www.controleng.com
tomation
ct, Cumming, GA USA. All rights reserved.
Get MORE I/O for LESS with the Productivity2000 PLC
CPU ONLY:
$255.00 P2-550
FREE
Programming Software
Discrete I/O
Analog I/O
$40.00
$143.00
starting at: P2-08NE3
starting at:
P2-08ADL-1
More DIN Rail Density: The Productivity2000 PLC is designed with a spacesaving, slim form factor that provides for lots of I/O in a little space. Easily fit over 220 discrete input points in a single 7-slot, 10 1/2� base and save your valuable real estate.
Easy Expansion with Remote I/O: Add thousands more I/O points to your system with the P2-RS high-performance Ethernet remote I/O expansion module. Up to eight remote base groups can be added with each I/O point being autoconfigured in the software. The P2-RS also includes a high-contrast OLED display for status messages and a micro USB port for remote CPU programming and monitoring.
Remote I/O Expansion Module priced at:
$225.00 P2-RS
Get more than you paid for . . .
www.Productivity2000.com
1-800-633-0405
www.AutomationDirect.com
input #1 at www.controleng.com/information
input #2 at www.controleng.com/information
DECEMBER 2016
30
Vol. 63 Number 12
Features 30 Robot advances in connectivity, collaboration, easier programming Cover Story: Advanced robotic developments include improved designs for safety and specialized environments, collaborative applications, better integration with other systems, and augmented monitoring to reduce risk of downtime and lower maintenance costs.
36 Easier, safer robotic programming is among results from an expanding open-source robotics software group Cover Story: ROS-Industrial, an open-source factory automation software project, celebrates its fifth anniversary in January 2017 by expanding into Asia, increasing visibility in a robotic competition, and is looking to improve workplace efficiency and safety with its programming.
38 Achieving operational excellence using APC In the chemical industry, advanced process control (APC) is the formula for reaching higher levels of operational excellence.
42 Wireless takes control for industrial applications Wireless transmitters are being widely used for monitoring, but recent developments show wireless also is suitable for real-time control for any application.
THREE COVER IMAGES: At top, motion planners based on Robot Operating System Industrial (ROSI) open source software reroute a Universal Robot arm when obstacles are encountered in an image courtesy of ROS-Industrial and Factory-in-a-day project (page 36). Lower left, an image from Siemens shows how robots easily connect to machine tools for automated production cell setup using Sinumerik 828D and 840D sl CNCs and related software, as shown at IMTS 2016. At right, a Yaskawa Motoman robot reaches for a box to place on a motor driven roller (MDR) conveyor, part of an updated Alvey 891i palletizer from Intelligrated (a Honeywell company), shown at 2016 Pack Expo International in Chicago, in a photo courtesy Control Engineering.
44
44 Using wireless to gain a network and data monitoring edge Gaining access and data from areas previously inaccessible allows for greater knowledge and visibility of what is going on throughout the manufacturing enterprise.
47 How to implement wireless sensor networks for difficult industrial settings Pairing low-power wide area network (LPWAN) and Bluetooth low energy (BLE) networks allows the enterprise Internet of Things (EIoT) to connect wirelessly to remote locations.
50 Best practices to help with multiplatform system integration Ease a multiplatform system integration process by doing vendor research, having a common network, and upgrading legacy equipment.
35 Digital Edition Exclusives Seeking truth in reporting helps manufacturing improve. Develop a process to make informed decisions with Big Data.
2
|
DECEMBER 2016
CONTROL ENGINEERING
38 CONTROL ENGINEERING (ISSN 0010-8049, Vol. 63, No. 12, 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
Limited time offer on the switch that saves you money.
Find out more at pages.moxa.com/savemoney linkedin.com/company/moxa
@moxainc
youtube.com/moxavideo
facebook.com/moxainc
input #3 at www.controleng.com/information
Re-Route Your Temperature Measurements Around Potential Roadblocks The new THZ3/TDZ3 Dual Input Smart HARTÂŽ temperature transmitters can help you avoid costly process interruptions and maintenance delays by ensuring your measurements always make it safely to your control system. Our Sensor Backup and Failover protection feature means you will never miss those critical readings - even if something goes wrong with one of the sensors. Plus, with Device Intelligence, a series of new and advanced features that enable smarter control and monitoring, the THZ3/TDZ3 gives you the conďƒždence that your temperature measurements will get from Point A to Point B despite any potential roadblocks.
input #4 at www.controleng.com/information
Demand Moore Reliability
To learn more about our Dual Input p Temperature p www.miinet.com/THZ3TDZ3 Transmitter, go to: 900 Or call 800-999-2900
DECEMBER 2016 Vol. 63 Number 12
Inside Machines Appears after page 50; If not, see the Digital Edition: www.controleng.com/DigitalEdition
M1 Controller for crane testing Verifying load parameters when testing mobile cranes is important to verify quality, which matters for functionality and safety. New testing systems included installing new proportional servo valves and high-performance, electro-hydraulic motion controllers.
M4 Advances in proximity sensors Inductive, magnetic, ultrasonic are among the technologies used for proximity sensing, and small sizes and extended ranges are among features in recently announced proximity sensors.
Departments 8 Think Again Finding IIoT benefits (See IIoT for Engineers, with this issue.)
10 Apps for Engineers Essential engineering applications
M1 M4
Products
60 Data logger, I/O; Portable controls; Slip ring diagnostic system (below); Screw feeders; illuminator for hazardous locations (right)
12 Research High to severe control system threat levels
Control Engineering International
16 Promote smart factory for manufacturing, products 18 Are we far from having digital factories?
Technology Updates
20 Ensure proper installation of monitoring, metering equipment 22 Easier way to use SCADA data for IIoT
24 Integrator Update Understanding the basic business valuation methods
64 Back to Basics Operate a three-phase motor using single-phase power.
News 25
Solution-ready platforms, IIoT applications; Innovation framework and business strategies for IIoT published
26
Automation and controls manufacturer: new facility, new president; drives, motion standard updated; System integrator expands
27 28
Demand for smart high-end safety solutions increasing
61 Ultrasonic distance and level sensors (far right); noncontact sensors; ultrasonic sensors; Surge protection (right); Digital controller for nanopositioning
62 Asset monitoring platform (right); Hygrometer; Design kit for motion controllers, PLC communications
EtherCAT with power; Motion control shipments increase; Events, online
www.controleng.com
CONTROL ENGINEERING
DECEMBER 2016
| 5
More resources posted daily at:
DECEMBER
IIoT
www.controleng.com
New Products
Control Systems
Process Manufacturing Discrete Manufacturing
System Integration
Ensuring SCADA/HMI cybersecurity There’s a lot more to read online. Go to www.controleng.com/news to read Control Engineering’s exclusive Web content. Six action items for an aging DCS/PLC Considerations when automating a task for a project Agricultural robots about to undergo a transformation Driverless-vehicle options expand to include scooters.
NEWSLETTER: PROCESS & ADVANCED CONTROL
Butterfly valve basics Keep up with the latest industry news by subscribing to Control Engineering’s 14 newsletters at: www.controleng.com/newsletters. It’s all about the outputs Enhance smart manufacturing with production process management Online process analyzer company acquired.
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
Nov. 11: IIoT and the Digital Oilfield: Making Data Actionable Oct. 20: Industrial Internet of Things Webcast Series 2016, Part Three: Security for IIoT Oct. 11: Simplifying IoT Value Creation: Physical Infrastructure and Wireless Sensing Sept. 29: Standards for Robotics Safety
Oil & Gas Engineering December issue Oil & Gas Engineering provides industryspecific solutions designed to maximize uptime and increase productivity through the use of industry Big Data, best practices and bigger solutions new innovations, increase efficiency 6 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
11 SCADA remains relevant | 14 Tablet technologies
Sensors are everywhere; get the most out of what they tell you
Engineers’ Choice Awards: Review products and vote for the best, until Dec. 21: www.controleng.com/VOTE2017.
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 and at www.controleng.com/contribute.
See www.controleng.com/videos
IIoT insights VP of IoT/Embedded Sales at Dell Inc., Jeff Brown, talked about the Internet of Things (IoT) and some of the latest developments in that industry with Plant Engineering content manager Bob Vavra at IMTS 2016. www.youtube.com/user/controlengineeringtv.
6
|
DECEMBER 2016
CONTROL ENGINEERING
Digital Edition The tablet and digital editions of this publication have unique content for our digital subscribers. This month has digital exclusives on: Five smart manufacturing hurdles to overcome; Know the risks of securing safety systems. www.controleng.com/DigitalEdition www.controleng.com
www.controleng.com
Can selecting the right I/O save you money? Absolutely.
Selecting the right combination of digital fieldbus, hardwired and wireless technologies can drastically reduce project, operational, and maintenance costs over time. System 800xA's Flexible I/O Solutions provide the freedom to choose the best fit for your next automation project creating a foundation for continuous improvement and support for life. For more information visit: www.abb.com/800xA
ABB Process Automation Division Visit us at www.abb.com/800xA Tel. +1 800 HELP 365
input #5 at www.controleng.com/information
THINK AGAIN smarter manufacturing 1111 W. 22nd St. Suite 250, Oak Brook, IL 60523 630-571-4070, Fax 630-214-4504
Finding IIoT benefits Industrial Internet of Things (IIoT) with smart applications of automation can include process optimization, higher quality, safer processes, lower energy use, regulatory compliance, higher profits, and more sustainable operations. Investments produce real benefits.
U
Use of automation
to efficiently enable a connected enterprise and realize benefits of Industrial Internet of Things (IIoT), Industrie 4.0, digital enterprise, smart manufacturing, and other initiatives, were among topics discussed at Automation Perspectives 2016, a conference prior to Automation Fair 2016 for media and analysts. The 25th Automation Fair conference and trade show, in November in Atlanta, was organized by Rockwell Automation for customers, prospects, and partners. Benefits of smart applications of automation include process optimization, higher quality, safer processes, less energy use, regulatory compliance, higher profits, and more sustainable operations. Ninveh Neuman, vice president, global commercial marketing, Rockwell Automation, said in introductory comments, that one size doesn’t fit all with automation; customers have pervasive needs, including better data management across the enterprise. Fortunately, she said, advantages of operational technology (OT) and information technology (IT) convergence are here today. Automation helps fill the skills gap
Blake Moret, president and chief executive officer, Rockwell Automation, said global trends pushing greater adoption of automation include the rise of the middle class in emerging economies around the world, stronger competitive pressures, and a widening skills gap, where, in the U.S., hundreds of thousands of good manufacturing jobs are unfilled
MORE
ADVICE GO ONLINE See the archived Dec. 15 IIoT case studies webcast, the last in the 2016 four-part IIoT series at www.controleng.com/webcasts. CONSIDER THIS With this issue, CFE Media launches IIoT for Engineers, a supplement that will help focus extensive Control Engineering coverage of IIoT benefits.
8
|
DECEMBER 2016
CONTROL ENGINEERING
because the talent doesn’t have the necessary skills. Workers that brought automation to plants are nearing retirement and are having trouble replacing themselves, Moret said. The lower cost of connectivity has driven opportunities, such as IT-OT convergence. Different levels of networks are collapsing and converging on Ethernet. With that infrastructure, another level of productivity can be achieved with information management and analytics applied at the right point in the architecture. Depending on the application, that may be at the plant floor, in the control room, and/or in the cloud, Moret suggested. Manufacturers and facilities are understanding advantages of connectivity. Value in connectivity
“Our vision of the connected enterprise is a practical way to get started and help companies along their journey,” Moret said, noting that value can be added four ways, by making companies realize: 1. Faster speed to market 2. Lower total cost of ownership (TCO) of critical assets 3. Increased asset utilization and less downtime 4. Greater ability to manage risk and comply with regulations.
Many have had trouble enabling these benefits through IT and OT convergence. Think again: Separate architectures aren’t needed. Info-enabled devices can turn data into useful information for better decisions and greater productivity. How much? In Rockwell Automation production facilities, implementation created a 4% to 5% annual productivity increase; 30% per year in capital expenditure avoidance, 50% reduction in lead time, and half the defects, among other benefits. 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
Corey Stefanszak, Senior System Architect Todd Williams, Vice President, Systems Integration
Optimize system functionalities. Implement an energy roadmap. Leidos Engineering is a trusted advisor for smart facilities across the nation, with forward-thinking solutions in systems engineering, energy management, software development, and wired and wireless infrastructure. Our experts help advance the enterprise and take on what’s next with the Internet of Things.
Activate Tomorrow, Today. leidos.com/activate input #6 at www.controleng.com/information
APPS FOR ENGINEERS data collection www.controleng.com/appsforengineers
USB TYPE-C HAS LANDED The new uEye LE USB 3.1 Gen 1 camera
USB 3.1 GEN 1
OEM
USB TYPE-C
MIC OPTION
Mobile apps for essential engineering applications Engineering 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. Apps are organized by category, company, and type. These are listed in the app as of December 2016.
Atlas Copco Construction iOS 8.0+, Android 4.1+
BOARDLEVEL VERSIONS
Cost: Free Company: Atlas Copco Construction Website: www.atlascopco.com
SOFTWARE SUITE
The Atlas Copco Construction app offers a range of products and service for onsite energy, compaction, paving, demolition, renovation, and recycling solutions for sustainable productivity. By using this app, engineers can request for quotes, contact the company, find the nearest Atlas Copco location based on location, engage on social media channels, see a video gallery, and get the latest news.
AutoCAD 360 iOS 9.0+, Android 4.0+ Cost: Free Company: Autodesk Inc. Website: www.autodesk.com Use AutoCAD 360 as an effective drawing tool to enhance the drafting experience with an adaptive grid to draw quickly and accurately. The app also has a redesigned smart pen to be more accurate and easy to use. The smart pen tool allows users to easily draw lines and arcs using a finger or Apple pencil.
Bitzer Refrigerant Ruler iOS 9.0+, Android 4.1+ Cost: Free Company: Bitzer Website: www.bitzer.de This app covers all of the common refrigerants and contains data on relevant physical properties. It offers an intuitive user interface to help work out temperature and pressure for various refrigerants. This tool is one of the few applications that enables the use of imperial and metric units at the same time. It is available in English and German. There are two other functions that allow users to select natural refrigerants and for global warming potential (GWP) values.
BuildingBlok iOS 7.0+, Android 4.0+ Cost: Free Company: BuildingBlok LLC Website: www.buildingblok.com BuildingBlok’s cloud-based construction management and communications software helps users manage the lifecycle of a project, including the planning/ bidding phase, construction document management, and closing/archiving. The helps increase transparency and accountability for all parties involved in residential, commercial, and industrial construction projects. BuildingBlok saves time, paper, and money, minimizes mistakes and related costs, and improves the efficiency and economics of managing construction projects.
®
www.ids-imaging.com input #7 at www.controleng.com/information
10
|
DECEMBER 2016
CONTROL ENGINEERING
www.controleng.com
When things just work, work gets done. Kepware’s industrial connectivity software provides secure and reliable data from the shop floor to the top floor, so you can focus on productivity. Learn more at kepware.com/CE
input #8 at www.controleng.com/information
No. of system integration projects per year 31 to 40
More than 40
3%
1 to 10
11% 8%
research
58%
20%
Average 14 projects
2016 CYBERSECURITY STUDY:
High to severe control system threat levels
O
One-quarter of respondents to
the Control Engineering 2016 Cybersecurity Study identified a high cybersecurity threat to their control systems, and another 9% said their systems are severely threatened. The most concerning threats to these at-risk systems are malware from a random source (28%) and attacks using vulnerable network devices (26%). Below are four more findings related to highly or severely threatened control systems: 1. Vulnerability assessments: Thirtynine percent of respondents reported that their companies have performed some type of vulnerability assessment within the past 3 to 6 months. The average facility checked vulnerabilities within 8 months. 2. Cyber-related incidents: More than half of respondents have experienced at least one malicious cyber attack on their control system networks and/or cyber assets—that they were aware of—within the past 24 months;13% were aware of 5
21 to 30 11 to 20
or more attacks; 43% of the incidents were accidental infections, 21% were targeted, and 36% were accidental and targeted. 3. Identifying cyber incidents: Seventytwo percent of respondents said that they were alerted about recent cyber incidents by their internal organization; 19% of incidents were identified through a third-party assessment; 9% were notified by the government or other outside party. 4. Risk factors: Lack of appropriate technologies and lack of training or enforcement related to technologies are the top risk factors identified by respondents with highly or severely threatened control systems. Other risk factors include age of existing assets (46%), lack of policies (46%), and lack of training or enforcement related to policies (41%). ce www.controleng.com/2016Cybersecurity has more. Amanda Pelliccione is research director, CFE Media, apelliccione@cfemedia.com.
The average system integrator works on 14 projects per year, with 14% taking on more than 30 projects annually. Source: Control Engineering 2016 System Integration Study
79%
of end users are familiar with the Industrial Internet of Things framework, up from 60% in 2015. Source: Control Engineering 2016 Industrial Internet of Things & Industrie 4.0 Study
26%
of facilities outsource maintenance operations and system integration to third-party providers. Source: Control Engineering 2016 Salary and Career Study
Vulnerable components in highly to severely threatened control systems 50%
Wireless communication devices and protocols 43%
Project files, control system operational procedures Connections to other internal systems
42% 39%
Network devices (firewall, switches, routers, gateways) Computer assets running commercial operating systems
38% 34%
Connections to the field SCADA network
33%
Control system cyber asset and application system backups Control system communication protocols used
32%
Embedded controllers and other components
32% 25%
OPC servers and connections Historians and connections Control system applications
21% 20%
The most vulnerable system components within respondents’ companies are wireless communication devices and protocols (50%); project files, control system operational procedures (43%); and connections to internal systems (42%). Courtesy: Control Engineering www.controleng.com/ce-research FOR MORE RESEARCH INFORMATION
12
|
DECEMBER 2016
CONTROL ENGINEERING
www.controleng.com
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.
input #9 at www.controleng.com/information
DAQRI SMART HELMET
TM
DEVELOPER EDITION
W E A R A B L E H U M A N - M AC H I N E I N T E R FAC E Raise productivity and efficiency. Connect with your world through the power of Augmented Reality. Available now - visit DAQRI.com
input #10 at www.controleng.com/information
ADVERTORIAL
WHAT’S YOUR AUGMENTED REALITY (AR) STRATEGY?
Rendering of DAQRI Smart Helmet User Interface
DAQRI Smart Helmet, an Augmented Reality (AR) wearable for industrial applications, is now poised to improve productivity and efficiency while lowering maintenance costs at your facility. DAQRI Smart Helmet connects you with your environment through a totally new kind of AR visual computing interface. It visually layers information about the world around you and is designed for use in industry. Because it uses common protocols and standards, it integrates to DCSs, PLCs, SCADAs, Historians, CMMSs, and ERPs making information previously constrained to the control room available right on the helmet, wherever you go. DAQRI Smart Helmet offers collaboration with remote experts, guided work instructions, an embedded thermal camera, data visualization, all hands-free. These capabilities, and the contextual relevance provided by AR, deliver on the promise of the Industrial Internet of Things. DAQRI Smart Helmet features an optical see-through display, with full color, high-resolution AR, in a large field of view, and industry-leading battery life. It provides an array of hardware and software capabilities, including Visual Inertial Odometry, setting a new standard for professional-grade wearables. This is an all-industry solution for improving common tasks in maintenance, operation, and production - providing the right data to the
right people at the right time to enable them to make more informed decisions. Isn’t it time to make DAQRI Smart Helmet an integral part of your AR strategy? Contact us today and learn how DAQRI Smart Helmet can impact workflow and business processes that lead to improved productivity and efficiency at your site. What are some applications of DAQRI Smart Helmet and what roles at your site would use it? Field personnel can collaborate with a Remote Expert from across the site or across the globe. Operators and Production Engineers can easily view upto-date standard operating procedures and Augmented Work Instructions to increase production efficiency. Field Operator/Maintainers can perform maintenance rounds with access to more information to shorten work order duration and decrease maintenance costs. DAQRI Smart Helmet users can capture photos, videos, and other sensor data to verify that the correct steps in a process were taken for improved compliance.
CONTROL ENGINEERING international
Promoting smart factory benefits Benefits of the smart factory, cyber-physical system, China Manufacturing 2025 all point to the integration of industrial and information technologies. Delta-Cimic Electronics Co. Ltd. explains smart factory benefits, in an interview with Control Engineering China.
I
Industrie 4.0 launched by Germany, cyber-
physical system (CPS) of USA and China Manufacturing 2025 all promote the integration of industrial and information technologies, and this is being done by China, according to Yin Xuanbo, deputy chairman of Delta-Cimic Electronics Co. Ltd., in an interview with Control Engineering China.
Smart factory integration
Xuanbo explained that the use of information technologies in the smart factory requires managing factory information as well as external commuADVICE nication. “Through such external communication, KEY CONCEPTS the enterprise can know customers’ demands Delta integrates smart factory quickly; the internal information flow of [a] comconcepts in manufacturing and in its pany can be directly touched by such information, automation products and products meeting customers’ demands can be Energy efficiency is important in production and products, helped with produced immediately,” Xuanbo said, which creates factory and information technology “powerful competitiveness for a smart factory.” integration When customers’ orders are received, he said, Manufacturers should focus through big data analysis, accurate and reasonable on high quality and ability to offer resource allocation can be performed, and the job customization without errors. will be allocated to specified suppliers, connecting GO ONLINE the supply chain effectively and seamlessly. See the Control Engineering IndusFuture industrial products, Xuanbo suggested, will trial Internet of Things (IIoT) page and learn more about international focus more on quality and details, another “objeccompetitiveness initiatives at tive pursued by smart factory.” Smart factory prodwww.controleng.com/international. ucts should have no defects; precise equipment CONSIDER THIS is needed with accurate control over dimensions. Operations and information technolHumans and current machines cannot achieve this, ogy integration in a smart factory can so coordination of machines and intelligent equipbring higher levels of quality, energy ment is needed, Xuanbo said. This is the value of savings, and more competitive products. How smart is your factory? industrialization; many key technologies and processes can be updated, easily realizing precision and quality required. The smart factory requires deep integration of industrial and information technologies, Xuanbo said, and after a smart factory is built, cost of production can be largely reduced throughout the enterprise. This is the objective pursued by green Yin Xuanbo, deputy chairman of Delta-Cimic Electronics manufacturing of China told Control Engineering China about smart factories. and by Delta.
MORE
16
|
DECEMBER 2016
CONTROL ENGINEERING
Diversified products, green manufacturing
“Delta always insists on the business mission of ‘environmental friendly, energy savings, and loving the earth.’ It continually develops innovative products and solutions, so as to continually improve the energy utilization ratio of products,” Xuanbo said. Delta has gradually transformed to integrating energy savings in solutions, rather than only manufacturer products, he said. Delta supplies smart factory applications with servos, servo drives, sensors, instruments, machine vision, industrial robots, power supplies, and other industrial controls. At the same time, communications capabilities are more diversified, easing interconnection among products. Delta assists customers in connecting machines via manufacturing execution system (MES), with equipment-level interconnections. The whole factory is connected via supervisory control and data acquisition (SCADA) configuration software, independently researched and developed by Delta, to exchange information within the line, outside the line, between levels, and across factories.
Interoperability, customization
The smart factory can meet the customer requirements for flexible customized production, but industrial automation products are mainly universal products, Xuanbo said. “In industrial automation, for 70% to 80% of customers, universal products can meet application needs; for industrial development, customized products are needed,” he said. As industries develop, it will be more difficult to show the competitiveness and core advantages of an enterprise, if only standard products are offered. Competitive differentiation of manufacturers’ products will be needed to improve competitiveness and exhibit advantages. As smart factories progress, Delta will transition from large-scale manufacturing to customization. To meet customer needs, Delta will the corporate vision of being environmental friendly, saving energy, and loving the earth, Xuanbo explained. ce Zehong Wang is executive editor, Control Engineering China at www.cechina.cn; Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com. www.controleng.com
Spend the Least … Get the Most MAQ®20 Industrial Data Acquisition & Control System
Dataforth’s 3rd Generation DAQ System Sets New Standards Signal integrity: Ensured by 1500Vrms isolation between field-side and system-side wiring plus per channel isolation in many modules Compact design: One communication module + 1 to 24 I/O modules = up to 384 channels; interface and power provided by the system backbone Application software: - IPEmotion: Advanced, intuitive, versatile; provides cutting-edge control, mathematical functions, and represents the next step in test & measurement - ReDAQ® Shape: Out-of-the-box and easy-to-use; an effective way to configure and customize the system for specific application requirements input #11 at www.controleng.com/information
• $17 per Channel Possible – Lowest Cost in Industry • Application Software from $250 • Up to 384 Channels in 19” Instrumentation Rack • ±0.035% Accuracy • Integral PID Control - Up to 32 Loops with ReDAQ® Shape Software - Unlimited Loops with IPEmotion Software • –40°C to +85°C Operating Temperature
Instrument Class® Signal Solutions dataforth.com • 800-444-7644
CONTROL ENGINEERING International
Are we far from digital factories? What are the attributes of a digital factory and how can they help you today? Control Engineering China provided insights after touring a plant touted as a model factory for Industrie 4.0.
A
Asking the question, “How far are we
Aileen Jin is editor in chief, Control Engineering China. Courtesy Control Engineering China
MORE
ADVICE KEY CONCEPTS High throughput, quality, and flexibility make an automation manufacturing plant in China a destination point for those applying Industrie 4.0 concepts. Knowing goals before starting is important. Robotics can be widely used but not at the expense of other potential goals, such as small batch flexibility. GO ONLINE See the Control Engineering Industrial Internet of Things (IIoT) page and learn more about international competitiveness initiatives at www.controleng.com/international. CONSIDER THIS Have you toured other sites to learn about IIoT or Industrie 4.0 best practices?
18
|
DECEMBER 2016
from the ideal digital factory?” may bring varied thoughts to mind, such as a production line full of robots or a factory with little human intervention. A tour of the Siemens Chengdu R&D Base, an “Industrie 4.0 Model Factory,” begins with a low-key exterior for a very famous plant. Standing at the gate of the simple, blue-gray plant, it is hard to imagine that, with an area no larger than a football field, the plant completes one product every 10 seconds, with daily capacity of more than 10, 000 products, with a defect rate of less than 10 per million products.
High quality manufacturing
This may be one of the factories that have the lowest product defect rate in the world, and another plant that can reach this standard is in Amberg (Germany). As early as 27 years ago, Siemens plant in Amberg was transformed into a digital factory: Under the circumstance that the original plant area is unchanged, the production capacity has improved eightfold, and production rate there also is one product per second. The Chengdu plant is built using best practices from the Amberg plant, becoming the first Siemens “digital factory” outside of Germany. According to plant manager, when the plant was built, it was not positioned to exhibit the Industrie 4.0 platform attributes. The original intention was to bring the most advanced technology to the most important market and provide better service to Chinese customers. The Chengdu plant includes manufacturing of programmable logic controllers (PLCs), human-machine interfaces (HMIs), and industrial PCs (IPCs), and 60% of them supply China. The launch of Industrie 4.0 and “China Manufacturing 2025” makes Siemens Chengdu plant a destination site for Chinese manufacturing enterprises eager to perform this transformation. In the 3 years since production began, more than 15, 000 people have visited the plant; the number of visitors is more than 30 times the number of Siemens Chengdu plant employees, the company said. The Siemens Chengdu plant assembly line vigorously displays “digital factory” concepts, such as real-time interconnections with the external world. This “transparent” factory demonstrates seamless information interconnections from the bottomCONTROL ENGINEERING
layer control system up to manufacturing execution system (MES), product lifecycle management (PLM) software, and enterprise resource planning (ERP) systems. The Siemens Chengdu plant provides practical examples to help avoid detours when building a digital factory. First, determine the purpose of constructing a digital factory. Industrial factories and the projects inside should not merely follow current fashion. Next, focus on whether an Industrie 4.0 application improves the product quality and production efficiency of the enterprise. Without clear objectives, becoming a successful Industrie 4.0 enterprise, even with advanced technology and software, may be a fantasy. Factory design flexibility
Mature top-level design capabilities are significant for new projects. In the Siemens Chengdu plant, above-ground wiring is barely visible; cables and pipelines are placed in a lower-level logistics area; and a power pipeline directly connects with equipment above. Positioning and wiring layout are elaborately planned and designed. For optimal production utilization, the lower level contains all equipment irrelevant to the production line (including the control cabinet), so that production can be arranged most efficiently on the manufacturing floor, creating more benefits. To dispel a potential misunderstanding, robots aren’t necessarily used on a large scale for digital production or intelligent manufacturing; it depends on the application. Use of too many robots can reduce production line flexibility. In the Siemens Chengdu plant, four product types can be produced simultaneously on most production lines. Reasonable planning ensures flexibility in future production capacity adjustments. In particular, for existing small-batch and diversified customized products, flexible production capacity can adjust and respond to customer needs quickly. There is no uniform model or time for each stop on the road to a digital factory; there is only opportunity. Are you ready? ce Aileen Jin is editor in chief, Control Engineering China at www.cechina.cn; Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com. www.controleng.com
On-demand Webcasts Earn continuing education credits by attending our 1-hour-long webcasts. Register and view today, from anywhere at www.controleng.com/ondemandwebcasts
CE_OnDemand_HALF_V1_KS.indd 1
10/28/2015 9:36:23 AM
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
TECHNOLOGY UPDATE equipment installation
Steps to ensure proper installation of monitoring and metering equipment Following best practices for proper field device installation, such as grounding and testing, will help avoid performance issues and help designers realize the true return on investment (ROI).
W
While investments in electronic monitoring and metering systems are made within complex industrial environments, and connections seem to be correct, problems still exist. Some devices function perfectly, others do not function at all, while some perform erratically or occasionally send error messages. The majority of problems seem to occur within sensitive control or power transmission assemblies. Often, a lack of attention has been given to the installation details of monitoring and metering device wiring during design and installation. Some of these important wiring issues include incorrect wire selection or installation, improper instrumentation grounding, and inadequate electromagnetic protection for wire and terminations. Four steps to proper monitoring and metering equipment installation
The following are best practices to ensure monitoring and metering equipment are functioning properly:
1. Ensure adherence
to manufacturer recommendations
Manufacturers will most likely provide extensive recommendations for the design, installation, and maintenance of power and communications wiring used in field bus products. This information Figure 1: Less attention is often given to the installation of monitoring and metering device wiring. Common wiring errors easily can be overlooked, with rolled wires visible. All graphics courtesy: Eaton
20
|
DECEMBER 2016
CONTROL ENGINEERING
typically spans INCOM [Industrial Communications network from Cutler-Hammer, acquired by Eaton], RS-485, and Ethernet physical layers. Adherence to these recommendations is vital to ensure robust and reliable communications. Network segments installed according to manufacturer recommendations will provide flexibility, simplicity, and noise immunity. Failure to follow recommendations often will result in sub-optimal system performance. For example, to minimize data corruption, it is not advised to run communications wiring in a power tray common with highfrequency loads, such as adjustable frequency drives or soft starters. Proper grounding is also an important aspect of field device installation. Most instrumentation systems have two grounds including the electrical or power ground and the instrument ground. It’s important to realize that these two grounding systems have different purposes. The shield should be continuous across a network segment and connected to the building’s electrical system grounding electrode conductor. The 2017 National Electric Code (NEC) provides guidance on grounding communication cables. Cable selection also is essential for robust communications. Cable developed for RS-485 communications is recommended. Control and instrumentation cables are unacceptable for RS-485 applications. Additionally, power distribution and automation applications require shielded cable. Most cable is available with two types of shielding, foil and braid-over foil. Either can be used, although braidover foil is preferred. The foil covers high-radio frequency and electrical fast transient exposures, while the braid-over foil covers low-frequency surge events. For typical terminal block connections, the cable must support a shield drain wire.
2. Understand infrastructure challenges and environmental factors
System capacity calculations should be performed when new systems are being developed or devices are being added to existing systems. www.controleng.com
The purpose of the calculation is to determine if the system design has the capacity to support the number and type of devices intended for use. Problems may be unrelated to capacity. For example, most loads in modern electrical distribution systems are inductive. These loads can include motors, transformers, gaseous tube lighting ballasts, and induction furnaces. Inductive loads need a magnetic field to operate. These inductive devices can cause harmonics to be created by electronic circuits, which can create problems for connected loads. All harmonics cause additional heat in conductors and other distribution system components. Harmonics also can cause electromagnetic interference (EMI), also called radiofrequency interference (RFI) when in the radio frequency spectrum, and is a disturbance generated by an external source that affects an electrical circuit by electromagnetic induction, electrostatic coupling, or conduction. High levels of harmonics and EMI can often result in erratic behavior of electronic equipment, including inconsistent data communication between computer equipment and field devices,which can jeopardize the effectiveness of energy monitoring and metering devices. These issues can be traced back to incorrect wiring schemes, such as installing unshielded communications cables too close to wiring carrying inductive loads. Replacing existing cable with a shielded alternative, or simply changing the proximity of communications wiring to inductive loads, can correct this problem. However, if wiring adheres to manufacturer recommendations and data is still unreliable, it is recommended to consult with the field device manufacturer or a power quality specialist to determine if line filters and conditioners can solve issues.
3. Diligently review pre-approval documents and plans
The potential problems outlined above can be avoided by giving adequate attention to the details of field device wiring recommendations during the design and installation phases. It is always a best practice to closely review pre-approval documentation and plans to ensure important wiring details are met, including proper treatment of each type of instrument, correct wiring for signals, proper grounding, and meeting specifications for instrumentation wire and terminations. As a result, possible issues can be identified www.controleng.com
and rectified prior to installation, which can save a tremendous amount of troubleshooting time and labor compared to the identification of issues after installation and commissioning.
4. Test systems before
and after installation
It is vital to use testing equipment to measure capacity, harmonics, and EMI before and after installation to streamline the field wiring process. Proactive testing can help designers identify possible obstacles and implement protective measures before a bill of materials is created. These studies also should be performed following installation to ensure wiring measures have correctly addressed identified issues. Paying close attention to field device data during startup, peak usage, and the ramping down of systems can also easily identify problems. EMI and harmonic levels can vary during these periods, so keeping an eye out for inconsistencies or data collection errors often can help correct the situation shortly after installation, and the field device can then function properly. If issues with data collection are identified, contacting the field device manufacturer directly for immediate troubleshooting and correction support is among other options. Without proper installation, it is impossible to reap the benefits of metering and monitoring devices. The real-time data these devices provide, simplifies maintenance, reduces downtime, and enhances efficiency. However, without properly functioning systems, most organizations never fully achieve the true return on investment for these devices. By following best practices for device wiring and installation, designers, installers, and plant management can achieve the full benefit of real-time data acquisition without the headaches of improperly performing equipment and the need for time-consuming troubleshooting and testing. ce Rick Schear is a product manager at Eaton; edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. CONTROL ENGINEERING
Figure 2: Malfunctions with monitoring and metering devices and instrumentations often can be traced to wiring errors, such as use of the wrong type of wire shown here.
MORE
ADVICE KEY CONCEPTS The benefits of properly installing metering and monitoring devices. The challenges due to incorrect metering and monitoring device installation. Following device wiring best practices. GO ONLINE For related links about field device wiring, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com. CONSIDER THIS How can businesses filter realtime data that is collected from monitoring devices to enhance business operations? DECEMBER 2016
| 21
TECHNOLOGY UPDATE IIoT data analysis
Easier way to use
SCADA data for IIoT Industrial Internet of Things (IIoT) intelligent data analysis can be obtained more easily with a modular, on-demand subscription software offering economical predictive process analytics to improve efficiencies.
T
To collect
and store data and monitor systems, most manufacturers are using technologies at least 30 years old. With the competition in today’s global market, most industrial companies hesitate to take advantage of new opportunities promised by the Industrial Internet of Things (IIoT), with concerns related to difficulty and cost. A recent LNS Research survey of more than 400 manufacturing executives showed the vast majority of companies do not have plans to invest in IIoT technology in the near future. It is understandable why industrial companies are reluctant to invest in new technology when considering the expense of existing systems. Old technologies that have been tweaked to try to take advantage of IIoT opportunities may require removing current systems. Affordable technologies developed for the Internet Age can work with existing systems to help manufacturers gain deep insight into process behavior that translates into fast return on investment (ROI).
Valuable SCADA information
MORE
ADVICE KEY CONCEPTS Online data mining software provides easy process analytics. It can augment existing historians. Most up-to-date version and capabilities are available with each log-in and use. GO ONLINE More information and links are available online on the IIoT analytics page at www.controleng.com. CONSIDER THIS See related advice in the IIoT Engineering supplement in this issue.
22
|
DECEMBER 2016
Supervisory control and data acquisition (SCADA) systems were originally designed to collect data and monitor processes. Since SCADA systems generate enormous amounts of data, historians were added to store this data. Initially, historians were used to fulfill regulatory requirements, such as generating reports for government agencies. Leading industrial companies recognized the data hidden inside historians could provide valuable information on plant processes and production, but accessing and using data could be very difficult because historians weren’t designed for “read” purposes or a two-way transfer of information. Manufacturing execution systems (MES) were introduced in the early 1990s in an attempt to bridge the gap between plant-floor SCADA systems and enterprise ERP software. They also promised to provide analytics, such as key performance indicator (KPI) data, to improve plant-floor operations. MES can provide more advanced capabilities
CONTROL ENGINEERING
than SCADA systems, but are expensive and often require extensive engineering for implementation. MES were developed for a business era in which systems were still largely siloed, and Internet optimization was largely an afterthought. Avoid a locked-in upgrade cycle
With the amount of time and money industrial companies have spent for traditional software, we can understand the reluctance of some manufacturers to enhance existing systems. They fear that a new solution would be expensive, require extensive engineering and training for employees, and lock the company into a cycle of difficult and expensive upgrades, patches, and limited scalability. Next-generation software offers ease of use and affordability.
Search engine for industry
As mentioned, accessing historian data and turning it into actionable information to improve operations has been time consuming and difficult. Data modeling applications required extensive engineering and data scientists to perform. As a result, only mission critical applications were targeted, leaving vast areas of improvement opportunities hidden. In 2008, engineers from Covestro (then known as Bayer MaterialScience) leveraged timeseries data by examining different analytics models and identifying limitations for scaling-up beyond pilot projects. Using deep knowledge of process operations the engineers created “pattern search-based discovery and predictive-style process analytics” for the average user. Unique multidimensional search capabilities of this platform enable users to find precise information quickly and easily, without expensive modeling projects and data scientists. A simple example of how this works is the song title recognition application Shazam (by Shazam Entertainment Ltd.). While the technology Shazam uses is different, the concept is similar. www.controleng.com
Combining live data with historical context shortens the analysis latency to immediate analysis, providing an opportunity to take actions even before an event can affect process performance. Courtesy: Trendminer
Instead of trying to map every note in a song to its vast database of songs, Shazam uses pattern recognition software that seeks “high-energy content” or the most unique features of a song then matches it to similar patterns in its database. This is a simple explanation of a complex process, but the point is that it enables users to quickly find a song title with a high rate of accuracy. Industry demands more sophisticated algorithms beyond search software by connecting to existing historian databases then implementing a column store database layer for an index. This software makes it easy to find, filter, overlay, and compare interesting time periods to search through batches or continuous processes. Moreover, this next generation software enables users to search for particular operating regimes, process drifts, operator actions, process instabilities or oscillations. By combining these advanced search patterns users unlock information they need. For example, an operator compares multiple data layers or time periods to discover which sensors are more or less deviating from the baseline then make adjustments to improve production efficiency. Contextualization, prediction
In addition to easier search, attention to process data contextualization and predictive analytics capabilities is needed. Engineers and operators can provide annotation to provide greater insight. Predictive analytics capabilities enable an early warning detection of abnormal and undesirable process events by comparing saved historical patterns with live process data. Calculating possible trajectories of the process can predict process variables and www.controleng.com
‘
Software enables users to search for particular operating regimes, process drifts, operator actions, process
’
instabilities or oscillations.
behavior before it happens. This gives operators the ability to see if recent process changes match the expected process behavior and proactively adjust settings when it does not. Online subscription model
To move beyond traditional software challenges, online subscription pricing can make process analytics affordable to all companies and frees businesses from having to spend the time and money on adding additional licenses and upgrades. When users log in, they automatically get the latest version of the software. Companies can enhance the investment made in high quality historians by connecting to lowcost predictive analytics software that complement existing historians to provide more valuable business insights. Affordable, plug-and-play software can uncover new areas for improving operation efficiencies for the emerging IIoT generation. Companies no longer can operate on existing systems if they want to stay competitive. ce Bert Baeck is CEO of Trendminer; Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com. CONTROL ENGINEERING
DECEMBER 2016
| 23
INTEGRATOR UPDATE create business value
Understanding the basic business valuation methods Part 5 examines ways to value a business: Several approaches may be used during the business valuation process. Understanding the process is a key step to obtaining a proper business value for a system integration firm or other engineering technology firm.
‘
The problem
M
with not knowing the value of a business, is that it creates issues making critical business decisions.
’
MORE
ADVICE KEY CONCEPTS The concept of a business valuation The basic methods that are used to value a company What approach to use for business valuations. GO ONLINE For more about business valuations and links to parts 1 to 4, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com. CONSIDER THIS How often should a business owner request an updated valuation report?
24
|
DECEMBER 2016
Many business owners understand the broad concept of a business valuation, but even financially savvy owners often do not understand the underlying concepts. While most business owners are busy day-to-day working, especially in system integration or engineering technology, it is critical for them to take time to also work on their businesses. The problem with not knowing the value of a business, is that it creates issues making critical business decisions. Situations such as the sudden illness or death of one partner, divorce, or being approached by an interested buyer, are all critical situations that call for an informed answer that can be guided by having an up-to-date valuation. Knowing the basic methods experts use to value a company is important to be more informed when speaking to an expert. The key is to understand all business components, not just the financial statements. A valuation is about the story behind the numbers. Asset approach
The asset approach derives a value by adjusting the company’s assets and liabilities from the reported book value (valued at original cost) to the estimated current fair market value. This approach reflects an orderly liquidation and does not consider the business’s future earning capacity. This approach assumes the business is worth more in liquidation than as a going concern, which is rarely the case. This method is appropriate for holding companies, such as companies owning real estate, capital-intensive companies, or companies that do not possess good-will value.
Market approach
The market approach is based on the concept of substitution. Transactions from publiclytraded companies, closely held comparable companies, and prior arms-length transactions of the subject company‘s equity provides the appraiser with earnings multiples to apply to the subject company to arrive at an indication of value. This method is frequently used as a “reasonableness test” to the income approach.
CONTROL ENGINEERING
Income approach
The income approach projects future earnings streams and discounts these streams have to their present value using a cost of capital reflective of a typical investor’s required rate of return. There are two methods used under the income approach: capitalization of historical earnings method and the discounted cash flow method. The capitalization of historical earnings method requires that an estimate be made for a normalized cash flow, which is adjusted for revenue or expenses that are out of the ordinary or not at market levels, and divide into that figure a capitalization rate to estimate the value of the business. This method only should be used when the company’s future is expected to look very similar to the recent past’s financial performance. This method applies to very few closely held businesses, as most are too dynamic to assume one earnings figure is reflective of the future of the business’s financial performance. The discounted cash flow method develops multi-year detailed projections of the company’s revenues, expenses, and cash flows that are discounted at a cost of capital that accounts for the risks and opportunities inherent in the business. The present value of the cash flows is then calculated, plus a residual value, to arrive at an estimate of the business value. Discounts for the lack of marketability and premiums for control are then determined and applied. An experienced valuation expert can help educate those who are starting the valuation process. If someone can’t or won’t explain these topics and instead wants to focus on using a multiple of some number from your financial statements, it should raise a red flag. An appraiser who is accredited through the American Society of Appraisers (ASA), for example, is educated and committed to following the proper practices when conducting business valuations. ce Catherine J. Durham is an accredited senior analyst, principal, and president, Capital Valuation Group; edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com
INDUSTRY NEWS and events Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
Solution-ready platforms, IIoT applications Improving industrial connectivity was one of the main themes at Advantech’s 2016 Industrial Internet of Things World Partner Conference (IIoT WPC) in Taipei, Taiwan, from Nov. 10-12. The meeting focused on accelerating Industrial Internet of Things application development in several industries, worldwide. Advantech is transforming into an IIoT solutions company offering device-to-cloud, solution-ready platforms (SRPs) that integrate hardware and middleware. Sharing platform business
KC Liu, CEO of Advantech, said the prevalence of IoT technology, the expanding application of the sharing economy, and the gradual adoption of platform operations for corporations are three phases that will evolove IoT for industry. “SRP removes obstacles in the transformation toward intelligent technology for our clients, at the same time as helping us expand IoT technology to various industries,” he said. “Among all groups in Advantech, the Industrial IoT group focuses on SRP; hardware-software integration as its core technology. With an innovative business model called WebAccess Sharing Platform Alliance, we will cooperate with our partners in the ecosystem to encourage development in several key IIoT vertical industries.” With a shared platform business model, Advantech envisions a transition from the old geo-region business market strategy to a vertical sector-lead business development for a more open, globalized market place. Advantech focuses on IIoT in general, industrial equipment manufacturing
(IEM), iFactory, energy & environment (E&E), transportation, and iNetworking. The IEM sector provides complete motion control and machine visionary components, including motion control, machine vision, robot controllers, and a software development platform for smart facilities. These technologies help an OEM construct smart facilities swiftly. The iFactory sector focuses on prioritized markets with higher automation maturity—those with the capability to incorporate smart factory and Industrie 4.0 technologies and concepts such as the automobile assembly industry, the food industry, and the home electronics industry. For traditional industries such as PCB, solar energy, LED, etc., Advantech introduces Industry 4.0 with open solutions to assist and encourage added capabilities. E&E sector adopts the communication standard IEC 61850 to provide solutions in building the infrastructure of smart electrical grids, aiming for a global rollout. Advantech incorporates telecommunication technology and expertise in data acquisition and control to help develop new functions that satisfy the requirement for reliability and security in IIoT communications. iNetworking sector accelerates wireless sensing networks and connects automation systems with Profinet and EtherNet/ IP protocol switches. These six vertical industries or sectors will see application solutions develop via SRP hardware/software integration. System integrators will also play important roles in providing services in more specialized markets.
Advantech invites its partners to work to build an IIoT ecosystem for global deployment. Left to right: Maurice Lim, senior solution architect, Bosch Software Innovations; Johnson Li, general manager, Midea Smart Technology Co., Ltd.; Luke Lee, general manager, semiconductor sales & applications, Texas Instrument Taiwan; Chaney Ho, president, Advantech. Courtesy: Advantech
Advantech also showcased its new campus with several IIoT applications, which included a control room for real-time video production line monitoring and data analysis, a solar-powered, auto-sensing green house, and smart building management system. “IoT is gradually becoming a reality, it’s not just ‘I Only Talk’ anymore as mocked by some skeptics,” said Chaney Ho, president of Advantech. Ho also predicted that SRPs will count for 50% of Advantech’s IIoT revenue in 10 years. Joy Chang is digital project manager, Control Engineering, CFE Media, jchang@cfemedia.com.
Innovation framework and business strategies for IIoT published
T
he Industrial Internet Consortium (IIC), a member-supported organization that promotes the accelerated growth of the Industrial Interne t of Things (IIoT) published the Business Strategy and Innovation Framework (BSIF). The BSIF is designed to help enterprises to identify and analyze issues to help companies capitalize on the opportunities emerging within the IIoT. The BSIF serves as a reference document for executives in enterprises planning to engage in IIoT concepts. It is a singlesource compendium of the issues and challenges enterprises should consider before they deploy IIoT initiatives. The BSIF also details frameworks and concepts designed to help enterwww.controleng.com
prises increase value for users, customers, and partners while helping to reduce market and technical uncertainties. The BSIF also outlines a set of best practices for companies engaging in IIoT, but companies are free to adopt a lighter touch or use an existing internal project model, especially within smaller companies. Alternatively, a range of project support processes may already be in place and the approach documented in the BSIF may be used to enhance existing infrastructures to address new IIoT opportunities (particularly for larger companies). - Edited by CFE Media from an IIC press release. CONTROL ENGINEERING
DECEMBER 2016
| 25
INDUSTRY NEWS and events
Automation and controls manufacturer moves to new facility, appoints new president Omega Engineering Inc., a global president. Vorih’s priority will be to manufacturer and supplier of process transform Omega from the best-known measurement and control products, is direct provider of process sensors into a moving its headquarters to a new facil- Web-based global partner for complete ity in Norwalk, Conn., from Stamford, process measurement and control soluwhich has been the company’s head- tions, including innovative wireless and quarters for 50 years. Industrial Internet Omega’s Norwalk of Things (IIoT)With wireless sensing corporate office is locatready offerings, the and cloud-based ed in a 5-story, 412,000company said in a sq-ft building. The open written release. solutions, what was floor plan is designed “Industrial cuswith collaborative workimpossible to measure is tomers today have spaces, where employaccess to an expobecoming attractive. ees can take advantage nentially increasing of the latest technologirange of new senscal advances. Facilities include a cafeteria, ing and control technologies. With wirefitness center, picnic areas, and shuttle ser- less sensing and cloud-based solutions, vice to nearby train stations. what was not possible to measure in The opening of Omega’s facility coin- the past is quickly becoming attractive,” cides with Joe Vorih’s appointment as Vorih said.
‘
’
Standards for drives and motion controllers updated
C
AN in Automation (CiA), the international CAN users’ and manufacturers’ group, has released a version of the CiA 402-2 CANopen profile for drives and motion controllers. Version 4.1 specifies the operation modes and the parameters in detail and is based on the IEC 61800-7-201 standard. The improvements include some editorial improvements and mainly error corrections. It is intended to introduce the changes into the IEC standard as early as possible. In addition, the association has released CiA 402-6. This part describes the process data object (PDO) mapping for CANopen FD. It comprises several sets of pre-defined PDOs. One is for single servo drives and stepper motors, another for single-axis frequency inverters, and a third one for multi-axes devices. In particular, PDO set for multiple-axes allows controlling simultaneously up to motors with one message. The specification also introduces the valid PDO mapping entries parameters for TPDOs and RPDOs. “The CiA 402 series is the most implemented drive profile,” said Holger Zelwanger, CiA managing director. “Part 6 is the first CANopen profile making use of the longer payload in CAN FD messages. This improves the system design to use CAN also in challenging motion control applications.” - Edited by CFE Media from a CAN in Automation (CiA) press release. CAN in Automation is a CFE Media content partner.
26
|
DECEMBER 2016
CONTROL ENGINEERING
About Joe Vorih, Omega Engineering president
Vorih was president of Clarcor Engine Mobile Solutions, where he worked to serve the needs of original equipment manufacturers (OEMs). He also launched several programs and opened a new manufacturing and sales presence in India. Vorih also served as senior vice president and chief commercial officer (CCO) at Stanadyne, where he oversaw the company’s successful shift from a traditional equipment supplier to a broad technology solutions partner. Vorih holds Bachelor’s and Master’s degrees in mechanical engineering from MIT and an MBA from Rensselaer Polytechnic Institute (RPI). - Edited from Omega Engineering press releases by CFE Media.
System integrator expands Northeast operations with New York office SUPERIOR CONTROLS, a New Hampshire-based automation systems integrator, has opened an office in Albany, N.Y., to serve upper New York state customers, according to Rick Pierro, president and cofounder. Ten automation engineers are currently working out of the new office. Ken Hackett, with 20 years’ experience in management for a New Yorkbased distributer, has been hired as the business development manager for the Albany office, Pierro said. Superior Controls implements custom, validated automation systems primarily for the biotech and food and beverage industries. The Project management company specializes in designing and implementing turnkey procedures include industrial automation and infordesign checks, simulation, mation systems. The company also performs project manageand documentation ment procedures including validation. design checks, simulation, and documentation validation. Superior Controls is a 2012 Control Engineering System Integrator of the Year winner. The company is also a member of the Control System Integrators Association (CSIA). Rick Pierro, the president and co-founder of Superior Controls, is one of the inaugural members of Control Engineering’s reestablished editorial advisory board, which provides input to editorial staff on content, relevancy, automation market, and audience. - Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
‘
’
www.controleng.com
Digital edition? Click on headlines for more details. See news daily at www.controleng.com/news
Demand for smart high-end safety solutions increasing
S
afety components alone are not enough to satisfy customer legislation on implementing safety practices in manufacturing. Howneeds. Safety solution packages are becoming popular, as the ever, in the EMEA market, sales of advanced drives are starting to demand for services and data is increasing. Smarter safety grow quickly. solutions meet safety requirements but also The focus on machine safety components in benefit other aspects of production. The idea mature markets is shifting from price to providMachine safety is that the more data that can be analyzed, the ing more features, benefits, and connectivity. greater efficiency, the shorter the downtime, the This shift means that the mature market tends components in mature lower the risk of equipment failure, and the betto use high-end components. Globally, IHS ter management of maintenance. markets are shifting from Markit predicts that revenues of laser scanIndustrial networking is part of safety soluners will surpass type 2 light curtains in 2018; price to providing more tions and connectivity. Some older Fieldbus and revenues from safety programmable logic technologies are inherently safe; but it has taken controllers (PLCs) will surpass those from features, benefits, and some time to ensure that some Ethernet techsafety relays in 2019. Neither of these trends is nologies are fully safe. There are still opportunipredicted to occur in the Asia-Pacific machine connectivity. ties for newer technologies with great potential safety markets where price pressure remains for high-end solutions. high. According to research from the Discrete Machine-Safety ComThe requirement for—and the use of—safety PLCs are gradually ponents Annual Service, revenues from safety input/output (I/O) are increasing every year. Mature markets are seeking advanced soluprojected to grow faster than those from standard I/O. Digital modtions. With this need in mind, there will be a push on the prices of ules in safety I/O remain the most popular globally; and most likely to high-end PLCs, and so the average selling price (ASP) will decrease. remain so, as analog costs more and can be seen as unnecessary. Susanne Cumberland is an analyst for IHS Markit. IHS Markit is a Basic drives are the most common and becoming commonplace CFE Media content partner. Edited by Chris Vavra, production editor, in emerging countries since they cost less and there is less stringent Control Engineering, CFE Media, cvavra@cfemedia.com.
‘
’
input #12 at www.controleng.com/information
INDUSTRY NEWS and events
EtherCAT specification document released The EtherCAT Technology Group (ETG) has published a first draft of the official EtherCAT P technology specification with the extension of all corresponding documents on its website. Additionally, an application note has been finalized as a guideline to implement EtherCAT P slaves. EtherCAT P is an industrial Ethernet technology that combines EtherCAT communication and power lines into one standard 4-wire Ethernet cable. Soon after the introduction of EtherCAT P, this technology extension to EtherCAT was included in the work of the EtherCAT Technology Group. Ever since, the ETG has been developing an official specification docu-
‘
EtherCAT P combines
EtherCAT communication and power lines into one standard 4-wire Ethernet cable.
G
28
|
DECEMBER 2016
- Edited by CFE Media from an EtherCAT Technology Group press release.
Headlines online
Motion control shipments are increasing in 2016 lobal shipments for motion control products increased by 5% to $2.4 billion in the first nine months of 2016, according to new statistics released by the Motion Control & Motor Association (MCMA), the industry’s trade group. “After a contraction in 2015, it is encouraging to see a return to growth for the motion control market in 2016,” said Alex Shikany, MCMA director of market analysis. “The year-to-date growth has been driven primarily by strong increases in actuators/mechanical systems (14% to $423 million), electronic drives (12% to $451 million), and motion controllers (6% to $119 million). Third-quarter 2016 saw shipments increase by 10% to $828 million over the same period last year.” MCMA summarizes market results from suppliers and distributors in quarterly tracking reports and trend analysis reports. These reports examine orders and shipments by major product category quarterly and annually with tables and graphics. Growth rates and book to bill ratios are provided for each product category. - Edited by CFE Media from a MCMA press release. MCMA is a part of the Association for Advancing Automation (A3). A3 is a CFE Media content partner.
’
ment and the first draft has now been published. The document, “ETG.1030 EtherCAT P Specification,” defines the basics of EtherCAT P as an extension of the physical layer of the EtherCAT technology. As such, all other EtherCAT standard documents in which EtherCAT P will be integrated also have been extended.
An EtherCAT P application note, which provides a guideline for designing EtherCAT P slaves, also has been published. This application note includes the according extension of the EtherCAT implementation including the associated connectors, electrical specifications as well as recommendations for EMC-compliant design. The application note highlights the different design requirements, especially with regard to the usage and connection of supply voltages, and describes calculations on the basis of existing currents and voltages in the network.
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: A3 Business Forum (RIA, AIA, MCMA), Lake Buena Vista, Fla., Jan. 18-19 www.a3automate.org/a3-events Motor and Drive Systems 2017, Orlando, Jan. 18-19 www.e-driveonline.com/conferences/ 21st Annual ARC Industry Forum, Orlando, Feb. 6-9 www.arcweb.com/events/ arc-industry-forum-orlando Automate 2017, Chicago, April 3-6 www.automateshow.com/ Hannover Messe, Hannover, Germany, April 24-28 www.hannovermesse.de/home
Top 5 Control Engineering articles Oct. 17-23 most visited articles: three-phase motor operation, PID velocity, PLC objectoriented programming benefits, Engineers’ Choice finalists, and scary automation. Manufacturing index hits 12-month high in November The purchasing manufacturers’ index climbed 1.3 percentage points to 53.2%, which is the highest point it has reached in over a year as general optimism continues. Six ways to avoid electrical testing problems It is important to safely and securely start up electrical systems after maintenance.
CONTROL ENGINEERING
GE: controlling interest in Baker Hughes GE has purchased a controlling interest in oil and gas services company Baker Hughes to bring greater productivity solutions, company officials believe. Lowering technology barriers could save manufacturers $100 billion National Institute of Standards and Technology (NIST) report found that manufacturing could save more than $100 billion annually by implementing more advanced manufacturing strategies and systems. Choosing the right PLC panel Programmable logic controller (PLC) panels come in many shapes, and configurations; choose the right solution for an application. OSHA best practices for safety, health A set of “Recommended Practices for Safety and Health Programs” was released by the Occupational Safety and Health Administration (OSHA) to help give employers a methodical approach to improving safety. The economy’s effect on manufacturing Manufacturers will have to continue to improve the efficiency of processing equipment and techniques in order to keep up with the economy’s attitudes and expectations.
CORRECTION The title for the bar chart that was included with the August 2016 research column should have read, “Top 10 devices firms have integrated and/or plan to integrate.” www.controleng.com
CFE Media’s
New Products for Engineers Database Looking for new products? Look no further! The New Products for Engineers Database is a platform that provides an opportunity for engineering and technical professionals to access the latest NEW product information for the manufacturing, commercial construction, and manufacturing control industries.
Start searching now! www.cfemedia.com/NP4E
COVER STORY robotic advances
Robotic connectivity, collaboration, easier programming Advanced robotic developments include improved designs for safety and specialized |environments, collaborative applications, better integration with other systems, and augmented monitoring to reduce risk of downtime and lower maintenance costs.
MORE
ADVICE KEY CONCEPTS Collaborative robotics offerings expand into more applications. Cloud-connected services aim to increase robot reliability, functionality. Integration is easier with CNCs. GO ONLINE See more photos and text with this article online, videos of robots integrated with a conveyor system, robot serving ice cream, and a robot juggling. Also see the Control Engineering robotic page, under the Discrete Manufacturing pull-down menu at www.controleng.com. CONSIDER THIS What applications at your location may be ready for robotics, with lower costs and easier integration?
R
obotic advances include modifications for safety and specialized environments, collaborative applications, improved integration with other systems, and better monitoring systems to reduce risk of downtime and lower maintenance costs. Information that follows includes announcements from International Manufacturing Technology Show (IMTS) 2016 and Pack Expo International 2016 in Chicago, in September and November, and Automation Perspectives in November in Atlanta.
Robotics for safety applications
Companies look to robots to perform tasks in hazardous environments that could be dangerous, repetitive, or too fast or precise for humans to do. As robots get more sophisticated and can perform more efficiently, the potential uses increase. At Pack Expo, a Yaskawa Motoman robot (Figure 2 and part of the cover image) worked in a robotic depalletizing cell in front of an updated Alvey 891i palletizer from Intelligrated with an
integrated with vertical reciprocating conveyor and motor driven roller (MDR) conveyor. At Pack Expos, Denso Robotics demonstrated a robot designed for aseptic pharmaceutical settings with hydrogen peroxide. It is designed to provide automation in clean environments and prevent contamination and human error. “It is set up to live in a sterilized environment for processing small assembly products,” said Peter Cavallo, robotic sales manager, Denso. Cavallo noted increased demand for a robot that could work in such an environment since they began the project 2 years ago. “We got the request from customers who were looking for a robot that could handle this kind of work,” said Cavallo. Other applications include regenerative medicine and cell culture. These delicate, precise applications might have been impossible a few years ago. Technology advances continue to remove potential barriers, and now roboties are going into arenas where they could have a major impact on worker safety. This is especially true when robots are designed to work collaboratively with humans.
Robot integration: Simpler setup of automated machine cells Figure 1: Siemens enables robots to be easily connected to machine tools for automated production cell setup using Sinumerik 828D and 840D sl CNCs. Different types of robots designed by various manufacturers can be connected to machines for handling tasks using the Sinumerik Integrate Run MyRobot / EasyConnect interface, as shown at IMTS 2016. This photo is part of the December Control Engineering cover. Courtesy: Siemens
30
|
DECEMBER 2016
CONTROL ENGINEERING
R
obots are becoming easier to connect with machine tools. The Siemens Sinumerik 828 CNC family offers a faster, less complicated means of connecting robots to machine tools, which has become an integral part of automated production cell set-up. (See Figure 1.) Different types of robots designed by different manufacturers can now be connected to CNC machines equipped with the Sinumerik 828D family using the Sinumerik Integrate Run MyRobot / EasyConnect interface to perform handling tasks. This enables companies of any size to setup automated cells, including serial machines, cost-effectively and without major effort, even with different types of CNCs using the same standard interface. Other features for automated cell setup are simple optimization of work processes on machine tools, mobile condition monitoring, and remote maintenance. www.controleng.com
Figure 2: A Yaskawa Motoman robot reaches for a box to place on an integrated motor driven roller (MDR) conveyor, part of an updated Alvey 891i palletizer with an integrated vertical reciprocating conveyor, at 2016 Pack Expo International in Chicago. Intelligrated is now part of Honeywell. This photo is part of the December Control Engineering cover. (For the third photo on the cover, see the robotics article starting on page 36.) Courtesy: Mark T. Hoske, Control Engineering, CFE Media
Figure 3: Kawasaki’s dual-armed “duAro” robot that works alongside humans for material handling assembly, machine trending, and dispensing applications. The dual-arm has the flexibility to be applied to production lines with a short production cycle with frequent changeovers, as shown at 2016 Pack Expo International in Chicago. Courtesy: Emily Guenther, Control Engineering, CFE Media
Collaborative robotics: benefits
Collaborative robots provide benefits and open opportunities in various industrial applications. At Pack Expo, one of the main concepts was the presence of collaborative robots and the bright future they have in optimizing and creating opportunities in various industrial applications. While automating processes isn’t new, implementing and realizing the return on investment (ROI) behind them are highlighted among many manufacturers. One philosophy of collaborative robots is that they work near humans, not replace them, helping to optimize operations. Collaborative robotics can: Reduce risk. With collaborative robotics, the risk significantly goes down on a plant floor by working a high-risk environment or areas too hazardous for humans. Improve quality and quantity control. Humans err, and robots can be programmed to do the same job to speed up processes without risk to quality. While a robot’s health status is important and needs to be maintained to ensure optimal Standards-based interface The interface is based upon a standard defined by the German Machine Tool Builders’ Association (VDW is the German acronym) and the German Engineering Association (VDMA) for connecting robots or handling systems to machine tools. For ease of use, the robots are connected through Ethernet (Profinet RT) or using I/O signals. In doing so, operators can easily synchronize processes between the machine tool and robots, thereby positioning efficient processes in the automated production cell. Automated work processes, an important aspect of automated cell setup, covers all aspects of machine tools. These processes begin with preparatory work to accessing all necessary information and data at the machine www.controleng.com
Figure 4: Baxter, left, fills a box from Sawyer, right, that used a guide to form the box. The two models of collaborative robots from Rethink Robotics, demonstrated ability to work with each other without direct communication, and with humans (not shown) at 2016 Pack Expo International in Chicago. Courtesy: Mark T. Hoske, Control Engineering, CFE Media
performance, performance is more predictable than humans. Create growth opportunities for workers. Humans may express concern about robots displacing workers, but collaborative is a key word. “Robotics aren’t replacing human workers per say, but giving them the opportunity to expand a
and efficiently operating the machine, including use of mobile terminal equipment for visualizing machine conditions. Siemens provides smart operation features, where smart touch technologies are being integrated into the production environment. Simultaneously, machine operators can access the factory network and can inspect contract documents at the user interface. The concept includes an application for prep work on the PC, such as for creation of part programs. Functions facilitating remote diagnosis of machine tools are another component of the solution for automated cell setup. Sinumerik Integrate Access MyMachine provides functionality for remote diagnostics using a corporate network or Internet access. The basic application facilitates data exchange
with connected machines from a Microsoft Windows PC. An IP address is used for addressing purposes within the plant network. Machine tool operators can access the machine over the Internet or outside the company network with appropriate configuration. Sinumerik Integrate Access MyMachine / Ethernet (ASP) provides a quick overview of the machine history in addition to machine access. The Sinumerik CNC permits the uploading and downloading of machine data, files, trip recorders, and configurable PLC traces. Text message (SMS) or e-mail notifications in cases of unusual machine conditions are possible. ASP allows cost-efficient monitoring of fault states and comprehensive integration of inhouse service and maintenance processes.
CONTROL ENGINEERING
DECEMBER 2016
| 31
COVER STORY robotic advances
Figure 5: Safety improves when humans avoid risk from handling blades; Anybus Wireless Bolt nodes from HMS instruct the Fanuc robot above the slitting machine to replace blades at an Automation Fair (Rockwell Automation) demonstration in Atlanta. Courtesy: Mark T. Hoske, Control Engineering, CFE Media
Figure 6: The Fanuc Zero Down Time software application, part of the Fanuc Intelligent Edge Link and Drive (FIELD) system, shows specific robot activities that could shorten time to maintenance, like the stress from an abnormally high number of emergency showdowns, which can inflict unneeded stress on the robots, joints, and motors, as explained at 2016 Pack Expo International. Courtesy: Mark T. Hoske, Control Engineering
32
|
DECEMBER 2016
worker’s skill set by learning how to program robots, become robot technicians, and robot maintenance,” said John Weber, senior project manager at Kawasaki Robotics (USA) Inc. Add flexibility. A growing application for collaborative robotics is in short-line processes because of greater flexibility compared to traditional robotics. Kawasaki demonstrated a dual-armed, collaborative robot that can be wheeled where needed (see Figure 3); Kawasaki duAro robots operated on a simulated line and one served ice cream (see video online). Increase economy. Manufacturing robots have become more cost-effective to integrate into a facility. Smaller robots can be maintained and controlled with a mobile app. Allied Technology, a Universal Robots system integrator, showed a vision-guided packaging and palletizing application using the UR5 robot arm to pick chocolates from an intelligent part feeder, arrange them by color, kit them in a box, and palletize them. Flexibility allows the robot to be integrated into many processes. “Customers can add new products to the system as needed, and the arm can articulate through just about any product orientation requirement,” said Greg McEntyre, CEO of HNJ Solutions. “The collaborative nature of the arm allows us to reach outside the machine environment and automatically handle components...near production personnel.” Collaborative robots are dependable, integrate easily with existing operations, and address a growing shortage of industrial workers. Using collaborative robotics may be easier as plants adjust to more automation and related operational benefits. At IMTS, Universal Robots launched Universal Robots+ in North America; it’s an app store for Universal Robots end-effectors, grippers, software, vision cameras, and other accessories, designed, tested, and certified to work with UR robot arms. Booth demonstrations included some offered in UR+ from Robotiq, Sick, OnRobot, and Airgate. Collaborative robots assemble, fill boxes
Collaborative robots can work with humans in some applications without traditional safety cages
CONTROL ENGINEERING
and also can work with each other, as shown in a Pack Expo demonstration (Figure 4) from Rethink Robotics. Photos and online video show Sawyer from Rethink Robotics using a pneumatic actuator to lift a box, position it over a guide to open the box, and position for flaps for taping the bottom of the box. Baxter from Rethink Robotics then fills the formed box with plastic bottles, said Thomas Miller, sales application specialist, Rethink Robotics. The robots shown do not communicate with each other directly; embedded vision and visual positioning indicators are used. Software upgrades from Rethink Robotics are available free for the robots and automatically can add functionality and speed to robot hardware performance without changes to the hardware, Miller noted. Applications vary for collaborative robots, including machine tending, kitting, and light assembly. Rethink Robotics recently noted that Sawyer improved Deco Lighting’s assembly time by 1,200%. By deploying Sawyer on each assembly line, Deco Lighting can explore using Sawyer robots to keep production running during off hours, further shortening lead time for customers. Wireless control enhances safety
Industrial wireless communications can control robots to reduce risk to humans, as demonstrated at the HMS booth at Automation Fair. An HMS Anybus Wireless Bolt access point (smaller than a hockey puck) moved commands from the controls enclosure for the slitting machine to the control cabinet for a Fanuc robot (Figure 5). The robot replaces the sharp slitting-machine blades. Wireless transmissions are Bluetooth or WLAN technology. and connections can be serial, CAN, or Ethernet.
More robotic collaboration
Fanuc America Corp., expected to offer collaborative robots early in 2017, showed potential offerings at IMTS and at Pack Expo. IMTS visitors saw demonstrations of Fanuc CR-4iA, CR-7iA table-top size collaborative robots, and the CR-35iA heavypayload collaborative robot, explained below with information from Fanuc. The CR-7iA, CR-7iA/L, and CR-4iA collaborative robots follow the launch of the larger CR-35iA collaborative robot. They have “highly-sensitive contact detection allowing them to share workstations with people,” said Greg Buell, product manager, Fanuc America, and allow “the robot to perform more strenuous tasks or repetitive operations without the need for expensive industrial safety barriers.” Robotic vision guided gear picking and placing into a box to build and then disassemble three assemblies. At Pack Expo, the Fanuc Intelligent Edge Link and Drive (FIELD) system demonstrated advanced analytics and deep learning capabilities for Fanuc www.controleng.com
Figure 7: Rockwell Automation, at Automation Fair in Atlanta in November, announced a 4-year, $12 million, commitment to the For Inspiration and Recognition of Science and Technology (FIRST) organization. Courtesy: Mark T. Hoske, Control Engineering, CFE Media
CNCs and robots, peripheral devices, and sensors used in automation systems. The FIELD system is based on edge computing where a large amount of data is processed within the manufacturing site to minimize the volume and cost of sharing data and provide a secure cloud connection for suitable applications. Data can be used for equipment collaboration, performance optimization, improved traceability, and quality control. Fanuc collaborated with Cisco, Rockwell Automation, and Preferred Networks, a provider of artificial intelligence (AI) software, to develop the system. Interconnections with robots and Rockwell Automation programmable automation controllers (PACs) were shown. Joe Gazzarato, director of product development, Fanuc America, expected the FIELD system to help “drive significant improvements in machine reliability, quality, flexibility, and speed to elevate manufacturing efficiency and profitability.” Year-end 2016 is the expected release. No robot down time
Zero down time (ZDT) software (Figure 6) collects data from more than 6,000 robots in 26 factories. ZDT monitors the robots to see if the application is causing abnormal wear that could lead to a failure, and if so, Fanuc sends parts with support to address the issue before downtime. With ZDT, Fanuc tracks robot usage and sends reminders at appropriate intervals to ensure important maintenance activities are completed on time. Fanuc expects the software to help customers with intelligent, condition-based maintenance notifications, optimizing robot performance and life. At the show, ZDT data collector running on a Cisco UCS (server) monitored robots in the booth and sent it to the cloud. A screen showed robot health data, such as motor, E-stop, energy usage, and maintenance reminders, adding value.
Rockwell Automation, FIRST Robotics
Rockwell Automation at its Automation Fair, announced a 4-year, $12 million, commitment www.controleng.com
to the For Inspiration and Recognition of Science and Technology (FIRST) organization, created to inspire youth to participate in science and technology, education, and math (STEM). Rockwell has made prior donations and provided support in the last 10 years for addressing the critical need to fill STEM jobs. Many such jobs go unfilled because of the lack of awareness of the kinds of high-tech jobs available and the lack of skills to qualify for today’s needs. Rockwell sponsored other FIRST programs (See Figure 7), including the FIRST Robotics Competition (FRC); nearly 200 Rockwell Automation employees donate time to the programs, and more than 300 employees volunteer for the organization in other ways. The company also donates products for the FIRST Robotics Competition playing fields and scoring systems, and parts kits to build robots.
Figure 8: Rockwell Automation showed its MagneMotion MagneMover Lite linear motor system at Automation Fair 2016 in Atlanta. The Fanuc robot in the background knows which ball to pick up with embedded radiofrequency identification (RFID) chips. See video clip online. Courtesy: Mark T. Hoske, Control Engineering, CFE Media
Integrated robotics, motion control
The Intelligrated IntelliGen palletizing software for robotic operations offers easy adjustment of layer patterns and load configurations for improved flexibility, speed, and load integrity, as explained at Pack Expo. The new software allows operations to easily adjust pallet load configuration without the need for extra programming or cumbersome integration. It is designed for robotic palletizing operations that handle various product types and sizes and allows operators to adjust load patterns and stacking characteristics based on changing product dimensions and other variables. The software comes integrated with the robotic cell’s standard control system and allows facility operations personnel to select user-defined load configurations, greatly simplifying product changeovers. Load configurations, patterns, and product sizes can be adjusted without making a service call or leveraging complex external software programs. Intelligrated, now part of Honeywell, offers intelligent automated material handling solutions for retailers, manufacturers, and logistics providers. CONTROL ENGINEERING
DECEMBER 2016
| 33
COVER STORY robotic advances
Figure 9: A demonstration of Yaskawa’s Motoman MH50 II- Series robots at Pack Expo showed a flexible design, allowing them to be used for various applications. The long reach of the MH50 II model and the extended reaches of the MH50 II-35 and MH50 II-20 make these robots well suited to process large parts. Extended reach models can eliminate the need for an external track, decreasing system cost, and simplifying programming. Courtesy: Emily Guenther, Control Engineering, CFE Media
Safety zone, CNC, robotic integration
Figure 10: At the ABB Robotics booth at 2016 Pack Expo International, new soft robotic grippers were shown to safely manipulate objects of various sizes and weights without bruising or damage. Courtesy: Mark T. Hoske, Control Engineering, CFE Media
34
|
DECEMBER 2016
At IMTS, Mitsubishi Electric Automation Inc. showed a variety of robots and safety automation, including Mitsubishi Melfa SafePlus safety zone technology, sensors that can be installed to create a cage-free safety zone around a conventional robot, slowing speed if anyone enters a cautionary area and stopping in the red zone closest to the robot without a full shutdown. The safety technology can be used with any robot 20 kg or below and represents the future of robots operating in the open, said Scott Zeller, manager FESG Midwest region, Mitsubishi. Also, 3 larger robots sharing the same frame size but varying by payload (30 kg, 45 kg, or 70 kg) became available this year, Zeller said. Mitsubishi Electric Automation M800s CNCs with controls integrated into the in-panel unit, were among highlighted technologies. Kuka Connect software was introduced to North America at IMTS. The subscription software platform connects Kuka robots to the cloud. Using Kuka Connect, customers can access and analyze their robots’ data on any device, anywhere, at any time. Built on open global standards, Kuka Connect securely leverages cloud computing technologies and Big Data analytics to provide customers maximum visibility into connected Kuka robots. The platform provides customers immediate access to new features and functionalities. Yaskawa Motoman, at IMTS, showed collaborative robots, mobile robotics, and machine vision CONTROL ENGINEERING
interaction with robotics for human-robot collaborative applications, material handling, mobile handling and logistics, vision, and welding applications. Highlights included: New mobile manipulation technology for multiple handling operations or logistics tasks New handling robot with IP67 rating with an easy-to-clean surface for use in harsh environments; photo (Figure 9) New hardware/software that uses one 3-D machine vision head for random bin picking Arc welding workcell suited for high-mix / low-volume production High-precision assembly with integrated, vision-guided force sensing and Functional Safety Unit (FSU) for collaborative operator interaction Robots for arc and spot welding applications Slim robotic part positioner with a 17% smaller width than standard positioners Collaborative robot designed to work safely with or in close proximity to humans. Picking, placing, maintenance
At Pack Expo, ABB Robotics highlights included: High-speed picking with the ABB FlexPicker and SCARA (selective compliance articulated robot arm) robots. New Soft Robotics grippers (Figure 10) can manipulate items of varying size, shape, and weight with one device. They can be used for environments where the uncertainty and variety of products being handled have precluded automation. ABB YuMi Collaborative Robot needs no barriers, cages, or zones for most applications. The dual-arm industrial robot can kit multiple components into packages, do component assembly, and pack fragile materials. High-speed palletizing: ABB FlexGrippers can do 2,190 cycles per hour; the 4-axis IRB 460 has a reach of 2.4 meters, takes 20% less floor area and runs 15% faster than its closest rival, ABB said. ABB Customer Service–Connected Services is an interconnected 24/7 ecosystem for the Internet of Things, services, and people. ABB robots are ready to be connected, wirelessly or hard-wired, offering predictive, proactive, and support. See related article, page 36: “Easier, safer robotic programming is among results from an expanding open-source robotics software group.” ce Contributors to this report are Emily Guenther, associate content manager, eguenther@cfemedia.com; Chris Vavra, production editor, cvavra@cfemedia.com; and Mark T. Hoske, content manager, mhoske@cfemedia.com, Control Engineering, CFE Media, in addition to source materials from some companies mentioned. 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 Seeking truth in reporting
helps manufacturing improve Manufacturing plant bonuses and incentive programs can result in inaccurate data if they are not structured and enforced properly. Three methods for focusing on the right targets are highlighted.
DE3 Develop a process to make
informed decisions with Big Data Big Data can help synthesize this information and provide users with the exact data they need to make informed, intelligent decisions. Developing a process that benefits everyone in the plant from the top on down is crucial.
ONLINE EXTRAS
(Click on the headlines or search www.controleng.com.)
Find patterns in corrupted data A team that includes researchers from MIT’s Computer Science and Artificial Intelligence Laboratory (CSAIL), has created a new set of algorithms that can efficiently fit probability distributions to high-dimensional data.
Industrial truck and lift market facing competition from AGVs IHS Markit reports that automatic guided vehicles (AGVs) are projected to have stronger growth over the next several years than the industrial truck and lift market as more companies use AGVs because they are more cost-effective.
Practicing the art of good research In the digital age, engineers need to ditch the instant-gratification mentality and develop in-depth research skills.
Using CAPEX as part of a maintenance management strategy When it comes to managing maintenance, capital expenditures (CAPEX) remains one of the key priorities.
MTTR can cause reliability problems if not used right The use of mean time to repair (MTTR) to improve reliability can cause problems in three situations.
Waste and remediation sector improves safety in 2015: report The United States Bureau of Labor Statistics (BLS) released its 2015 Workplace Injury and Illness Data and the waste and remediation sector reported an overall decrease in injuries, job transfers, and lost workday cases.
www.controleng.com
CONTROL ENGINEERING
DECEMBER 2016
| 35
DIGITAL EDITION exclusive
Seeking truth in reporting helps manufacturing improve Manufacturing plant bonuses and incentive programs can result in inaccurate data if they are not structured and enforced properly. Three methods for focusing on the right targets are highlighted.
B
onus plans and incentives have been placed under a microscope since news broke of the Wells Fargo employees who “secretly opened unauthorized accounts to hit sales targets and receive bonuses,” according to Richard Cordray, director of the Consumer Financial Protection Bureau. More than 2 million fraudulent accounts were created and 5,300 employees lost their jobs because of the fraudulent scheme. It is
‘
Drive continuous improvement through transparency; acknowledge the reality or the truth of the situation.
MORE
ADVICE KEY CONCEPTS Manufacturing bonuses and incentive programs can result in inaccurate data if they are not structured and enforced properly. Driving continuous improvement through transparency requires exposing a plant’s dirty laundry. Establishing a company culture of honesty and accuracy helps the plant and employees see improvement and success. GO ONLINE Read this story online at www.controleng.com for additional stories about how to improve manufacturing and leadership. CONSIDER THIS What other steps can be taken to ensure that data is being recorded accurately?
DE1
|
DECEMBER 2016
’
not uncommon for acts similar to this to take place in many manufacturing facilities. While the extent and severity may not compare to what occurred at Wells Fargo, but manufacturing plant bonuses and incentive programs could also implicate employees if they aren’t structured and enforced properly. There are clever ways of justifying and calculating metrics in order to meet bonus numbers, reach key performance indicators, or goals. In many cases, it’s about hitting some designated number for the plant to be considered worldclass. For instance, a plant can appear to have operational availability (OA) at 90% or above. However, when accurate information is entered, the OA may actually be closer to 50% to 60%. With this in mind, how effective would it be to get clever about what should or shouldn’t be included in that percentage? For example, if a machine is taken out of production for scheduled preventative maintenance (PM), that time frame needs to be considered downtime. Since downtime counts against the plant’s OA goals, preventive maintenance time is often not properly accounted for. CONTROL ENGINEERING
The same tracking philosophy often occurs when production lines are stopped for required employee training or meetings. Failure to track start up times can be considered an example of manipulating the system, all in the quest for meeting the goal to secure any employee incentives tied to that goal. Plants don’t often use theoretical capacity for production goals. Instead, goals are set at what has been done already to make sure the production throughput, or overall equipment effectiveness (OEE) number, is achieved. In an effort to drive continuous improvement through transparency, a plant’s dirty laundry should be exposed. Plants should acknowledge the reality or the truth of the situation. Unfortunately, many bonus plans conflict with this approach, leaving plants reluctant to expose the truth. Instead of creative environments where good people are justifying the wrong behavior like Wells Fargo, here are three methods to focus on the right targets:
1. Focus on a rate of improvement
To be world-class, teams need to stop focusing on hitting a number. Rewards should be given to production lines that continually identify and eliminate problems. Employees should be empowered to research ways to increase production on their individual plant lines. Cooperation is needed to encourage teams to find solutions versus just identifying problems. When everyone focuses on improvements, the entire plant wins.
2. Keep bonus plans focused on problem solving
The greatest motivator of all may be discovered when people feel like they are making a difference and their work matters. When this kind of environment is present, bonus or incentive plans become less important. It might be time to restructure an incentive plan, or realign www.controleng.com
When a team is focused on the right objectives, there will be no room for slight-of-hand accounting, diminished opportunities to fudge the numbers, and less desire to only report good data. Courtesy: Leading2Lean
the company’s motivations and instill a stronger culture of transparency, if incentive plans tempt employees to cover up an issue. Transparency creates accountability within a company. Everyone from managers to co-workers knows whether an employee is doing his or her job or not. Transparency also allows for more commendations, too. When an employee excels, it is visible to their managers and peers. Real-time technology that allows for continual visibility and transparency can be a key component in creating this kind of environment.
3. Embrace truth in your reporting
When acknowledging the truth of the situation is truly celebrated as part of company culture, reporting will be more accurate. This makes the information more reliable for decision-making. With accurate data plant managers, technicians, and line workers will be able to make decisions quicker, solve problems more efficiently, and even justify capital purchases for the plant. Ultimately, the company becomes much more effective. Companies should embrace the good, the bad, and the ugly in their reporting. By seeing the ugly, the most important problems to solve can be solved. www.controleng.com
‘
With accurate data plant managers, technicians, and line workers will make decisions quicker, solve problems more efficiently, and even justify capital
’
purchases for the plant.
When a team is focused on the right objectives, there will be no room for slight-of-hand accounting, diminished opportunities to fudge the numbers, and less desire to only report good data. Despite how painful it may seem at first, establishing a company culture of honesty and accuracy helps the plant and employees see accelerated improvement and success. ce Bob Argyle is the chief customer officer for Leading2Lean, a Nevada-based manufacturing tech solution provider. Leading2Lean is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.
CONTROL ENGINEERING
DECEMBER 2016
| DE2
DIGITAL EDITION exclusive
Develop a process to make informed decisions with Big Data Big Data can help synthesize information and provide users with the exact data they need to make informed, intelligent decisions. Developing a process that benefits everyone in the plant from the top on down is crucial.
T MORE
ADVICE KEY CONCEPTS Big Data can provide users with the information they need to make informed, intelligent decisions. Manufacturing intelligence software provides the ability to bring real-time and business data together into a centralized location and allow users to align data collection with goals and objectives. When implementing a Big Data program, start small and expand the program in increments. GO ONLINE Read this story online at www. controleng.com for additional stories about Big Data and its potential benefits for a plant. CONSIDER THIS What other benefits can Big Data provide to a plant?
DE3
|
DECEMBER 2016
here is a tremendous amount of information out there; dissecting the information can be overwhelming. Especially when the information comes from different sources and may not be accessible to everyone who needs it. Big Data can help synthesize this information and provide users with the exact data they need to make informed, intelligent decisions. Knowing how to capture the Big Data and make it useful is the key. In an enterprise manufacturing system, it is important to be able to see the whole picture when evaluating a problem. An operator on the plant floor can use supply chain information to understand upcoming production schedules. Executives can use the production capacity of their various plants to shift production overloads from one location to another. Just look at trying to estimate a plant’s production. The company would need information about production-line capacity, warehouse capacity, personnel utilization, and sales forecasts to name a few. All of this data comes from different sources. Individuals throughout the company work many hours building reports in different formats. Manufacturing business intelligence software is designed to help simplify this process. The business systems available today provide the ability to bring real-time and business data together into a centralized location and allow users to align data collection with goals and objectives. Reports and information generated from these systems are standardized, repeatable, and can be available enterprisewide. These business software systems provide data aggregation, actionable alerts, and predictive analysis. They allow users to optimize the information and allow users to create business decisions quickly and intelligently. CONTROL ENGINEERING
The business software systems include both data collection and visualization, but the key item that brings everything together is the abstraction layer. This helps normalize manufacturing process data and make the information relevant to the operational teams. This software is normally a configuration utility or modeling tool which allows you to model and contextualize data pulled from the many disparate systems throughout your manufacturing process. ISA-95 modeling standards were followed in the development of these tools. It is best practice to utilize these standards when developing a system. For example, when collecting data from a production process such as filling, there may be several types of fillers enterprisewide, and the users may want to calculate overall equipment effectiveness (OEE) for each. Even though the various fillers may have different inputs and outputs they have the same basic properties. When a filler is defined, the user will want to know the capacity, number of items filled, and downtime. The user will also want to calculate planned production time, which would require production schedules and personnel availability. Lab or quality data could be used to help calculate rejected or scrap material. The image diagrams use of the abstraction layer to consolidate data from different sources. Instead of having several bits of data in different locations, all the information about the equipment is combined within a filler object. Data is aggregated into useful information that will now be accessible enterprisewide. A major complication with making Big Data useful is the expertise that is needed from so many different resources throughout a manufacturing process. Organizing the data within www.controleng.com
The image diagrams the use of the abstraction layer to consolidate data from different sources. Data is aggregated into useful information that will now be accessible enterprisewide. Courtesy: Maverick Technologies
these model-driven software systems provides a collaborative and secure environment where data is accessible to everyone who needs it. Users will have the ability to access the data they need through pre-developed dashboards and reports or via ad-hoc capabilities using Microsoft Excel and other client tools for creating trends and charts. Successful implementation requires a team effort and all users to buy into the system. Find champions in various areas of the process to define business requirements and to model the data so it makes sense to everyone. It is best to start small and introduce new data or new functionality slowly. This will insure the system will be useful for everyone—especially when the company starts considering multisite implementations. ce Patty Feehan, senior developer, Maverick Technologies. Maverick Technologies is a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. www.controleng.com
‘
Organizing the data within these model-driven software systems provides a collaborative and secure environment where data is accessible to everyone who needs it; find champions in various areas of the process to define business requirements and
’
to model the data.
CONTROL ENGINEERING
DECEMBER 2016
| DE4
COVER STORY open-source robotics
Easier, safer robotic programming from open-source software group ROS-Industrial, an open-source factory automation software project, has celebrated its fifth anniversary in January 2017 by expanding into Asia, increasing visibility in a major robotic competition, and it is looking to improve workplace efficiency and safety with its programming. MORE
ADVICE KEY CONCEPTS ROS-Industrial, an open-source industrial robotic software framework and working group, celebrated its fifth anniversary. The group expanded into the AsiaPacific region and has established operations in Singapore. ROS-Industrial is developing technology to improve efficiency and allow robots to work safely for humans. GO ONLINE Read this story online at www.controleng.com for more information on ROS-Industrial and some of the projects they’ve worked on in the past and how they help control engineers. CONSIDER THIS What development do you think ROS-Industrial should work on next?
O
pen-source robotic programming with increased efficiency and safety are among results noted as the Robot Operating System Industrial (ROS-I) open-source software is about to celebrate its fifth year, noting continued expansion. ROS-I is an opensource industrial robotic software framework and working group established by Southwest Research Institute (SwRI). ROS-I builds on ROS, which is maintained by the Open Source Robotics Foundation. The ROS-I project will celebrate its fifth anniversary in January 2017 by adding a third branch in Asia to complement its U.S. and European organizations, and ROS-I software was used by the victors in a major robotics competition in May 2016. The group has come a long way in 5 years and shows no signs of slowing down. “We are delighted that things have turned out as well as they have. ROS has brought consensus to R&D robotics across the board. I
think we’re only beginning to realize the benefits of that for manufacturing, and there’s a lot of hope for the future,” said Paul Hvass, the ROS-Industrial Consortium (RIC) Americas program manager at SwRI. Robotic programming has brought many companies of different sizes and goals together to create a singular language and system that benefits everyone. “Engineering in an open-source way is something you think would never work in theory because of competition and commercial obligations. But it’s great how we’ve been able to harmonize,” Hvass said. “A rising tide lifts all boats, and it helps improve the value of automation for everyone.” Pick-and-place competition
In June, Team Delft competed in the Amazon Picking Challenge in Leipzig, Germany, and won with a robot that was controlled by ROSIndustrial software in conjunction with their deep learning perception system (see Figure 1). The challenge was a global competition with teams from the U.S., Germany, and Japan. Teams were challenged to program their robots to pick objects from totes (stow task) and put them on shelves and also pick objects from stocked shelves and place them in containers (pick task). The robots had to work with a variety of objects and an unstructured environment, which made the tasks more difficult. “Winning was amazing on so many levels,” Hvass said. “Team Delft are avid contributors to ROS, and it was great to personally see them be rewarded for their hard work and ingenuity. The community was very honored with the win.”
Figure 1: Team Delft’s robot presenting its 1st place trophy for a winning performance at the 2016 Amazon Picking Challenge, held in Leipzig, Germany. Courtesy: ROS-Industrial, Team Delft www.controleng.com
Figure 3: Participants at the inaugural ROS-I Workshop Asia-Pacific, held at ARTC in Singapore in July 2016. Courtesy: ROS-Industrial, ARTC Figure 2: The ReApp project aims to make robot programming for small and medium manufacturers more intuitive by overlaying modelbased programming on top of ROS and making it a “Plug & Produce” user experience. Courtesy: ROS-Industrial, Fraunhofer IPA
Figure 4: Cover image: ROS-based motion planners reroute the Universal Robots arm when encountering obstacles. Courtesy: ROS-Industrial, Factory-in-a-day project
Group expands into Asia
The big goal for ROS-I in 2016 was establishing a base in Asia, which has seen a surge in robotics over the last several years. The group’s Asia-Pacific branch formally launched this year and will be managed by Advanced Remanufacturing Technology Centre (ARTC) in Singapore. Singapore might not seem like the first choice for the Asia-Pacific region, but they are recognized internationally for innovation. “It’s a smaller market compared to China, but it’s globally connected to so many countries, and it’s kind of at the center of where everything is happening with ROS in Asia-Pacific.” Singapore, which Hvass called the Switzerland of Southeast Asia, is also a major investor in the robotic industry. “There’s more public investment in robotics per capita than anywhere else in the world,” he said. The response in the Asia-Pacific region, Hvass said, has been very positive thus far, and the group is looking to strengthen its presence. ARTC and Nanyang Technical University (NTU) hosted a sold-out industrial workshop in July 2016 and are looking forward to the 2017 IEEE International Conference on Robotics and Automation (ICRA 2017), which will be in Singapore.
ROS-I technology developments
Fraunhofer IPA, which leads the ROS-Industrial Consortium in Europe, led the EU-funded ReApp project, which developed an ontologydriven programming IDE that is designed to provide signal flow graph and state flow graph programming tools. It also supports drag-anddrop library nodes, which help make robot apps easy to find and use. ReApp also helps make robot manufacturing for small and medium manufacturers intuitive by overlaying model-based programming on top of ROS. (see Figure 2). www.controleng.com
The SwRI team developed a QT Creator ROS Plugin, which provides a ROS-centric development environment with ROS component templates. SwRI also is developing a graphical 3-D setup tool called CAD-to-ROS that is designed to make kinematic chains easy to create and modify. The Factory-in-a-Day project led by TU Delft Robotics Institute also is developing hardware and software components for cost-effective robotization using ROS-Industrial. One development they’re working on is an artificial skin. Each “cell” in this robot skin includes distance, force, and temperature sensors as well as a 3-axis accelerometer that can be used to enable safe interaction with humans (see Figure 4). “It’s locally smart, and it knows where everything is,” Hvass said. “It uses signals to change course, and we believe it will be a powerful tool from a control and safety standpoint.” ce Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com. CONTROL ENGINEERING
DECEMBER 2016
| 37
OPTIMIZATION advanced process control
Achieving operational excellence using APC In the chemical industry, advanced process control (APC) is the formula for reaching higher levels of operational excellence. See 10 APC opportunities, including 3%-5% capacities gain and 3%-15% energy savings. MORE
ADVICE KEY CONCEPTS Advanced process control (APC) is a process control and optimization technology that takes into account the multivariable interactive nature of process units to reduce variability and drive the process to an optimum on a minute-by-minute basis. The first step when implementing an APC program is to understand what process units or part of the units are good candidates for APC. Some companies today have moved beyond the traditional methods to a more advanced technology by integrating adaptive process control with APC technology. CONSIDER THIS In addition to the chemical industry, what other industries could benefit from APC?
O
perational excellence is a business necessity to achieve and maintain a strong market position within the chemical industry. A way to gain a higher level of operational excellence maturity is with a wellplanned advanced process control (APC) implementation program. While the goal of APC implementation in the chemical industry is simple: to maximize margins while meeting customer expectations, there are a few factors chemical operators must consider to ensure a successful implementation. Understanding the benefits of APC
When APC was originally introduced in the early to mid-1980s, it was designed for refineries and petrochemical sites. Since then, this technology has evolved. APC is a process control and optimization technology that takes into account the multivariable interactive nature of process
units to reduce variability and drive the process to an optimum on a minute-by-minute basis. This is done by manipulating variables, such as feed flow, temperature settings, pressure settings, and reflux flows, which are normally changed by operators who run the unit. Due to the multivariable nature of process interactions and variability inherent in process units, operations cannot fully optimize the process manually, as this will result in key variables moving out of the desired range of operation from time to time. To be on the conservative side, operations are forced to move the process out of optimum and into a more comfortable operating range (represented by “A” in Figure 1). However, this often results in higher costs and/ or lower production rates. There is more energy usage, lower yields, and lower feed rates compared to operating with APC. For decades, APC has proven to reduce the variability in the process (represented by “B” in Figure 1) by actively controlling key process parameters on a minute-by-minute basis. The controlled variables are stabilized, and the standard deviation is reduced. When the key variables are stabilized, the optimizing nature of APC is used to move the process to a more optimal point (represented by “C” in Figure 1). This results in consistently operating the unit close to the maximum possible profit day in and day out, safely and reliably. Figure 1: This graph shows how advanced process control (APC) delivers benefits by reducing variations and optimizing operations. All images courtesy: Aspen Technology Inc.
38
|
DECEMBER 2016
CONTROL ENGINEERING
www.controleng.com
Identifying APC opportunities
The first step when implementing an APC program is to understand what process units or part of the units are good candidates for APC. To be able to quantify benefits and improvement opportunity, it is necessary to first understand the economics of the unit and the production process. It is also necessary to consider the unit by itself, or in many cases, its role within the bigger production value chain. If organizations have business or process key performance indicators (KPIs), they can serve as a good starting point for analyzing the APC opportunities. However, there are other ways potential APC benefits can be calculated. The following 10 criteria can be used to quantify the benefits associated with an APC project.
1. Production increase: Typically, APC projects have proven to increase capacity by 3% to 5%. By reducing the variability in the process and operating closer to limits, APC debottlenecks the process, or part of the process, allowing higher production rates. For this to happen, however, an understanding of how the intermediate products affect downstream units and why is required. 2.
Energy savings: Energy savings from APC implementation have been reported to be in the range of 3% to 15% depending on the process and current operations. Most of the time, utilities management, especially steam, is a complex control issue that spans across the site and at times also affects the electric grid. APC applications can be designed to manage utility systems effectively by matching steam production to the site’s demand. Benefits come from reducing pressure let-downs and reducing or eliminating vented steam onsite. Many companies report a 60% to 90% reduction in vented steam using APC. After the steam header pressures are stabilized, APC also can be used to optimize energy production. For example, boiler loads, gas turbines, or other sources of energy can be adjusted to maximize the efficiency of the overall system while ensuring stable header pressures, day in and day out.
3. Quality improvements: It’s important to reduce variability in the final product quality. Some products—for example, certain types of polymers and specialty chemicals—are sold at a value that depends on the quality variability of the batch produced. Many companies report a reduction in standard deviation of product qualities of up to 50%. www.controleng.com
4. Yield improvement: Many organizations experience a yield improvement of 1% to 2% through APC deployments. Typically, this is achieved by optimizing the reactor part of the process and/or the separation portion. In almost all cases, the reaction is highly exothermic or endothermic, meaning good reactor temperature control is key. In addition, good control and optimization of the ratio of feed components to catalyst are very beneficial. Well-controlled reactors typically see an increased yield of 0.5% per pass at the same throughput rates, while maintaining safe operating temperatures. In some cases, it has been proven that a well-controlled polymer reactor online time is increased by up to 5% before a shutdown is required to clean out the reactor, resulting in improved yields and throughput. For the nonreaction part of the process, such as distillation columns, maintaining the specifications on the final product can increase the yield of the desired product by increasing impurities up to the contracted specifications. Higher amounts of lower value products (impurities) in the final product are sold as higher value product, while maintaining the specifications and customer expectations. 5. Optimizing the polymer production wheel: In polymer production, the production wheel usually is not optimized to market needs, as difficult transitions may be rejected by operations. Without APC, grade transitions take longer and result in low-value products produced during these transitions. It’s common to see a 20% to 50% reduction in grade transition time. Through APC, it is possible to “bust the production wheel” and produce grades when they are in demand, while minimizing the time when the low-value transition products are produced. Companies using APC in conjunction with supply chain software can exploit the new capabilities to further optimize the production wheel (see Figure 2).
Figure 2: Companies using advanced process control (APC) in conjunction with supply chain software can exploit the new capabilities to further optimize the production wheel.
‘
Pell-controlled reactors typically see an increased yield of 0.5% per pass at the same throughput rates, while maintaining safe operating temperatures.
6. Recycle ratios: Units that have recycles are good qualifiers for APC. The addition of the fresh feed components depends on the quality of recycle. Without APC, a fixed ratio of fresh feed to recycle is maintained. This does not consider the product quality, downstream equipment CONTROL ENGINEERING
DECEMBER 2016
| 39
’
OPTIMIZATION advanced process control conditions. Diurnal effects, humidity, or even cloud cover have an effect on cooling water temperature, which can result in changes in compressor throughput limits. Operators cannot be expected to exploit the benefits associated with ambient temperature changes. This would mean anticipating the ambient temperature effects on the process and adjusting the process parameters only to reverse all changes as the sun rises in the morning. Units that are affected by ambient conditions can benefit from APC applications as they can anticipate these changes and adjust process parameters accordingly on a minute-by-minute basis.
Figure 3: This diagram shows the phases associated with a traditional advanced process control (APC) project lifecycle.
operation, or the unit constraints. The multivariable nature of APC allows for optimizing the fresh feed-to-recycle ratio to maximize throughput and/or maintain quality at specifications.
7. Emissions control: APC implementation also can help control environmental constraints. By using APC to model and actively control the furnaces and boilers on a steam utility plant through APC, it is possible to operate closer to the emissions limits without violating them. It also helps decrease energy usage and minimize costs to meet NOX and SOX emissions constraints. 8. Exploiting ambient temperature effects: APC has proven to exploit the benefits associated with ambient conditions. Ambient temperature has an effect on compressor performance, condensation capacity, gas turbine operation, cooling water temperature, refrigeration capability, gas volumes, and many more process-related
9. Dynamic opportunities: Without APC, disturbances arising from upstream or downstream will affect process units and reduce margins. For example, in temporary situations where feed quality is decreasing by 1% to 5%, operators will react to keep the product on spec, but most likely not in an optimal way. When things are more stable, the unit may not be optimized because the situation is temporary. This is at best a means of producing on-spec product but at a very large giveaway. At worst, it would mean decreasing feed to cope with the situation. With APC technology, units will constantly react to the disturbance optimally. 10. Site-wide optimization opportunities: Operating units with APC presents a larger scope of optimization opportunity for the site. Optimizing a part of the process as a standalone would mean lost opportunity compared to optimizing multi-units together. For example, pushing a reactor to maximum throughput might not make sense if the bottleneck of the unit is the offgas stripper. If this happens, light materials that should be removed are pushed into either flare or off-gas where they are lost. At some point, this may mean reduced margins. These interactions and constraints are considered in the design of APC systems and can lead to significant benefits for the overall site. APC deployment and project lifecycle
Figure 4: This diagram shows the project lifecycle of advanced process control (APC) technology, such as Aspen DMC3, which is integrated with adaptive process control.
40
|
DECEMBER 2016
CONTROL ENGINEERING
After identifying the business case for an APC project, the next step is to start building and implementing the APC controller. Traditionally, APC projects have been long and expensive with many defined steps needed for successful APC commissioning. For example, organizations would be required to go through countless phases of step testing, model building, controller development, and commissioning before moving onto deployment (see Figure 3). As a result, many companies were faced with lost margins during the lengthy www.controleng.com
deployment phase and disruptions to the process for gathering data to build APC models. Additionally, this process required highly experienced users to build and sustain controllers. Some companies today have moved beyond the traditional methods to a more advanced technology by integrating adaptive process control with APC technology. With adaptive process control, these four phases have been combined into one, allowing users to experience faster deployments and sustained benefits through continuous model updates in the background with no disruptions to the process (see Figure 4). In addition, these tools enable more and less experienced users to deploy and sustain APC controllers, which can save time and money within the organization. Advanced APC technology also helps companies sustain benefits. In the past, any changes to the process or equipment after deployment would require re-identifying the model, which would involve costly step testing and would be handled as a project. However, with adaptive process control technology integrated into today’s APC solutions, sustaining controllers is no longer handled as a project but rather as a continuous process.
Sustainability tools in these advanced APC solutions also include automatic bad-model identification. These models can be calibrated online, in a closed loop with no disruptions to the process. This makes sustaining benefits easier and cheaper. Additionally, maintaining APC controllers requires fewer resources, and as a result, controllers maintain peak performance, which in turn enables companies to deploy and sustain more controllers leading to a best-in-class APC program. APC is key for operational excellence
The chemicals market is very competitive, volatile, and fast-paced. To maintain a strong market position, companies need to look harder and deeper into their equipment, production, and operations to ensure the production chain is optimized. At leading chemical companies, APC is a key strategic tool in the quest to reach higher levels of operational excellence. ce Tushar Singh is a product marketing manager Aspen Technology Inc. Kate Kulik is a senior principal business consultant at Aspen Technology Inc. Edited by Jack Smith, content manager, CFE Media, Control Engineering, jsmith@cfemedia.com.
‘
With adaptive process control, four phases have been combined for faster deployments and sustained benefits through continuous model updates in the background without disruption.
’
2016
Industrial Internet of Things & Industrie 4.0 Turning research into insights makes for better business decisions This study was conducted by CFE Media to gauge the engineer’s understanding and current implementation of the Industrial Internet of Things (IIoT) and Industrie 4.0. Respondents to the 2016 Industrial Internet of Things & Industrie 4.0 study identified five key findings regarding their familiarity and implementation of the IIoT framework and Industrie 4.0 platform. According to the study, familiarity with the IIoT framework and the Industrie 4.0 platform has significantly increased since 2015; 79% of respondents are very/somewhat familiar with IIoT, compared to 60% last year, and 53% are very/somewhat familiar with Industrie 4.0, compared to 33% previously. More than half of respondents expect IIoT and Industrie 4.0 to improve connections between people, data, and machines at their facilities. Other expected benefits include increased information flow, increased innovations, and improved data analysis.
Access the 2016 Industrial Internet of Things & Industrie 4.0 report with additional findings and insights. www.controleng.com/2016IIoTStudy
WIRELESS data monitoring
Using wireless to gain a network and data monitoring edge Gaining access and data from areas previously inaccessible allows for greater knowledge and visibility of what is going on throughout the manufacturing enterprise.
M
uch to the surprise of workers at one major oil and gas organization, they found more than 250,000 network interfaces that never carried traffic at all. This anonymous organization went out and bought and installed network switches, but came to find out they had all these ports on these switches that went completely unused. Better use of existing resources
MORE
ADVICE KEY CONCEPTS The wireless sensor network market is projected to reach $1 billion by 2020 with utilities, manufacturing, and government having the most connected devices. Wireless gives a manufacturer more knowledge, which means a stronger capability to understand what is occurring throughout the process. Leveraging the data to make smarter investment decisions is really where the manufacturer will see a big benefit. GO ONLINE Read this story at www.controleng.com for additional stories on networking and data monitoring from ISSSource. CONSIDER THIS What else can a user do to gain a network and data monitoring edge and improve efficiency from an operations standpoint?
42
|
DECEMBER 2016
Instead of buying all new switches every year, they learned they could redeploy all the ones they already had to serve the network traffic. That is a major lesson in network monitoring 101. Wireless can provide financial benefits and improve productivity. Gaining access and data from areas previously inaccessible allows for greater knowledge and visibility of what is going on throughout the manufacturing enterprise. The numbers back that up with the forecast for industrial wireless sensor networks to reach close to $1 billion by 2020, according to market research conducted by MarketsandMarkets. On top of that, Gartner predicts that by 2020, utilities, manufacturing, and government will have the three highest numbers of connected devices. Along those lines the Berg Institute said the installed base of wireless devices in industrial
‘
applications reached 10.3 million connections at the end of 2014, with the number expected to expand at a 27.2% compound annual growth rate to 43.5 million devices by 2020. Analyst firm IDC said the Internet of Things (IoT) market in manufacturing operations will grow from $42.2 billion in 2013 to $98.8 billion in 2018, a 5-year growth rate of 18.6%. On top of the booming growth of wireless devices and wireless sensor networks, the use of wireless backhauls, which are significantly less expensive to install, and provide secure data transmission, make it easier to set up new nodes or temporary data centers. Throughout the operational technology (OT) enterprise, wireless backhauls make it possible to extend sensor and control networks anywhere in the plant. Wireless gives a manufacturer more knowledge, which means a stronger capability to understand what is occurring throughout the process, which increases the potential for cost savings, productivity, growth, and profitability. Benefits and tradeoffs
There are potential issues that come with all these potential benefits. Knowledge and understanding of wireless is sometimes tenuous at best. There are those that have not put a thought around the concept of super reflection, retransmission and
Wireless gives a manufacturer more knowledge, which means a stronger capability to understand what is occurring throughout the process, which increases the potential for cost
’
savings, productivity, growth, and profitability. CONTROL ENGINEERING
www.controleng.com
interference from other signal sources. They think all they have to do is put up an aerial with a wireless signal and then go out and find the other end and receive it. Being able to report on what is actually happening with those connections on either side including the errors and faults and retransmission times where packets end up resent because of an error, is not something people look into. The need for more visibility is vital. Wireless ISPs that do long haul wireless use the right equipment. However, some have no way of measuring or capturing metrics with their standard set of devices, but one goal is to use the correct tool to look at, understand, and then act upon the data. This allows them to get actionable data that shows them central processing unit (CPU) usage versus traffic retransmission or dropped frames or retransmission requests. They could learn what channel the device is operating on or they could set an alert saying if it is not working on one channel let me know if something has changed on the network. It is also possible to get GPS metrics from some of the wireless devices. That becomes important when an engineer has to go out to the device. It is possible to pull information from the device such as the output power signal, the number of other detected devices, interference, signal levels, and other detected clients. Connections over time
The user also can find the number of clients that connected over time. In an OT environment, those numbers should be stable. Typically, when devices connect, they stay connected forever. If there are quite a few up and down changes in that count of connected clients, there might be a problem in that link. If there are a high amount of bit error rates, there might be an issue with the reliability of the link. Those are data points the manufacturer can monitor—and keep the history forever to learn what was really happening on Tuesday, March 24, 2014, compared to today. That is also a fundamental component of a good security strategy in keeping an audit trail and history. Let’s face it, the end user will not always catch or stop an attacker from doing something, and since the victim may not find out until later that something happened, then it is possible to go back and find the history and find out who did what and when. This way the user can find out who connected at such and such time and what device did they access. www.controleng.com
Connections and traffic load
In a wireless environment, the number of connected devices relative to the number of physical connections is high. It is kind of like virtualization, when there may be one physical server and have 10 or 20 virtual machines running on it, it is the same thing with wireless. There might have one access point and have several hundred clients connected to it. And every one of those clients has an IP address and is generating traffic on the network. Monitoring that traffic load and what the
‘
A fundamental component of a good security strategy in keeping
’
an audit trail and history.
clients are generating remains paramount. When the traffic load increases, it is time to start capacity planning. By watching the traffic generated on the network, the user can figure out if they make subtle changes to their network architecture they could save money by redistributing the way traffic is carried between the links they already have. Or, if there is heavy traffic for clients going to specific servers, what if they locate the servers closer to the clients’ location. Now the manufacturer is not carrying all that traffic over a wide area it is paying for every month. If the user has a good picture of where the traffic comes from and where it is going, then he or she can make some smart decisions and get the most value. Leveraging the data to make smarter investment decisions is really where the manufacturer will see a big benefit. In a cost-conscious environment, that is a profitable lesson learned in network monitoring 101. 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. CONTROL ENGINEERING
DECEMBER 2016
| 43
WIRELESS CONTROL benefits and applications
Wireless takes control for industrial applications Wireless transmitters are being widely used for monitoring, but recent developments, such as energy harvesting, show wireless is also suitable for real-time control for any application.
W MORE
ADVICE KEY CONCEPTS The benefits of wireless transmitters for fast processes. New developments in wireless controls. Solutions wireless sensors provide for any application. GO ONLINE For related links about wireless transmitters, read this article online. In the digital edition, click on the headline or search the headline for www.controleng.com. CONSIDER THIS What kind of training is necessary in order to maximize ROI from installing wireless controls?
ireless sensing is being used worldwide in tens of thousands of process industry applications, and manufacturers are reporting that wireless networks are in high demand and a growing segment within the industry. For connecting instrumentation to control and monitoring systems in the process industries WirelessHART from the FieldComm Group and ISA100 from The Instrumentation, Systems, and Automation Society (ISA) are widely used. While wireless is primarily used for monitoring equipment and diagnosing problems, current trends indicate that wider use of wireless control is just around the corner, especially with new tools to make networks easier to setup and use. Wireless equipment benefits
A primary reason for using wireless is low cost. In comparison, a wireless transmitter can be installed and connected to the control system at a fraction of the cost of using a wired transmitter. For about one fifth to one third of the cost of a wired transmitter, a wireless transmitter can be installed and connected to the control system. (“Information from wireless transmitters saves energy,” Control Engineering, July 2016, p.23.)
Figure 1: A Rosemount 708 wireless acoustic transmitter monitoring a steam trap can be installed in locations that are too expensive or too difficult to reach with wired instrumentation. All graphics courtesy: Emerson Automation Solutions
44
|
DECEMBER 2016
Another major reason for using wireless is due to easy installation, particularly for batterypowered wireless transmitters. Wireless transmitters don’t need signal wiring back to a corresponding wireless gateway, which is in turn hardwired to one or more control and monitoring systems. Battery-powered units don’t require power wiring, so they can be installed virtually anywhere to monitor just about anything. This means that equipment such as steam traps (see Figure 1), heat exchangers, pumps, compressors, and pressure relief valves easily can be monitored wirelessly. In many cases, these types of equipment are too expensive to monitor with wired instrumentation, often because they are in a location where a wired infrastructure is unavailable. Wireless works in truly remote locations, such as offshore platforms, wellheads, lift stations, pumping stations, pipelines, tank farms, and oil terminals. In these situations, the wireless instruments are connected to a gateway, which can be hardwired to a local control and monitoring system. The gateway also can be hardwired to a longrange wireless transmission system. Using its attributes of low cost and simple installation, wireless helps fulfill the needs of plants to optimize operations, save energy, increase efficiency and reduce maintenance costs.
Figure 2: Wireless steam trap acoustic sensors, combined with Emerson asset monitoring application software, use sensor data to give actionable information and find small problems before they become major issues.
CONTROL ENGINEERING
www.controleng.com
Figure 3: Thermal energy harvesters, such as this Power Puck from Emerson, generate electricity from temperature differences between industrial heat sources and ambient air.
For example, wireless sensors and specialized software (see Figure 2) can detect steam trap problems. These systems diagnose the problem, determine the probable cause, and notify maintenance that a device is failing or operating erratically. When the maintenance person goes into the plant to troubleshoot, he or she will “know before they go.” Similarly, because WirelessHART provides access to all of the diagnostic and status conditions available in HART instrumentation, plant engineers and technicians can detect pending problems before the problems shut down a process. To date, wireless has almost exclusively been used for monitoring and maintenance purposes, primarily because of update rates. To preserve battery life, most plants set the update time of a wireless transmitter to a relatively slow rate compared to wired transmitters. With an 8-second update rate, a battery can last from 5 to 7 years. Unfortunately, an 8-second update rate is not suitable to control fast processes, such as liquid or gas flow. Despite the update rate, wireless control has already started for fast processes. For example, wireless control is being used on remote tanks to prevent overflows. When wireless level transmitters detect a potential overfill condition, the control system sends a signal to a valve actuator fitted with a wireless adapter to shut off flow. In Mexico, work is underway to shut down remote pumps wirelessly. Recent trends and developments are changing, making wireless more suitable for real-time control in certain applications. New developments in wireless controls
Various advances and developments are coming together to make wireless control more feasible. Energy harvesting converts energy found in a process plant to electrical power that can be used by wireless devices. One energy harvesting device designed to power wireless instrumentation is the recently released a thermal harvester (see Figure 3). Thermal harvesters generate electricity from temperature differences between industrial heat sources and ambient air. www.controleng.com
Figure 4: An Emerson WirelessHART system illustrates how wireless sensors, access points, and a mesh network connect to the control system. In one application, when wireless level transmitters detect a potential overfill condition, the control system signals a Fisher Controls valve actuator fitted with a WirelessHART adapter to shut off flow. Another plant used three Emerson wireless THUM adapters for the three magnetic flowmeters and a wireless gateway to create a WirelessHART network to supply instantaneous flow information that operators can monitor from the control console. Emerson’s PIDPlus programming optimizes PID control for wireless communication.
Heat sources are found throughout industrial facilities on rotating equipment—such as motors, fans, compressors, and pumps—as well as pipes carrying steam and other heated process fluids. Configurations are available for a wide range of potential heat sources including flat or cylindrical surfaces at temperatures up to 450°C (845°F). Because thermal energy harvesting solutions work with a battery, they have the additional security of redundant power; that is, the battery takes over in case there’s a disruption of heat to the energy harvester. Table 1 shows the battery life (in years) of a wireless pressure transmitter with energy harvesting. With as little as a 40°C (72°F) heat differential, an energy harvester enables operation at a 1second update rate without using back-up battery power for over 10 years. The next trend is the increasing availability of wireless adapters that allow legacy instrumentation and plant equipment to connect to a wireless network. Several instrument vendors offer adapters that convert a standard 4-20mA transmitter to WirelessHART or ISA100. Hundreds of thousands of 4-20 mA instruments enabled with HART communications are installed in process plants worldwide, but many plants have yet to exploit all of HART capabilities for each instrument. Many plants use handheld CONTROL ENGINEERING
DECEMBER 2016
| 45
WIRELESS CONTROL benefits and applications HART interfaces to detect the instrument’s status and diagnostic information manually, but this information is unavailable to the control room. Interfacing a legacy instrument into a control system often requires installation of a HART modem, power-wiring to the modem, and software in the control system to extract the data. Some legacy control systems can’t accommodate HART data without extensive custom coding. Energy harvesting (EH)
Battery only No EH
(∆T = Temperature difference) ∆T °C
20
25
30
35
∆T °F
36
45
54
63
≥72
≥40
1 sec.
0.6
0.7
0.9
1.3
2.7
>10
2 sec.
1.3
2.0
5.2
>10
>10
>10
4 sec.
2.2
5.5
>10
>10
>10
>10
8 sec.
3.7
>10
>10
>10
>10
>10
16 sec.
5.8
>10
>10
>10
>10
>10
32 sec.
8.6
>10
>10
>10
>10
>10
60 sec.
10.0
>10
>10
>10
>10
>10
Table 1: With energy harvesting, a wireless transmitter can operate at update rates once per second for more than 10 years without needing a battery replacement. Figures shown are for a Rosemount 3051S wireless pressure transmitter with energy harvesting from Emerson.
WirelessHART protocol adapters address these issues by converting the HART protocol to Modbus RTU or one of the Ethernet protocols. For example, the Monroe County waste treatment plant in Rochester, N.Y., relied on operator rounds to take flow meter readings for three lines. The flowmeters were located in a separate building in the mile-long plant, and were too far away from the main control system for hardwiring. No conduit was available, and the existing input/output (I/O) rack of the local control system was full. So operators would travel to the building once an hour, write down the instantaneous flow readings, and manually calculate the total of the flows. The plant purchased three wireless adapters for the three magnetic flow meters that needed to be brought online and one wireless gateway that provided an infrastructure for the wireless network. Now the plant has instantaneous flow information that operators can monitor from the control console. Wireless adapters also can be installed on control devices. On control valves, for example, a wireless adapter can be installed on a digital valve positioner for a wireless closedloop control. A similar setup could be feasible for control of a variable-speed motor drive.
46
|
DECEMBER 2016
CONTROL ENGINEERING
Another interesting development is a modified proportional-integral-derivative algorithm that can be used to control processes with a response time of 30 seconds or less, such as a distillation column. The modified programming modifies the PID algorithm to automatically account for slower update times from wireless sensors. Research at the University of Texas shows that real-time control of a dividing wall distillation column using the advanced PID programming with wireless transmitters is comparable to control achieved using PID control with wired transmitters. Wireless control is coming
All of the pieces are in place to apply wireless control for many applications. Figure 4 shows a typical wireless system with wireless sensors, access points, and a mesh network that connects them to the control system. Wireless transmitters can operate with an update rate of 1 to 2 seconds, which is fast enough for most process control applications. The wireless system’s network manager can schedule whatever measurement update rates are needed from the wireless sensors, so critical sensor data can get to the control system quickly. If the control system uses fieldbus or 4-20mA connections to control devices, there’s no problem. However, if control signals are being transmitted via wireless, the problem is that network managers cannot schedule wireless output transmit times the same way wireless inputs are scheduled. It can take anywhere from 10 seconds to several minutes for a wireless control signal to reach a device. There are developments in the works for a network manager that allows the scheduling of wireless output signals to complete the last piece of the wireless control puzzle. The wireless advantages of low-cost and simple installation help plants increase efficiency, optimize operations, reduce maintenance costs, and find small problems to assist in preventing or minimizing downtime. Until now, because of slow response times and battery life issues, wireless transmitters have been used only for monitoring, not control. Recent developments—including energy harvesting, wireless adapters, and an advanced control algorithm—mean that wireless control is right around the corner for virtually any application. ce Melissa Stiegler is the director of wireless product management at Emerson Automation Solutions. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com
WIRELESS NETWORKS remote locations
How to implement wireless sensor networks for difficult industrial settings Pairing low-power wide area network (LPWAN) and Bluetooth low energy (BLE) networks allows the enterprise Internet of Things (EIoT) to connect wirelessly to remote locations.
S
ome of the most interesting and impactful implementations of Enterprise Internet of Things (EIoT) technology are in industrial settings, where wireless sensor networks and controls enable organizations to monitor and manage machinery in ways that have never been possible before. Wireless sensors that operate on a small battery—free from hardwiring—can be located within industrial settings in spots that were not feasible with prior generations of industrial sensors and controls. An enterprise-class version of Internet of Things (IoT) technology–EIoT–has enhanced reliability, security, and comprehensive interoperability to address the stringent requirements of wireless implementations for industries such as manufacturing, health care, financial services and others. EIoT addresses these needs with technical features and design elements that far surpass those of traditional IoT used for less stringent consumer or commercial applications. Industrial EIoT challenges
EIoT-enabled sensors and controls can go nearly anywhere within a given industrial environment, but until now there has been a catch. Not every industrial application has been ideal for going wireless because IoT deployments have two basic elements: Wirelessly connected network of devices, which is installed with a series of sensors and controls linked with a short-range, lowpower technology The network of IoT sensors needs to collectively communicate with other machines, controllers, and other parts of the network over a longer range of distance. www.controleng.com
Figure 1: The LoRa network diagram shows how sensors connect to a LoRa client and connect via a LoRa gateway. All graphics courtesy: Laird
The ability to reliably communicate over a long distance is often a significant obstacle in industrial settings for a very simple reason: telecommunications connectivity via wire lines or cell tower signals is not always available at sites where industrial equipment is located. Even when connectivity is available, the cost of using cellular service just to deliver a few packets of sensor data at a time does not make a lot of sense—financially or technically. In addition, there are often similar issues when it comes to utility power, which may be hard to come by in remote locations where the equipment or infrastructure is not powered. Despite the ubiquity of connectivity in populated areas, some areas do not have reliable wireless telecommunication service. That is often very true when it comes to rural and remote locations for industrial equipment, such as remotely located oil/gas/pipeline machinery, water/wastewater systems that are far from metropolitan areas, holding tanks and pumps, and other applications. These sites also are often located far from the nearest technician who can drop by to check on equipment. It is not uncommon for onsite visits to take a full day for an engineer, or even a multi-day trip when visiting several remote sites. Often, finding workers to operate in these remote locations is difficult. EIoT-enabled sensors and CONTROL ENGINEERING
MORE
ADVICE KEY CONCEPTS Challenges for EIoT implementations and industrial applications. The benefits of combining LoRa and BLE technologies. LPWAN technologies for IoT applications. GO ONLINE For related links about wireless network solutions, 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 limitations for LPWAN technologies for industrial applications? DECEMBER 2016
| 47
WIRELESS NETWORKS remote locations
Figure 2: Applications far from urban centers and traditional telecommunications service can benefit from a low-power wide area network communications protocol, such as LoRa.
controls are equally rare in remote settings, and in these settings low-power wide area networks (LPWAN) can help. Wireless EIoT: BLE, LPWAN
The most widely used, short-range wireless technology in EIoT deployments is Bluetooth low energy (BLE; also known as Bluetooth Smart). The biggest reason for BLE’s popularity for EIoT is its power efficiency, which allows
‘
The most dramatic impact of LoRa and BLE is giving wireless sensors and controls and other devices the ability to be installed anywhere.
’
sensors and controls to operate for extended periods on a small battery. It manages sleep cycles and active cycles to conserve energy while meeting the data collection and reporting for certain applications. BLE is also widely used because of its radio frequency (RF) signal strength, which performs well even in complex environments with RF noise, computing signals, and physical obstructions—all of which are common in industrial settings. BLE is the core short-range technology for many industrial EIoT projects that are implemented or in
48
|
DECEMBER 2016
CONTROL ENGINEERING
the design phase, but a network of BLE-enabled devices must have a way to relay data and receive instructions over distance. The reliance on traditional telecommunications infrastructure (which enables that bi-directional communication via Wi-Fi or cell signal) has put growth limitations on these sensor and control networks, which is why a complementary, long-range technology is so important. By combining BLE with the ultralong range and low-energy capabilities of LoRa (from the LoRa Alliance, which announced plans to form in January), companies no longer have to limit EIoT deployments to locations where telecommunications and power infrastructure is immediately available. This opens up an entirely new geography for IoT implementations. The LoRa wide area network protocol often is referred to as a LPWAN because it provides secure, bi-directional data transfer and communications with IoT networks over long distances for years without a battery change. It can send and receive signals up to 10 miles, and repeaters can extend that distance to hundreds of miles if needed. When LoRa is paired with short-range BLE technology in one integrated solution, the geographic restrictions that previously existed for EIoT implementations can be mitigated in a way that makes it possible for these low-power, short-range device networks to go nearly anywhere without the need to build a www.controleng.com
telecommunications infrastructure onsite. For sites where cell service is available but expensive because of the lack of competition in remote locations, LoRa and BLE make EIoT implementations more cost-effective. Previously, they were not due to the high cost of network fees when a cellular connection was needed to be used. LoRa technology has many benefits for IoT applications due to its cost-effective specifications and capabilities including the following: It works well for battery-powered networks of IoT devices because, like BLE, it is also an ultra-low-power technology that can operate on a battery for an extended period of time and requires infrequent maintenance. The nodes are inexpensive and allow companies to bypass the high cost of cellular data fees or fiber/copper installation, which removes a major cost barrier to remote locations and means zero ongoing data charges. It works well with device networks located indoors, including in difficult industrial environments, which might otherwise present difficult challenges to other technologies. LoRa is highly scalable and interoperable, supporting up to a million nodes and compatible with public and private networks for data backhaul and bi-directional communications. The tradeoff for using a low-power, ultralong-range technology like LoRa is throughput, which makes it a poor fit for applications that require streamed data. But this limitation does not come into play with a wide range of IoT applications where small batches of event data are being delivered. While other emerging LPWAN technologies have promise for addressing this long-range backhaul aspect of IoT implementations, LoRa offers bi-directional communications, immunity to interference, and large data payloads needed for IoT deployments. Using LoRa, BLE technologies for EIoT networks
LoRa’s potential becomes apparent once it is paired with a technology like BLE. Together, they provide a set of short-range and long-range ultralow-power wireless capabilities that expand the possibilities for EIoT networks. In urban areas, www.controleng.com
for example, an entire metropolitan area could be covered with just a few LoRaWAN gateways that serve as the backbone for BLE sensor networks that do not rely on traditional telecommunications infrastructures. In this way, LoRa and BLE lowers a number of barriers to expand IoT in populated areas like cities and towns, which would be significant because it provides a foundation for waves of creative IoT applications. However, the most dramatic impact of LoRA and BLE is giving wireless sensors and controls and other devices the ability to be installed anywhere. BLE makes that possible by allowing wireless devices to be squeezed in any physical location. BLE also allows those devices to work together in an integrated, short-range network that is controllable from, for example, smartphones or tablets that serve as remote wireless displays. LoRa builds on BLE’s mobile capabilities by serving as a relay that can send and receive data over very long ranges that can be extended with simple gateways to pass the signals along. BLE makes EIoT possible in even the smallest corner of a facility, and LoRa makes EIoT possible on any spot on the map. This will significantly speed up the IoT revolution. BLE sensors collect temperature data, a LoRA and BLE module can then forward the information over a long-distance LoRaWAN network to be processed. It blazes an entirely new trail for this kind of sensor project because of how LoRa and BLE unlocks the ability to transfer data over much further distances, how it eliminates many of the most challenging aspects of deploying IoT, and how it represents a simple style of programming due to the pre-built components that are part of the module. The promise of BLE is that sensors for temperature, moisture, vibration, liquid level, flow, and pressure valve controls can go anywhere, and that becomes literally, geographically true when it is combined with LoRa. The pairing of LoRa and BLE is enabling EIoT networks to go beyond its previous limits technically and geographically. In doing so, this combination of technologies is opening up a new galaxy of exciting, new wireless possibilities to explore for industrial applications. ce
Figure 3: Laird offers the RM1xx module, which incorporates communication capabilities for the LoRa and Bluetooth wireless network protocols.
Zach Hogya is the director of software engineering at Laird and Jonathan Kaye is the director of product management of connectivity solutions at Laird. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com CONTROL ENGINEERING
DECEMBER 2016
| 49
SYSTEM INTEGRATION integrating multiple platforms
Best practices to help with multiplatform system integration Ease a multiplatform system integration process by doing vendor research, having a common network, and upgrading legacy equipment.
L
earn these tips when integrating industrial automation devices and systems across control system platforms. When integrating different platforms for devices at a plant, there are many steps to take to make sure different platforms are integrated correctly and efficiently. These three key tips and tricks can help determine if multiplatform system integration is the best path to take.
devices. Ethernet can be reliable and effective for getting different devices communicating. If you can’t get the devices to communicate using the existing network, try researching gateways and protocol converters. With this method, you can have multiplatform devices communicating on a common network.
3. Sometimes it’s better to update
There’s a lot of outdated equipment in the manufacturing realm. ARC Advisory Group estimated Doing the research will save a lot of time and money that there’s $65 billion worth of installed process automation sysin the long run. Having to take several steps back in tems in the world today that are nearing their end of their useprojects because of not doing enough research is ful lifecycles, which, in many cases, can exceed 25 years. Legnot an efficient approach. acy equipment might not even have the capability to communicate via Ethernet. Sometimes the 1. Research automation best method to effectively integrate devices is to vendor devices upgrade the legacy equipment. Many vendors Ensure that automation and control devices and system integrators provide migration tools MORE from multiple vendors will integrate effectively. and plans to help with time and budget. Overall, Many vendors can provide documentation, such an equipment upgrade can save a lot of time and ADVICE as case studies, white papers, or a brochure with money for your client. KEY CONCEPTS detailed information on devices. It’s also imporSteps to take for multiplatform tant to stay up-to-date with the latest technoloFollowing these tips will help ease the prosystem integration. gies from vendors with “lunch and learns” or cess of multiplatform system integration. Being How to do the proper research for multiplatform system integration. by attending industry conferences. Doing the educated when it comes to what kind of equipMethods to ease the system integraresearch will save a lot of time and money in the ment needs to be upgraded at a facility and what tion process. long run. Having to take several steps back in is compatible with each device will set a path for projects because of not doing enough research is success and shorten project timelines. ce GO ONLINE For related links about system not an efficient approach.
‘
’
integration, 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 migration tools to help with system integration?
50
|
DECEMBER 2016
2. Look for a common network to share
Ethernet is becoming more popular in the industry due to its cost effectiveness and ability to communicate plantwide to a variety of
CONTROL ENGINEERING
Nathaniel Kay is an engineer at MartinCSI, and Laura Mann is the marketing coordinator at Martin CSI. Edited by Emily Guenther, associate content manager, Control Engineering, CFE Media, eguenther@cfemedia.com. www.controleng.com
INSIDE MACHINES hydraulic control
Controller
for crane testing Verifying load parameters when testing mobile cranes is important to verify quality, which matters for functionality and safety. New testing systems included installing new proportional servo valves and high-performance, electro-hydraulic motion controllers.
H
iab, an operating unit of Cargotec of Helsinki, Finland, provides of onroad load handling equipment. The company rigorously test its mobile hydraulic crane products to ensure that they meet design specifications. Testing protocols involve driving the cranes and monitoring crane operation to verify performance. A wide range of hydraulic fluid flows are required, from 10 lpm to 150 lpm. If the flow is not precisely regulated, especially low fluid flows, the ability to make very precise lifting motions cannot be verified. Hiab’s old test system consisted of a main 270 kW hydraulic power unit (HPU) that feeds 6 test stands at 350 bar (5,000 psi) continuous pressure. Each stand can simulate either a fixed flow or a variable flow pump. Each test stand used a programmable logic controller (PLC) providing closed-loop control via a standard performance proportional valve and a pressure compensator to maintain the desired flow. The test system worked, but Hiab’s quality control people were dissatisfied with test quality in some operating modes. The system was very sensitive to pressure compensator device performance, which had difficulty regulating the target differential pressures at very small fluid flows or at highload induced pressures. The need to perform frequent calibrations of the compensators to adjust for weakening internal springs had also become a maintenance headache. Hiab contacted Ihber of Zaragoza, Spain, a hydraulic company specializing in advanced customized applications, such as motion control and testing. Hiab wanted improved test stands to “cover the complete flow range and dramatically reduce maintenance tasks,” said Javier Berné, Ihber technical manager. The Ihber team proposed the installation of new proportional servo valves and high-performance, electro-hydraulic motion controllers. “Avoiding the pressure compensator means less www.controleng.com
Figure 1: The new Ihber test system simulates either fixedflow or variable-flow hydraulic pumps for crane operation. Shown are the control and hydraulic panels for one test stand. All images courtesy: Delta Motion Systems
maintenance, and use of the high performance valve and controller means better performance,” continued Berné. Two weeks during summer were available to disassemble existing test stands, install the new systems (one stand is shown in Figure 1), and test and tune the controls (see Figure 2). “Perfect performance from the first day was a must,” said Berné. “We chose to use particular twoaxis controllers because of their performance, the capabilities of the software that is supplied for free with the controllers, and the high level of technical support that the vendor provided was impressive.” Each motion controller (shown in Figure 3 as mounted in one test stand’s control panel) was programmed to simulate the performance of hydraulic pumps in two operating modes. Each mode employs a different sensor configuration. A programming feature called custom feedback allows the controller to easily switch between modes. Programming advantages
The first mode simulates feeding with a fixed flow pump and a pressure-limiting valve. In this mode, the motion controller is interfaced to a servo valve, a flowmeter, and a pressure sensor. The controller is programmed using a velocity control loop with force limiting feature. In this mode, the controller runs the velocity and force proportionalintegral-derivative (PID) algorithms in parallel and CONTROL ENGINEERING
Figure 2: A black crane is visible in the background while testing is in process.
MORE
ADVICE KEY CONCEPTS Upgrades of motion control test stands were needed to improve quality and decrease maintenance. New controllers increased capabilities. Related software adds functionality. GO ONLINE See additional information and link to the Control Engineering motion control page with this article online at www.controleng.com/archives. CONSIDER THIS Can a new controller upgrade add capabilities making it worth the investment, even if existing controllers still work?
DECEMBER 2016
| M1
Bring Your Machine To Life With Custom Drives
INSIDE MACHINES hydraulic control
Figure 3: Inside the control panel: Each test stand is controlled via a programmable logic controller (PLC) (center left) and a Delta Computer Systems RMC75P motion controller (center right). The PLC and motion controller are connected via Profibus (the purple cable).
A d va n c
ed C ont Al go r i t h m ro l s
Ethernet Connectivity Automation Controller
Custom Drives
Custom Motor Design Custom Software Vision
Aerotech can partner with you to design a custom automation solution for your specific application at a minimum price. In our concept machine above, Aerotech’s drive packaging can be customized to fit into the wasp body with special algorithms developed at the firmware layer for flight control. Aerotech can accommodate your custom automation controller needs by using our plug-in architecture for specific algorithms such as 2D bar code, interfaces to non-standard sensors, signal outputs synchronized to servo sample time, and more. If you have a need for custom hardware or firmware in your drive package, contact Aerotech today. We customize Aerotech automation for you • Hardware • Software • HMI • Firmware • Packaging • I/O • Motors • Electronics
Global sales, service, and support
The Americas • Europe • Asia-Pacific Contact our Control Systems Group at 412-967-6839 or sales@aerotech.com to discuss your application today, or see go.aerotech.com/csg77 AH0315C-CSG
Dedicated to the Science of Motion input #13 at www.controleng.com/information
uses the minimum of 2 PID control signals to drive the actuator. In testing, Ihber’s engineers programmed the velocity loop to control hydraulic fluid flow to the crane, while the force loop is set to limit the applied pressure. The second operating mode of the test system simulates a variable flow pump with load sensing and a cut-off compensator. Force limiting was employed in programming the controllers, with the first loop controlling differential pressure across the crane valve (using 2 pressure sensors, one for crane supply and another for load-sensing) and pressure limiting by the second loop. “The use of the motion controller’s force-limiting capability allowed us to avoid transitioning between separate control modes for velocity or differential pressure and pressure regulation during system operation,” said Berné. “This makes for smoother operation and minimizes test system maintenance issues.” Motion-control loop tuning
The development tool software also provides support for tuning motion-control loops for precise operation. “Real-time plotting of all the motion parameters using the plot manager allowed us to very quickly understand the system and find a good and smooth response in every situation, even after an emergency stop or during the first movements, when there is entrapped air in the crane circuit,” said Berné. Each test stand has a PLC and a touch screen human-machine interface (HMI). All elements communicate over Profibus and connect via Profibus to an additional PLC that controls the HPU and manages alarms. Using the touch screen, the user can specify the control type, target parameters (such as flow, maximum pressure, differential pressure), and other information the controller needs. The touch screen also receives information from the controller, including actual parameter values measured during system operation. “With the new controls in place, the performance of the system is much better than our customer expected,” said Berné. “Thanks to valve and controller performance, flow control is very accurate, even with small flows, and pressure limiting works fine for light and heavy crane loads and different speeds.” ce Richard Meyerhoefer is regional applications specialist at Delta Computer Systems Inc.; Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
M2
|
DECEMBER 2016
CONTROL ENGINEERING
input #14 at www.controleng.com/information
INSIDE MACHINES discrete sensors
Advances in
proximity sensors Inductive, magnetic, ultrasonic are among the technologies used for proximity sensing, and small sizes and extended ranges are among features in recently announced proximity sensors.
When a sensor is needed to sense proximity to an object, then distance, material, and other variables may dictate the technology or features required for the application. AutomationDirect, Carlo Gavazzi, Pepperl+Fuchs, Sick, and Telemecanique (part of Schneider Electric) recently announced proximity sensing products. Details follow.
Longer distance prox sensors
MORE
ADVICE KEY CONCEPTS Varied sensing technologies serve as proximity sensors Smaller sizes and extended ranges are among advances Different configuration suit many applications. GO ONLINE Control Engineering has a sensors and vision page under the Discrete Manufacturing pull-down menu near the top of www.controleng.com. CONSIDER THIS Is it time to rethink some proximity sensor applications, given longer ranges and other expanded options?
M4
|
DECEMBER 2016
AutomationDirect offers the Contrinex DWseries of extended and triple-distance proximity sensors in 3 mm to 30 mm cylindrical and 20 mm rectangular styles. With 10 to 30 V dc operating voltage and sensing distances ranging from 1 mm 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. DW-series 3 mm proximity sensors are fitted with a 2-m axial cable; other sizes offer 2-m axial cable, M8, or M12 quick disconnects. DW-series proximity sensors are designed with an LED status indicator and are available with NPN and PNP, as well as normally open or normally closed outputs. The DW series proximity sensors have an IP67 protection rating and provide overload protection. AutomationDirect www.automationdirect.com/proximity Input #200 at www.controleng.com/information
Miniature inductive proximity sensors AutomationDirect’s miniature inductive proximity sensors range in sizes from 4 mm to 8 mm and feature stainless steel shielded housings. Offered as NPN (negative positive negative) or PNP (positive negative positive) models and with normally open or normally closed outputs, CONTROL ENGINEERING
sensors are available with standard sensing distances of 0.8 mm or 1.5 mm; available extended distance models have either 1.5 mm or 2 mm sensing ranges. The miniature sensors are IP67-rated, are equipped with a 360-degree-visible yellow output LED, and come with built-in overload protection. Models are offered with an attached 2-m axial cable or with an M8 connector; axial and right angle zinc-plated mounting brackets are also available. The new miniature inductive proximity sensors are CE-, RoHs-, and Reach-compliant. AutomationDirect www.automationdirect.com/proximity Input #201 at www.controleng.com/information
Magnetic proximity sensors AutomationDirect’s M-series cylindrical magnetic dc proximity sensors are available in 8 mm, 12 mm, and 18 mm sizes. With 10 models available, the magnetic sensors feature stainless steel shielded housings, are offered as NPN or PNP models with normally open or normally closed outputs, and are available with standard sensing distances of 0 to 70 mm. M-series sensors are IP65/IP67 or IP68/IP69Krated and come with built-in overload protection. Models are offered with an attached 2-m axial cable or with an M8 or M12 connector; proximity sensor damping magnets also are available. AutomationDirect www.automationdirect.com/magnetic-sensors Input #202 at www.controleng.com/information
www.controleng.com
integrated h intouch bu mi ndles
g n i t c e t i h c r A Solutions
Applicat ion Assista nce
Superior Technical Support
Wonderware
Acceler Speed- ated To-Mar ket
Distributor
Wonderware Distributors Possess Powerful HMI and SCADA Capabilities for your Automation Projects Wonderware Distributors have been known to pull off some heroic automation feats for their customers. One of their most powerful capabilities include the integrated, InTouch HMI Bundle – a pre-packaged and ready-to-go solution for real-time success in plant operations. North American locations include:
NorCal — norcal.wonderware.com • 866.966.3376 PacWest — wonderwarepacwest.com • 888.449.0494 West — wonderwarewest.com • 713.209.8884 Great Plains — logic-control.com • 913.764.4400 Midwest — wonderwaremidwest.com • 866.826.9725 Canada East — wonderwarecaneast.ca • 905.829.9300 Cincinnati — atrdistributing.com • 513.353.1800 North — wonderwarenorth.com • 877.900.4996 Southeast — insource.solutions/wonderware • 877.467.6872
2016
Powered by:
Ask about our Integrated InTouch HMI & Hardware Bundle input #15 at www.controleng.com/information
WINNER
ECONOMICAL. VERSATILE. SAFE.
r
Su r e ow P O
EC
EPSITRON® ECO Power Supplies r Ideal for industrial applications, as well as household/commercial appliances r Versatile mounting - DIN-rail and screw-mount r &RVW HƬHFWLYH SRZHU VXSSO\ ZLWK :$*2 TXDOLW\ www.wago.us/eco input #16 at www.controleng.com/information
s
lie pp
INSIDE MACHINES discrete sensors Longer range inductive proximity sensors
Carlo Gavazzi expanded its ICB Series Inductive Proximity Sensors to include new “Extra Extended” range sensors, providing up to three times the sensing distances of standard inductive proximity sensors. By extending the sensing range up to 10 mm (M12), 20 mm (M18), and 40 mm (M30), a broader range of applications are possible. A microprocessorbased design allows calibration after the assembly, enabling greater temperature stability, reliability, and repeatability. The microprocessor design also simplifies original equipment manufacturer (OEM) customization requests, such as special output types, switching frequencies, and timing functions. A diagnostic LED is easily viewed from any direction and provides status, set-up, short circuit, and overload indication. With up to 2,000 Hz operating frequency, the new ICB Series is useful for high-speed counting and monitoring rotational speed. Permanently legible laser-engraved part number, cULus and CE marks, and serial number are readily visible on the front face of the sensor. All ICB Series sensors are cULus listed and rated for operation from -25 to +70 °C (-13 to 158 °F). A range of 3-wire dc inductive sensors are available in M12, M18, and M30 housings. Single, extended and extra extended sensing distances are available. Long or short nickel-plated brass housings, for flush or nonflush mounting, are available, either normally open (NO) or normally closed (NC) PNP or NPN outputs. Connection options include either a 2-m PVC cable or M12 disconnect plug. Carlo Gavazzi, www.GavazziOnline.com Input #203 at www.controleng.com/information
Small-sized ultrasonic sensors
Smaller than a match box, these acoustic sensors from Pepperl+Fuchs come offering high-end features; F77 series ultrasonic sensors are designed to fit in tight spaces, can be used for dirty and dusty application environments, and are adept at handling color variations or transparent targets. Because these miniature sensors can detect objects within an area rather than being restricted to sensing only what is directly in front of them, the F77 series is suitable for applications where the pin-point accuracy of a photoelectric beam is too focused to accurately sense the target. The sensors are insensitive to color, provide reliable clear object detection, and ignore target holes and ridges, “Resulting in a coverage area that is more forgiving than that of most photoelectric sensors,” said Marcel Ulrich, product manager, Pepperl+Fuchs. “This is particularly significant, for example, in a printed circuit board application where cuts and holes in the board and shiny copper tracks on a dull background would result in false readings for optic-based products.” www.controleng.com
The sensors also are highly immune to acoustic interference and have minimal deadband, important characteristics for sensors mounted on machinery with noisy pneumatic cylinders. With a housing size of 31 mm x 11 mm x 23 mm, the sensors fit in spacerestricted applications and provide up to 50 Hz switching frequency for fast response times. High visibility LEDs provide an at-a-glance status indication. Intuitive range adjustments make it easy to make on-the-fly changes. The IP67-rated sensors can be used in temperatures ranging from -25 to 70 °C (-14 to 158 °F). A 4-pin Nano-style M8 connector makes installation easy. The sensors provide one PNP, NO (normally open) or NC (normally closed) switch point output, use inexpensive discrete programmable logic controller (PLC) inputs, offer high- or low-frequency options, and deliver a 2 Hz/mm maximum resolution. They are available in diffuse (up to 400 mm sensing range), retroreflective (up to 400 mm sensing range), and through-beam models (up to 800 mm sensing range). Pepperl+Fuchs, www.pepperl-fuchs.us Input #204 at www.controleng.com/information
Inductive adaptability in a proximity sensor
A new sensor from Sick features 4-corner LEDs, a rotating sensor head, and application-specific, integrated circuit (ASIC) technology for reliable detection even in harsh environments; the Sick IQG inductive proximity sensor provides reliable detection in a wide variety of applications and fit into most brackets for easy replacement and less downtime. With the lowest manufacturing tolerances on the market, the customer or OEM no longer needs to readjust the sensor during replacement, which saves time. In addition, the 4-corner LEDs enable straightforward status monitoring, regardless of mounting position. Together, these features simplify installation and monitoring. The sensor head can be rotated in 5 directions, allowing the sensor to easily be adapted to suit a wide range of applications. Using a proprietary Sick ASIC, the IQG inductive proximity sensor features ambient temperature range from -25 to 85 °C, excellent resistance to shock and vibrations, and electromagnetic compatibility. The IQG sensors now have IP68 and IP69K enclosure ratings for operation in harsh environments.
Sick USA, www.sickusa.com Input #205 at www.controleng.com/information
CONTROL ENGINEERING
DECEMBER 2016
| M7
INSIDE MACHINES discrete sensors
Cost-effective prox with improved performance
Telemecanique Sensors (part of Schneider Electric) have a renewed basic range of cylindrical inductive sensors, available in flush and nonflush versions in 12 mm, 18 mm, and 30 mm diameter. They feature a new cable design, improved waterproofing, internal LED, and laser tagging. The sensors provide great performance in noisy environments and a high switching frequency for fast detection. The inductive proximity line is called OsiSense XS, for noncontact sensing of metal objects with extended offerings up to 60 mm, and the capacitive proximity line is OsiSense XT for noncontact sensing of any material up to 20 mm. They comply with international standards and have an IP69K rating. Full stainless steel and plastic versions work for dedicated food and beverage applications, with cubic and full stainless steel cylindrical for automotive including welding applications. Telemecanique Sensors, (part of Schneider Electric) www.tesensors.com/un/en Input #206 at www.controleng.com/information
IP69K rated stainless steel fork sensors
Balluff fork sensors now includes IP69K rated stainless steel self-contained through-beam sensors designed for the most challenging environments. The sensors have a 316 L stainless steel housing that can withstand aggressive cleaning solutions, coolants, and lubricants. Protection provided by the housing makes these sensors suited for food and beverage, packaging, metalworking and pharmaceutical industries. These stainless steel fork sensors are available in 50 mm and 80 mm widths. Features include normally open and normally closed outputs to solve most applications and allow for easy integration into control schemes. Powerful infrared light sources solve application with mist and other airborne particulates, while red light allows for easy alignment in general application. LED’s for power and switching indication in the connector allow for easy troubleshooting and sensor status. The “F” series of C / U slot or fork sensors are universal selfcontained through-beam sensors. Industries these sensors are used in include food and beverage, pharmaceutical, semiconductor, life science, automotive, and metal forming.
Balluff, www.balluff.us/photoelectric Input #207 at www.controleng.com/information
Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering, mhoske@cfemedia.com.
MEDIA SHOWCASE FOR ENGINEERS POWER + CONTROL
1
In
Connection
Up to 5 contacts for POWER + 6 contacts for CONTROL Provide electrical power and control motor drives, communicate alarms Power or monitor process Contact parameters with only 1 connection. Auxiliary Contact
Ratings up to 250A, 600V, Type 4X
Flexible Temperature Sensor Saves Time and Money
Limited time offer on the switch that saves you money.
The WORM, an innovative exible sensor, installs in minutes into most thermowells. It bends and slides right in without having to remove the transmitter enclosure or assembly components.
Watch the video www.miinet.com/TheWORM or call 800-999-2900 Find out more at pages.moxa.com/savemoney
meltric.com 800.433.7642
A company of MARECHAL ELECTRIC GROUP
Input #100 at controlengineering.hotims.com
Demand Moore Reliability Input #101 at controlengineering.hotims.com
Input #102 at controlengineering.hotims.com
MEDIA SHOWCASE FOR ENGINEERS Your place for new products, literature, Apps, Videos, Case Studies and White Papers. Loop Powered 4...20ma Isolating Conditioners
Canada East
Serving Eastern Canada Ask About Our InTouch HMI
• Safe and reliable inputs for PLC’s. Protects from surge voltages and eliminates ground potential differences.
Contact us for all your challenging HMI, SCADA and Automation projects. Powered by:
• 4kV and 10kV isolation. • 5 years guarantee. distributors wanted, more information: www.arian.cl/din
Web: www.wonderwarecaneast.ca Email: Info@wonderwarecaneast.ca Phone: 905.829.9300 Input #103 at controlengineering.hotims.com
12/2/16 Want to receive your Control Engineering magazine as a
AIS EstCan-Fxcn-CE0-120216.indd 1
Input #104 at controlengineering.hotims.com
PLC HMI
ad4-2.indd 1
2:34 PM
digital publication?
Input #105 at controlengineering.hotims.com
2/12/2015 7:03:37 AM
Save with the All-in-One Advantage!
ALL IN ONE
Learn how a PLC+HMI cut costs and improve efficiency: Update your subscription, and get our digital edition, on a more interactive and user-friendly platform, in your email in-box.
http://unitronicsplc.com /success-stories-all/
Update now at:
www.controleng.com Input #106 at controlengineering.hotims.com ce2014_digitlEditn_6th.indd 1
www.controleng.com
2/24/2014 11:44:33 AM
Input #107 at controlengineering.hotims.com
Input #108 at controlengineering.hotims.com
CONTROL ENGINEERING
DECEMBER 2016
| 59
NEW PRODUCTS and software Data logger with field removable I/O modules Watlow’s D4T with Intuition is a data logger that features field removable input/output (I/O) modules for design flexibility. Configurations can be customized to meet the scaling needs of a tremendous range of equipment and applications while providing exactly the hardware types required for compatibility. The D4T data logger features a 4.3-in., color touch panel with a high-resolution, graphical user interface, which allows channels, alarms, inputs, and outputs to be personalized with user-defined names. Users can choose where to store the files including inside the controller, on a connected USB memory device, or to a connected PC anywhere in the world. The D4T is provided with Composer graphical configuration PC software. Watlow,
www.watlow.com,
Input #208 at www.controleng.com/information
Slip ring diagnostic system for analyzing wind turbine equipment
Portable control system for load banks Asco Power Technologies’ Sigma LT is a portable control system designed for load banks. The handheld controller, which features a 4.3-in. color touch screen, networks up to 25 load banks using CAN bus communications protocol. Operators can monitor and control all networked load banks or a single unit in the network, up to 800-ft away. The capability to vary, accept, or reject load on a single unit within a network from a remote controller allows data centers to easily simulate hot zones to determine how an HVAC system reacts to temperature changes at specific server rack locations. A robust, aluminum case protects controller components. The touch screen displays 3-phase voltage, power, current, frequency readings, and selected load. Asco Power Technologies,
www.asco.com
Input #209 at www.controleng.com/information
Leine and Linde’s ADSR is a diagnostic system designed for analyzing condition and predicting remaining service life within slip rings, especially useful in onshore and offshore wind turbines. This is a new smart solution for condition-based maintenance of slip rings. The ADSR’s integrated sensors measure vibrations, the level of voltage and current, number of revolutions, internal and external humidity, and temperature. This systematic monitoring and analysis enable the expected remaining service life of the slip ring to be displayed, both in terms of time and revolutions. Having this knowledge in advance makes it possible to use up the slip ring’s entire service life. The ADSR’s diagnostic system monitors the contact systems and other key functions of the slip ring, enabling conditionbased maintenance. Leine & Linde,
www.leinelinde.com
Input #210 at www.controleng.com/information
Volumetric screw feeders for metered dispensing Scaletron’s Model VMF-28 volumetric screw feeders are designed for metered dispensing of powdered or pelletized chemicals into water, wastewater, and chemical treatment processes. Precise dosage amounts are automatically weighed and added to treatment processes without requiring an operator to measure and weigh amounts. Data is displayed at a central monitoring station where operators can quickly make adjustments as necessary from the control panel. The integrated scale employs four load cells each with an adjustable stainless steel leveling bolt. The scale measures changes in volume to 0.5% accuracy. Controls are housed in a NEMA 4X, UL-approved enclosure. The VMF-28 models are compatible with Scaletron’s line of scale indicators and controllers. Scaletron Industries Ltd.,
www.scaletronscales.com
Input #211 at www.controleng.com/information
Offshore illuminator for hazardous locations Clark-Reliance’s Jerguson LumaStar EPL-316 offshore illuminator is designed to provide high contrast, white LED light for any transparent glass level gage. With its all-316 stainless steel construction, the LumaStar Illuminator is ideal for offshore or other hazardous service environments. Its LED lights are essentially maintenance-free and are rated to approximately 100,000 hours. It is approved for use in Class I, Div 1, Group B, C, & D and Zone 1 & 2 environments. A single explosion-proof power supply with intrinsically safe lighting circuit can service illuminators up to 58-in. long, which translates to up to four size nine gage sections or up to five size seven gage sections. The illuminators are field-upgradeable to fit any glass gage. Clark-Reliance Corp.,
www.clark-reliance.com
Input #212 at www.controleng.com/information
60
|
DECEMBER 2016
CONTROL ENGINEERING
www.controleng.com
See more products daily at www.controleng.com/products.
Noncontact displacement sensing system Ultrasonic distance and level sensors for automation, tank level applications Omega’s LVTX-10 series of sensors are ultrasonic transmitter modules designed to provide continuous measurement of fluids, pastes, or uneven solid bulk materials in constrained working zones. The LVTX-10 sensors are designed to provide accurate measurement for factory automation, warehouse materials control, pipe and conveyor belt blockage, or tank level applications with non-uniform surfaces. LVTX-10 sensors features include an advanced diagnostic feature that will retrieve the ultrasonic waveform for analysis. An integrated mounting plate with pre-formed holes is provided for easy installation. Other features include diagnostic and monitoring outputs, protection from over voltage, short circuits, and reverse polarity. Operating from 12 to 24 Vdc, all LVTX-10 sensors provide a linear output of either 0 to 10 Vdc or 4 to 20 mA, that are proportional to the measured distance to the target.
Kaman Precision Products’ KD-2306 single-channel, multi-purpose, noncontact displacement sensing system is designed to act as a replacement for linear variable differential transformers (LVDTs), air gauges, dial indicators, and micrometers. Ideal for applications ranging from lab work to production/process automation, the KD-2306 supports both dual and single coil sensors. Its DIN-rail mount interface makes it ideal for integration into original equipment manufacturer (OEM) equipment and industrial control applications. The KD-2306 features terminal input/output (I/O) connections, autosynchronization of multiple channels, and analog dc and 4 to 20mA outputs. With single-ended, bipolar, and differential voltage outputs, the KD-2306 offers front face coarse and fine calibration controls. Kaman Precision Products,
www.kamansensors.com
Input #214 at www.controleng.com/information
Ultrasonic sensors for harsh conditions Massa Products Corp.’s MassaSonic PulStar TTL ultrasonic sensors are designed to provide advanced user controls with low power and communicate with the customer’s control system using asynchronous UART TTL signals operating at 1.8 V levels. They are able to rule out false and unwanted echoes and are designed for original equipment manufacturers (OEMs) and integrators who work with solids, chemicals, and fluids even when vapors are present. The MassaSonic PulStar Plus combines transducer design, with software and firmware and is IP 68 rated. It has an operating temperature range from -40 to 70°C and can provide accurate measurements within 0.1% over distances as close as 8-in. to 13 ft.
Omega Engineering
Massa Products Corp.
www.omega.com
www.massa.com
Input #213 at www.controleng.com/information
Input #215 at www.controleng.com/information
Surge protective devices for commercial, light industrial applications
Digital piezo controller for nanopositioning applications
Eaton’s SPC Series of surge protective devices are designed for commercial and light industrial applications and enable facilitywide protection to improve business continuity. The SPC Series also provide flexibility to facility managers for a broad range of applications and serve as an essential component of any surge protection strategy. The devices feature a compact design that can be configured to protect most electrical applications, including service entrances, distribution panelboards and pointof-use applications, as well as other critical-use cases. Features include a thermally protected metal oxide varistor (MOV) technology, 20 kA nominal discharge current rating, and a 50 to 200 kA per phase peak surge current capacity ratings.
Physik Instrumente’s (PI) E-727 digital piezo controller is designed for multi-axis nanopositioning applications, such as 3-D imaging in super-resolution microscopy, laser beam steering, image stabilization in astronomy, and fast alignment applications such as used in fiber alignment and semiconductor CD testing. It features digital high-speed interfaces, such as SPI, Ethernet, and USB as well as three additional high-resolution analog inputs. Low noise 20-bit DAC & ADC converters provide high resolution and stability. Four integrated piezo power amplifiers with an output range of -30 to 130 V as well as circuitry for capacitive feedback sensors, piezoresistive sensors, and strain gauges are also featured. Applications include nanopositioning, nano-automation, semiconductor technology, photonics, bio-nano-technology, metrology, microscopy, micro-manipulation, including cleanroom applications.
Eaton Corp.,
Physik Instrumente (PI),
www.eaton.com
Input #216 at www.controleng.com/information
www.controleng.com
www.pi-usa.us
Input #217 at www.controleng.com/information
CONTROL ENGINEERING
DECEMBER 2016
| 61
NEW PRODUCTS and software See more products daily at www.controleng.com/products.
Asset monitoring platform for operations management Emerson’s AMS Ares platform is designed to prioritize and deliver asset and device health data, enabling maintenance decisions that increase operational and asset availability. Users can access and share key data with asset health summaries available on traditional desktop PCs, laptops, smartphones, and tablets—inside or outside the plant. The AMS Ares Platform represents an evolution toward a new, modern portfolio of AMS technologies and services, focused on providing digital intelligence and tools to help customers operate their plants and assets more effectively. The AMS Ares Platform gathers data from multiple sensing technologies and provides a holistic view of the current health status of plant assets. Persona-based access to information ensures the right personnel have instant access to clear health overviews of assets that are relevant to their plant responsibility. Emerson,
www.emerson.com,
Input #218 at www.controleng.com/information
Chilled mirror hygrometer for industrial, laboratory settings
Design kit for communicating with motion controllers, PLCs
Michell Instruments’ S8000 RS precision chilled mirror hygrometer is designed to measure dew points down to -90°C (0.1ppmV) with an accuracy of ±0.1°C. It is designed for calibration laboratories and industrial settings. No additional external cooling equipment is needed to accurately reach these dry dew points. It is designed to fit into a standard 19-in. rack and features an optical system that detects very small changes in moisture condensed on the mirror surface. The S8000RS uses frost assurance technology (FAsT) to ensure that ice, not liquid water, is present on the mirror surface at low temperatures to ensure that your measurements are always a known quantity.
The Galil Design Kit (GDK) by Galil Motion Control is designed to provide easy communication with motion controllers and programmable logic controllers (PLCs). The GDK contains six tools: A scope, turner, terminal, editor, viewer, and setup. The scope is designed to emulate a traditional digital oscilloscope. The tuner is designed to assist in optimizing a system’s performance. It provides a single interface for editing filter parameters such as pole, notch, and PID. The viewer tool allows customized real-time viewing of the controller’s input/output (I/O) status, motor position, and more. The setup tool allows the user to view, edit, backup, and load controller memory such as parameters, variables, arrays, and the program buffer. The terminal tool provides easy communication to and from controllers, and it can be used to query the controller’s parameters or execute a program.
Michell Instruments,
Galil Motion Control,
www.michell.com
Input #219 at www.controleng.com/information
www.galilmc.com
Input #220 at www.controleng.com/information
PRODUCT & LITERATURE SHOWCASE 5B / 7B / 8B Signal Conditioning Solutions
More Models, More Protection, Less Noise, Lower Cost 580+ different 5B, 7B, and 8B signal conditioners provide accurate, isolated Instrument Class® performance to ensure the integrity of your industrial automation, data acquisition, process control, and quality assurance systems. Custom modules available. • ± 0.03 to ± 0.05% Accuracy
• ANSI/IEEE C37.90.1 Transient Protection
• 1500Vrms Isolation
• 3- to 6-Pole Low-Pass Filtering
• Up to 240Vrms Input Protection
• -40°C to +85°C Operating Temperature • CSA C/US Certified & ATEX Compliant (5B, 7B) • C-UL-US Listed (8B)
Call 800-444-7644 or visit www.dataforth.com
Acromag Signal Conditioners & Ethernet I/O We have the experience to help improve reliability, increase productivity, & reduce your costs. Get your new product guide today. • 4-20mA Isolators and Splitters • Ethernet, Modbus, Profibus Remote I/O
877-295-7057 www.acromag.com/ce ■
Input #101 at www.controleng.com/information
Place Your Classified, Literature Showcase or Product Mart ads today! Contact: Iris Seibert at 858-270-3753 or ISeibert@CFEMedia.com
Input #100 at www.controleng.com/information
62
|
DECEMBER 2016
CONTROL ENGINEERING
www.controleng.com
Advertising Sales Offices ContentStream
Patrick Lynch, Director of Content Marketing Solutions 630-571-4070 x2210 PLynch@CFEMedia.com AL, FL, GA, MI, TN
ad index Company
Page#
RSN
Web
ABB Inc . . . . . . . . . . . . . . . . . . . . . .7 . . . . . . . . . . . .5 . . . . . .www.abb.com/800xA AutomationDirect . . . . . . . . . . . . . .C2 . . . . . . . . . . .1 . . . . . .www.automationdirect.com CFE Media 2016 Industrial Internet of Things & Industrie 4.0 Study . . . . . . . . . . .41 . . . . . . . . . . . . . . . . . .www.controleng.com/2016IIoTStudy CFE Media’s New Products for Engineers Database . . . . . . . . . . . .29 . . . . . . . . . . . . . . . . . .www.cfemedia.com/NP4E Control Engineering Digital Reports. . . . . . . . . . . . . . . . .19 . . . . . . . . . . . . . . . . . .www.controleng.com/DigitalReport/lloT Control Engineering On-demand Webcasts. . . . . . . . . . .19 . . . . . . . . . . . . . . . . . .www.controleng.com/ondemandwebcasts DAQRI . . . . . . . . . . . . . . . . . . . . . . .14, 15 . . . . . . . 10 . . . . .www.DAQRI.com Dataforth Corp . . . . . . . . . . . . . . . .17 . . . . . . . . . . 11 . . . . .www.dataforth.com FORCAM . . . . . . . . . . . . . . . . . . . . .13 . . . . . . . . . . .9 . . . . . .www.forcam.com iDS . . . . . . . . . . . . . . . . . . . . . . . . . .10 . . . . . . . . . . .7 . . . . . .www.ids-imaging.com Kepware Technologies . . . . . . . . . .Bellyband, 11. . .8 . . . . . .www.kepware.com/CE Leidos . . . . . . . . . . . . . . . . . . . . . . .9 . . . . . . . . . . . .6 . . . . . .www.leidos.com/activate Moore Industries - Intl. Inc . . . . . . .4 . . . . . . . . . . . .4 . . . . . .www.miinet.com Moxa Technologies . . . . . . . . . . . . .3 . . . . . . . . . . . .3 . . . . . .www.moxa.com Sealevel Systems Inc . . . . . . . . . . .27 . . . . . . . . . . 12 . . . . .www.sealevel.com SEW-EURODRIVE, Inc. . . . . . . . . . .C4 . . . . . . . . . . 18 . . . . .www.seweurodrive.com Unitronics . . . . . . . . . . . . . . . . . . . .1 . . . . . . . . . . . .2 . . . . . .www.unitronics.com Yaskawa America, Inc. . . . . . . . . . .C3 . . . . . . . . . . 17 . . . . .www.yaskawa.com
Inside Machines Aerotech Inc . . . . . . . . . . . . . . . . . .M2 . . . . . . . . . 13 . . . . .www.aerotech.com American Industrial Systems (AIS) . . . . . . . . . . . . . . . . .M5 . . . . . . . . . 15 . . . . .www.aispro.com Beckhoff Automation LLC. . . . . . . .M3 . . . . . . . . . 14 . . . . .www.beckhoff.com WAGO Corp. . . . . . . . . . . . . . . . . . .M6 . . . . . . . . . 16 . . . . .www.wago.us
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
Maggie Hatcher, Classified, Product Mart, Media Showcase 630-571-4070, x2221 MHatcher@CFEMedia.com AR, IL, IN, IA, KS, KY, LA, MN, MO, MS, NE, ND, OK, OH, SD, TX, WI, Central Canada
Bailey Rice (630) 571-4070 x2206 BRice@CFEMedia.com AK, AZ, CA, CO, HI, ID, MT, NV, NM, OR, UT, WA, WY, Western Canada
Iris Seibert (858) 270-3753 ISeibert@CFEMedia.com CT, DE, MD, ME, MA, NC, NH, NY, NJ, PA, RI, SC, VA, VT, WV, DC, Eastern Canada
Julie Timbol (978) 929-9495 JTimbol@CFEMedia.com Internation (outside U.S., Candada)
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 DECEMBER 2016
| 63
BACK TO BASICS motors and drives
How to properly operate a three-phase motor using single-phase power There are several methods to operating a three-phase motor using single-phase power to make what would be an otherwise expensive and arduous process a little easier.
S
So, you told a neighbor you work with electrical equipment, and now he thinks you can solve his problem because there’s a three-phase motor that can’t run on single-phase power. Being asked to convert this motor already sounds like more trouble than it’s worth. That’s not quite true, though. Some methods can make the process easier.
MORE
ADVICE KEY CONCEPTS Phantom leg method. Rotary phase converter method. Variable frequency drive method ...all can be used to make a 3-phase motor work with single-phase power. ONLINE EXTRA Search “Back to Basics” for more tutorials at www.controleng.com. CONSIDER THIS What other methods can be used to operate a 3-phase motor on singlephase power?
The phantom leg method
Three-phase power involves three symmetrical sine waves that are 120 electrical degrees out of phase with one another (see Figure). One method of converting single-phase power that worked well for decades was connecting two phases to the incoming 220 V single-phase power and create a “phantom leg” for the third phase by using capacitors to force an offset between the main and auxiliary windings. In this case, the offset is 90 electrical degrees. For this method, the capacitors must be appropriately sized for the load. The current will be unbalanced if it isn’t. Rather than the 120-deg phase shift depicted in the lower half of the Figure, the incorrect pairing of the capacitor and load may result in a large deviation. The bigger the discrepancy, the lower the torque. Rotary phase converter
The top graph shows single-phase power, and the bottom graph shows 3-phase power. Courtesy: EASA
64
|
DECEMBER 2016
Another viable method is with a rotary phase converter. A wood shop, for instance, might use a rotary phase converter to run several three-phase machines on a single-phase power input. One drawback is that the process can be very expensive during the entire time the rotary phase is converting, regardless of whether any machinery is being used. The current might be balanced when specific machinery is running, but if few machines are operating, or all of them are heavily loaded, the three-phase power—current and voltage—is drastically unbalanced. “NEMA Stds. MG 1: Motors and Generators” calls for motors to operate from voltage that is balanced
CONTROL ENGINEERING
within 1%. If the 10x rule is applied (percent current unbalance can be as high as 10 times the percent voltage unbalance) to a motor operating with 1% voltage imbalance, the current imbalance could be 10%. This is beneficial because a majority of three-phase motors running on a system described above are operating between 15% and 50% current imbalance. Even with the NEMA MG 1 derating graph no motor should operate with such a large current imbalance. Variable frequency drive method
A variable frequency drive (VFD) rectifies each pair of phases to dc and inverts the dc to the power for the three-phase output, which means a VFD can be used with single-phase input to operate a threephase motor. Manufacturer support varies, and it is cautiously recommended to derate the drive by 1 divided by the square root of 3 (about 58%). Also note that the hp/kW VFD rating is there for convenience in sizing drives since they’re rated by current. A 10 hp (7.5 kW) motor would use a VFD rated for 15 hp (11 kW). It is strongly recommended for the user to work with the drive manufacturer in selecting and sizing the VFD for this use. Compressors, machine shop and woodworking equipment and decorative fountains are good candidates for this method. Rather than buying an expensive single-phase motor, changing the controls and dealing with speed control and starting torque issues, it is a better idea to use a VFD to operate the existing motor from single-phase power. For many applications up to 5 hp (4 kW), a suitable VFD can be purchased for far less than the cost of rewinding a threephase motor and providing the necessary controls to operate it. A three-phase motor is usually less expensive to buy, the controls do not require replacement or modification, and the VFD has the value-added bonus of providing speed control. ce
Chuck Yung is a senior technical support specialist at the Electrical Apparatus Service Association (EASA). EASA is a CFE Media content partner. Edited by Chris Vavra, production editor, CFE Media, cvavra@cfemedia.com. www.controleng.com
ENTER THE MATRIX
Using complicated systems for low harmonics or power regeneration? Try the efficient way with the U1000 Industrial Matrix Drive. Our greenest drive ever, the U1000 goes beyond the performance of conventional drives. Enjoy extremely low harmonic distortion and regeneration in a space-saving design, completely without the need for additional components.
ACTIVE COMPONENT SYSTEM
12/18-PULSE SYSTEM
Input Fuses
LC Filter
Active Rectifier
2016
Standard Drive
WINNER 12/18-Pulse Transformer
U1000 INDUSTRIAL MATRIX DRIVE SYSTEM
For more info: http://budurl.me/YAI978
YASKAWA AMERICA
Input Fuses
3 Wires In
Standard Drive
U1000
3 Wires Out
input #17 at www.controleng.com/information DRIVES & MOTION DIVISION
YASKAWA.COM
1-800-YASKAWA
Things heating up at work? Inefficient drive systems create heat. A bunch of drives generating heat raises your cooling costs. So, if you aren’t using the ultra-efficient (IE4) MOVIGEAR® Mechatronic Drive System from SEW-EURODRIVE, then you are paying for energy twice! MOVIGEAR combines the motor, gearing and electronics into one highly reliable, efficient and hygienic unit. Independent research has proven that it reduces startup and operating costs by 20-30%. It’s time to stop running the heat and air conditioning at the same time!
movigear.com / 864-439-7537
input #18 at www.controleng.com/information