Intec India | Bengaluru
Email: sales.asia@portescap.com | Tel: +91-22-4200-6200
Email: info@in.schunk.com | Tel: +91-80-4053-8999
A&D India | Feb-Mar 2016
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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T
Highlights - Apr/May 2016 (8th Anniversary) IMPRINT
Automation & Drives
Publisher / Chief Editor ShekharManufacturing Jitkar Efficient
shekhar.jitkar@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net Features Writer Maria Jerin maria.jerin@publish-industry.net
» Chemical & Process Change is dramatic in the chemical & process engineering industry. A major factor is the globalisation of industry. The old competitive advantage of inventing and keeping technologies in-house and then using them around the world has become an outdated model. The next issue takes a look at how chemical and process engineering developments have transformed in the present manufacturing landscape and analyses the various innovations and technology developments on-site, in context with automation.
» Gears & Motors Due to increased demand for reliable power, smaller sizes and more energy-efficient power transmission systems gear motor industry is seeing several opportunities in the manufacturing sector. The industrial gear drives and gear motors market is expected to experience a positive growth trend in the years to come. This is giving rise to more technological innovations in this segment. The upcoming issue will track the developments in this field through technology articles and case studies.
» Safety & Integration Industrial machinery risk analysis and risk reduction techniques can create a very complex matrix of solutions. Industrial safety integration can help one to make informed decisions that will help keep employees safe. In order to meet the ever-increasing requirement to assess industrial safety, the next edition takes a stock of how industrial safety integration is a continuous improvement process and how it forms an integral part of risk reduction and safety management.
Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Jogindar J Dumde (Graphics Designer) jogindar.dumde@publish-industry.net Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Ph: + 91 - 20 - 6451 5752
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Altair Engineering India . . . . . . . . . . . . . . . . . 1 Apex Dynamics . . . . . . . . . . . . . . . . . . . . . 19 B&R Industrial Automation . . . . . . . . . . Cover, . . . . . . . . . . . . . . . . . . . . 6 , 7, 8, 26, 44, 61 Bosch Rexroth . . . . . . . . . . . . . . . . . . . . . 11 Cognex Sensors India . . . . . . . . . . . . . . . . 61 Contrinex Automation . . . . . . . . . . . . . . 13, 61 Delta India Electronics . . . . . . . . . . . . . . . . . 3 Endress+Hauser . . . . . . . . . . . . . . . . . . . . 12 Epson India . . . . . . . . . . . . . Back Inside Cover EtherCAT Technology Group . . . . . . . . . . . . 24 Fluke Process Instruments . . . . . . . . . . . . . 62 Hannover Messe . . . . . . . . . . . . . . . . . 23, 58 Harting . . . . . . . . . . . . . . . . . . . . . . . . . 8, 62 HBC Radiomatic India . . . . . . . . . . . . . . . . . 29 HMS Industrial Networks . . . . . . . . . . . 10, 53
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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Honeywell Process Solutions . . . . . . 10, 14, 55 Hummel Connector Systems . . . . . . Back Cover ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 IESA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 IFM electronic India . . . . . . . . . . . . . . . . . . 39 igus India . . . . . . . . . . . . . . . . . . . . . . . 2, 12 InnoVista Sensors . . . . . . . . . . . . . . . . 21, 61 JK Fenner India . . . . . . . . . . . . . . . . . . . . . 15 Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . 40 KSB Pumps . . . . . . . . . . . . . . . . . . . . . . . 62 Kuebler Automation . . . . . . . . . . . . . . . 36, 45 Mayr . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Messe Frankfurt Trade Fairs . . . . . . . . . . . . . 43 Messung Group . . . . . . . . . . . . . . . . . . . . . 10 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . . . . 5 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . 41
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Murrelektronik India . . . . . . . . . . . . . . . . . . 35 National Instruments . . . . . . . . . . . . . . . 12, 26 NTPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Omron Automation . . . . . . . . . . . . . . . . . . . . 9 Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . 63 Pilz India . . . . . . . . . . . . . . . . . . . . 49, 52, 63 Portescap . . . . . . . . . . . . . . . . . . . . . . . . . 63 Power Grid Corporation of India . . . . . . . . . . 12 Red Lion . . . . . . . . . . . . . . . . . . . . . . 26, 48 Renu Electronics . . . . . . . . . . . . . . . . . . . . 37 Rockwell Automation . . . . . . . . . . . . . . . . . 30 Schmersal India . . . . . . . . . . . . Front Gate Fold Schunk Intec India . . . Front Inside Cover, 8, 63 Sick India . . . . . . . . . . . . . . . . . . . . . . . . . 33 Titan Industries . . . . . . . . . . . . . . . . . . . . . 47 Vega India . . . . . . . . . . . . . . . . . . . . . . . . 51
Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `600 AandD.india@publish-industry.net Tel: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.aandd24.in Digital edition http://issuu.com/publishi/docs
A&D India | Feb-Mar 2016