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OCTOBER 2016 Vol. 63 Number 10

Features 36 Finding the right tools to delve into process data Cover Story: New tools beyond the spreadsheet are needed to empower process engineers so they can derive insights from the data that is being transmitted.

38 Implementing cloud connectivity for IIoT and Industrie 4.0 As information technology and automation technology continue to converge, cloud-based communication and data services increasingly are used in industrial automation projects. I/O components compatible with Industrial Internet of Things (IIoT) enable easy-to-configure and seamless integration into public and private cloud applications.

36 COVER: Many process industry firms find they have a wealth of data and few insights or information. This is known as data rich, information poor (DRIP). Courtesy: Seeq

40 How to implement the Industrial Internet of Things Industrial organizations need an effective way to get started with the Industrial Internet of Things (IIoT). See the seven ways to get started with IIoT, including appropriate processes, devices, systems, and expertise in operations, industrial automation, and controls.

42 How to avoid control design pitfalls with dynamic simulation

42

Adopting multi-purpose dynamic simulation (MPDS) solutions as a design standard can help with visualization of control interactions and control pre-tuning and ease challenges in later stages of the project, including startup.

43 Managing processes with the IIoT The Industrial Internet of Things (IIoT) is creating more streamlined and efficient methods to manage processes.

49

44 Roundtable on robotics Where should robotics be used? How are collaborative robotics progressing? What’s the value proposition for robotics? And how is the Industrial Internet of Things (IIoT) affecting the future of robotics? Get answers from Concept Systems, a 2016 System Integrator of the Year.

45 Digital Edition Exclusives - Five smart manufacturing hurdles to overcome for IIoT - Know the risks of securing safety systems

46 Vote now for Engineers’ Choice Finalists The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, for a limited time.

Cast your vote at www.controleng.com/VOTE2017.

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CONTROL ENGINEERING

CONTROL ENGINEERING (ISSN 0010-8049, Vol. 63, No. 10, GST #123397457) is published 12x per year, Monthly by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/ Co-Founder. CONTROL ENGINEERING copyright 2016 by CFE Media, LLC. All rights reserved.

CONTROL ENGINEERING is a registered trademark of CFE Media, LLC used under license.

Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@cfemedia.com. Postmaster: send address changes to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Publications Mail Agreement No. 40685520. Return undeliverable Canadian addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@ cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $150/yr; Canada/Mexico, $180/yr (includes 7% GST, GST#123397457); International air delivery $325/yr. Except for special issues where price changes are indicated, single copies are available for $30.00 US and $35.00 foreign. Please address all subscription mail to CONTROL ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.

www.controleng.com

Industrial Wireless Connectivity

This isn’t the same as wireless for your office.

Your devices may be in constant motion, subject to harsh temperatures and conditions, or need to operate autonomously. If you use a commercial-grade wireless router, it may not be optimized for these situations: • Outdoor, factory, or harsh environments • Operations sensitive to intermittent connection failure • Remote, unmanned, or roaming applications With an industrial-grade wireless router, you can have peace of mind knowing that your devices have the most reliable connection, regardless of the conditions.

Moxa has spent 30 years developing communications solutions for industrial users. Our hardware is tested and certified for high interoperability, wide temperature tolerances, and mission-critical performance.

We provide wireless connectivity for nuclear power plants, municipal transportation systems, and the International Space Station.

To learn more about industrial wireless connectivity, visit Moxa.com.

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input #3 at www.controleng.com/information

Remote I/O Has Never Been More Rugged and Reliable

Whatever W hatever Your Your E Extreme xtreme The Moore Industries NET Concentrator ® System connects instruments and systems via Ethernet, MODBUS and wireless technologies, while protecting your data from the real world.

The NCS’s rugged industrial design protects against RFI/EMI, ground loops, vibration and the most severe temperature extremes: -40°C to +85°C (-40°F to +185°F).

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OCTOBER 2016 Vol. 63 Number 10

M1

Inside Machines Appears after page 50; If not, see the Digital Edition: www.controleng.com/DigitalEdition

M1 Machine vision lessons learned from applications Setup, testing, and start-up can be easier and faster than prior machine vision technologies, as explained at NIWeek 2016.

M2 How to cut costs and maximize production with servo automation Lumber machine manufacturer’s moves to servo control yields increased precision, productivity.

M2

M9 Six steps to reliable integrated machine vision systems Track and trace inspection applications can offer high speed and high accuracy, said a 2016 System Integrator of the Year, Matrix Technologies.

Departments 8 Think Again Controlling the Smart Grid

10 Product Exclusive

Products

61 Foundry robot (right) for material handling and machine tending applications; Converter series (below) for process control, measurement

Drive solutions for reducing energy costs, increase uptime

12 Apps for Engineers Programming, work flow, energy, time management apps

17 Technology Update Journey to the center of the plant: SCADA returns to the field

20 IT Insight Tips on determining what is IT, OT

22 Control Engineering International Three layers of intelligent manufacturing

News 23

Future engineering students showcase projects

24

Hybrid machines, democratization help grow additive manufacturing

25

Appeal to the next generation of manufacturing workers

26

Testbed: sensor data to the cloud; Merger

27

Events, online headlines: automation company buys system integrator

www.controleng.com

Proximity sensor series (right) has cylindrical, rectangular styles

62 Rotary encoder (right) for motion control applications

CONTROL ENGINEERING

OCTOBER 2016

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More resources posted daily at:

OCTOBER

IIoT

www.controleng.com

New Products

Control Systems

Process Manufacturing Discrete Manufacturing

System Integration

Creating SIF validation procedures There’s a lot more to read online. Go to www.controleng.com/news to read Control Engineering’s exclusive Web content.

Using modern computer and TV screens to enhance HMIs Testbed for sending sensor data to the cloud approved Developing security from the inside out Power market projected to have modest growth.

NEWSLETTER: ENERGY AUTOMATION

New regulations will improve energy efficiency beyond existing motor efficiency standards Keep up with the latest industry news by subscribing to Control Engineering’s 14 newsletters at www.controleng.com/newsletters: How Anchor Glass improved plant and energy efficiencies with a modern DCS Lessons and advice to make VFD commissioning easier Advice on implementing and controlling VFDs for large boiler motors.

Share your knowledge; teach others See how to contribute articles, tutorials, case studies, new products, trend pieces to Control Engineering. Learn more at: www.controleng.com/mediainfo www.controleng.com/contribute

Video library at www.controleng.com/videos Industrie 4.0 and IIoT adaption: Where are we right now?

Beckhoff Automation North America CEO Aurelio Banda, addressed the current state of IIoT implementation in manufacturing and showcased cloud-based tools to connect data and machines at IMTS 2016, the International Manufacturing Technology Show.

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CONTROL ENGINEERING

Networking & Security

Info Management

Education & Training

Webcast education On-demand webcasts Couldn’t catch a recent webcast? See it on-demand at www.controleng.com/webcasts.

Webcasts

Oct. 11: Simplifying IoT Value Creation: Physical Infrastructure and Wireless Sensing Sept. 29: Standards for Robotics Safety Sept. 22: System Integration case studies Aug. 18: Leveraging Network Building Blocks and Cisco Validated Designs for Industrial Ethernet Deployment

Oil & Gas Engineering October issue Oil & Gas Engineering provides industryspecific solutions designed to maximize uptime and increase productivity through the use of industry best practices and new innovations, increase efficiency from the wellhead to the refinery by implementing automation and monitoring strategies, and maintain and improve safety for workers and the work environment. Read the digital edition at www.oilandgaseng.com

Digital Edition The tablet and digital editions of this publication have unique content for digital subscribers. This month’s exclusives are: Five smart manufacturing hurdles to overcome; Know the risks of securing safety systems. www.controleng.com/DigitalEdition

www.controleng.com

The Only Switch that Matters Is the One You Need And We’ve Got It

In stock and ready-to-ship. See it all at thinkallied.com/switches

1.800.433.5700 © Allied Electronics, Inc 2015. ‘Allied Electronics’ and the Allied Electronics logo are trademarks of Allied Electronics, Inc.

input #5 at www.controleng.com/information

An Electrocomponents Company.

THINK AGAIN electricity flow 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 630-571-4070, Fax 630-214-4504

Controlling the Smart Grid How is the U.S. Grid Modernization Initiative progressing? Read eight things you should know about controlling the flow of electricity on the Smart Grid and why. Monitoring and control are at the core.

E

Electricity doesn’t flow

like water, and the U.S. grid is leaking reliability as many more renewable resources are added.

Grid modernization is needed to continue to allow anticipated growth in renewable and other energy sources, according to Mark Buckner, Oak Ridge National Laboratory (ORNL), power and energy systems group leader.

Smart Grid advances

Buckner, with a doctorate in applied artificial intelligence, previously worked in the machine learning area of ORNL. He discussed Smart Grid opportunities and challenges at NIWeek 2016. Eight summarized points follow.

1. Regulations: Smart Grid advancements are occurring more slowly than some might have expected, in a regulated industry that can have different owners for distribution, transmission, and generation assets.

2. Advancements in distribution systems may happen more quickly than transmission or large generation, because as the number of control points increases, there’s a greater need for very precise control and more orchestration. With available advancements, there’s a need to equip engineers and educate customers how to use the next killer app for energy.

3. Big Data: There’s more data than is needed to solve the problems in creating and maintaining a Smart Grid. Intelligence on edge, near where data is measured, will help.

These initiatives are needed; several states have been looking at halting grid-connected renewables until grid capabilities catch up.

4. Grid modernization: Many smart people associated with the Department of Energy (DOE) Grid Modernization Initiative (GMI) have been working to upgrade U.S. electrical

MORE

ADVICE GO ONLINE With this article online at www.controleng.com, see images; link to DOE Grid Modernization Initiatives.

A stage demonstration at NIWeek 2016 showed how IEEE Time Sensitive Networking (TSN) initiatives enable Smart Grid modernization.

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OCTOBER 2016

CONTROL ENGINEERING

infrastructure, which has served us well, but needs updates to deal with emerging threats, rapid addition of renewable generation (often in much smaller increments and in many more locations than traditional generation), extreme events, and new services.

5. Modern methods to accelerate grid research: Scrum methodologies (twice the work in half the time) are among initiatives being applied to create an open framework for accelerated grid research. Prototyping platforms address microgrid and nanogrid designs and utility connections; demo sites are being created, and accelerated testing is underway.

6. Higher visibility and management of small systems: Efforts include an additive manufacturing site with integrated energy services; a powerline conductor accelerated testing facility; nanogrid sites where electric vehicle (EV) car batteries help balance grid load with smart inverters; home generators and battery management systems; and secondary use electrical storage using collections of de-rated EV batteries.

7. Simulation to advance research: Grid simulation software provides an open framework for advanced grid research. High-speed models help with grid tuning in real time, as it now exists in the field. Capability exists to monitor small (or large) renewable (or other) generating or storage resources offline and synchronize with the grid instantaneously for smarter load balancing. IEEE Time Sensitive Networking (TSN), an extension of Ethernet under development, is being used.

8. Grid resiliency and cybersecurity: exercises are underway using machine learning, artificial intelligence, and Big Data to detect, isolate, and recover from threats.

Intelligent automation, control, and monitoring advances are helping owners and users of electrical energy to think again about Smart Grid capabilities. ce

Mark T. Hoske, Content Manager MHoske@CFEMedia.com

Content Specialists/Editorial Mark T. Hoske, Content Manager 847-830-3215, MHoske@CFEMedia.com Jack Smith, Content Manager 630-907-1622, JSmith@CFEMedia.com Emily Guenther, Associate Content Manager 630-571-4070 x2220, eguenther@cfemedia.com Amanda Pelliccione, Director of Research 631-320-0655, APelliccione@CFEMedia.com Joy Chang, Digital Project Manager 630-571-4070 x2225, JChang@CFEMedia.com Chris Vavra, Production Editor 630-571-4070 x2219, CVavra@CFEMedia.com

Contributing Content Specialists Frank J. Bartos, P.E., braunbart@sbcglobal.net Peter Welander, PWelander@CFEMedia.com Vance VanDoren, Ph.D., P.E., controleng@msn.com Suzanne Gill, Control Engineering Europe suzanne.gill@imlgroup.co.uk Ekaterina Kosareva, Control Engineering Russia ekaterina.kosareva@fsmedia.ru Wojciech Stasiak, Control Engineering Poland wojciech.stasiak@trademedia.us Lukáš Smelík, Control Engineering Czech Republic lukas.smelik@trademedia.us Aileen Jin, Control Engineering China aileenjin@cechina.cn

Publication Services Jim Langhenry, Co-Founder/Publisher, CFE Media 630-571-4070, x2203; JLanghenry@CFEMedia.com Steve Rourke, Co-Founder, CFE Media 630-571-4070, x2204, SRourke@CFEMedia.com Trudy Kelly, Executive Assistant, 630-571-4070, x2205, TKelly@CFEMedia.com Elena Moeller-Younger, Marketing Manager 773-815-3795, EMYounger@CFEMedia.com Kristen Nimmo, Marketing Manager 630-571-4070, x2215, KNimmo@CFEMedia.com Brian Gross, Marketing Consultant, Global SI Database 630-571-4070, x2217, BGross@CFEMedia.com Michael Smith, Creative Director 630-779-8910, MSmith@CFEMedia.com Paul Brouch, Director of Operations 630-571-4070, x2208, PBrouch@CFEMedia.com Michael Rotz, Print Production Manager 717-766-0211 x4207, Fax: 717-506-7238 mike.rotz@frycomm.com Maria Bartell, Account Director Infogroup Targeting Solutions 847-378-2275, maria.bartell@infogroup.com Rick Ellis, Audience Management Director 303-246-1250, REllis@CFEMedia.com Letters to the editor: Please e-mail us your opinions to MHoske@CFEMedia.com or fax us at 630-214-4504.

Letters should include name, company, and address, and may be edited for space and clarity.

Information: For a Media Kit or Editorial Calendar, email Trudy Kelly at TKelly@CFEMedia.com.

Reprints For custom reprints or electronic usage, contact: Brett Petillo, Wright’s Media 281-419-5725, bpetillo@wrightsmedia.com

Publication Sales: See ad index Editorial Advisory Board www.controleng.com/EAB David Bishop, president and a founder Matrix Technologies, www.matrixti.com Joe Martin, president and founder Martin Control Systems, www.martincsi.com Rick Pierro, president and co-founder Superior Controls, www.superiorcontrols.com Mark Voigtmann, partner, automation practice lead Faegre Baker Daniels, www.FaegreBD.com

www.controleng.com

Versatile Panel PC for Industrial Applications

Advantech’s PPC-3000S series of fanless panel PCs are designed to have high computing capacity with low power consumption. In addition, they feature a true-flat resistive touch screen and an ultra-slim chassis (only 48.3mm deep) which allows them to be installed in tight spaces.

The mSATA or 2.5” SSD makes this panel PC rugged with no moving parts and fully solid state. The PPC-3000S is a great choice for the most challenging of industrial environments.

PPC-3060S 6.5” Fanless Panel PC with Intel ® N2807 Processor

PPC-3100S 10.4” Fanless Panel PC with Intel ® N2930 Processor

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PPC-3120S 12” Fanless Panel PC with Intel ® N2930 Processor

PPC-3151S COMING SOON 15” Fanless Panel PC with Intel ® i5-6300U Processor

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PRODUCT EXCLUSIVE adaptive control

Drive solutions for reducing energy costs, increase uptime Allen-Bradley PowerFlex 755T drives from Rockwell Automation are designed to provide harmonic mitigation, regeneration and common-bus system configurations.

R

Rockwell Automation

has launched new drives to help users reduce energy costs and increase machine uptime for assets running in high-demand applications. Allen-Bradley PowerFlex 755T drives are designed to provide harmonic mitigation, regeneration, and common-bus system configurations and are compliant to the IEEE 519 specification.

The latest PowerFlex drive offering marks the introduction of TotalForce technology from Rockwell Automation, said to deliver superior motor control through precise, adaptive control of velocity, torque, and position for electric motors. The three new drive solutions have advanced, predictive diagnostics to estimate and provide notification of the remaining life span of drive components. Users can actively monitor parameters of the drive and motor to allow for preventive action if necessary.

The PowerFlex 755TL drive uses active, front-end technology and an internal harmonic filter to reduce harmonic distortion. The drive is available from 250 to 1,800 hp (160 to 1250 kW).

Delivering power from 250 to 3,000 hp (130 to 2,300 kW), the PowerFlex 755TR drive includes regenerative and harmonic

mitigation capabilities. The drive helps reduce energy consumption and costs by delivering energy back to the incoming supply, resulting adding energy efficiency.

The PowerFlex 755TM drive system allows users to build the system that best fits their needs for regeneration and coordination of multiple motors in common-bus configurations. To optimize system requirements and meet power-consumption needs, users can select from a series of predesigned modules with a power range from 250 to 3,000 hp (130 to 2,300 kW). ce Rockwell Automation, www.rockwellautomation.com Input #200 at www.controleng.com/information

MORE

ADVICE www.controleng.com/products has additional products. Also see the product section in the October 2016 print/digital edition of Control Engineering.

Interested in introducing a product to the world here? Contact Mark T. Hoske, mhoske@cfemedia.com.

Operator panels

The X2 series is the next generation of HMIs from Beijer Electronics. Six product families combine great design with strong performance to power your HMI solutions. Create smart integrated solutions boosted by iX HMI software and WARP Engineering Studio.

Learn more at www.beijerelectronics.com/x2

X2 series Strong. Stylish. Smart.

Find a perfect match for every requirement within a powerful range of more than 23 models with additional options.

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Join forces wITH THE FUTURE OF

GLOBAL MANUFACTURING We Deliver Results in Productivity.

FORCAM provides analytical solutions to complex manufacturing industries through innovative Shop Floor Management technology.

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APPS FOR ENGINEERS mobile connectivity www.controleng.com/appsforengineers

UNSURPASSED STRONG PERFORMANCE!

Mobile applications for engineers

The USB 3 uEye CP with 5 MP Sony Pregius IMX264 or IMX250 sensor

Drive programming, workflow, energy, and time management mobile applications have potential to help engineers do their jobs better. CFE Media’s Apps for Engineers is an interactive directory of engineeringrelated applications for Apple iOS and Android operating systems from various companies. These are in the app as of October 2016.

Altivar Programming Tool iOS 5.1+

SONY

PREGIUS IMX264 & 250

Cost: Free Company: Schneider Electric USA Inc. Website: www.schneider-electric.us This application contains simple menu-driven parameter sets that walk users through the drive configuration process. Digitizing the start-up and programming of a drive streamlines the process, allowing customers to store pertinent drive information in a single location, and facilitates a standard drive configuration throughout a facility.

Infor EAM Mobile Connected iOS 6.0+, Android 4.0.3+ Cost: Free Company: Infor Global Solutions Inc. Website: www.infor.com

USB 3.0 AOI

“Infor EAM Mobile for Phone” provides functions such as View Work Order, Create Work Request with Image, Book Labor, Issue part, View Work Order map and route and others. Infor EAM version 8.5, or higher, is required to work with this version. Network connection is required for the app. A database script may be required to support certain versions of Infor EAM.

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1 SOFTWARE FOR ALL

EQ Energy Efficiency Analzyer iOS 4.0+ Cost: Free Company: Quincy Compressor Website: www.quincycompressor.com

VISION in Stuttgart, Germany: Visit us in Hall 1, Booth 1F72

Calculate the overall efficiency of a compressed air system and identify potential energy savings with this easy five-step process to receive the system’s Efficiency Quotient or EQ Rating. A calculation “worksheet” estimates overall operating costs, system efficiency level and potential savings from having an complete EQ analysis performed. Improve air system efficiency today!

Learn more about the ultra strong USB 3 uEye CP: www.ids-imaging.com/usb3

ExakTime Mobile/PocketClock iOS 7.0+, Android 2.3.3+ Cost: Free Company: ExakTime Inc. Website: www.exaktime.com ExakTime Mobile allows monitoring of hours and activities, checking GPS locations and verifying employee IDs for every time punch, and attaching field notes and photos to job sites for instant viewing at the office.The app automatically syncs with related cloud-based time tracking software, making it easier to manage labor expenses, stay compliant, and improve workforce productivity from any web-based device. Data is easily shared with accounting software.

®

www.ids-imaging.com input #9 at www.controleng.com/information

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CONTROL ENGINEERING

www.controleng.com

Solutions

With our design house

TRACO POWER SOLUTIONS Ltd. we have the facility to expeditiously design customised power supplies and to manufacture prototypes and pre-series.

Our design engineers have access to fully equipped and modern test laboratories. It gives us the opportunity to provide solutions adjusted to special demands in terms of compliance, cost, performance and functionality. We initiate high volume production for effective pricing with our qualified manufacturing facilities in Asia while we supervise the production quality.

Our design competence to meet exigence regarding: • Safety requirements • EMI compliance • Electrical specifications • Form factor, connection, fastening • Mechanical robustness • Thermal resistance • Control features and functionality (logic boards) • Cost /performance optimisation

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input #11 at www.controleng.com/information

With an impressive -40°C to +71°C operating range, the Relio R1 industrial computer is ™

redefining “extended.” Designed to exceed high shock and vibration standards for military, heavy equipment and automation

applications, the Relio R1 operates on ®

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Compact, reliable, and can take the heat: Meet the R1.

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2016 System Integration Turning research into insights makes for better business decisions This study was conducted by Control Engineering to better understand system integration of devices and systems as applied to controls, automation, and instrumentation from the perspectives of the system integrator and the engineer hiring the system integrator.

According to the study the majority of respondents (74%) perform system integration services, either in-house or to third parties, while the remaining 26% hire system integrators for some or all of their projects. Hiring engineering talent for both system integration (49%) and industry expertise (40%) remains a big challenge for system integrators. Other challenges include client relations (38%), a lack of communication skills (35%), and keeping up with changing regulations/codes and standards (33%).

Access the full Control Engineering 2016 System Integration report with additional findings and insights.

www.controleng.com/2016SystemIntegration

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TECHNOLOGY UPDATE supervisory control and data acquisition

Journey to the center of the plant: SCADA returns to the field After the supervisory control and data acquisition (SCADA) software is in place and the system is optimized, system information flows from field instruments to the control room and back.

Users must provide automatic and manual control commands to alter the process.

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To understand the return of supervisory

control and data acquisition (SCADA) to the field, the journey begins at the programmable logic controller (PLC). Reasons for looking at the PLC will become apparent by considering an example of a transmitter measuring a tank’s temperature and a solenoid valve opening to allow steam to pass through a heating coil in the tank to heat its contents. In the example, PLC logic (not the SCADA) controls the solenoid valve.

PLC control logic

Consider that the process operations department is asking for the tank’s temperature to be controlled at 75°C (167°F) with a process temperature variation between 70°C (158°F) and 80°C (176°F). The control is designed according to these parameters: When tank temperature drops below 72°C (161.6°F), turn “ON” the solenoid valve.

When tank temperature rises above 78°C (172.4°F), turn “OFF” the solenoid valve.

Having documented the control parameters, they can be translated into a single-rung ladder diagram (see Figure 1).

The next step is to run a simulation which works as expected. The logic seems to be airtight. But now consider, how will the SCADA interface with and/or interrupt this air-tight logic? Stay tuned.

Preparing the PLC program

The PLC program must be prepared to receive SCADA commands. The first step is to define and document the operator’s involvement with the valve. The operator must: Observe the valve status Have program access to change the valve’s control mode—automatically with the logic or manually from the SCADA screen Have the capability of issuing a manual command to open or close the valve from the SCADA screen.

The second step is to allocate a location in the PLC memory for each function so that when the SCADA wants to do these functions, it has to only www.controleng.com

Figure 1: After documenting control parameters, they can be translated into a single-run ladder diagram. All images courtesy: Shady Yehia, The Control Blog

Figure 2: After allocating memory locations in the PLC for each function, modify the PLC program.

write (or read) information to (or from) these locations. In this case, three memory bits (or internal relays or markers—the name highly depends on the PLC vendor’s manual, but they are all the same) will be allocated. Bits and not words were chosen because these are discrete commands and information. Allocate memory locations as follows: For valve status, allocate M10 For AUTO selection, allocate M11 For Manual Command, allocate M12.

Now it’s time to modify the PLC program (see Figure 2).

Now the updated PLC program is ready to receive SCADA commands. It’s also time to add these new variables to the OPC server. Note that

MORE

ADVICE KEY CONCEPTS To understand the SCADA return to the field, the journey begins in the middle at the programmable logic controller.

It is not advisable to use only the PLC output because in doing so, there could be an unknown actuator failure.

The interface relay is also sometimes called the interposing relay.

GO ONLINE Link to additional online resources, SCADA software, and related content at www.controleng.com/archives, under October 2016.

CONSIDER THIS Ensure all of the planning is done before you embark on the project.

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TECHNOLOGY UPDATE supervisory control and data acquisition

Figure 3: The OPC configuration file is modified by adding three items to the “TANK” group.

Figure 5: The interface relay base, or socket, shown in green, provides the connections to the coil and contacts of the relay. The actual relay, shown in white, contains the coil and contacts, which provide the switching function needed.

Figure 4: The SCADA screen is updated to reflect the changes to the tags’ database including the addition of the mode selection and manual toggle switches.

in actual applications, users mostly rely on an external feedback signal to indicate the actual valve status in the field. It is not advisable to use only the PLC output because in doing so, there could be an unknown actuator failure. This is done here only to simplify the subject.

Modify the OPC server

Note that

Referring to the steps performed in the article, Journey to the center of the plant: SCADA systems information flow, open the ABC OPC server and modify the configuration file by adding three more OPC items to the same OPC Group “TANK.” The configuration should look like the one in Figure 3.

The PLC’s OPC server software can be used to test the required functionality by writing 1s or 0s into these memory bits. After operation is verified, modify the XYZ SCADA software.

in actual

Update the SCADA

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applications, users mostly rely on an external feedback signal to indicate the actual valve status in the

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Back to the SCADA software, first create three new tags in the “Tags Database” for three new variables: Valve_Status Valve_Auto Valve_Manual_Command.

Next go to the graphics editor, open the “Tank” screen, add a valve symbol, set the data source property to the “Valve_Status” tag, and click “save.” Now there is a valve symbol that is changing according to the actual solenoid valve status.

Add a couple of toggle switch symbols to the screen—one for the mode selection and one for the manual command. Link them to the tags, and this is a fully functioning system (see Figure 4).

Run the SCADA, test everything live, and it works like a charm.

What? The valve is not operating? No? Why? CONTROL ENGINEERING

Let me have a look … oh, here you go, you forgot to connect the solenoid valve to the PLC output, wait let me see…

The solenoid valve nameplate says it operates at 220 V ac, and the PLC output module is a transistor type that can only handle up to 24 V dc. This should have been planned from the beginning. But don’t worry. If there is a will, there is a way. This time the way is called the interface relay.

The interface relay

The interface relay is also sometimes called the interposing relay. Now, an interface relay must be installed in the PLC panel. It provides isolation between the PLC output and the solenoid valve, allowing the PLC to operate the relay coil with 24 V dc, and the relay contact will connect the 220 V ac supply to the solenoid valve.

As with normal relays, interface relays have two parts (see Figure 5). The relay base (or socket) provides the connections to the coil and contacts of the relay and an easy way to plug and unplug the device.

The actual relay contains the coil and contacts, which provide the switching function needed.

With the interface relay installed, the solenoid can be controlled using the PLC output Q1.

The SCADA application is fully functional. ce

Shady Yehia is the founder and author of The Control Blog and is the instrumentation, control, and automation proposals and engineering manager in a process technology integration company based in Qatar and operating in the EMEA region. The Control Blog is a CFE Media content partner. Edited by Jack Smith, content manager, CFE Media, Control Engineering, jsmith@cfemedia.com.

www.controleng.com

Find YOUR Integrator Industrial Control and Design (ICAD)

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Industrial Control and Design (ICAD) is a Californiabased control systems integrator providing worldclass process control systems to customers in Joel Ratto, General Manager food & beverage, chemical Telephone: (559) 498-0290 processing, water and Email: jratto@icadautomation.com high-tech markets since 1991. ICAD offers a full Primary Industries suite of services including Chemical Processing controls design, on-staff Food & Beverage PE stamped electrical Water engineering, PLC/HMI programming & UL508A panel assembly. Installation services are also available through our sister company, Lighthouse Electrical. We pride ourselves on service and after sales support with live 24/7 support for all of our customers. We do not strive to be the biggest; we strive to be the best!

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INSIGHT IT and engineering

Tips on determining what is IT, OT Companies determining what systems belong to information technology (IT) organizations and to operations technology (OT) organizations should focus on what the systems do rather than what they are to resolve potential conflicts. OT/IT cooperation helps Industrial Internet of Things connectivity.

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The continuing conflicts between information technology (IT) organizations and operations technology (OT) organizations are not going away, and it doesn’t look like there will be negotiated peace any time soon. The conflicts are taking place in many medium and large manufacturing companies. IT support organizations are taking responsibility for all computer systems, regardless of use. Support is being centralized in organizations that have little understanding of autoDennis Brandl mation and OT requirements.

President of BR&L The only systems that are exempt from IT conConsulting trol are programmable logic controllers (PLCs), distributed control system (DCS) servers, and clients, but everything else seems fair game for IT ownership. Meaningful OT/IT cooperation helps Industrial Internet of Things (IIoT) initiatives.

Most centralized IT organizations will set up a separate priority system for handling production-stopping problems on production equipment. However, IT Granting OT a portion of the work required to support the normal day-to-day development work IT budget used to purchase, on process improvements, supporting new products, and supporting install, and maintain systems new work processes usually falls into the IT “we’ll get to it when we is the only way to bring the have time” bucket. advances in information This often leaves the automation organization in the unfortutechnology into operations. nate position of appearing to hold up new product introductions, process improvements, and changes to standard work.

This leads to the conflict, as the automation group tries to do their job but is continually stymied by IT policies. Often an “underground” OT organization develops, which leads to “creative” solutions for the problems. These creative solutions result in additional conflict when IT management discovers the workarounds.

The cause of the problem is the rule used to MORE determine what is under the control of IT: “Is it a computer (server or client), and can we pick the ADVICE hardware, O/S, and database?” If the answer is yes, GO ONLINE then IT owns it and is responsible for buying it, At www.controleng.com/archives, installing it, and servicing it. DCS servers and clifind more info under this headline. ents are often exempt from IT control because the At www.controleng.com, search related topics. vendors determine the hardware and infrastructure.

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CONTROL ENGINEERING

It would be difficult to design a less effective organization or one that would produce more built-in conflicts. The ownership rule needs to change. Responsibility for systems should not be based on what the system is, but what the system does. If the system supports activities that are critical to plant safety, critical to plant reliability, critical to plant operational efficiency, critical to product quality, or critical to maintaining product, safety, and environmental compliance, then the entire system should be under the responsibility of the operations department. This includes data historians, data analysis systems, manufacturing execution systems (MES), and laboratory information management systems (LIMS).

OT needs some of the IT budget

This will require many changes, starting with granting OT a portion of the IT budget used to purchase, install, and maintain the systems. This is a radical change for most companies, but it is the only way to bring the advances in information technology into operations. It means that IT organizations, within manufacturing companies, need to give up some of their budget to OT. A change this sweeping must come from the CEO level and can only happen when the company’s executive management is aware of the incredible costs and losses associated with their current way of doing business.

It is not a matter of operating under the same rules that created the current conflict. As Albert Einstein said, “No problem can be solved by the same kind of thinking that created it.”

The conflict between IT and OT will not go away by just moving all OT functions into the IT organization because OT will get lost in the everyday work of IT. Executives need to realize that the solution is to give OT organizations a seat at the table rather than creating more underground organizations. Those that don’t will fall far behind as other organizations apply the new technologies into manufacturing and reap the benefits. ce

Dennis Brandl is president of BR&L Consulting in Cary, N.C., a firm that focuses on manufacturing IT. Find more advice by searching “Brandl” at www.controleng.com. www.controleng.com

TIA Portal – more than an engineering framework

Reduce your time-to-market

Integrated engineering in the Totally Integrated Automation Portal (TIA Portal) substantially shortens development times.

Time-to-market is greatly reduced thanks to coordinated work in the interdisciplinary teams and the automatic generation of automation solutions instead of manual programming. That makes the TIA Portal the perfect gateway to automation in the Digital Enterprise.

input #13 at www.controleng.com/information

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CONTROL ENGINEERING international

Intelligent manufacturing, three layers Use of the Internet with manufacturing has evolved for more than 10 years and continues with advancements in industrial cloud, Industrial Internet of Things (IIoT), and Big Data, as manufacturing upgrades progress, explained Mitsubishi director Nan HeHao to Control Engineering China.

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The tide of Industrie 4.0 with intelligent manufacturing at its center is sweeping global manufacturing. The Chinese government is making efforts to boost and upgrade the transformation with integrated development of manufacturing and the Internet. As a factory automation manufacturer, what will Mitsubishi Electric do to realize the future “Intelligent” manufacturing? At the recent “Industrial Automation and Standardization” seminar, Control Engineering China interviewed director Nan HeHao of the e-F@ctory Promotion Department of Mitsubishi Electric Nagoya Laboratory.

Manufacturing intelligence, 3 layers

Industrie 4.0 and related initiatives fit nicely with Mitsubishi e-F@ctory concepts, as explained by director Nan HeHao of the e-F@ctory Promotion Department of Mitsubishi Electric Nagoya Laboratory.

Courtesy: Control Engineering China, Mitsubishi Electric

MORE

ADVICE GO ONLINE See other Control Engineering international articles at www.controleng.com/international.

Control Engineering China’s website: www.cechina.cn.

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Industrie 4.0 has not been clearly defined by many experts and manufacturers. HeHao said Mitsubishi Electric has centered its understanding of Industrie 4.0 with intelligent manufacturing. The intelligence should be in mass production of the manufacturing site and extended and optimized through the industrial value chain. HeHao said manufacturing intelligence includes three layers.

1. Intelligence- and information-based capabilities should extend beyond manufacturing to higher level systems.

2. Beyond mass production, coordination is required through the entire business flow and system from design through mass production.

3. More than within the company, intelligencebased and information-based operations also should include suppliers and contractors qualified to participate in supply chains.

HeHao explained, “Before the implementation of intelligent manufacturing, first, the purpose should be clarified: improving productivity, enhancing production quality, or lowering the production cost. Intelligence cannot be made just for the purpose of intelligence.”

HeHao said Mitsubishi can offer technology for full production line automation, but automation and robotics may not suit all processes. Sometimes human-assisted operations may better fit the application; designs and associated costs should meet the identified needs.

Mitsubishi Electric offers technologies for realizing all three layers of manufacturing intelligence.

Information can be shared seamlessly between the production site and upper systems. HeHao said

CONTROL ENGINEERING

different information is required for different layers in the production site and IT systems (such as production management and business support backbone systems). Especially on the IT system side, data required usually is not the same as production equipment data. Summarized data is required based on units, such as lines or factories.

With Mitsubishi e-F@ctory solutions, information sharing groups for the intermediate layer (factory automation and information technology) bridge the production site and the IT systems.

For the second layer, from design to mass production and then to business flow and system sharing, HeHao said setup tools include computer-aided design (CAD), computer-aided manufacturing (CAM), computer-aided engineering (CAE), simulation software, and analysis tools. The universal interface platform EZSocket from Mitsubishi connects software tools, allowing easier sharing of data between tools or between equipment and software tools, which can greatly improve the design efficiency of each link of the engineering chain.

For the third layer, HeHao said that extending overall intelligence beyond the company involved requires attention to all parties in the manufacturing value chain, such as the equipment manufacturers, design software manufacturers, and system integrators. Intelligence and digitalization should be extended to supplying manufacturers.

“With the continuous development of e-F@ctory for several years, we’re heading for the effective utilization of the collected visualized data,” which HeHao called a “perfect match for Industrie 4.0.”

The e-F@ctory requires sensing, data collection and analysis, transmission based on an interlinked network, and coordination of upper-level systems, such as the cloud, manufacturing execution systems (MES), and enterprise resource planning (ERP).

These efforts fit with the trend to integrate “Made in China 2015”and “Internet+” initiatives from the Chinese government. HeHao said the efforts will bring about a new generation of intelligent manufacturing by coordinating the digital space, machinery, and human activities. ce Stone Shi is executive editor-in-chief, Control Engineering China; edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com. www.controleng.com

INDUSTRY NEWS and events Your Global Automation Partner

Sixth and seventh graders showcase their engineering products at the 2016 ChiS&E Summer Math & Science Enrichment Program closing ceremony.

Image courtesy: Joy Chang, CFE Media

Future engineering students showcase projects A group of sixth and seventh grade students from the South and West sides of Chicago demonstrated algebra skills and engineering projects among 150 parents, teachers, and friends. Students spent some of summer vacation in the Chicago Pre-College Science & Engineering Program (ChiS&E) Summer Math & Science Enrichment Program. Curricula focused on algebra, computer science, and engineering design. Students received handson computer programming and learned about advanced algebraic concepts in the 4-week program.

The summer program is designed to prepare sixth and seventh graders for science, technology, engineering, and mathematics (STEM) education and careers.

Kenneth Hill launched the program in 2008, and the mission of ChiS&E is to provide hands-on education and experience to increase the number of students from historically underrepresented communities to be motivated and academically competitive to pursue careers in STEM. With growing support and donations from the industry and community, ChiS&E is planning on expanding its program further into higher grades and develop a sustainable learning path for students. ChiS&E provides free programs for Little Civil Engineers (kindergarten), Little Chemical Engineers (first grade), Little Electrical Engineers (second grade), Little Mechanical Engineers (third grade), and www.controleng.com

Little Structural Engineers (fourth grade).

After third grade, students participate in this Summer Math & Science Enrichment Program at the University of Illinois-Chicago. The most recent evaluation determined that after 3.5 years, there has been a 90% retention rate among students.

Endorsement from UIC chancellor

CFE Media interviewed Michael Amiridis, the Chancellor of the University of Illinois-Chicago, on Aug. 5 about the importance of early education and the chancellor’s view on the future of STEM education. Amiridis praised the ChiS&E program for focusing on fundamentals, creating a path where students can keep learning during K-12 education, and allowing parents to learn alongside students.

“This program focuses on the right elements. First of all it really stressed the fundamentals. To be successful in the STEM field, you need the foundation. The second element for success is persistence. The program indeed follows students over a number of years. It’s not like parachuting in and hoping to resolve the problem. This program stays with the students for a period of time. The third element that’s important is the involvement of the parents. It’s important for the parents to buy in the ideas and support the students,. You can both win,” Amiridis said.

Joy Chang is digital project manager at CFE Media, jchang@cfemedia.com.

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INDUSTRY NEWS and events

Hybrid machines, democratization help grow additive manufacturing Additive manufacturing (AM) has made many technological improvements, which have allowed for larger and more productive machines. These developments should encourage machinists and designers to try new concepts that will allow to be democratized, said Greg Hyatt, senior vice presHybrid machines can ident and chief technical officer include additive manufactur(CTO), DMG Mori, in his presentaing (AM) and subtractive tion “New Approaches to Additive manufacturing (SM) capabiliManufacturing” at the Internationties in the same machine and al Manufacturing Technology Show perform operations simul(IMTS) on Sept. 13. Hyatt said that taneously. Image courtesy: his company “Started looking at Chris Vavra, CFE Media additive manufacturing and asked, ‘What were the enabling technologies, and what could we do to help improve the process?’” and that this is a process many companies involved in additive manufacturing are pursuing to improve production.

Hyatt said that democratizing AM requires: Cost reduction (faster deposition), measuring weight in kilograms rather than grams per hour. Work needs to be measured in meters rather than centimeters.

The ability to build on existing structures by leverage castings, forgings, plate, or bar to reduce the mass of product being built as well as cycle times.

Integration of subtractive processes during the machine build.

Bimetallic builds and graded materials, so different components can be made from different alloys during production.

Better software. A common computer-aided manufacturing (CAM) system that can be easily used and understood by the machinist and the designer is crucial.

Hyatt said a hybrid machine can include additive and subtractive manufacturing (SM) capabilities in the same machine and perform operations simultaneously. Hyatt gave examples of how it can reduce residual stress and keep separate parts from moving around during the machining process, which can slow production.

Hybrid machines can aid assembly that involves multiple alloys.

Hyatt said that willing partners are essential. With additive manufacturing and hybrid machines, Hyatt stressed that the process still requires a lot of testing to confirm design and implementation, given how complex the process can be. Most of these developments are are not in mass production; still Hyatt is pleased with the results so far. “Are we there yet? I hope so,” he said. “I hope we’ve determined what technologies are needed to realize and achieve AM’s potential for the future.”

Chris Vavra, production editor, Control Engineering, cvavra@cfemedia.com.

See more from IMTS 2016 at www.controleng.com.

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Digital edition? Click on headlines for more details.

See news daily at www.controleng.com/news

Your Global Automation Partner

Appealing to the next generation of manufacturing workers

A

recent survey inquired about the 2. Meaning. More than previous generashortage of a “skilled workforce” in tions, millennials want to know their work manufacturing. Though the survey’s has meaning. They want to see in real time basic premise, which addressed training how their contribution is making a differand recruiting, is valid, the survey questions ence to operations and expect visibility into missed a major component. their own performance. They are inspired The issue regarding the manufacturing with stories on how a factory’s products are workforce isn’t education, training, or bethelping people. ter incentives—it’s people. The real issue 3. Technology. While we all hold techis that a whole generation of workers has nology in our hands daily that allows us to a desire to be part of this new dynamic and communicate over the phone, take a piccomplex workplace that differs from the ture, or summon a product, this is all millenfactory environment of former generations. nials know. It’s standard to them. The same The prior generations of should go for their work, factory workers were the they assume. By putting “get it done” workforce. technology in their hands With real-time The work culture required that gives them real-time information, they’ll information, they’ll be able everyone to perform the same way with limited be able to make to make decisions, solve interruptions. Uniformity problems, and contribute decisions, solve and conformity got the job in real time. They want done. This adage still holds conditions where plant problems, and fast within too many minds floor teams meet, solve past and present. contribute in real problems, collaborate, and With the millennial decide—not in just meettime. workforce, we venture into ing places, but within the new territories of societal processes and tasks. evolution powered by emotionally driven 4. Leadership. Millennials don’t necescareer choices. Millennials’ opportunisarily just want to have fun at work—they ties are enhanced through technology to want to see and experience good leaderadvance interpersonal communication, ship and the opportunity to serve in increassocialize, network, and interact. ingly bigger ways. Millennials want to For work environments, millennials seek show leadership and earn opportunities to opportunities to innovate, improve, and advance when they feel they’ve contributed change more immediately. Millennials seek instead of “paying dues” over time. places where they feel significant and can It is vital for companies to create a plant be seen as an individual and be part of the floor culture that encourages human input team and acknowledged for their value. and interaction; sends a wave of hope and Millennials are full of creative imaginaenthusiasm; and implants a sense of pride, tion and are untethered by limitations, ownership, and belonging. which is ideal for manufacturing right now.

The only way to make this profitable and Manufacturers have one simple task: create sustainable culture happen is to build its the environment to attract them. environment. Motivate new skilled workers Manufacturers should focus on: to become part of this faceted and dynamic 1. Immediacy. The millennial workforce industry so manufacturing can survive and wants things to happen or change right prosper. If you build it, millennials will come. away. They have immediacy in so many ways in their life—from on-demand to Keith Barr is president and CEO of Leadinstant analytics—so why can’t they have it ing2Lean, a CFE Media content partner. at work? Factory equipment, processes, and Edited by Chris Vavra, production editor, CFE data reporting need to be up to date.

Media, cvavra@cfemedia.com.

‘

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OCTOBER 2016

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Custom Connectivity Whether it’s a harness with custom wiring topology or a custom cable color for a standard connector, Turck’s expertise creates your best solution.

Call 1-800-544-7769 or visit info.turck.us/connectivity input #16 at www.controleng.com/information

INDUSTRY NEWS and events

Testbed: sensor data to the cloud The Industrial Internet Consortium (IIC) has approved an IIC testbed on sensor-to-the-cloud connectivity called the Smart Manufacturing Connectivity for Brownfield Sensors Testbed. IIC members TE Connectivity, SAP, ifm, and the OPC foundation are carrying out this testbed. The idea for the testbed was publicly unveiled at the Hanover Fair in April 2016.

The objective of sensor-to-the-cloud connectivity is to make sensor data available to information technology (IT) systems in near real time, enabling advanced analytics. This is of particular interest to operators of existing manufacturing facilities, as it provides them with opportunities to increase efficiencies through reductions in energy consumption. Unlike new deployments, where the appropriate connectivity may be designed in from the beginning, smart solutions are required for these “brownfield” installations to enable easy integration at both the operational technology

(OT) and the IT level to reduce downtime and save costs.

The Smart Manufacturing Connectivity for Brownfield Sensors Testbed is designed to: Introduce a retrofit hardware solution (the “Y-Gateway”) that makes use of existing physical connectivity Extract sensor data from the automation system without impacting operations Deliver the sensor data to SAP’s IT platform through a secure OT/IT communication based on OPC UA (IEC 62541) Define and implement a common device model based on an available open standard to allow for the easy integration of an IO-Link sensor with IT, enabling the remote configuration of the sensor.

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input #17 at www.controleng.com/information

“Testbeds are a major focus and activity of the IIC and its members”, said Richard Soley, IIC executive director.

“Our testbeds are where new technologies, applications, products, services and processes—the innovation and opportunities of the industrial Internet—can be initiated, thought through and rigorously tested to ascertain their usefulness and viability before coming to market.”

Edited from a TE Connectivity press release by CFE Media.

Merger between information companies completed

D

ell Technologies announced the completion of the acquisition of EMC Corp. for $67 billion. The merger creates a family of businesses designed to provide infrastructure for organizations looking to expand their digital network and information technology (IT) assets. This combination creates a $74 billion market leader with an expansive technology portfolio that solves complex problems for customers in the industry’s fast-growing areas of hybrid cloud, software-defined data center, converged infrastructure, platformas-a-service, data analytics, mobility, and cybersecurity.

Michael Dell, chairman and CEO of Dell Technologies, said, “We are at the dawn of the next industrial revolution. Our world is becoming more intelligent and more connected by the minute and ultimately will become intertwined with a vast Internet of Things (IoT) paving the way for our customers to do incredible things.”

The Dell client solutions business and the Dell EMC infrastructure solutions business are both supported by Dell EMC Services. In addition, Dell Technologies contains Boomi, Pivotal, RSA, SecureWorks, Virtustream, and VMware. This structure is designed to combine the focus and innovation of a startup with the scale and service of a large enterprise.

Dell Technologies’ scale will enable it to deliver more innovation and investment in R&D, sales, services, support, and solutions for customers.

Edited from a Dell Technologies press release by CFE Media.

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Digital edition? Click on headlines for more details.

See news daily at www.controleng.com/news

More headlines online Industry events At www.controleng.com, on the right side, click on the events box and scroll by month to see related industry events including: The Assembly Show, Rosemont, Ill., Oct. 25-27 www.theassemblyshow.com Pack Expo and Pharma Expo, McCormick Place, Chicago, Nov. 6-9 www.packexpointernational.com Automation Fair 2016, Atlanta, Ga., Nov. 9-10 www.rockwellautomation.com/global/events/ automation-fair/overview.page SPS IPC Drives, Nuremberg, Germany, Nov. 22-24 www.mesago.de/en/SPS/

System integrator acquired by automation company Rockwell Automation has acquired systems integrator company Maverick Technologies in an effort to expand its control and information solutions. Maverick, with 21 U.S. locations, said in a statement that it would remain platform-independent.

Researchers learn that 3-D printed structures remember their shapes Engineers from MIT and Singapore University of Technology and Design (SUTD) learned that three-dimensional structures return to their original shapes even after being stretched, twisted, and bent at extreme angles.

Power market projected to have modest growth IHS Markit projects that the merchant power supply market will continue to grow with the ac-dc non-commodity market having the most growth over the next several years.

Rugged Precision The MAQ®20 Industrial Data Acquisition & Control System

Top 5 Control Engineering articles Sep. 19-25: The most visited articles included level instruments, piezoelectric measuring, PID control and loop tuning fundamentals, motor efficiency standards, and process control simulation benefits.

Manufacturing index slides in August The Purchasing Manufacturers’ Index (PMI) fell 3.2 points to 49.4% due to a general slowdown in the manufacturing industry.

IT, OT teams need to work together Information technology (IT) and operations technology (OT) experts agreed that both sides can learn from one another and need to be willing to share and open up so both sides can benefit.

Automation president testifies at Congressional subcommittee hearing on advanced robotics Jeff Burnstein, the president of the Association for Advancing Automation (A3), testified before the House of Representatives subcommittee on commerce, manufacturing, and trade on how the current state of robotics is impacting the economy as well as trade and commerce.

Signal Integrity, Compact Design 2 Software Packages for DAQ or T&M • $17 per Channel Possible – Lowest Cost in Industry • Up to 384 Channels in 19” Instrumentation Rack • Application Software from $250 • ±0.035% Accuracy

Technical college opens manufacturing innovation center Greenville Technical College (GTC) has opened the Gene Haas Center for Manufacturing Innovation (CMI) to bring more skilled workers into the manufacturing industry.

• 1500Vrms Channel-to-Bus Isolation

For much more IMTS and GAMS coverage, search either word at www.controleng.com.

• –40°C to +85°C Operating Temperature

CONTROL ENGINEERING

OCTOBER 2016

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• PID Software Control - Up to 32 Loops with ReDAQ® Shape - Unlimited Loops with IPEmotion Instrument Class® Signal Solutions dataforth.com • 800-444-7644

input #18 at www.controleng.com/information

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Modifying Electrical Enclosures to Fit Every Application Lindsay Hartman | Corporate Sales Coordinator, Allied Moulded Products, Inc.

Electrical enclosures house a tremendous variety of electrical components, monitors, and machinery.

They are utilized in industries as diverse as telecommunications and wastewater treatment; and from solar power to security systems. Due to the breadth of applications that electrical enclosures must protect, the ability to easily and affordably modify electrical enclosures is increasingly important for OEMs and panel shops.

To meet this demand, enclosure manufacturers continue to invest in equipment capable of handling these modifications, as well as customer support personnel who can aid product engineers in designing the enclosure that best meets their needs.

protection. Nonmetallic enclosures make it easy and affordable for customers to get exactly what they need with every order. Whether its custom cut-outs, silkscreened logos, or electromagnetic shielding, make sure to discuss modification capabilities with your enclosure providers and get protection designed specifically for your application.

Nonmetallic enclosure providers are best equipped to provide modification capabilities at a competitive price due to the ease of handling, drilling, and cutting molded fiberglass-reinforced-polyester and polycarbonate materials. Factory-provided modifications can include:

• • • • • • •

Custom Holes & Cut-Outs Factory-Supplied Silk-screening

Download the paper: www.alliedmoulded.com/ media/1427738/White-Paper_Modifications.pdf

Color-Match Molding Custom Panels & Windows EMI/RFI Shielding Engineering & Customer Support Modification Ownership

Electrical enclosures need to be as diverse as the systems and applications that rely on them for

sales@alliedmoulded.com www.alliedmoulded.com

input #19 at www.controleng.com/information

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PLCs and PACs Simplify Data Acquisition Jeff Payne | Product Manager, PLC, I/O and PC-based Controls In today’s competitive market, companies need detailed and timely information about process variables, and production amounts, as well as alarms in real time. In the past, PLCs did not have the capabilities to provide such information, and PACs were not yet widely available.

Fortunately, newer PLCs and PACs can perform many data acquisition tasks within the controller, giving businesses a low cost, easier method for advanced, real-time data collection as compared to proprietary or stand-alone data acquisition systems.

Many of these PLCs and PACs are full-featured systems that can provide both control and data acquisition for existing I/O. Moreover, additional I/O can be added to acquire data from areas that do not require control, only monitoring.

Data logging can be triggered by an event within the process or scheduled to occur at regular intervals.

Data transfers from the controller to other systems are typically done by an Ethernet port, which comes standard with most new PLCs and PACs. Popular protocols are also supported, eliminating the need to write complex drivers for the transfer of data from the controller to external systems.

Modern PLCs and PACs perform basic data acquisition as part and parcel of real-time control tasks. This double duty approach ensures the lowest overall cost, smallest footprint and simplest data acquisition systems.

Download now: http://library.automationdirect.com/plcs-and-pacs-simplify-data-acquisition/

sales@automationdirect.com • 1-800-633-0405 www.automationdirect.com

input #20 at www.controleng.com/information

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Connecting the potential of Industry 4.0 with real manufacturing Bosch Rexroth Corporation

Bosch Rexroth explores how today’s manufacturers can begin to translate Industry 4.0 concepts into practical production technologies. Bosch Rexroth sees Industry 4.0 as a rapid transformation, where the virtual world of information technology, the physical world of machines and the Internet become one. In this world, open web-based platforms create the foundation for keeping companies competitive and responsive, while creating new opportunities. Industry 4.0 technologies can improve a manufacturer’s flexibility and speed, enabling more individualized products, efficient and scalable production, and greater production control. It can also enable small-scale production of single lots alongside mass production, as well as optimized processes and inventory stocks through real-time information.

Bosch Rexroth has identified five key factors in bringing about a true Industry 4.0 manufacturing environment. The first is Decentralized Intelligence, or distributed intelligence, in which intelligent drive and control technologies network with other devices with decentralized autonomy. This gives machines the capacity to make event-specific or product-specific adjustments in real-time. Another factor is Rapid Connectivity, in which systems facilitate instant vertical or horizontal connectivity, allowing data to flow freely across the enterprise structure.

A third factor is Open Standards and Systems, which allows more flexible integration of software-based solutions and migration of new technologies into existing automation structures. Bosch Rexroth’s Open Core Engineering (OCE) platform is a significant step in this direction. The fourth factor is Real-time Context Integration, using real time machine and plant performance data to execute rapid process and production changes in order to make products for specific customer needs.

The final factor is Autonomous Behavior, with the goal of designing workstations and modules that can adapt to individual customer or product needs.

According to Bosch Rexroth, much of the technology for Industry 4.0 is already in place. Through the smart use of pilot projects and step-by-step changes in manufacturing platforms and operations, we can all determine the best ways to make Industry 4.0 deliver on the promise it offers.

Download the paper at: www.boschrexroth-us.com/i40potential

input #21 at www.controleng.com/information

info@boschrexroth-us.com www.boschrexroth-us.com

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How to Acquire the Best Application Advantage MICROMO and Motor Consultants, LLC

Brushless DC motors are used worldwide for their basic benefit of optimizing performance per package size – no other technology can match it. In addition, brushless brings tremendous advantages to many applications, combining the best features and benefits of past successful designs while also incorporating additional, unique advantages.

Industry Pushed Developments At the dawn of the industrial age, the predominant machine was the AC induction motor, which is basically a constant speed device. Thus when applications required different speeds, the pulley would be changed, resulting in significant production down time - due to the excessive time required to change pulleys. The industry needed a more efficient method to attain different speeds.

with permanent magnets the field remains constant, this provides linear and predictable speedtorque characteristics, i.e. speed is dependent upon applied voltage, and torque delivered is dependent on current. Since PM (permanent magnet) torque/current relationship provides high torques, these motors are used in applications where accurate positioning control exists.

Brushless Motor Technology The next motor technology enhancement was the brushless DC motor. This design has tremendous advantages; it combines the best benefits of both AC and DC designs plus brings its own unique advantages to applications. It combines the long life of the induction motor and linearity of the permanent magnet motor, plus adds higher speed range capability (productivity), size weight reduction (compact design), and improved torque capability (precision). Therefore it provides machine designers with a competitive edge in their marketplace by increasing production capability, improving machine reliability and increasing life.

Download the paper at: https://goo.gl/elC11D

Brush & Permanent Magnet Motors It wasn’t until the development of the DC motor that this would be accomplished. By simply changing the applied voltage, motor speed could be varied. DC motors remain in use today in applications needing variable speed control. The next design was the PM (permanent magnet) DC motor. Since the stator field is generated

www.micromo.com marketing@micromo.com

input #22 at www.controleng.com/information

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How to Modernize Your Factory on Your Terms Jim Wilmot | Controls Product Manager, Siemens Underperforming automation systems can compromise productivity and profits Downtime is a plant’s #1 enemy. Thus, many manufacturers are contending with outdated or insufficient automation systems and components that are compromising productivity. The time to modernize is now! But manufacturers may still hesitate to invest in their automation systems because they fear downtime during changeover, the need for more staff training, having to convert existing code or taking a hit to their budgets.

To avoid these challenges, manufacturers should seek automation solutions that have integrated functionality and are engineered to migrate seamlessly into future technologies to lower their total cost of ownership. These solutions should be based on a single engineering framework that seamlessly integrates controllers, distributed I/O, HMI, drives, motion control and motor management using a common database as well as integrated security, safety and diagnostics.

Is staying with your current vendor the best choice?

While it may seem like the least painful route is to upgrade components from a current vendor, it may not be the best option for manufacturers. Many vendors have dead-ended or are phasing out legacy hardware, and no spare parts are available.

Some vendors may offer more advanced versions of obsolete parts, but manufacturers may still need to convert their code to new programming software.

A total systems approach or individual component replacement?

Manufacturers have two options when deciding to modernize their production: a total systems approach or individual component replacement. A total systems approach is best for manufacturers that want the full benefits of totally integrated automation — a necessary step to integrating your entire value chain, from design and engineering, to sales, production and service. When total replacement is not feasible, manufacturers should seek advanced automation components that can easily integrate with existing systems while providing additional functionality.

Doing nothing can compromise your competitiveness When it comes to modernizing, manufacturers have installation options to match their production and budget requirements – enabling more informed decisions for greater flexibility and competitiveness.

James.Wilmot@Siemens.com www.usa.siemens.com/modernize Register to download the paper at:

www.industry.usa.siemens.com/topics/us/en/modernization/resources/Pages/Modernize-White-Paper.aspx input #23 at www.controleng.com/information

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Considering a Smart Camera?

Keep These 5 Features in Mind Christopher Chalifoux International Applications Engineer, Teledyne DALSA Unlike PC-based vision systems—with their distinct cameras, frame grabbers, and I/O boards—today’s smart cameras incorporate embedded lenses, processors, software, I/O capabilities, and sometimes even lighting in an “all-in-one” package that can simplify and streamline the integrationand deployment of machine vision systems.

Combine this with a small form factor and cost-effective price point, and it is easy to see why smart cameras are being used in many new application deployments, as well as in existing machine vision processes, from barcode reading to object recognition, and process monitoring to quality control.

Before you invest in a smart camera solution, however, it is critical to understand how you’ll use the data the application provides; the environment in which your vision system will operate; the expertise level of the team that will program, use, and maintain the system; and even the budgetavailable to invest in the system and its deployment.

Some applications are better suited to one type of vision system versus another. Once the goals for the application you are planning to deploy have been clearly established, you can refine your thinking about which camera solution will bemost ideally suited to achieving your goals.

There are five important criteria to keep in mind as you consider whether a smart camera system is the solution you need.

Download the paper at goo.gl/bc4gaU

sales.ipd@teledynedalsa.com www.teledynedalsa.com

input #24 at www.controleng.com/information

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Top Considerations When Designing an Ergonomic Control Room Winsted

Defined as “the science of fitting workplace conditions and job demands to the capabilities of the working population,” by the Occupational Safety and Health Administration, ergonomics sounds like a simple match game between the employee and work conditions. However, with all the factors that affect control room ergonomics, it has become more about designing the console around the employee.

To truly satisfy today’s heightened ergonomic standards, console design has experienced a dramatic shift to deliver solutions that are smaller, with improved functionality and more appeal than ever before.

Current console design is done with a more comprehensive, top-down approach to control room planning, examining every element of the console itself, as well as the overall layout of the room. Control room planners are now incorporating every aspect of human, machine and environment interaction, from monitor tilt and indirect lighting to air temperature and movement, to create the optimal working conditions and comfort level.

Consoles have extensive functionality advantages over basic office furniture.

A control room acts as a person’s “eyes and ears,” making the design of it extremelyimportant. When designing a control room, it’s critical to consider all factors. This white paper provides a comprehensive overview of control room design considerations, including room architecture, furniture, environment and operator requirements. It also discusses the advantages of console over office furniture within a control environment.

Download the paper: www.controleng.com/index.php?id=15663

eMail: info@winsted.com • www.winsted.com

input #25 at www.controleng.com/information

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Reliable VFD Cables Boost Productivity, Minimize Downtime John Gavilanes | Director of Engineering, Lapp Group NA From fans and blowers to 24/7 production line equipment, variable frequency drives (VFDs) are a mainstay of the industrial world due to their remarkable ability to improve the efficiency of motor-driven equipment. As part of a complete VFD package, high quality cable is one of the most important components in terms of achieving maximum productivity and minimizing downtime. When designing a robust VFD cable, the materials used in its production are critical to ensuring that the cable’s electrical properties will guarantee peak performance. For system engineers and others involved in specifying VFDs, cable quality should be one of the most decisive factors..

The cable itself is often considered the most critical component of the VFD system. In order to protect cables from power distortions during rectification, the 2015 National Electrical Code (NEC) requires the size of source power conductors to be 125% of the drive’s full load current. Although filters, reactors and isolation transformers can be added to the drive to clean off harmonics, these can cause additional voltage drops from the power supply. Due to these and other issues, cable materials can make a big difference in the lifetime and reliability of the overall VFD system.

Download the paper here: http://landing.lappusa.com/VFDWP2016_PE ce201610_whitePpr_lappHLF.indd 1

sales@lappusa.com www.lappusa.com

input #26 at www.controleng.com/information

9/9/2016 1:35:36 PM

DIGITAL REPORTS 2016 D igital R epoRt IIoT

It's clear by now that the Industrial Internet of Things (IIoT) is a transformative manufacturing strategy that will improve operations, reduce cost and increase quality and safety. This digital report is one of the many ways CFE Media will educate audiences on the importance of IIoT. To view and download this digital report visit:

www.controleng.com/DigitalReport/lloT Sponsored by:

CE_DigitalReport_HalfHorizontal_IIoT.indd 1

7/25/2016 12:02:53 PM

COVER STORY Big Data

Finding the right tools to delve into process data New tools beyond the spreadsheet are needed to empower process engineers to derive insights from the data being transmitted. Big Data analysis helps enable Industrial Internet of Things (IIoT).

MORE

ADVICE KEY CONCEPTS More data is being produced; more of it is unused, widening the gap.

Modern replacements for the spreadsheet must contain all spreadsheet features and characteristics.

Process engineers need to be on the front lines in closing the data gap.

GO ONLINE Go to www.controleng.com to see additional stories about Big Data and process engineers. See the IIoT page.

See other Big Data and IIoT articles in this issue.

CONSIDER THIS What other features should a spreadsheet replacement have?

D

ata collected and stored by process manufacturing organizations can reach terabytes daily, hourly, or by the minute. Much of this data isn’t used or leveraged to improve plant operations.

According to Gartner, 70% of data collected isn’t used for analytics or insight. McKinsey & Co. documented scenarios closer to 99% (see Figure 1). This is reflected by the reality known as data rich, information poor (DRIP) where users and organizations are drowning in data while desperately needing information at the same time (see Figure 2).

How can this be? This is an important question for process manufacturing organizations. Delivering “actionable intelligence” has been a constant message for process analytics over the last two decades.

A cloud of acronyms and, more recently, cloud computing, have been proposed as solutions to close the gap between data and insights. Even “Big Data,” an expression that dates back to the 1990s,

hasn’t made a dent in the issue. Instead, more data is being created, and more is being unused.

Process data benefits

It is helpful to consider who in a manufacturing facility is most responsible for process data insights and who receives related benefits. The obvious answer is the process engineer, a proxy for the engineering professionals within a production facility.

They have titles such as plant automation engineer, head of distributed control system (DCS) manufacturing, and principle asset process specialist.

Despite different titles, what ties them together is that they are experts in their organization’s assets and processes. They know what to look for and which data sets are relevant for analysis. Process engineers represent the front line of employees with the ability and incentive to leverage production data to improve outcomes in quality, yield, and margins.

Figure 1: The management consultant firm McKinsey & Co. has documented cases where up to 99% of collected data goes unused.

Courtesy: McKinsey & Co.

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Another consideration is the tools process engineers rely on to find insights in process data. The most common bridge between data and insight for process manufacturing organizations is an engineer and a spreadsheet. Every historian offers a connector to a spreadsheet to help facilitate the investigation of time series data from production equipment.

Data acceleration

Accelerating data use must enable and facilitate the process engineer’s work. This approach contrasts with many proposed innovations to the DRIP issues—Big Data, machine learning, advanced statistical packages—that focus on use and implementation by software architects, programmers, and data scientists. This is an odd miss in an environment where the engineer has the critical context in the plant and operations to derive insights from the data. The engineer should be the first rather than the last focus for production insight tools.

A solution also must address and/or upgrade the key capabilities offered by spreadsheets that have caused them to remain the engineer’s tool of choice for the last 30 years. Spreadsheets have become popular, and any next-generation solution to accelerate and close the gap between data and insights must improve upon this tool. Necessities include: Data integration—ARC Advisory Group said the “average” investigation of a process manufacturing issue in an enterprise manufacturing intelligence environment requires access to seven data systems. To move past spreadsheets, software must ingest data in many systems, formats, and types.

Flexibility—The process of a data investigation involves an iterative, trial and error approach to problem solving with many small steps such as data aggregation, data cleansing, calculations, visualizations, and collaboration. If a conclusion isn’t reached, the user moves backwards in the analysis and starts over on a new investigative path.

Reporting—The spreadsheet’s role allows users to share information and create new insights. They may be posted, printed, embedded, e-mailed, shared, and published by users. They may be viewed on any device, in an application or a browser, and run on-premise or in the cloud. Spreadsheet replacements will need view-only graphics like an executive dashboard, templates that limit user interaction to a valid range of options, or full fidelity access to enable collaboration across teams.

Beyond the spreadsheet

Innovations in Big Data technologies, data science, and horizontal scaling architectures are made accessible to the process engineer as an application experience or feature without extensive training or specialized information technology (IT) skills. www.controleng.com

Figure 2: Many process industry firms find they have a wealth of data and a paucity of insights and information. This is known as data rich, information poor (DRIP). Courtesy: Seeq

Figure 3: Information presented in a visual format allows engineers and other manufacturing experts to directly interact with data and gain quick insight.

Courtesy: Seeq

That model works in consumer experiences such as Google’s search engine or Siri’s voice recognition technology. Why can’t analytics applications mask this complexity in the same way for process engineers? This is a great opportunity to deliver the usability and flexibility of spreadsheets by leveraging the technology and innovation of our consumer experiences in one solution.

Providing the process engineer with the right application to bridge the gap between data and information is essential. Modern solutions require just minutes to assemble, cleanse, and organize data, which provides employees with more time to investigate production issues. The result is improved employee productivity and insights, which lead to better yields, margins, product quality, and safety (see Figure 3). ce

‘

Improve employee productivity and insights for better yields, margins, product quality,

’

and safety.

Michael Risse is a vice president at Seeq Corp.

Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.

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IIOT cloud communications

Implementing cloud connectivity for IIoT and Industrie 4.0 As information technology and automation technology continue to converge, cloud-based communication and data services are increasingly used in industrial automation projects.

MORE

ADVICE KEY CONCEPTS Understanding cloud-based communication services The advantages of private and public cloud services for data analysis How to optimize data processing and analysis GO ONLINE For related links about cloud-based connectivity, read this article online.

In the digital edition, click on the headline or search the headline for www.controleng.com.

Read more online about creating a compretitive edge with Industrie 4.0 and IoT, and collecting and analyzing process data.

CONSIDER THIS What are the cybersecurity implications for cloud-based data services?

Figure: The traditional communication pyramid requires significant data transfer between the field level and higher levels in the system.

Courtesy: Beckhoff Automation

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eyond the scope of conventional control tasks, applications such as Big Data, and data mining enable the implementation of advanced automation solutions.

New hardware and software products for Industrie 4.0 and Industrial Internet of Things (IIoT) provide simple implementation for advanced solutions.

Industrie 4.0 and IIoT strategies place strict requirements on the networking and communication capabilities of devices and services. In the traditional communication pyramid in the Figure, large quantities of data must be exchanged between field-level sensors and higher level layers in these implementations.

Cloud-based communications

Cloud-based communication and data services now avoid prior issues that collecting and and analyzing data in production facilities had by providing the user with an abstract view of the underlying hardware and software systems. “Abstract” meaning that a user does not have to give any thought to the respective server system when using a service.

Rather, only the use of the respective services has to be considered. The maintenance and update work on the IT infrastructure is performed by the provider of the cloud system. Such cloud systems can be divided into public and private clouds.

Public cloud service providers offer users with a range of services from their own data centers.

This starts with virtual machines, where the actual user has control of the operating system and the applications installed on it, and stretches to abstracted communication and data services, which can be integrated by the user in an application.

These can include access to machine learning algorithms, which can make predictions and perform classifications regarding specific data on the basis of certain machine and production information.

The algorithms obtain the contents with the CONTROL ENGINEERING

aid of the communication services.

Such communication services are usually based on communication protocols, which in turn are based on the publish/subscribe principle. All applications communicate through the central cloud service. Data communication with a cloud service via the message broker involves an outgoing communication connection from the perspective of the terminal device–regardless of whether data is sent (publish) or received (subscribe). The advantages for configuring the IT infrastructure are that no incoming communication connections have to be configured. This significantly reduces IT infrastructure set-up time and maintenance costs. Transport protocols used for data communication are lean and standardized, such as message queuing telemetry transport (MQTT) and advanced message queuing protocol (AMQP). The standardized communication protocol, OPC Unified Architecture (OPC UA), has likewise recognized the added value of a publish/subscribe-based communication scenario and taken the steps to integrate this communication principle in the specification. This means that an additional standard besides MQTT and AMQP is consequently available as a transport mechanism to the cloud.

Publish/subscribe mechanisms can also be used in a private cloud for companies or machine networks. For MQTT and AMQP, the infrastructure that is required can be installed and made available easily on any PC in the form of a message broker.

This means that both machine-to-machine (M2M) scenarios can be implemented and any terminal devices can be connected to the controller.

Industrie 4.0 and IIoT are key concepts when innovative business models are a requirement for the underlying infrastructure. Cloud-based data services can help implement such automation projects, as they save the machine manufacturer or end customer from providing IT expertise. ce Sven Goldstein is TwinCAT product manager of connectivity and embedded systems at Beckhoff Automation. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

The Industrial Internet of Things (IIoT) is transforming the manufacturing industry as we know it.

Control Engineering, Oil & Gas Engineering and Plant Engineering are partnering with industry experts who present an in-depth look at IIoT-related issues, strategies, and opportunities. The IIoT webcast series offers four educational webcasts packaged with continuing education credits available for free.

Now on-demand, register at www.controleng.com/IIoT

Webcast One: Effective Change Management

Effective IIoT integration includes technology and changing the way plants operate. The convergence of operational and information technologies are crucial to successful IIoT deployment. This Webcast looks at how to manage these changes and bring about a company-wide commitment to an IIoT strategy.

Presenter: Stan Schneider, Industrial Internet Consortium GE Digital

Event Sponsors: Now on-demand, register at www.controleng.com/IIoT

Webcast Two: Information Management for IIoT

With the existing network of sensors and gauges on the plant floor today, getting data has not been the issue. The challenge for manufacturers is to analyze that information to allow manufacturers to make better plant floor decisions. This Webcast discusses how data management can lead to better and faster decision-making and better asset management.

Presenter: Sal Spada, Research Director, ARC Advisory Group Event Sponsors:

Webcast Three: Security for IIoT • Thursday, October 20, 2016

CFE Media research says data security is a top-of-mind issue. Threats exist from internal and external sources, so manufacturers need a robust strategy to understand the source of threats and how to be prepared to ward them off. This Webcast will look at the issue of data security from all aspects.

Event Sponsors:

Webcast Four: IIoT case studies: strategies in action • Thursday, December 8, 2016

Organizations promoting IIoT strategies are working on case studies to show related benefits. In a list of 20 major technology areas, CFE Media research found that IIoT ranked the highest for potential to increase productivity, and the lowest for having already changed how end users work. This Webcast will review best practices, showing how the strategies have been implemented into operations.

Event Sponsors:

Register for the IIoT series today at www.controleng.com/IIoT

IIOT how to get started

How to implement the Industrial Internet of Things Industrial organizations need an effective way to get started with the Industrial Internet of Things (IIoT). See the ways to get started with IIoT, including appropriate processes, devices, systems, expertise in operations, industrial automation, and controls.

I

but rather the

ndustrial organizations worldwide are seeking to employ the Industrial Internet of Things (IIoT), a transformative digital evolution focused on Big Data analytics, to improve production efficiency, operational reliability, and supply chain performance. To be successful, operating companies should develop a flexible IIoT framework to enable secure collaboration across sites and disciplines, change work processes to improve information sharing and cooperation between functional teams, and leverage external expertise and knowledge vendors to complement internal resources.

people who

Assets, processes, connectivity

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The true promise of the IIoT is not about the ‘things,’

interact with the

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operation.

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ADVICE KEY CONCEPTS The key factors behind successful IIoT implementation How industrial organizations should implement an IIoT solution The benefits of implementing IIoT for industrial processes.

GO ONLINE For related links about IIoT, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com.

See more information about realizing the power of IIoT and getting started with IIoT online at www.controleng.com.

CONSIDER THIS How can industrial organizations measure ROI after implementing IIoT? ONLINE EXTRA Get started in seven ways with IIoT.

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Almost every industrial facility stands to benefit from the emergence of the industrial Internet. On one hand, operating sites with widely distributed assets are frequently limited to localized expertise to manage connectivity and aggregation of data. On the other hand, entrenched traditional work processes constrain many facilities and do not contribute to improved performance and profitability.

Equipment health is an important concern for all types of operations. If an asset fails, too often, there’s no logical way to analyze what happened because there’s not enough meaningful information, or the right people cannot analyze it until hours or days after the failure.

It is not uncommon for plant facilities to suffer from a lack of visibility to real-time performance against business metrics. They require better techniques for collecting and storing all relevant data in the organization, visualizing information to gain valuable insights, and then predicting and detecting issues and opportunities.

Putting the IIoT into perspective

Today, manufacturers and other industrial firms are contemplating the next step to effectively manage and exploit data at single sites or in enterprisewide operations. Business success demands that the right decisions are made at the right time with the right information.

A growing number of companies are looking to harness the power of the IIoT. By using machine learning, Big Data, and automation technologies CONTROL ENGINEERING

to create a “system of systems” that can accurately and consistently capture, analyze, and transmit data, they hope to achieve greater efficiency, sustainability, and quality control across the supply chain.

The IIoT is the next big evolution in performance and operations, employing existing technologies such as advanced computing, intelligent sensors, mobility applications, cloud-based platforms, and enterprise digitization to help turn data into actionable knowledge. At the heart of this approach are several key elements: Smart and secure collaboration Predictive analytics Data management and onsite control Smart and connected assets and devices.

An effective IIoT strategy relies on consolidating data in the cloud from multiple disparate systems, applying higher level analytics and leveraging experts who are often physically remote from the plant site. Predictive analytic solutions can transform work processes from manual and reactive to automatic and proactive, helping to avoid unplanned downtime and improving performance and safety. They allow businesses to keep closer track of everything going on in the plant, at remote locations, at subcontractor and supplier facilities, and on goods in transit anywhere in the world.

Develop an effective IIoT framework

Several important factors are involved in realizing maximum value from the IIoT. Its real power comes from centralizing data and then integrating applications to digest and process this information.

Instead of deploying applications in a control system, they can be located in the cloud, totally eliminating maintenance requirements in the plant and making additional data available in those applications from multiple sites. Typical applications that add value in the cloud include advanced process control (APC) monitoring, condition-based monitoring (CBM), enterprise data historian, mobility solutions, and scheduling among others. www.controleng.com

Industrial organizations should consolidate data from different sources using open integration and communication technologies like OPC Unified Architecture (UA).

This provides support for existing communications protocols so installed equipment is integrated in the IIoT architecture in a secure way. Next, they can move data from the plant to the enterprise and apply smart analytics to extract meaningful information. It is then essential to apply domain knowledge to understanding the data, leveraging in-house expertise, remote subject matter experts, or third-party knowledge vendors.

With a larger, consolidated data set, firms can apply and develop more advanced analytics in the cloud and deploy these analytical models in edge devices for more detailed insight, scale the data as needed to meet the varied requirements of single-site or enterprisewide operations, and take advantage of a wider pool of data experts for monitoring and analysis.

problems. This approach can also extend to internal resources across the globe.

It’s no coincidence that the knowledge and experience of OEMs and process licensors can have the greatest impact on the reliability of plant equipment and process operations. The IIoT is not just about monitoring; it’s about taking the diagnostic know-how of subject matter experts and

embedding it in applications at the edge that can predict and prevent failures. ce Ben Blanchette is the strategy and business development manager of digital transformation at Honeywell Process Solutions.

Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

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IIoT Data.

Processes.

Devices.

Locations.

IIoT collaboration, implementation

The true promise of the IIoT is not about the “things,” but rather the people who interact with the operation. Organizations that think about connecting people first and then connecting things will be well-positioned to optimize their plant’s operations.

The key to the success of any IIoT implementation is a willingness to operate differently, which means acquiring the tools necessary to support new roles, responsibilities, and work processes.

If an IIoT plan doesn’t include changes in how functional groups work together, then it probably should be rethought.

Building all of the in-house expertise needed for complex industrial sites is becoming increasingly difficult. As mature markets face the loss of knowledge of retiring baby boomers, the best operations will be those that learn when to develop skills in-house and when to leverage external resources to drive business outcomes.

A major opportunity for the IIoT to improve operational effectiveness is to embrace collaboration with third-party experts. Today’s technology makes it possible to securely tap the domain expertise of a whole ecosystem of partners in the cloud, where other organizations such as process licensors and original equipment manufacturers (OEMs) can help solve specific

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Red Lion has been connecting devices and moving data for years, enabling customers to easily advance to the Industrial Internet of Things (IIoT). Our IIoT-ready industrial automation and networking products: • Connect: Extend equipment lifespan with protocol conversion • Monitor: Improve process visibility with visual management • Control: Push control to the edge with remote monitoring • Network: Expand network reliability with industrial Ethernet Learn more today at www.redlion.net/moreIIoT

McCormick Place Convention Center Lakeside Upper Hall Booth # E-7260

Connect. Monitor. Control. I www.redlion.net © 2016 Red Lion Controls, Inc. All Rights Reserved.

input #27 at www.controleng.com/information

CONTROL DESIGN dynamic simulation

How to avoid control design pitfalls with dynamic simulation Adopting multi-purpose dynamic simulation (MPDS) solutions as a design standard can help with visualization of control interactions and control pre-tuning and ease challenges in later stages of the project, including startup. Simulation is part of the Industrial Internet of Things (IIoT).

U MORE

ADVICE KEY CONCEPTS How to avoid control design issues with dynamic simulation Understanding dynamic simulation The multi-purpose dynamic simulation (MPDS) workflow process.

GO ONLINE For related links about dynamic simulation, read this article online.

In the digital edition, click on the headline or search the headline for www.controleng.com.

Read more online about the added value of dynamic simulation, benefits/ drawbacks of each dynamic simulation approach, using dynamic simulation, and how dynamic simulation can be applied in various industries.

CONSIDER THIS What are the requirements to use dynamic simulation?

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sing multi-purpose dynamic simulation (MPDS) has helped several large companies visualize control interactions, helps with controller pre-tuning, and eases startup challenges and later updates, leading to adoption of MPDS as a design standard. Simulation is part of the Industrial Internet of Things (IIoT). Dynamic simulation models can be developed along with plant designs and can evolve through the project execution, aiding in every stage from design through operation: 1. Design: A model is initially built to test feasibility and design operability. Static simulators traditionally used during this phase provide the basic information but miss important operational and control details.

2. Distributed control system (DCS) and programmable logic controller (PLC) configuration: Implementation of the control logic into the platform that is chosen by the client is tested with the aid of the dynamic simulator. At this point, the model has been developed to provide the controls with all of the required inputs and outputs.

3. Start-up: Once the controls configuration is validated, start-up scenarios can be tested in the dynamic simulator, without risk of lost production or increased downtime, to ensure the plant is operable. The operators can start receiving training well before the plant’s construction is completed.

4. Operations: At this point the model is a mature, accurate representation of the plant and can be used as a training tool and test bed for plant modifications.

The value of dynamic simulation for controls design

Traditionally, control logic is tested through simple loopback testing, which involves linking the control loop output back to its input, usually adding some expressions to account for process lag and direction of change. The control loops are tested individually, and it becomes very difficult to develop expressions that describe the physical

CONTROL ENGINEERING

process on which two control loops may operate.

Dynamic simulation is often added to a project to address the limitations of simple loop testing.

The control logic, already created in a PLC or DCS, is connected to a dynamic simulation model, which generates inputs for the control system and evaluates the control response. This has proven to be a cost-effective way to test controls before commissioning, usually resulting in shorter commissioning and start-up times.

Usually, three approaches are available when applying dynamic simulation to a controls checkout—tie-back, medium fidelity, and rigorous simulation—that have their own benefits and drawbacks.

Using dynamic simulation during the controls design phase can work as a proof-of-concept method to validate the control strategy, while its implementation in the control code is tested during the subsequent controls checkout phase. This way, expensive rewriting of the control code and correcting logic diagrams and documentation is avoided.

Using a dynamic simulator

Any process that can be accurately modeled in a dynamic simulator is a candidate for such analysis. The only requirement is that the simulator has complete libraries that can model the process and the controls and that it can solve with sufficient precision to produce an appropriate set of data. Dynamic simulation for control validation has been successfully applied to many industries including upstream oil and gas, liquid natural gas, steam and utility systems, mining operations, refineries, and flare systems. ce

Andres Lipinski is a senior consultant of Dynamic simulation studies at Schneider Electric.

Dr. Ian Willetts is the simulation and training global practice director at Schneider Electric Simsci. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

PROCESS MANAGEMENT IIoT

Managing processes with the IIoT The Industrial Internet of Things (IIoT) is creating more streamlined and efficient methods to manage industrial processes.

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t is becoming more advantageous to switch from legacy technology to Industrial Internet of Things (IIoT) technology because of the widespread innovations and the growing amount of data each plant needs to handle. IIoT technology can provide access control through many mediums (Wi-Fi, Bluetooth, Ethernet, etc.), providing a flexible and powerful interconnected system.

With IIoT-supported technology, there is less reliance on localized systems, and it allows organizations the freedom to access live data whenever from wherever. The mobility to access information can provide a more streamlined effort, increasing efficiency and reducing the downtime between operations. These smart devices are revolutionizing the way data is communicated not only via human to machine, but machine to machine as well.

Practical applications and benefits

By building a plant around smart technology, organizations are able to monitor live stream of data. What it means for plant operators is the freedom to monitor and resolve any issues from a smart device such as a smartphone, tablet, or laptop.

Because the equipment can communicate remotely, the necessity of having staff on-site around the clock is no longer required. Most issues can be solved remotely using smart devices.

Another benefit is the predictive nature of alarms and maintenance.

By having real-time communication between devices, preventing any problems before they occur is easier. The caveat is that this equipment can get quite expensive and requires software to tie the devices together.

On the manufacturing execution systems (MES) side, legacy equipment such as servers can be overwhelmed by large amounts of incoming/outgoing transactions. IIoT technologies are designed to eliminate the headaches that come from dealing with configurations such as OPC DCOM. Since all of the equipment www.controleng.com

is connected through the network, data can be saved in a cloud-based server, which is much cheaper and less onerous than traditional dedicated servers.

IIoT challenges

There are several challenges that IIoT faces.

Most of these challenges have to deal with the security, integrity, response times, and cost. Having multiple channels of communication methIIoT has the ability to track ods means security must be more robust to ensure and eliminate inefficiencies, that these devices are unable to be tampered prevent critical errors, and with remotely. add convenience within a Also, devices requiring network connectivity process. is a double-edged sword.

On one hand it improves the cohesiveness of the system. On the other hand, it provides another avenue where problems can arise such as network issues during a process. Because of this, many IIoT devices will MORE allocate some memory in the case that they do ADVICE disconnect from the network. However, if it disconnects for an extended period of time, data KEY CONCEPTS may possibly be lost during the process.

The Industrial Internet of Things (IIoT) can provide access control Even with these potential challenges, the IIoT through many mediums such as Wi-Fi, still has enormous potential and has the ability to Bluetooth, and Ethernet. track and eliminate inefficiencies, prevent critiBuilding a plant around smart cal errors, and add convenience within a process. technology allows organizations to be As this technology becomes more commonplace, able to monitor data through a variety IIoT devices will have more functionality, be of technologies. more robust, and cheaper. ce IIoT devices will have more function-

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’

Michael Zhang is an associate developer at Maverick Technologies. Maverick Technologies is a CFE Media content partner, a CSIA Level 1 member, the Control Engineering System Integrator of the Year in 2011, and an inductee into the Control Engineering System Integrator Hall of Fame in 2012. Edited by Chris Vavra, production editor, CFE Media, Control Engineering, cvavra@cfemedia.com.

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ality and versatility as they become more common.

GO ONLINE Link to additional online resources on the IIoT and process management, at www.controleng.com/archives, under October 2016.

CONSIDER THIS What other challenges will the IIoT encounter as it becomes more common on the plant floor?

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SYSTEM INTEGRATOR OF THE YEAR advice on robotics

Roundtable on robotics Where should robotics be used? How are collaborative robotics progressing? What’s the value proposition for robotics? And how is the Industrial Internet of Things (IIoT) affecting the future of robotics? Get answers from Concept Systems Inc., a 2016 System Integrator of the Year.

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oncept Systems Inc., a CFE Media 2016 System Integrator of the Year, participated in a robotics panel discussion at the Global Automation and Manufacturing Summit at International Manufacturing Technology Show, IMTS 2016. Robotic answers follow from Michael Lindley, vice president, business development Concept Systems, who augmented his replies from the summit.

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Look for opportunities to incorporate IIoT readiness into their retrofits and new capital investments.

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MORE

ADVICE GO ONLINE With this article online, see Control Engineering pages on robotics, system integration, and the Global System Integrator Database, to find an integrator with expertise in robotics or other engineering specialties.

Search IMTS at www.controleng.com to see other show coverage.

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CFE Media: Where should robotics be used and why?

Lindley: The areas that companies should first select for are those where workers are required to do repetitive, dirty, or dangerous tasks. These tasks are often the easiest to replicate with a robot and/ or provide a high value by removing workers from hazardous environments; grinding and painting are examples of jobs that fit this criterion. Not all manufacturing tasks are suited for robotic automation because of the complexity of the task or production volume isn’t great enough to create necessary savings. We advise clients to use an return on investment (ROI) analysis and consider all contributing factors: increased throughput, reduction in rework, labor savings, and work safety. Material handling, dispensing, painting, and assembly are common areas for robotic automation.

CFE Media: Is the Industrial Internet of Things (IIoT) affecting robotics?

Lindley: Many of our clients are asking questions about how they can upgrade their process control platforms and prepare themselves for IIoT. They see the benefit in production visibility, real-time reporting, and interconnectivity but are grappling with how to keep data secure while opening their manufacturing environments to cloud data. As companies work to develop their enterprisewide IIoT strategies, they can presently take advantage of investing in robots and machine solutions that are capable of preventive maintenance and condition-monitoring functionality.

These abilities reduce costly unplanned downtime events and keep operators informed via real-time reporting. We encourage clients to look for opportunities to incorporate IIoT readiness into their retrofits and new capital investments.

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CFE Media: Will there be more collaborative robotics used?

Lindley: Definitely. The applications for collaborative robotics will continue to expand in coming years. Robots will become more aware of their surroundings as technologies used for feedback and vision continue to advance. We will also see a continued trend towards programming collaborative robots through fast teaching methods and simple operator control. The leaders in industrial robotics: ABB, Fanuc, and Kuka each have their own variation of what collaboration looks like. The current range of robot options spans from dual-arm capabilities, ABB YuMi, to handling payloads up to 35kg (Fanuc CR-35i).

Based on the level of interest and investment in collaborative robots, I think this category will rapidly grow.

CFE Media: Is the value proposition for robotics changing?

Lindley: I don’t think it is changing as much as becoming a lot more attainable. Companies are seeing 2- to 3-year returns on their investments because of competitive pricing and easier integration. The added bonus of a robot investment is that the platform will often last 10 to 15 years, allowing it to be repurposed perhaps several times. Another advantage is that by using area scanners or collaborative solutions, robots can be integrated almost anywhere on a production floor.

CFE Media: How’s the future for robotics?

Lindley: Based on what leading technologists are predicting, we should expect to see exponential growth in industrial robotics. Robots will continue to be smarter, faster, and more agile making them applicable for a wider range of applications.

Robots will also become mobile, whether moving on guided rails or mounted atop of automated guided vehicles. These culminating factors will create significant cost savings and efficiencies for manufacturers. ce Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com. www.controleng.com

More resources posted daily at:

www.controleng.com

digital edition Exclusives, Online Extras: Benefits of the Control Engineering Digital Edition include tablet-friendly viewing (HTML5), exclusive content in every issue; headlines link to the longer version posted online; links are live where a URL is provided; and an email link arrives when ready. In addition, link to additional “Online Extra�articles.

DE1 Five smart manufacturing hurdles to overcome

Smart manufacturing is designed to rapidly create applications that enable collaboration among people, systems, and assets; key hurdles need to be addressed for this to happen, enabling the Industrial Internet of Things (IIoT).

DE3 Know the risks of securing safety systems

Even if a safety system is isolated and separate from a network, the potential for a cyber attack remains and companies and users need to be vigilant and take necessary precautions.

ONLINE EXTRAS

(Click on the headlines or search www.controleng.com.)

Health and safety checks for engineering, manufacturing Health and safety checks in engineering and manufacturing workplaces are paramount and companies should be aware of potential hazards. Three of the biggest concerns are highlighted with some solutions.

Tolerance-based machining for improving CNC process Tolerance-based machining is designed to help automate the computer numeric control (CNC) programming process, speed up delivery times, improve quality and consistency, and eliminate 2-D drawings from the process.

The culture of successful leadership Everything about business begins with people.

Knowing the future: predictive maintenance and risk mitigation Predictive technology proves to be the answer to help prevent plant downtime, safety, and environmental risks.

Improving operations can save real dough Reducing operating expenses does not mean compromising product quality and human safety.

Six ways to build a manufacturing culture from the bottom up Companies need to establish an environment and culture where workers are just as active in creating a positive, safe environment as the executives and managers. Consider the six tips to get started.

www.controleng.com

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DIGITAL EDITION exclusive

Five smart manufacturing hurdles to overcome Smart manufacturing is designed to rapidly create applications that enable collaboration between all people, systems, and assets, but there are key hurdles that need to be addressed for this to happen.

Enable more Industrial Internet of Things (IIoT) functionality through the right use of Big Data.

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anufacturing generates more data than any other industry. New levels of connectivity, advanced computing, smarter sensors and devices, and improved data access and storage are increasing the breadth, volume, and resolution of available data. If you just listen to the Big Data hype, the assumption is that business value can be derived if data can be harnessed. In the future, manufacturing companies will gather more data with more Industrial Internet of Things (IIoT) connectivity, but will it be used effectively? That’s the key question that needs to be addressed, and smart manufacturing is working on answering that.

Smart manufacturing goals

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The overall goal of smart manufacturing is to rapidly create applications that enable collaboration between all people, systems, and Legacy systems are often assets across a value c h ai n - appl i c at i on difficult to extend and and architecture that build a new smart manufacturing softsupport and cannot be ware platform for the future. quickly adapted to align M a nu f a c t u r i n g enterprises know with evolving needs. that access to data is important for improving operational performance. Performance improves when contextual information is provided at the right time to the right role to enable decision-making.

New technologies are making more data available every day. Some manufacturers are applying Big Data and analytics technologies in the hope that intelligence mined from this data will enable them to reach new levels of operational performance.

Success is not merely about data acquisition and providing visibility to more detailed and

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diverse data. In fact, it is not just about data. It is about rapid creation and delivery of rich interactive applications. Examples include: Applications that provide just the right amount of the right information to the right role at the right time to allow them to make the right decision and take immediate action Applications that communicate between systems driving workflows and autonomous action Applications that prevent and predict issues by applying artificial intelligence and machine learning technology.

In other words, it is not just pumping out Big Data, it is about applications using and providing “right data.”

Smart manufacturing applications are essential for extracting value from data, and they are role-based and real-time. They also address specific use cases aligned with unique business challenges.

The applications provide proactive notifications to enable rapid resolution of issues. They are deployed to diverse form factors ranging from wearables to mobile devices to industrial touchscreen PCs. The applications may merge the physical and digital worlds using augmented reality. The right applications are agile, and they quickly and easily change with the business. Smart manufacturing requires the right applications. But there are obstacles to delivering smart manufacturing applications.

Five smart manufacturing hurdles

1. Data contextualization Enterprises want to make intelligent decisions from data. But an enterprise typically has many diverse software systems so techniques for www.controleng.com

Legacy systems, new data source opportunities, and rapid application composition can help companies achieve smart manufacturing. Courtesy: MESA International

obtaining data from these systems vary. It also can be difficult to combine business system data with manufacturing process data, yet data contextualization is essential to make intelligent decisions.

2. Underfunded and overwhelmed IT Internal information technology (IT) organizations are often underfunded and overwhelmed. They do not have the capacity to deliver the applications needed, and in the future there will be a demand for more applications and application management. Optimally, application composition should be democratized so that it can enable business users to make smart decisions.

3. Change and change management Today, change is the norm. So applications must be agile because the business strategy, products, customer demands, and IT systems are constantly changing. These challenges will be compounded in the future because advancements in technology will drive a massive increase in the amount of available data resulting in demands for more applications.

4. Legacy software Even if the applications are built, conventional software is not sufficient to meet the scale and diversity of the applications required. Most manufacturing personnel are often given access to read-only dashboards providing a rearview mirror perspective on performance and offering no means of issue resolution or avoidance. Also, there are issues within the two approaches typically www.controleng.com

applied to applications: IT and operations technology (OT).

Applications supporting manufacturing must span these approaches (IT and OT). Continuous improvement inherently necessitates agile applications. But, legacy systems are often difficult to extend and support. They cannot be quickly adapted to align with evolving needs.

5. Disparate systems Existing interfaces between disparate systems can be problematic. Current approaches center on systems of record and on moving data between systems. As the volume of data increases this approach becomes more complex and less practical.

Cloud, mobile, analytics can help

A new approach is needed to reach the goal of smart manufacturing. Luckily, solutions can be built without replacing legacy systems. In fact, we can use the same modern software technologies we use in our personal lives to build new composite, role-based applications that can span legacy systems and new sources of data. Modern software technologies include cloud, mobile, Big Data, social, and advanced analytics technologies which are robust and proven. ce

Brad Williams is a consultant at ThingWorx. He is also a MESA International smart manufacturing working group member. This article originally appeared on MESA International’s blog. MESA International is a CFE Media content partner.

Edited by Chris Vavra, production editor, CFE Media, cvavra@cfemedia.com.

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MORE

ADVICE KEY CONCEPTS The overall goal of smart manufacturing is to rapidly create applications that enable collaboration between all people, systems, and assets.

Smart manufacturing applications are essential for extracting value from data, and they are role-based and real-time.

Smart manufacturing solutions can be built without replacing legacy systems.

GO ONLINE Link to additional online resources on the IIoT and process management at www.controleng.com/archives, under October 2016.

CONSIDER THIS What other benefits can smart manufacturing provide for users and companies?

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DIGITAL EDITION exclusive

Know the

risks

of securing safety systems Even if a safety system is isolated and separate from a network, cyber attack potential remains, and companies and users need to take necessary precautions to lower risk, especially with increased connectivity via Industrial Internet of Things.

O MORE

ADVICE KEY CONCEPTS The manufacturer needs to treat its safety systems like any other in a facility and understand any and all strengths and weaknesses.

Understand the pros and cons of a separate or integrated security system.

Vigilance and proactivity are crucial regardless of the security system used.

GO ONLINE See additional ISSSource stories about cybersecurity online at www. controleng.com.

CONSIDER THIS What other methods can be done to improve a company’s safety system?

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ne assumption about safety systems is they need to remain isolated from the control system, ensuring nothing will hinder their mission to keep the plant and workers safe.

If we have learned anything in this cyberaware world, isolation is not security. That means no matter if safety is separate, integrated or interfaced, there is always a path in, especially as companies increase Industrial Internet of Things (IIoT) connectivity.

In these days of working in open, connected manufacturing enterprises, security threats hover over a facility like a looming blizzard, potentially undercutting the vast ability connected plants have to reduce cost and increase productivity and profitability. Control systems, and just as importantly, the safety system, need to stay secure.

That means the manufacturer needs to treat its safety systems like any other in a facility and conduct a risk assessment to understand any and all strengths and weaknesses.

“The risk-assessment process is the same as with a control system in that you have to identify the system and how it interfaces with the rest of the system, which is pretty critical,” said John Cusimano, director of industrial cybersecurity at aeSolutions.

“Generally speaking, it is always best practice to treat the safety systems as its own zone and then you perform a risk assessment on that safety zone.”

While the process control system and safety system have similarities, there is one major distinction.

“The biggest difference with a safety system is the consequences,” Cusimano said. “When you do the risk assessment in the safety system zone it comes out at a higher risk, it will change your protection and your decisions on how you are going to secure that zone. It will be a higher level of security

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and require stronger mitigations. Generally, you are trying to minimize the communications and reduce the attack surface.”

Safety systems remain a vital cog not just in keeping the plant and people safe, but also enabling successful business performance.

“We have to remember something that is very important-something security professionals don’t always remember: The existence of our group is to enable business performance,” said Jay Abdallah, director of cybersecurity, EMEA, Schneider Electric. “That needs to be our number one objective. Safety falls directly in line with those business objectives in keeping people safe, keeping the plant safe, keeping reputations safe, and keeping equipment safe which tends to help the bottom line.”

Knowing which direction a safety system attack could come from is a top priority.

“The biggest thing users are coming to realize is the attack will most likely come from inside the network than outside,” said Sven Grone, industrial automation turbomachinery control business development at Schneider Electric.

“Things like inadvertent viruses on flash drives, contractors coming in with their machines and hooking up to the network to work on gear. These are people you invited into your systems to work on it, and you are not controlling their machines and not controlling what they are putting on the network. There is definitely an element of social engineering and having to deal with people’s behavior and operational behavior in the cybersecurity process that is often not nearly as prevalent than doing functional safety,” Grone said.

Security whether separate or integrated

When it comes to securing a safety system, the age-old question of integrated or separate systems www.controleng.com

continues to rear its ugly head.

“I am a personal believer in a separate system. The little amount of money you save making it integrated is just the engineering portion of it,” said Nasir Mundh, global director of safety services at Schneider Electric. “To me a project is two years or three years where you design it, install it, and run it. After that, the plant is running for 25 to 30 years. So you are adding additional risk to the process for 30 years just to save some money in this two-year project. To me that never makes sense. A distributed control system (DCS) or a control system is a workhorse, it is doing something every single moment. It is controlling the plant. That whole line has commands going up and down, and now you have a safety system sitting on that same network. It is opening yourself up to risk.”

“Integrated systems have some advantages with operations and the communications between the safety systems and the DCS. However, if you have an integrated system and you somehow are breached, there is a very high chance you lose both layers of protection,” said Farshad Hendi, safety service practice lead, Americas and EURA at Schneider Electric. “That means someone is in your house, and the halls are somehow connected together. If the systems are separated, it is not impossible to do that, it is more difficult.”

Maintain vigilance

No matter the type of system, vigilance remains the key priority.

“Integrated, interfaced, or separate. There is no right, no wrong, only choice,” said Steve Elliott, senior director offer marketing for process automation at Schneider Electric.

“An upstream operating company had integrated www.controleng.com

‘

If you have an integrated system and you somehow are breached, there is a very high chance you lose both

’

layers of protection.

control and safety,” Elliott said. “There was a master clock on the network that had a fault develop that was broadcasting a time across the network to all the controllers. Eventually it bombarded the controllers to the point they stopped, and they had to do a shutdown on the platform and had to black start. All the power on the platform had to be dropped, and they had to vacate it. They had integrated control and safety and a failure mode that actually caused them to shut the platform down.

When you look at it, they didn’t do a failure mode effect analysis.

“We integrate safety and now security becomes an issue—we are seeing a movement back to maintaining as much distance between the control system and safety as possible,” Elliott said. “Thinking about moving toward open standards and connecting everything together, next security is a consideration—solving one problem, creates another.” ce Gregory Hale is the editor and founder of Industrial Safety and Security Source (ISSSource.com), a news and information Website covering safety and security issues in the manufacturing automation sector.

ISSSource is a CFE Media content partner. Edited by Chris Vavra, production editor, CFE Media, Control Engineering, cvavra@cfemedia.com.

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ENGINEERS’ CHOICE awards finalists

Vote now for

Engineers’ Choice Finalists The official ballot is open for voting for Control Engineering North American print and digital edition subscribers, for a limited time.

Cast your vote at www.controleng.com/VOTE2017.

V 2017 FINALISTS

ote now! For a limited time, the official Engineers’ Choice ballot is open for voting for Control Engineering North American print and digital edition subscribers. At www.controleng.com/VOTE2017, vote for the best Engineers’ Choice finalists of 116 entries across 28 categories.

Based on your experience, please vote in as many categories for which you feel qualified based on technological advancement, service to the industry, and market impact. Details and photos are available for each product. Winners and honorable mentions will be featured in more detail in the February 2017 issue of Control Engineering.

Hardware — Data acquisition Memograph M RSG45 Data Manager, Endress+Hauser, www.us.endress.com UC-8112-ME-T-LX Programmable 4G LTE Modbus Data Logger, Moxa Inc., www.moxa.com M-4839 Wide-Band Power Meter, Ohio Semitronics Inc., www.ohiosemitronics.com Hardware — Handheld test, measurement, calibration SMART Air Hood Balancing Instrument, Dwyer Instruments Inc., www.dwyer-inst.com AEGIS Shaft Voltage Tester Digital Oscilloscope, Electro Static Technology / AEGIS, www.est-aegis.com AMS Trex Device Communicator, Emerson, www.emersonprocess.com Fluke 279 FC Thermal Multimeter, Fluke Corp., www.fluke.com Fluke Condition Monitoring, Fluke Corp., www.fluke.com

Allen-Bradley PanelView 5500 Graphic Terminal, Rockwell Automation, www.rockwellautomation.com TP700 Comfort Outdoor Panel HMI, Siemens Industry Inc., www.usa.siemens.com Hardware — Integrated HMI controllers

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IER3 Optical Encoder, Micromo, www.micromo.com BOA Spot Vision Sensor, Teledyne Dalsa, www.teledynedalsa.com Machine & Embedded Control — PLCs, PACs, industrial PCs

XV-300 Operator Interface touch HMI and PLC, Eaton, www.eaton.com

APAX-5580 hot-swappable industrial PC, Advantech, www.advantech.com

Industrial PC v800-P with touchscreen, Lenze, www.lenze.com

CX8095 Embedded PC with an EtherNet/IP connection to EtherCAT, Beckhoff Automation, www.beckhoff.com

Samba 7 PLC, touchscreen, and I/O, Unitronics, www.unitronicsplc.com Machine & Embedded Control — CNCs, board-level products AcroPack PCIe-based I/O Modules, Acromag Inc., www.acromag.com ConnectCore for i.MX6UL system on module, Digi International, www.digi.com EZTimer, a digitally programmable multifunction timer, EZAutomation, www.ezautomation.net

Hardware — HMI, operator interface, thin-client GOT Mobile wireless connection for graphical operator terminals, Mitsubishi Electric, https://us.mitsubishielectric.com/fa/en

Voting, an important responsibility: Voting on this ballot is only open to qualified* subscribers of Control Engineering products. One ballot per qualified subscriber will be accepted; multiple ballots from the same qualified subscriber will be invalid.

Ballots received from non-qualified subscribers will be invalid. *Employees of product manufacturers with a finalist in the current program and their properties, agencies, vendors, and representatives, even if Control Engineering subscribers, are ineligible to vote.

Amanda Pelliccione is CFE Media director of research, events & awards programs, apelliccione@cfemedia.com.

Machine & Embedded Control — Discrete sensors, machine vision LP Series Encoder, heavy-duty rotary encoder, BEI Sensors, www.beisensors.com

CONTROL ENGINEERING

IndraControl XM 22 PLC, Bosch Rexroth Corp., www.boschrexroth.com Click Ethernet Standard PLC; Koyo Electronics Industries, AutomationDirect, www.automationdirect.com MELSEC iQ-R Programmable Automation Controller, Mitsubishi Electric, https://us.mitsubishielectric.com/fa/en Allen-Bradley CompactLogix 5380 Programmable Automation Controller, Rockwell Automation, www.rockwellautomation.com Motion Control — Drives, motor control centers EJ7211-0010 Servomotor Module, Beckhoff Automation, www.beckhoff.us www.controleng.com

Read more about the 2017 finalists, see images, and, if eligible, cast your vote at www.controleng.com/VOTE2017.

EFC3610 Frequency Converter (VFD), Bosch Rexroth Corp., www.boschrexroth.com IndraDrive ML modular universal inverter, Bosch Rexroth Corp., www.boschrexroth.com

Network Integration — Ethernet switches LNP-1002G-10G-SFP Gigabit PoE+ Unmanaged Ethernet Switch, Antaira Technologies, www.antaira.com

FlashGard Arc-Resistant Motor Control Center, Eaton, www.eaton.com

LNX-2012GN-SFP Gigabit Managed Ethernet Switch, Antaira Technologies, www.antaira.com

FR-A800 Plus for Cranes and Hoists, a VFD, Mitsubishi Electric, https://us.mitsubishielectric.com/fa/en

eWorx SE300 Ethernet Switch, B+B SmartWorx, http://advantech-bb.com

Altivar Process 900 VSD, Schneider Electric, www.schneider-electric.com Motion Control — Servo drives MotiFlex e180 servo drive, ABB Inc., www.abb.com IndraDrive Mi Cabinet-Free Technology servo drive and power supply, Bosch Rexroth Corp., www.boschrexroth.com MR-J4-GF-RJ Servo Drive with CC-Link IE Field, Mitsubishi Electric, https://us.mitsubishielectric.com/fa/en

790 Shield Clamps with Latching Spring, Wago Corp., www.wago.us Network Integration — Signal conditioning

Universal Analog Signal Isolator and Converter, Weidmuller, www.weidmuller.com

EK9160 IoT Bus Coupler, Beckhoff Automation, www.beckhoff.us C-more Micro EA-ECOM, Ethernet to operator interface expansion module; Koyo Electronics Industries, AutomationDirect, www.automationdirect.com LCP DX refrigerant-based cooling for enclosures, Rittal Corp., www.rittal.us Allen-Bradley Stratix 5950 Security Appliance, Rockwell Automation, www.rockwellautomation.com

www.controleng.com

SA Series Flow Sensor, ifm efector inc., www.ifm.com/us meriGauge Plus Digital Pressure Gauge, Meriam Process Technologies, www.meriam.com Sitrans FC430 Coriolis flowmeter, Siemens Industry Inc., www.usa.siemens.com Process Control Systems

Field Logic Controllers Powered by ARGEE programming environment, Turck, www.turck.us

Servo Press Kit YJKP, Festo Corp., www.festo.us

Network Integration — Ethernet hardware

Micropilot FMR20 non-contact radar transmitter, Endress+Hauser, www.us.endress.com

EtherCAT P, communication and power in one cable, Beckhoff Automation, www.beckhoff.us

microBlox uB31 DC Voltage Input Module, Acromag Inc., www.acromag.com

EPOS4 Module 50/15 position controller with integrated amplifier, maxon motor, www.maxonmotorusa.com

Process Control — Flowmeters, process sensors

ADAM-3600 Intelligent Remote Terminal Unit, Advantech, www.advantech.com

Energy Efficiency Module MSE6-E2M, Festo Corp., www.festo.us

Platinum e PMAC and Inverter, permanent magnet ac motor and integrated drive, Leeson Electric, www.leeson.com

SC On-line UPS, Falcon Electric Inc., www.falconups.com

Network Integration — I/O systems

Allen-Bradley ArmorBlock IO-Link Master, Rockwell Automation, www.rockwellautomation.com

iMotion Modular Application Design Kit (MADK), Infineon Technologies, www.infineon.com

Eaton 2-3 kVA 9PX UPS, Eaton, www.eaton.com

Managed Switch 7000, Phoenix Contact, www.phoenixcontact.com

Sigma-7 Servopack servo amplifier for rotary, linear, and direct-drive motors, Yaskawa America Inc., www.yaskawa.com

M100 Direct Drive Motor, Electric Torque Machines, http://etmpower.com

Bedrock Uninterruptible Power Supply (UPS.500), Bedrock Automation, www.bedrockautomation.com

IEX-408E-2VDSL2 Ethernet Extender Switch, Moxa Inc., www.moxa.com

Bedrock Ethernet I/O Module (SIO4.E), software configurable IIoT enabler, Bedrock Automation, www.bedrockautomation.com

HexGen hexapod positioning system, Aerotech Inc., www.aerotech.com

Power — Energy, power protection, UPS

Cisco Industrial Ethernet 1000 Switch, Cisco Systems, www.cisco.com

MR-J4-TM Multi-Network Servo Drive, Mitsubishi Electric, https://us.mitsubishielectric.com/fa/en

Motion control, motors

Quint Power supply, Phoenix Contact, www.phoenixcontact.com

Network Integration — Wireless products SmartSwarm 351 Modbus eavesdropper, B+B SmartWorx, http://advantech-bb.com Digi Connect Sensor, battery-powered cellular gateway, Digi International, www.digi.com EZWiFi, EZAutomation, www.ezautomation.net AWK-4131A-US-T Weatherproof Wireless Access Point, Moxa Inc., www.moxa.com TC mGuard secure cellular communication product, Phoenix Contact, www.phoenixcontact.com Wireless Ethernet and Serial Device Server, Weidmuller, www.weidmuller.com Power — Energy, power protection OEM Line Isolation Switch, Eaton, www.eaton.com Power Xpert Branch Circuit Monitor, Eaton, www.eaton.com

PlantPAx Modern Distributed Control System, Rockwell Automation, www.rockwellautomation.com Foxboro Intelligent Marshalling FBM 248, a Universal Fieldbus Module, Schneider Electric, www.schneider-electric.com PlantStruxure PES v4.2 digital automation system, Schneider Electric, www.schneider-electric.com Safety — Machine safety CSI 6500 ATG stand-alone machinery protection, Emerson, www.emersonprocess.com PSRmini, a thin safety relay with forceguided contacts, Phoenix Contact, www.phoenixcontact.com Allen-Bradley Compact GuardLogix 5370 Controller, Rockwell Automation, www.rockwellautomation.com AZM400 Motorized Bolt Lock with Integrated RFID Safety Sensor, Schmersal, www.schmersalusa.com Safety — Process safety, intrinsic safety Safety Lifecycle Manager (SLM) v2, safety instrumented system lifecycle management software, Mangan Software Solutions, www.mangansoftware.com SPA2IS Programmable Limit Alarm Trips with Intrinsically-Safe Field Connections, Moore Industries, www.miinet.com ProSafe-RS SIL 3 SIS, Yokogawa Electric Corp., www.yokogawa.com more

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ENGINEERS’ CHOICE awards finalists Software — Applications Custom Order Engineering - Fusible Circuit Protection Solutions, Eaton, www.eaton.com Fuse and SPD Selector Tools, Eaton, www.eaton.com

Read more about the 2017 finalists, see images, and, if eligible, cast your vote at www.controleng.com/VOTE2017.

Rockwell Software Studio 5000 Development Environment, Rockwell Automation, www.rockwellautomation.com Software — Data analytics, diagnostics Honeywell Uniformance Suite, process analytics software, Honeywell Process Solutions, www.honeywellprocess.com

DeltaV Alarm Mosaic, Emerson, www.emersonprocess.com

PlantTriage v13 to monitor and diagnose plant control loops, Metso, www.expertune.com

Rockwell Software Quality Management, Rockwell Automation, www.rockwellautomation.com Software — Asset management, reporting ARES Asset Management Platform, Emerson, www.emersonprocess.com Dream Report v4.72, automation-related reports and dashboards, Ocean Data Systems, www.dreamreport.net FactoryTalk AssetCentre Software v7.0, Rockwell Automation, www.rockwellautomation.com

FactoryTalk VantagePoint EMI Software v7.0, Web-based manufacturing business intelligence software, Rockwell Automation, www.rockwellautomation.com

Software — Control design Autodesk AutoCAD Electrical, Autodesk Inc., www.autodesk.com Adams Explore, multibody dynamics simulation software for Microsoft Excel, MSC Software, www.mscsoftware.com

VTScada v11.2 HMI / SCADA software, Trihedral Engineering Ltd., www.trihedral.com Software — Industrial Internet of Things connectivity TwinCAT IoT, Beckhoff Automation, www.beckhoff.us IoT Gateway Suite, Iconics, www.iconics.com

Line Performance Suite v1.0, Schneider Electric Software, www.indusoft.com

KEPServerEX 5.21 device and IoT connectivity software, Kepware, www.kepware.com

ROMeo 6.4 process optimization software, Schneider Electric Software, www.indusoft.com

FieldPoP Device Cloud and the IIoT Gateway, Sierra Monitor Corp., www.sierramonitor.com

Software — HMI software

XLReporter v12.0 process automation reporting software, SyTech Inc., www.sytech.com

InduSoft Web Studio 8.0 + SP1 platform agnostic SCADA/HMI development and runtime software, Schneider Electric Software, InduSoft, www.indusoft.com

Software — Mobile apps for controls, automation, instrumentation

Fuji Electric Monitouch V-SFT Screen Configuration Software v6.0.15.0, Fuji Electric Corp. of America, http://monitouch.fujielectric.com

Asset View messaging application for asset management software, Emerson, www.emersonprocess.com

Movicon.NExT v3.0 industrial automation software architecture, Progea, www.progea.com

Honeywell Pulse industrial mobile app, Honeywell Process Solutions, www.honeywellprocess.com

InTouch Machine Edition customizable HMI software, Schneider Electric Software, www.indusoft.com

myMOBILE, independent HMI/SCADA application for iOS and Android devices, mySCADA Technologies, www.myscada.org

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AUTOMATION calculating ROI

The benefits of calculating ROI to measure a facility’s performance objectives For automation, return on investment (ROI) is more important than total cost of ownership (TCO). When making a capital investment in automation, companies need to determine value based on the solution’s impact on facility performance and its workforce. Also consider cost of downtime and services.

W

hen it comes to making a capital investment in automation, many companies determine value by looking at the cost to install and operate a system over the course of its lifecycle. However, what isn’t considered, and what’s arguably even more important, is the solution’s impact on the overall facility’s performance and workforce.

Operators in the industrial process industry can use any number of metrics and methodologies to determine the viability of their capital investments. In recent years, in an effort to optimize overall cost, many have turned to total cost of ownership (TCO) as a means of driving purchasing decisions. While this has allowed stakeholders to quantify (albeit roughly) how much will be spent on an investment over the course of its lifecycle, applying TCO strictly on CAPEX and OPEX (capital expenditures and operating expenditures) fails to capture many of the benefits generated from improving the performance of an asset and/or process.

When it comes to choosing among automation solutions, using TCO as the sole metric for making a decision is contradictory because one of the primary purposes of implementing an integrated solution like a distributed control system (DCS) is to achieve measurable performance

improvements in the forms of efficiency, production, safety, and compliance.

Ironically enough, by focusing only on cost when evaluating a capital investment in automation, operators may inadvertently end up doing the exact opposite of what they are trying to accomplish, which is to select the option that offers the most value given the operational life of the facility.

When looking at automation solutions, it is necessary to treat TCO as one piece of the equation used to calculate return on investment (ROI). And keep in mind, when talking about ROI, we are looking at the functional definition—not the accounting definition. In our equation, ROI is a function of combining TCO with the positive impacts that come from performance improvements (see Figure).

Understand TCO versus ROI

MORE

ADVICE KEY CONCEPTS The benefits of calculating ROI Inefficiencies of only applying TCO Determining value through calculating ROI. GO ONLINE For related links about ROI, read this article online. In the digital edition, click on the headline or search the headline for www.controleng. com.

Read more online about improved safety and compliance, Where TCO falls short, and asset health monitoring.

CONSIDER THIS Are there other metrics to account for when considering a facility’s performance objectives?

Generally speaking, TCO consists of two parts. The first is the cost to actually purchase and implement the solution (such as hardware, software, and networking). This is often referred to as total installed cost (TIC). In today’s environment, with capital expenditure budgets stretched thin, many operators have placed a particular emphasis on TIC. While it certainly should be considered when making a decision, doing so without taking into account lifecycle costs or operational

To determine the best overall value, look at the entire ROI equation, which takes into consideration the total cost to install, operate, and maintain the system, plus the operational impact and monetary savings generated by performance improvements. Image courtesy: Emerson www.controleng.com

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AUTOMATION

‘

In the event of an upgrade,the knowledge and expertise of the automation partner will play a critical role in ensuring that value from the investment is maximized.

’

calculating ROI impact is an approach that often results in missed opportunities.

The second part of TCO is the total cost to manage and maintain the solution throughout its lifecycle (including the cost of decommissioning), which typically ranges anywhere from 30 to 40 years. It is this part of TCO that often distinguishes one option or vendor from another.

However, sometimes it takes a backseat in prefront-end engineering design evaluations to the cost of acquisition.

As its name indicates, TCO looks at the cost aspect of implementing an automation system, including the cost of doing business, opportunity costs, replacements, or upgrades. But it does not take into account performance improvements, and thus it fails to provide an accurate representation of a solution’s true value.

To obtain a more precise and realistic calculation, looking at the entire ROI equation is vital, which takes into consideration the total cost to install, operate, and maintain the system, plus the operational impact and monetary savings generated by performance improvements.

Consider the cost of downtime

Lost revenue from equipment downtime can have a substantial impact on the overall facility profitability. As a result, it should be included when calculating ROI. When estimating downtime, many operators look at hardware maintenance requirements to determine scheduled shutdown frequency and duration. What they don’t consider, however—and what’s arguably more important—are the losses that arise from unscheduled shutdowns.

Although difficult to predict, unplanned downtime due to equipment failure can typically be mitigated by implementing proactive strategies, such as asset health monitoring.

For many operators, the cost associated with implementing instrumentation that provides the capability to perform this type of monitoring is reflected in TCO as a maintenance expense. But by accounting for benefits such as higher plant uptime, extended life of equipment, and shorter equipment maintenance outages—the instrumentation is seen for what it truly is: a source of measurable and substantial savings.

Overall, when calculating the cost of downtime, operators should consider revenue losses, the cost to return the process or piece of equipment to operation, indirect cost associated with regulatory compliance, and the capital costs of carrying excess production capacity.

The cost to service an ROI investment

Applying TCO to process control also fails to

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CONTROL ENGINEERING

capture many of the intangible benefits that arise from partnering with a company that has proven automation and process control expertise.

Since process infrastructure typically has a lifespan of 20 to 40 years, making continuous improvements and upgrades to modernize is inevitable. In the event of an upgrade, the knowledge and expertise of the automation partner will play a critical role in ensuring that value from the investment is maximized.

Engaging with the right process control expert is vital. A trusted automation partner is continuously adjusting process inputs and evaluating emerging technologies to enhance the overall operation of an asset.

Companies that operate with a “run-tofailure” mindset end up spending even more because failing to maintain systems leads to unplanned downtime and shortens the lifespan of capital investments. Engaging with a strategic partner to implement a proactive approach is essential to controlling the timing and cost of modernization projects, but it’s something rarely considered by operators when implementing an integrated automation solution.

Leveraging the knowledge and expertise of the automation partner to make strategic engineering decisions early in the developmental phases of the project—and throughout the lifecycle of a facility—can generate benefits that are difficult to capture in TCO or TIC. Maximize automation value

To ensure that the optimal solution is selected, companies should look beyond TCO and instead apply ROI by taking into account the benefits that come from partnering with a control systems expert to implement an integrated solution. This includes any improvements in safety, reduced unplanned downtime, increased production, and improved workforce effectiveness.

Considering the total installed cost of automation solutions and the lifecycle costs for a project—along with the operational impact that is derived and enabled by automation from the aforementioned improvements—will allow for a selection of options that more appropriately aligns with the specific requirements and performance objectives of a facility. Doing so will ultimately lead to more efficient use of capital budgets in today’s increasingly cost-conscious environment. ce

Sean Sims is the vice president of lifecycle services for process systems and solutions at Emerson. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com

INSIDE MACHINES vision tips

Machine vision lessons learned from applications Machine vision isn’t as challenging as it used to be. Setup, testing, and start-up can be easier and faster than prior technologies, especially with help from machine vision system integrators, as this application advice shows, shared at NIWeek 2016.

T

wo recent automotive case studies show value in recent, high-powered machine vision applications, as discussed at NIWeek 2016. A highspeed, clear, plastic bottle inspection also showed how processing power and smart software helped speed integration of the machine vision applications. The case studies were part of the Vision Summit, looking at high-speed, highresolution continuous motion inspection.

Fast-moving web blurs defects

In production of automotive 20-ft-wide rolls of ceiling foam, human-eye detection in a 600-ft/ minute web process was impossible, especially with defects in the foam or attached fabric as small as 0.020/in., explained Craig Borsack, PE, president G2 Technologies. Human inspectors were missing tears in the foam longer than a foot.

The vision system integrator used a fourth generation automated web inspection platform, which evolved from reflective memory, local storage, to field programmable gate array (FPGA)-based, realtime image processing.

The integrated technologies provided automatic defect detection, marking of defect areas, thickness detection, and other capabilities with off-the-shelf components, Borsack said.

The FPGA handled image processing, acquiring, and the 20-ft-wide image, at 70MB/sec bandwidth.

Multi-threaded process was used, with information going to the human-machine interface to apply a binary mask and edge detection, which is used for continuous width measurement; a second thread was used for image defect processing and another for image storage to a database for data analysis and recording of defect location and images of the defect, he explained.

The installation used nine cameras in 3 sets of three to provide unique orientations required to highlight the defects. Instead of defective rolls causing customer anguish, defects could be detailed and offered at a discount. Information allowed customers to easily work around the defects, Borsack said, at the right price. www.controleng.com

Edge detection, pattern matching

FCC Indiana rebuilds clutches for Honda.

Dirt and scratches are not part of the piece being inspected, and the prior vision system couldn’t always make that distinction, said Tanner Blair, embedded systems engineer with National Instruments. Issues with the application included inconsistent lighting, metallic surfaces, dirt, grease, and scratches, Blair said. Also in the field of vision were varied rivet types. The customer wasn’t interested in changing the lighting and focused on changing the algorithms for image analysis.

Within the field of interest, the inspection software focused on circular edge detection from the inside out, dark to light, ignoring a center hole, and providing an accurate inspection, he said.

Bottle thread inspection

There can be challenges with inspecting thread quality in molded, clear, plastic bottles, explained Vivian Le, application engineering with Graftek Imaging. Sometimes hanging flash can be mistaken for multiple threads. The area of interest was an “S” measurement, which is an industry standard measurement for the distance between the top of the bottle to the top edge of the top-most thread. The bottle was backlit and imaged the full 360 degrees, with an image acquired every 10 degrees of rotation. Within the area of interest, five-measurement pattern matching was used. The challenge was that the thread shape changed with angle, and the top of the bottle looked similar to threading, she said.

Pattern matching was used so the software could learn the threads as the template, since view varied depending on rotation. Three pattern matches were used, and the software selected the top score of all matches. Rakes were used to detect the edge detection, looking at the top edge of the threads and the top of bottle, calculating the distance between two points. Continuous acquisition identifies features and dimensions, variations as small as 0.05 in., Le said. ce Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.

CONTROL ENGINEERING

Pattern matching using NI Vision Builder for Automated Inspection software, withing the field of interest to ignore grease or scratches or other variables and focus on a proper inspection of clutch parts, as explained in a National Instruments presentation at NIWeek 2016. Courtesy: CFE Media, National Instruments

MORE

ADVICE KEY CONCEPTS Machine vision handles high-speed, high-resolution inspection.

Field programmable gate array (FPGA)-based processors provide multithread analysis.

System integrators can help with implementations.

GO ONLINE For more details, photos, and links to NI vision training and more Control Engineering vision articles, see this article online at www.controleng.com.

CONSIDER THIS What fast moving in-line inspection could help reduce your scrap?

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INSIDE MACHINES motion control

How to cut costs and maximize production with servo automation Lumber machine manufacturer’s moves to servo control yields increased precision, productivity.

A

2x4-ft piece of lumber is the construction industry’s ultimate commodity, which is why a leader in the lumber industry is using sophisticated automation to gain a competitive advantage for this price-sensitive product.

Creating a solution with automation

MORE

ADVICE KEY CONCEPTS The benefits of integrating servo motors and replacing hydraulic components How to maximize production with servo automation Solving production challenges with automation.

GO ONLINE For related links about servo motors, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com.

CONSIDER THIS What are the challenges behind integrating servo motors for other applications?

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WaneShear Technologies creates the sawmill machinery that puts a finished edge on dimensional lumber to create straight, clean, highgrade 2x4-ft, 2x6-ft, 2x8-ft, and larger boards.

The equipment created by WaneShear’s Ukiah, Calif., location has the challenge of processing this consistent product from rough lumber that was sawed from raw logs, which can vary widely in width and length before entering the edging machinery. The technical challenge increases because of the constant need to increase production volumes made necessary by the pressure to maintain profitability amid fluctuating prices in the volatile construction industry.

While automation has been part of this equation, WaneShear has been pioneering a different solution. Traditional edging automation equipment used hydraulic components. Hydraulics deliver the powerful, high torque output the application demands but often result in leaks of hydraulic fluid. Spilled fluid can damage the lumber and make it unacceptable for sale. Fluid also can combine with sawdust to create a sticky substance that gums up machinery and makes cleanup difficult.

“We knew that by switching from hydraulics to servo automation, operators could solve a lot of our problems,” said Ron McGehee, president and chief designer of WaneShear’s equipment and the holder of more than 25 patents on sawmill related inventions. “In the past we didn’t look very carefully at servo automation because we felt servos wouldn’t have the torque strength to get the job done, and they would be too large to fit in the physical space of our machines without a lot of re-engineering.”

CONTROL ENGINEERING

Figure 1: Motion automation manufacturer Yaskawa provides servo motors and engineering support for challenging applications. Machine vision, Yaskawa MP3200 motion controller, cam editing tool, SigmaLogic servo amps, and smart system integration helps with efficient lumber cutting. All graphics courtesy: Yaskawa America Inc.

This attitude changed in the last few years, as the footprint of servo motors has been reduced and new, more powerful servo motors have come into the market.

“The time had come for a new approach, and we saw the opportunity to be an industry leader,” said McGehee.

Servo automating for edging

Servo motion offered an opportunity to improve the precision of WaneShear edgers, which would lead to more usable boards from every log. WaneShear pioneered the www.controleng.com

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INSIDE MACHINES motion control

Figure 2: Yaskawa SigmaLogic Servo Amplifiers can be programmed through a programmable logic controller (PLC) interface.

use of vision systems and variable frequency drives to stage rough boards for edging. The staging of boards is especially challenging because squaring an irregular board doesn’t always call for a perfectly straight cut. Cutting angles can often vary by 6 degrees, requiring the use of precise camming routines that often must change quickly to compensate for a variety of board contours. Because board lumber is quality graded, a better quality of cut means the machine’s output can be sold at a higher price.

The edgers manufactured by WaneShear must be integrated with the other equipment in a crowded sawmill, which presents a separate set of challenges for automating the edging process. Each edger is customized to fit the available space on a sawmill floor that is filled with a variety of other

equipment, which makes minimizing the footprint of each machine critical.

“Linking machines in tight spaces gets to be pretty much essential,” said McGehee. “If we can replace gearboxes and hydraulic equipment with servos in the same physical space, we can add capability without adding an integration problem for our customers.” Control system integration is equally important, with most mills using programmable logic controller (PLC)-focused control architecture for their production equipment. “PLCs are the customer’s comfort zone,” said McGehee. “Whatever automation you add, it must integrate with the PLC in a way that gives a minimum of trouble for the personnel on the sawmill floor otherwise they won’t buy into it.”

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INSIDE MACHINES motion control Reliability was the primary concern and requirement for WaneShear when considering the switch to servo control. Sawmills must run around the clock, 365 days a year to remain profitable. This desire for reliability led McGehee and the other members of the engineering team to a motion automation manufacturer providing reliable servo motors and engineering support for challenging applications.

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Aerotech will also customize the controller for your needs.

Contact an Aerotech Application Engineer today to learn how our automation controllers can benefit your application.

Figure 3: This is an illustration of board staging and saw box output using the previous method in comparison to the servo method.

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CONTROL ENGINEERING

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lie pp

INSIDE MACHINES motion control Vision system identifies target

Application technical challenges began with the staging of boards for cutting. The edger’s vision system extrapolated each board’s position into four position points, which were translated by a motion controller into more than 1,000 positioning points. The motion controller’s cam editor tool was used to

create a set of motion profiles, which were used by servo-based conveyors to precisely stage boards for the most accurate edging possible with the least waste.

The interface between the PLC and servo axes was simplified by the addition of servo amplifiers that can be controlled using the add-on-instructions from a standard PLC. This

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feature proved to be particularly important for the WaneShear software development team to avoid requiring customers to learn an entirely new programming interface to successfully integrate the new servos.

Integrating servo motors

Integration of the servo motors themselves proved to be one of the most positive outcomes in the development process. The servo motor dimensions made them an easy fit into the spaces once occupied by hydraulic components.

The torque ratings of the motors suited them well to conveying lumber at the high-power, low-RPM rates needed by a sawmill application. The torque density profiles of the servo motors also made it possible to replace a gearbox on one of the WaneShear machine designs, resulting in cutting component costs. The precision of the motion control components allowed WaneShear to reduce errors on its conveyors from ⅛ in. down to ½50 in., allowing the company to shorten the length of its conveyor belts without compromising the accuracy of the cut.

The servo motor implementation allowed the edger to reach performance targets. The goal was to increase output to 75 boards per minute, requiring a cycle time of 800 microseconds per board. The design team also expected to improve the quality of boards due to the extra precision of the servo-driven control system. All targets were exceeded. Board output quality increased by 25%, and the new WaneShear servo-equipped edger is processing standard 8-ft boards at more than 20 ft per second, well beyond the 800 microsecond goal.

The servo motors and drives used are being designed into all WaneShear machines going forward. “We are also seeing other machines within our customers’ mills using the [servo] products.” McGehee anticipates continuing to use the automation technology provider “for a long time to come.” ce Hunter Stofferahn is the regional motion engineer for Yaskawa America Inc. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com.

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INSIDE MACHINES vision tips

Six tips: Improve vision systems Machine vision advances have made machine vision implementations easier than before; track and trace inspection applications can offer high speed and high accuracy.

A

ccuracy of vision systems that verify food and beverage product labels is critically important to those with allergies. Reading barcodes on shiny cans traditionally required specialized systems of high cost, but Matrix Technologies, a 2016 System Integrator of the Year, offers advice and integrated technologies for easier and lower cost machine vision implementations.

1. Use off-the-shelf industrial prepackaged vision systems; some can handle up to 1,000 cans and product codes per minute.

2. It’s easier than it used to be. Configuration and use are easier and more reliable than higher level customized systems. Customers often have expertise or staff to reconfigure the system.

3. Machine vision software with the ability to do geometric pattern matching can verify a machine-printed product code.

4. Machine vision software also uses optical character recognition (OCR) to verify product

codes and multiple product labels using pattern recognition to help with varied orientations.

5. Such machine vision systems can have an IP67 rating to withstand industrial environments.

6. Integrate other sensors, controllers, and visualization as needed for the application. Other technologies, such as a laser sensor, can detect if a label isn’t properly glued to a can. A proximity sensor can trigger both the laser sensor and vision system.

A controller can send a signal to reject products that fail. A human-machine interface (HMI) helps with setup and operations and can feed information to other systems. ce Edited by Mark T. Hoske, content manager, Control Engineering, mhoske@cfemedia.com, from information provided by David J. Bishop, president and a founder of Matrix Technologies and member of the Control Engineering Editorial Advisory Board.

MORE

ADVICE KEY CONCEPTS Track and trace can be high-speed and provide high accuracy.

Other technologies can be integrated to extend functionality.

GO ONLINE Link to Matrix Technologies in the Global System Integrator Database and see other related resources with this article online.

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CONTROL ENGINEERING

Input #107 at controlengineering.hotims.com

Input #108 at controlengineering.hotims.com

www.controleng.com

NEW PRODUCTS and software See more products daily at www.controleng.com/products.

Foundry robot for material handling and machine tending applications ABB Robotics’ IRB 1200 Foundry Plus 2 is designed for material handling and machine tending applications.

The IRB 1200 can improve and reduce cycle times for precision die casting processes such as smart phone cases and other electrical components. Now protected with Foundry Plus 2, ABB’s protection system, the IRB 1200 is designed to withstand harsh environments and meets IP66/67 requirements. The IRB 1200 Foundry Plus 2 is IP66/67 compliant from base to wrist, meaning that the robot’s electrical compartments are sealed against liquid and solid contaminants. ABB Foundry Plus 2 robots also have resistance to corrosion and capability to withstand high-pressure steam washing. The IRB 1200 also is available with clean room protection.

ABB Robotics,

www.abb.com/robotics

Input #201 at www.controleng.com/information

Proximity sensor series with cylindrical, rectangular styles AutomationDirect offers the Contrinex DWseries of extended and triple-distance proximity sensors in 3 to 30 mm cylindrical and 20 mm rectangular styles. With 10 to 30 V dc operating voltage and sensing distances ranging from 1 to 40 mm, cylindrical sensors are available in shielded and unshielded models with nickel silver, nickel silver/chrome, chrome-plated brass, or stainless steel housings. The 3 mm proximity sensors are fitted with a two-meter axial cable; other sizes offer two-meter axial cable, M8, or M12 quick disconnects. They have an LED status indicator and are available with NPN and PNP, as well as normally open or normally closed outputs. They have an IP67 protection rating and overload protection.

AutomationDirect,

Power supplies for configuration and diagnostic applications Phoenix Contact’s Quint Power power supplies are designed to give control engineers improved configuration and diagnostics to ensure reliable power to the control system. The models feature near-field communications (NFC), real-time monitoring, coordinated surge protection, and a configurable dc output. With secured NFC, the power supplies can be configured while still in the box. User-definable settings allow monitoring of real-time dc current, power, or voltage using a 4 to 20 mA analog output. The Quint power supplies can also be made tamper-proof by locking out the push buttons on the front panel and creating a user-defined password.

www.automationdirect.com

Input #202 at www.controleng.com/information

Ultrasonic sensor for wireless tank monitoring applications Banner Engineering’s Sure Cross U-GAGE K50U ultrasonic sensor is designed for use in wireless tank monitoring applications. Optimized for use with Banner’s Q45U Wireless Node, the pair is designed to provide a plug-and-play solution to monitor levels in mobile or remotely located tanks and totes. The K50U can detect distance from target to sensor in ranges between 300 mm and 3 m and features built-in temperature compensation designed for accurate measurements. The sensor is also an ideal solution for a range of applications beyond liquid or chemical tank level monitoring, such as pallet presence sensing or monitoring dry material level in a hopper. The K50U is available in two models, with a 1-wire serial interface or a model that functions as a Modbus slave via RS-485.

Banner Engineering,

Phoenix Contact

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Input #203 at www.controleng.com/information

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Converter series for process control, measurement TDK Corp.’s TDK-Lambda 15W CCG15S series of dc-dc converters operate over a 4:1 input range and are enclosed in a 1x1-in., six-sided, shielded metal case. They are designed for telecommunications, process control, broadcast, and test and measurement equipment applications. The CCG15S is available with 3.3, 5, 12, or 15 V outputs and can operate from either a 9 to 36 V dc or 18 to 76 V dc input. The converters can operate from either 12 and 24 V or 24 and 48 V nominal inputs. It has an operating efficiency of up to 88%, and the CCG15S series can operate in ambient temperatures from -40° to 85°C (-40° to 185°F). All models have a +/-10% output trim function, remote on/off, and overvoltage and overcurrent protection. The CCG series has an input to output isolation of 1,500 V dc and 1,000 V dc input or output to case.

TDK Corp.,

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Input #205 at www.controleng.com/information

CONTROL ENGINEERING

OCTOBER 2016

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NEW PRODUCTS and software See more products daily at www.controleng.com/products.

Statement of Ownership, Management and Circulation 1.

2.

3.

4.

5.

6.

7.

Rotary encoder series for motion control applications Leine and Linde’s RXI and RXA 500 series of rotary encoders come in stainless steel versions and are designed for motion control applications in severe environments where regular washdown is necessary. They can be used in everything from forestry to windpower, with shaft and hollow-shaft options to suit virtually any application and can be used in harsh environments such as food processing salt spray in offshore environments.

Absolute versions of the 500 series are available with up to 14-bit single-turn outputs, with parallel TTL, HTL, SSI, and CANopen interfaces. Incremental versions are available with up to 10,000 PPR resolution and are capable of operating at temperatures up to 100°C (212°F).

Leine & Linde

www.leinelinde.com Input #206 at www.controleng.com/information

Publication Title: CONTROL ENGINEERING Publication Number: 813-430 Filing Date: 9/26/16 Issue Frequency: 12x, monthly Number of Issues Published Annually: 12 Annual Subscription Price: USA $150 CAN $180 MEX $180 INTL $325 Complete Mailing Address of Known Office of Publication (Not printer): CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523 8. Complete Mailing Address of Headquarters or General Business Office of Publisher (Not printer): CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523 9. Publisher: Jim Langhenry, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523 Editor-in-Chief: Mark Hoske, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523 Editor: Chris Vavra, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523 10. Owner: CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523 Jim Langhenry and Steve Rourke, CFE MEDIA, LLC 1111 West 22nd St., Ste #250 Oak Brook, IL 60523 11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgages, or Other Securities: None 12. Does not Apply 13. Publication Title: Control Engineering 14. Issue Date for Circulation Data Below: September 2016 15. Extent and Nature or Circulation Average No. Copies Each Issue During Actual No. Copies of Single Issue Preceding 12 Months: Published Nearest to Filing Date: 52,486 52,116 a. Total Number of Copies (Net Press Run): b. Paid and/or Requested Circulation: 00 00 (1) Paid/Requested Outside-County Mail Subscriptions Stated on Form 3541.

51,528 51,368 (Include advertiser’s proof and exchange copies) (2) Paid In-County Subscriptions Stated on Form 3541.

0 0 (Include advertiser’s proof and exchange copies) (3) Sales Through Dealers and Carriers, Street Vendors, Counter Sales, and Other 0 0 Non-USPS Paid Distribution (4) Paid Distribution by Other Classes of Mail Through the USPS 107 101 c. Total Paid and/ or Requested Circulation [Sum of 15b, (1), (2), (3), and (4)-** 51,635 51,469 d. Free or Nominal Rate Distribution (By Mail and Outside the Mail) (1) Outside-County as Stated on Form 3541 0 0 0 0 (2) Free or Nominal Rate In-County Copies Included on PS Form 3541 (3) Free or Nominal Rate Copies Mailed at Other Classes Through the USPS 533 407 (4) Free or Nominal Rate Distribution Outside the Mail (Carriers or other means) 0 0 e. Total Nonrequested Distribution [Sum of 15d (1), (2), (3), and (4) 533 407 f. Total Distribution [Sum of 15c and 15f] 52,169 51,876 g. Copies not Distributed 317 240 h. Total [Sum of 15f and 15g] 52,486 52,116 i. Percent Paid [15c divided by 15f times 100] 98.98% 99.21% 16. Electronic Copy Circulation 28,816 28,907 a. Requested and Paid Electronic Copies b. Total Requested and Paid Print Copies (Line 15c) + 80,451 80,376 Requested/Paid Electronic Copies (Line 16a) c. Total Requested Copy Distribution (Line 15f) + 81,302 81,023 Requested/Paid Electronic Copies (16a) d. Percent Paid and/or Requested Circulation (Both Print & Electronic Copies) 98.95% 99.20% (16b divided by 16c x 100) 17. Publication of Statement of Ownership: Publication Required. Will be printed in the October 2016 issue of this publication.

18. I certify that all information furnished on this form is true and complete. I understand that anoyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalities). Jim Langhenry (signed), Publisher

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Contact: Iris Seibert at 858-270-3753 or ISeibert@CFEMedia.com

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Patrick Lynch, Director of Content Marketing Solutions 630-571-4070 x2210 PLynch@CFEMedia.com AL, FL, GA, MI, TN

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ADVANTECH . . . . . . . . . . . . . . . . .9 . . . . . . . . . . . . . .6 . . . . .www.advantech.com Advantech Corporation . . . . . . . .14, 15 . . . . . . . . . 11 . . . .www.advantech.com Allied Electronics . . . . . . . . . . . . .C1, 7 . . . . . . . . . . .5 . . . . .www.alliedelec.com Allied Moulded Products, Inc. . . .28 . . . . . . . . . . . . 19 . . . .www.alliedmoulded.com AutomationDirect . . . . . . . . . . . . .C2, 16A-16D, 29 . . 1, 20 . . .www.automationdirect.com Beijer ELECTRONICS . . . . . . . . . .10 . . . . . . . . . . . . .7 . . . . .www.beijerelectronics.com/x2 Bosch Rexroth Corporation . . . . .30 . . . . . . . . . . . . 21 . . . .www.boschrexroth-us.com/i40potential CFE Media, Engineering Is Personal . . . . . . . .48 . . . . . . . . . . . . . . . . . . .www.controleng.com Control Engineering 2016 System Integration Study . .16 . . . . . . . . . . . . . . . . . . .www.controleng.com/2016SystemIntegration Control Engineering Digital Reports. . . . . . . . . . . . . . . .35 . . . . . . . . . . . . . . . . . . .www.controleng.com/DigitalReport/IIoT Dataforth Corp . . . . . . . . . . . . . . .27 . . . . . . . . . . . . 18 . . . .www.dataforth.com

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REQUEST MORE INFORMATION about products and advertisers in this issue by using the http://controleng.com/information link and reader service number located near each.

If you’re reading the digital edition, the link will be live. When you contact a company directly, please let them know you read about them in Control Engineering. www.controleng.com

CONTROL ENGINEERING

Stuart Smith +44 208 464 5577 stuart.smith@ssm.co.uk

CFE Media Contributor Guidelines Overview Content For Engineers. That’s what CFE Media stands for, and what CFE Media is all about – engineers sharing with their peers.

We welcome content submissions for all interested parties in engineering. We will use those materials online, on our website, in print and in newsletters to keep engineers informed about the products, solutions and industry trends. www.controleng.com/contribute explains how to submit press releases, products, images and graphics, bylined feature articles, case studies, white papers, and other media. * Content should focus on helping engineers solve problems. Articles that are commercial in nature or that are critical of other products or organizations will be rejected.

(Technology discussions and comparative tables may be accepted if non-promotional and if contributor corroborates information with sources cited.) * If the content meets criteria noted in guidelines, expect to see it first on our Websites. Content for our e-newsletters comes from content already available on our Websites. All content for print also will be online.

All content that appears in our print magazines will appear as space permits, and we will indicate in print if more content from that article is available online. * Deadlines for feature articles intended for the print magazines are at least two months in advance of the publication date. Again, it is best to discuss all feature articles with the appropriate content manager prior to submission.

Learn more at: www.controleng.com/contribute OCTOBER 2016

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BACK TO BASICS selling a technology business

How to sell an automation or system integration business Part 3: How should an automation or control system integration business be sold?

Who are potential buyers? Looking at the business as an investment can help.

See five ways to identify business buyers.

‘

Record ideas about possible buyers for the business as you read industry articles, attend tradeshows, attend networking

’

events, etc.

MORE

ADVICE KEY CONCEPTS Keep a list of potential buyers for a business.

Update the list as you go.

Increasing visibility can help identify additional buyers.

GO ONLINE With this article online, see more information, an online chart of buyers and link to Part 2 in this series: How to manage an automation or system integration business as an investment CONSIDER THIS Starting with the end in mind includes considering potential business buyers.

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I

It comes as a surprise to many people, but every privately owned business has different values, depending on who the buyer of the business might be. This is because different types of buyers are motivated differently and perceive risk differently. Selling a business requires identifying potential buyers and how those buyers perceive risk and opportunity resulting in realizing higher value for the business.

For example, about 5 years ago, John bought out his partner in a medium-sized system integration business specializing in the water and wastewater industries. While the sale came sooner than they had planned due to an unexpected illness of John’s long-time business partner, they followed the terms of their buy/sell agreement and had a fairly smooth transition of ownership. John took 100% control based on their mutual desire to keep the business’s equity with the original owners as they navigated a period of rapid growth.

As John looks ahead toward retirement in another 5-10 years, he feels he’s in a good position to sell the business based on current success.

He knows he will consider a variety of options for buyers; however, he doesn’t have any ideas who those might be other than an employee of the business who has shown some level of interest and potential. He is unsure he wants to place his retirement bet on just one person who has no binding obligation to even stay as an employee, let alone take on ownership.

While John’s retirement may be at least 5 years away, it’s never too early to think about an exit strategy. A situation can change quickly based on the market, health, or other factors. So now is a good time to start thinking about possible buyers based on objectives. The chart (online) shows types of buyers and the relative values that each would pay for a business.

Amounts vary because each group is motivated differently and perceives risk differently. The buyer types listed in the chart range from those who would likely offer the lowest enterprise value (lowest sales price) such as the undiversified passive investors up to the highest enterprise value, the strategically positioned buyer.

CONTROL ENGINEERING

Five ways to identify buyers

Many business owners have not thought much about who the buyer of the business might be; here are a few tips to get started.

1. Check your buy/sell agreement. If you have a partner in your business, are there any stated provisions about what types of buyers you can/ cannot sell to within your agreement?

2. Identify your exit objectives. Do you want to/need to keep your business within your family or certain group of employees? Or no matter what happens, are you just looking for ways to maximize sales price? While they may change over time, put exit plan goals in writing.

3. What are your potential buyer types?

Based on the chart and your objectives, what two or three buyer types could you see as the best fit to sell the business to when the time comes?

4. Keep a running list. Who are your top five contacts you’d call if you needed to sell today?

While your list is sure to evolve over the years, record ideas about possible buyers for the business as you read industry articles, attend tradeshows, attend networking events, etc. If the time comes to sell the business sooner than you think, you’ll have the comfort of knowing you’ve positioned yourself for success by keeping a long list of prospective buyers.

5. Make yourself known. Ensure potential buyers know about your business even before thoughts of a sale begin. Write or speak about some of the successes the business has had in your industry publications or at your industry’s conferences.

Future articles in this nine-part series will discuss how to increase the value of a business. ce Catherine J. Durham is accredited senior analyst, principal, and president, Capital Valuation Group; edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com. www.controleng.com

ONE FOR ALL

Robots, Servos & Drives, now Controlled by ONE SOFTWARE Yaskawa introduces Singular ControlTM: robotics, servo systems and variable speed drives working together under one software package. Singular Control uses the same ladder logic you’ve used for years, allowing you to develop new automation without the need for a robot programmer.

Pick, pack and palletize with new programming power, superior speed and industry-leading effectiveness, thanks to an innovation that puts Yaskawa performance and reliability into more innovative automation designs than ever before.

For more info: http://budurl.me/YAI958

Visit us at Pack Expo / Chicago Booth E-4154 November 6 - November 9

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YASKAWA AMERICA

DRIVES & MOTION DIVISION

YASKAWA.COM

1-800-YASKAWA

Less is more.

Too much inventory? We can help! The MOVIGEARÂŽ Mechatronic Drive System from SEW-EURODRIVE substantially reduces your inventory with its ability to cover a broad range of gear ratios with a single unit. Independent research has also proven that the MOVIGEARÂŽ reduces start-up and operating costs in material handling by 20-30%. So, relax...we got this!

movigear.com / 864-439-7537

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